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112 > Additive Manufacturing > Flashcards

Additive Manufacturing Flashcards

1
Q

Name 4 Benefits of 3d Printing to other Manufacturing Processes

A

More Complex Geometries

Rapid Prototyping

Print on Demand

Minimises Waste

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2
Q

Explain what a .stl File does?

Explain what a .sli file does?

A

Software Generates a Tesselated Object Description

File Consists of XYZ coords of each triangle/patern of the Tesselated object

Produces a series of 2d cross sections of a .sti file.

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3
Q

What are the 7 Major Sectors of 3D Printing

A

Material Extrusion
Vat Polymerisation
Powder Bed Fusion
Material Jetting
Binder Jetting
Directed Energy Deposition
Sheet Lamination

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4
Q

Describe Material Extrusion.
What Materials can be Used
What its Dimensional Accuracy

A

Fused Deposition Modelling (FDM)
Material is extruded through a nozzle
Plastics,Metals, Foods, Concrete
+- 0.5% (Lower limit +- 0.5mm)

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5
Q

Name the Strengths and Weaknesses with Material Extrusion

A

Lowest cost 3d printing method
Can create parts with multiple materials.

Lower Strength
Lower Durability
Low Dimensional Accuracy

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6
Q

Describe Vat Polymerisation.
What Materials can be Used
What its Dimensional Accuracy

A

Streolithography
Liquid photopolymer is selectively cured by light-activated polymerization
Photopolmer Resins
+-0.5% (lower limit +-0.15mm)

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7
Q

What are the Design Considerations with Vat Polymerisation

A

Orientation & Placement of support Structures
Poor Surface Quality (Rough)
Trapped Liquid
Bubble Formation
Limit on Feature Size

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8
Q

Describe Powder Bed AM .
What Materials can be Used
What its Dimensional Accuracy

A

SLS & SLM (Selective Laser Sintering and Melting)
Create Solid products using Laser & Material Powders.
Plastic, Metallic and Ceramic Powders
+-0.3% (Lower limit +-0.3mm)

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9
Q

Explain the Difference Between Electron beam Melting and Selective Laser Melting

Which is Faster at Part Production?

A

SLM
Contains High Energy Laser
Laser is directed by a Mirror

EBM
Contains High Energy Electron Beam
Beam Directed by Magnetic Field

EBM , Electron beams can change direction faster

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10
Q

Name the Strengths and Weaknesses with Powder Bed AM

A

Higher Strength
Higher Durability
Complex Geometries
Wider Range of Materials

High Machine Cost
Low Build Rate
Post Processing Required
Varing Mechanical properties in different directions (Anisotropic)
Trapped Powder
Residual Stresses and Porosity
Requires Support Strucuture

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11
Q

Describe Material jetting .
What Materials can be Used
What its Dimensional Accuracy

A

Droplets of material, selectively applied inkjet print heads. Then Cured and Solidified with UV Light
Photopolymer Resin
+-0.1mm

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12
Q

Name the Strengths and Weaknesses with Material Jetting

A

Can Create Parts with Multi-Materials
Frabrication of parts with varing Light Absorption Levels

Not Suitible for Mechanical Parts
Expensive System.

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13
Q

what process is this

A
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14
Q

what process is this?

A

FDM
Fused deposition modelling

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15
Q

What process is this?

A

Powder bed fusion

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16
Q

What process is this

A

DED

Metallic object

Doesn’t require as much infrastructure as powder bed fusion

17
Q
A

Material Jetting

18
Q
A

Sheet Lamination

19
Q
A

SLS
Powder Bed Fusion

20
Q
A

Directed Energy Deposition

21
Q

Made from Ceramic

A

Powder Bed Fusion

22
Q

Describe Binder jetting .
What Materials can be Used
What its Dimensional Accuracy

A

Liquid Bonding Agent Selectively deposited onto powder materials which fuses the particles
Sand, Polymers, Metal , Cermaics
+-0.2mm (Metal), +-0.3mm (Sand)

23
Q

Name the Strengths and Weaknesses of Binder Jetting

A

High Print Speed
Low Cost
Large Build Volumes
Support free Design
Colour Reproduction

Limited Materials Can be Used
Non Durable Polymer Parts
Multi Step Process for Metals
Trapped Powder causing Defects

24
Q

Describe Directed Energy Deposition .
What Materials can be Used
What its Dimensional Accuracy

A

Focused Thermal energy fuses feedstock material by melting, as its being deposited

Metals or ceramics in wire or powder form

+-0.1mm

25
Q

Name the Strengths and Weaknesses of Directed Energy Deposition

A

Excellent Physical Properties (Very Dense)
Wide Range of Processing Materials
Can produce produce products with varying microstructures
Can Produce Products with Embedded Sensors

Cannot complex shapes that require supoorts
Poor Surface finish
Difficult to Control

26
Q

Describe Sheet Lamination .
What Materials can be Used
What its Dimensional Accuracy

A

Sheets of material are bonded together to form a larger part.
In a Adhesive or Welding Process

Paper, Polymers, Metals in Sheet Form

+-0.1mm

27
Q

Name the Strengths and Weaknesses of Sheet Lamination

A

Inexpesnive Materials
Ability to Add COlour
Quick Production
Composite Materials

Restricted Functionality
Low Mechanical Strength
Expensive System in some cases

28
Q
A

112 (9 decks)

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