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Flashcards in Additive Manufacturing Deck (13):

What is Additive Manufacturing and how does it differ from other manufacturing processes?

Additive Manufacturing creates parts/objects by adding up layers.

All other processes are subtractive manufacturing and create parts by taking material away.


Advantages of Additive Manufacturing

- Can be faster
- Can require less mechanical effort
- Can generate less waste material


Current applications of (AM)

- 3D printed Homes
- Dental material
- Food


5 different kinds of additive manufacturing

- Fused deposition modeling (FDM)
- Stereolithography (SLA)
- Polyjet printer
- Binderjet printing
- Selective laser sintering


What is FDM and what are the Advantages and Disadvantages

The additive process of depositing filament from a spool into a high temperature extruder, whose path is generated by a computer

- low cost
- Low Printing time
- Large build volume
- can't make complex/detailed parts


What is SLA and what are the Advantages and Disadvantages

SLA used a process called photopolymerization where resin is cured from underneath by a UV laser

- Very versatile
- Small build volume and is messy


What is polyjet printing and what are the Advantages and Disadvantages

Analogous to inkjet 2D printing. Prints 3D jets of 'ink' on a build plate to form a 3D model

- can produce very complex parts with lots of detail
- Large build volume
- Raw material for this is extremely expensive than the other processes


What is Binderjet printing and what are the Advantages and Disadvantages

A printer head deposits an inorganic binder material onto a layer of powdered material

- Creates photorealistic parts
- parts are fragile and brittle
- not very functional


What is Selective laser sintering and what are the Advantages and Disadvantages

based on selectively sintering of polymeric or metallic powders into an individual jet

- allows us to create very strong complex parts
- Larger
- more expensive


3D printing process

1) Construct your 3D CAD model
2) import model into 3D printer software
3) 3D print the model
- This is not fast
- small parts can print in 30-40 minutes
- Large can take up to 2 days
4) Remove completed part from printer for post-processing
- Clipping/trimming/sanding required to finish part


How do you know what 3D printer and materials are appropriate?

- Application
- Aesthetics
- Function
- Certification


Research in AM

- Faster
- 3D bio
- Reducing waste
- Cybersecurity


Important Considerations when 3D printing

- Raft: a layer between model and build plate
- Bed leveling: need to level the build plate before every print, warping can occur
- Overhanging: Parts with angles over 45 degrees need some support structure
- Infill: you don't want to print a solid part unless necessary
- Infill ranges between 10% and 100%
- Wall Thickness: needs to support the structural integrity (min 0.8 - 1mm)
Level of detail: More detail = more layers = more time, material, and cost