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ME2162 > Chapter 5.1 Additive Manufacturing > Flashcards

Chapter 5.1 Additive Manufacturing Flashcards

(53 cards)

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1
Q

What are the advantages of AM?

A
  • Create complex geometries
  • Customise every item
  • Lower fixed costs (No tools + moulds)
  • Rapid prototyping (Less fiscally risky to produce)
  • Less waste material
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2
Q

What are the drawbacks of AM

A
  • Higher costs for large production runs
  • Less material choics / colours / finishes
  • Limited strength & endurance
  • Lower precision
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3
Q

What is the purpose of AM supports?

A
  • Prevent deformation & curl
  • Separate part from platform
  • Anchor unattached sections
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4
Q

What are the Advantages of STL?

A
  • Simple method of representing 3D CAD data
  • De facto standard
  • Small and accurate files for certain shapes
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5
Q

What are the disadvantages of STL?

A
  • Redundant information eg. Duplicate vertices & edges -> Larger file size
  • Geometry flaws generated from CAD models, needs repairing
  • Long time to slice large STL files
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6
Q

Problems in STL Files

A
  • Missing Facets / Gaps
  • Degenerate Facets
  • Overlapping Facets
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7
Q

Subtypes of binder jetting

A
  • ColorJet Printing (CJP)
  • Digital Part Materialisation (DPM)
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8
Q

Subtypes of Material Extrusion

A
  • Fused Deposition Modelling (FDM)
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9
Q

Subtypes of Material Jetting

A
  • Polyjet
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10
Q

Subtypes of PBF (Powder Bed Fusion)

A
  • Selective Laser Sintering (SLS)
  • Selective Laser Melting (SLM)
  • Electron Beam Melting (EBM)
  • Multi Jet Fusion
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11
Q

Vat Photopolymerisation Subtypes

A
  • Stereolithography (SLA)
  • Digital Light Processing (DLP)
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12
Q

Subtypes of DED (Directed Energy Deposition)

A
  • Electron Beam Direct Manufacturing (EBDM)
  • Laser Metal Deposition (LMD)
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13
Q

Sheet Lamination Subtypes

A
  • Laminated Object Manufacturing (LOM)
  • Selective Deposition Lamination (SDL)
  • Ultrasonic Additive Manufacturing (UAM)
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14
Q

Sources of energy in DED (Directed Energy Deposition)

A
  • Laser
  • Friction stir
  • Electron beam
  • Arc
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15
Q

Binding mechanisms in PBF (Powder bed fusion)

A
  • Solid state sintering
  • Chemically induced binding
  • Liquid phase sintering (Partial melting)
  • Full melting
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16
Q

Advantages of binder jetting

A
  • Wide range of materials (polymers, metals, ceramics (sand))
  • Faster (Main bulk of material that’s actually deposited is via powder spreader, small portion through print heads)
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17
Q

Disadvantages of binder jetting

A
  • Poor accuracy and surface finish
  • Post-processing (Infiltration / furnace / sintering) needed for high density / good mechanical properties (Binders need to be removed)
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18
Q

Advantages of CJP (Colour Jet Printing)

A
  • High speed
  • Versatile
  • Simple to operate
  • Minimal material wastage
  • Complex colours
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19
Q

Disadvantages of CJP (ColorJet Printing)

A
  • Limited functional parts (Relative to SLS)
  • Poor surface finish
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20
Q

Advantages of DPM (Digital Part Materialisation)

A
  • Fast (85000 cm^3 / hr)
  • Flexible
  • Reliable
  • Large Parts (1800 x 1000 x 700 mm)
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21
Q

Disadvantages of DPM
(Digital Part Materialisation)

A
  • Large space
  • Limited materials (Metal / sand)
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22
Q

Advantages of DED
(Directed Energy Deposition)

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A
  • Can produce fully dense parts
  • can repair defective / damaged components
23
Q

Disadvantages of DED
(Directed Energy Deposition)

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A
  • Poor resolution + surface finish
  • Low complexity only
24
Q

Advantages of EBDM
(Electron Beam Direct Manufacturing)

