Lecture 2

Question 1

The 3 manufacturing shaping principles

Answer 1

Subtraction-Machining/turning-V1>V2

Constant volume- Moulding-Stamping, Forging V1=V2

Additive-Material Extrusion,Material Jetting - V1

Question 2

AM opportunities

Answer 2

Shape complexity
Material complexity
No tooling

Question 3

Design opportunities with AM

Answer 3

Personalise
Weight reduction via odd geometries using FEA

Part consolidation- Turbocharger takes 23 parts and time to put together OR AM used 3 parts

Constant design development

Question 4

Functional complexity/Part consolidation

Pros

Answer 4

-Single component
Reduce weight
Improved performance
Eg fluids less leaks as one part. 
More reliable and robust design

Question 5

Functional complexity/Part consolidation

cons

Answer 5

Build time
Surface finish associated with AM
If it brakes its trashed

Question 6

Drawbacks of Support structure

Answer 6

-increase material use
-Increase build time
-Increase energy use
-Increase post processing time
-increase waste
– Reduce the surface quality of the part

Question 7

What requires supports

Answer 7

Overhangs

Metal parts to avoid distortion

Question 8

How to avoid overhangs

Answer 8

part segmentation
Fill overhangs
Change build orientation
Self supporting
Integrate Support

Question 9

Design sls

Answer 9

Gap of .2mm

Can be used for door hinges