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Additive Manufacturing Processes Flashcards

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1
Q
A
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2
Q

What is the core principle of additive manufacturing (AM)

A

Successive layer-by-layer creation of components by adding material to form final shape

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3
Q

How does additive manufacturing differ from conventional manufacturing

A

AM builds components by adding material while conventional methods like machining remove material to shape parts

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4
Q

In which DIN 8580 process group does additive manufacturing belong

A

Creating cohesion

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5
Q

Who invented stereolithography and when

A

Charles W Hull in 1986 US Patent 4575300

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6
Q

How does stereolithography work

A

A laser selectively hardens layers of liquid plastic guided by CAD data until the full 3D component is formed

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7
Q

What data is needed to run an additive manufacturing process

A

3D CAD model plus software to slice geometry into layers

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8
Q

What are the three categories of AM applications

A

Rapid prototyping
Rapid tooling
Rapid manufacturing

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9
Q

Key examples of AM use in rapid manufacturing

A

Custom medical prosthetics spare parts small-batch parts for automobiles and aircraft

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10
Q

Which certification did Airbus obtain in 2016

A

Airworthiness for titanium AM parts in A350 from European Aviation Safety Agency EASA

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11
Q

What AM technologies are advancing aerospace use

A

Selective Laser Sintering SLS
Selective Laser Melting SLM
Selective Electron Beam Melting SEBM

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12
Q

What are key benefits of AM in production

A

On-demand manufacturing
No tooling required
Location-independent
Inventory reduction

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13
Q

What are legal challenges of AM

A

IP and copyright protection
Producer liability
CE safety compliance
Unclear responsibility between designers and manufacturers

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14
Q

Why is AM vulnerable to product piracy

A

Design files CAD can be easily shared copied or modified without proper control

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15
Q

What makes legal responsibility complex in AM

A

Separation between designer and manufacturer often leads to unclear liability for failures

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16
Q

What happens if AM component properties deviate from OEM specs

A

May lead to loss of approval especially in regulated sectors like automotive and aerospace

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17
Q

What is stereolithography (STL)

A

An early additive manufacturing process that builds components layer by layer by curing liquid photopolymers like Duroplasts using UV or heat

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18
Q

What materials are commonly used in STL

A

Light-curing epoxy or acrylic resins often mixed with additives for improved properties

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19
Q

What are the main components of an STL machine

A

Liquid polymer tank
Height-adjustable build platform
XY-controlled laser
Software-controlled mirror
Curing agent mixed into polymer

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20
Q

How does the STL process work

A

Laser beam selectively cures thin layers of resin based on CAD data the platform lowers after each layer to build the 3D structure

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21
Q

What happens after the STL building process is complete

A

Component is lifted out of the bath post-cured with heat or UV cleaned with solvents and may undergo machining or surface finishing

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22
Q

Why are support structures needed in STL

A

To stabilize soft or thin areas during the build process they are removed after curing