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A
  • Fast and cost effective for large metal parts
  • Multi-material printing
  • High deposition rate (relative to other DEDs)
  • Near 100% usage efficiency -> Less material waste (Compared to powder bed fusion)
  • Wire feedstock less flammable, cheaper than powder feedstock
25
Disadvantages of EBDM (Electron Beam Direct Manufacturing)
- Poor resolution (No fine details) - No supports (No complex internal geometries) - Only weldable metals that aren't highly flammable
26
Advantages of LMD (Laser Metal Deposition)
- Superior material properties (Fully dense) - Complex parts (Worse than powder bed fusion, better than EDM) - Add material on to existing parts (Use for repairs / hybrid manufacturing) - Multiple materials can be blended - Low powder cost (Wide powder size range - 150-200mm usually)
27
Disadvantages of LMD (Laser Metal Deposition)
- Geometric complexity (Worse than powder bed fusion) - surface finish (Rougher than powder bed fusion) - Dimensional accuracy (Worse than powder bed fusion)
28
Advantages of FDM (Fused Deposition Modelling)
- Can fabricate functional parts - Minimal wastage - Ease of support removal - Ease of material change - Large build volume (eg. 900 x 900 mm)
29
Drawbacks of FDM (Fused Deposition Modelling)
- Limited accuracy (By filament, between 0.2-0.5mm) - Slow process (Restricted by extrusion rate / flow rate) - Unpredictable shrinkage (Due to rapid cooling, needs compensation)
30
Advantages of Polyjet
- High quality - High accuracy - Fast process speed - Smooth surface finish - Wide range of materials (Acrylic, plastic, rubber etc) - Easy usage (Cartridges) - SHR (Single head replacement) - Replace nozzles instead of whole unit - Safe, clean, Low noise - Multiple materials in 1 run (Also multiple colours)
31
Disadvantages of Polyjet
- Post-processing required to wash away support material - Wastage of support material
32
Advantages of PBF (Powder bed fusion)
- Wide range of materials (Polymers, metals, ceramics) - Fast
33
Disadvantages of PBF (Powder bed fusion)
- Support structures needed for metals - Expensive and time consuming post processing (for metals) - Lower resolution and accuracy (Compared to liquid processes for polymers)
34
Advantages of SLS (Selective Laser Sintering)
- Good part stability (Precise controlled environment) - Wide range of processing materials (Any material in powder form) - No parts supports required - Little postprocessing required - No post-curing required
35
Disadvantages of SLS (Selective Laser Sintering)
- Large physical size - High power consumption (High laser wattage) - Poor surface finish (Large particle size of powders)
36
Advantages of SLM (Selective Laser Melting)
- High quality metal parts (100% density) - Large range of metal materials (Stainless steel, titanium, aluminium, etc) - Fast and low cost - High accuracy - Complex geometries
37
Disadvantages of SLM (Selective Laser Melting)
- Large physical size - High power consumption - Slow process (Compared to machining)
38
EBM Advantages (Electron Beam Melting)
- Superior material properties (Fully dense parts) - Excellent accuracy (Less shrinkage, no impurities from oxides) - Excellent finishing - Good build speed
39
EBM Disadvantages (Electron Beam Melting)
- Need to maintan vacuum chamber - High power consumption - Gamma rays
40
Multi Jet Fusion Advantages
- Fast (Faster than FDM and SLS) - Low cost per part (Cheaper than FDM and SLS) - High quality functional parts - High accuracy and fine details - Add additional parts whilst printing
41
Multi Jet Fusion Disadvantages
- Only STL files can be used - Post-processing required to clean and cool part - Only thermoplastics and elastomers can be used
42
Vat Photopolymerisation Advantages
- High accuracy, resolution, good surface finish - Compatible with different sizes and machine configs
43
Vat Photopolymerisation Disadvantages
- Only photopolymers - Lower impact strength and durability compared to injection moulding - Material ages and mechanical properties degrade over time
43
SLA Advantages (Stereolithography)
- Unattended round the clock operation - Various build volumes - High accuracy - Good surface finish - Wide range of materials
44
SLA Disadvantages (Stereolithography)
- Support structures required - Post-processing required for support removal - Post-curing required to ensure structure integrity
45
DLP Advantages (Digital Light Processing)
- High building speed (Faster than SLA) - Office friendly process - Small quantity of resin during build - No wiper / leveler (No stability issues to part) - Less shrinkage (immediate curing) - Safe supply cartridges (Lower risk of user coming into contact) - Additional components (Integrated into system to allow for higher quality tougher parts)
46
DLP Disadvantages (Digital Light Processing)
- Limited build volumes (Structures build from bottom) - Peeling of completed part (May damage model during peeling process) - Post-Processing (And maybe post curing) required
47
Sheet Lamination Advantages
- High speed - Low cost
48
Sheet Lamination Disadvantages
- Strength depends on bonding strength - Highly anisotropic (Non-uniform), may delaminate due to weak interlayer bonding - Material wastage
49
SDL Advantages (Selective Deposition Lamination)
- Low cost (Its literally paper) - High precision (0.012mm precision, 0.1mm accuracy) - Safe (Its literally paper) - Eco-friendly (Its literally paper) - High resolution in colour printing (More than 1 million colours, 5760 × 1440 × 508 dpi)
50
SDL Disadvantages (Selective Deposition Lamination)
- Low strength (Its literally paper) - Small build volume (Only A4 / letter size area because its literally paper)
51
UAM Advantages
- No concerns on shrinkage, residual stress or distortion (Low temp operation) - Can process multiple materials which are dissimilar
52
UAM Disadvantages
- Low interfacial bonding and bonding strength - Fixed layer thickness

ME2162 (6 decks)

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