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23
Q

What are the typical layer thicknesses in STL

A

Approximately 0.05 to 0.3 mm depending on the application

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24
Q

What is the accuracy of STL components

A

Around 50 micrometers µm

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25
What are key mechanical properties of cured epoxy resins in STL
High strength Low impact sensitivity Abrasion resistance High dimensional accuracy Good adhesive strength and flexibility
26
What are some advantages of STL
High precision surface quality good for filigree and fine structures
27
What are some disadvantages of STL
High material costs Need for support structures Post-processing required
28
What is Selective Laser Sintering (SLS)
An additive process where metal or polymer-coated powders are bonded layer by layer using a laser to superficially melt and fuse particles
29
What is the main difference between SLS and SLM
SLS melts plastic-coated metal powders to fuse particles while SLM directly melts pure metal powders to form fully dense layers
30
What is Selective Electron Beam Melting (SEBM)
A process similar to SLM that uses an electron beam in a vacuum to directly melt metal powders layer by layer
31
How are layers built in SLS
Laser melts the plastic coating on metal powder particles layer by layer followed by heat treatment to burn off plastic and bond metal by diffusion
32
What happens after the SLS build process
The part is heat treated to remove the plastic binder and to form atomic diffusion bonds for mechanical strength
33
Which materials can be processed with SLS and SLM
Steels aluminum and titanium alloys as well as polymer-coated metals and even sand particles
34
What are key advantages of SLS and SLM
No need for molds high part density complex geometry capability and fast turnaround for small batches
35
What is the layer thickness in SLM or SEBM
Approximately 50 to 150 micrometers
36
Why is vacuum used in SEBM
To prevent interference from oxygen and nitrogen in ambient air during high-temperature processing
37
What is the benefit of bionic designs in additive manufacturing
Optimized for load and weight resulting in lighter components that are difficult to produce conventionally
38
How is beam movement data generated in SLS and SLM
From the 3D CAD model converted into layer-specific instructions for the laser or electron beam
39
What are some post-processing steps in SLS and SLM
Cleaning excess powder and optionally machining or surface finishing
40
What is Fused Deposition Modeling (FDM)
An additive manufacturing process that builds parts layer by layer from molten thermoplastic using a heated nozzle
41
What materials are used in FDM
Thermoplastics thermoplastic elastomers and molding waxes
42
How does the FDM head work
It melts the plastic drawn from a spool using an extruder and applies it in layers using a motor-controlled heated nozzle
43
What are the movement directions of the FDM head and platform
FDM head moves in X and Y axes while the build platform moves in the Z axis
44
What is the layer thickness in FDM
Typically between 0.025 and 1.0 mm
45
What accuracy can be achieved with FDM
Approximately 0.1 to 0.15 mm
46
What happens after each layer is deposited
The material cools and hardens then the build platform lowers to allow the next layer to be added
47
What are common applications of FDM
Prototypes fasteners tools medical prostheses parts for automotive and aerospace industries
48
What is Multi-Jet Modeling (MJM)
An additive manufacturing process where liquid plastic or wax is sprayed in layers using inkjet-like print heads and cured layer by layer
49
What materials are used in MJM
Thermoplastics photopolymers and waxes
50
How are layers cured in MJM
With ultraviolet light for photopolymers or solidified by cooling if wax is used
51
What is the function of multiple nozzles in MJM
To spray different materials and colors simultaneously and to build both the component and support structures
52
What happens after each layer is built in MJM
The build platform lowers and the next layer is applied
53
How are support structures handled in MJM
Often made of wax and can be easily melted off after printing
54
What is the powder and adhesive variant in MJM
Adhesive is sprayed onto powder to bond it into layers creating a component which can then be sintered
55
What happens during sintering in MJM powder process
Adhesive burns off forming a solid metal or glass part and the porosity allows infiltration of other materials
56
What are the benefits of MJM
High accuracy adequate strength multicolor capability and simultaneous material deposition
57
What is the 3D printing process
A method of manufacturing three-dimensional components using additive principles by building them layer by layer
58
Where was the 3D printing process developed
Massachusetts Institute of Technology (MIT) in Boston U.S.
59
When did 3D printing systems become commercially available
Around 1994
60
What is the basic principle of 3D printing
Powder is dispensed onto a build platform in thin layers and a bonding agent is injected to solidify the powder locally layer by layer
61
What is the role of the unbonded powder in 3D printing
It stabilizes the component supports the structure and can be reused in further building processes
62
What materials can be used in 3D printing
Powdered metals ceramics sand plastics and other materials that can be wetted by a bonding agent
63
What are some applications of 3D printing
Producing components prototypes molds for casting and small batch manufacturing
64
How does 3D printing compare to conventional manufacturing processes
It eliminates the need for molds reduces the number of operations and is ideal for small batches and individual items
65
What role does CAD play in 3D printing
CAD data is used to create the geometry and movement data for the print head during the building process
66
What is the significance of 3D printing in casting
In sand casting 3D printed molds have gas permeability and porosity that help with gas release during metal solidification
67
What is Layer Laminated Manufacturing (LLM) and Layer Object Modeling (LOM)?
Additive processes where building materials like paper plastic films or metal foils are cut and applied layer by layer using adhesives or polymerization
68
What materials are used in LLM and LOM?
Paper plastic films metal foils such as steel aluminum and titanium
69
How are the layers bonded together in LLM and LOM?
Layers are glued or polymerized to form strong bonds using adhesives or welding processes like laser beam diffusion and ultrasonic welding
70
What equipment is used to cut and shape the foils and films?
Laser cutting devices for metals cutting wires for plastic films and milling equipment
71
What is the advantage of LLM and LOM?
Suitable for producing large solid components cost-effectively
72
What are the limitations of LLM and LOM?
Difficult to cut undercuts and recesses geometry is limited and reworking surfaces is costly
73
What is anisotropy in LLM and LOM?
Mechanical strengths vary depending on the direction of the foil or film leading to directional dependence of the properties
74
What challenges exist with reworking components in LLM and LOM?
High cost for manual removal of cutouts holes and surface reworking
75
What is the issue with cutting bevels in LLM and LOM?
Shallow bevels are difficult to produce due to cutting devices typically cutting perpendicular to the material
76
What additional consideration is needed for paper components in LLM and LOM?
Paper components must be treated to protect them from delamination
77
What is Selective Mask Sintering (SMS)?
An additive manufacturing process where plastic powder is applied layer by layer and selectively melted using a planar infrared (IR) emitter with masks directing the energy.
78
How is the energy directed to the plastic powder in SMS?
Masks are used to focus the energy of the IR emitter to the area of the plastic layer to be melted while leaving other areas unaffected.
79
What is the role of the non-melted powder in SMS?
The non-crosslinked powder serves as a support material for overhangs and can be reused in further production cycles.
80
How are mask patterns created in SMS?
A glass plate is coated with toner selectively exposed to light to form a mask and used to direct IR light for melting the powder layer.
81
What are the characteristics of the plastic powder used in SMS?
Plastic powder particles are about 20–100 µm in diameter and packed closely together in the powder bed.
82
How does the SMS process melt and solidify the plastic powder?
The IR light melts the plastic locally and solidification occurs by cooling after thermal conduction.
83
What happens after a layer is completed in SMS?
The build platform is lowered and the next cycle begins with another layer being applied and exposed.
84
What is the advantage of SMS over Selective Laser Sintering (SLS)?
SMS is faster because the entire surface can be exposed at once with a mask pattern while SLS requires point-by-point surface traversal.
85
What is an alternative variant of SMS using imaging optics?
In this variant IR light is directed by mirrors with the mask and light source positioned outside the build space offering flexibility and improved energy efficiency.

Production Engineering (6 decks)

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