V - Plastics to 3D Printing

Question 1

Material which is solid at room temperature, but as temperature rises, it becomes a viscous liquid. Generally EXTRUDED

Answer 1

THERMOPLASTICS

Question 2

Extrusion machine which operates at lower temperature and pressure, which includes a die to shape the plastic pellets which have been melted.

Answer 2

PLASTICS SCREW EXTRUDER/ PLASTIC EXTRUDING MACHINE

Question 3

The plastics equivalent of metal “Die Casting”. A charge of material is forced into a die cavity.

Answer 3

INJECTION MOLDING

Question 4

INJECTION MOLDING can also be used for _____________.
Ex. Placing one type of plastic over another or molding a plastic handle on a metal screwdriver shaft.

Answer 4

OVERMOLDING

Question 5

Molding technique where metal parts are imbedded in the plastic mold

Answer 5

INSERT MOLDING

Question 6

Manufacturing process for forming hollow plastic parts. It is also used for forming glass bottles or other hollow shapes.

Answer 6

BLOW MOLDING

Question 7

Technique used to make beverage bottles. A “gob” of input charged is blown with hot air into a injection molded precursor called a ______. The _____ is projected down into a split mold cavity.

Answer 7

BLOW MOLDING
PARISON

Question 8

Technique used to make trash bags. Pellets form a hopper are fed to a heat screw conveyer that squirts the plastic vertically out of an annular nozzle. “— —–” gather the cooled plastic film together.

Answer 8

BLOW MOLDING- “Nip Rolls”

Question 9

Plastics equivalent of “Centrifugal Casting” Only spun around 2 axis.

Answer 9

ROTATIONAL MOLDING

Question 10

Steps of ROTATIONAL MOLDING

Answer 10

charging
heating
cooling
demolding

Question 11

Machine in which ROTATIONAL MOLDING is performed. Biaxially spinning machine.

Answer 11

ROTOMOLDING MACHINE

Question 12

What products are made in a ROTOMOLDING MACHINE?

Answer 12

Plastic Trash Cans
Plastic Tanks
Plastic Containers

Question 13

Technique where there isn’t a metalworking equivalent. Used to form a plastic sheet into a 3D shape with one open side.

Answer 13

THERMOFORMING (food tray, jet fighter canopies)

Question 14

Type of THERMOFORMING which involves a vacuum to pull down the sheet of plastic onto the mold

Answer 14

Vacuum Forming

Question 15

Type of THERMOFORMING which involves air pressure to push down the sheet of plastic onto the mold

Answer 15

Pressure Forming

Question 16

What technique is used to create THERMOFORMING MOLDS

Answer 16

Powder Metallurgy (PM)

Question 17

A plastic manufacturing process that has a glass making equivalent, it is the same as “Pressing”, and similar to “Cold Extrusion” of metals.

Answer 17

COMPRESSION MOLDING

Question 18

Similar to metal casting, however, no heat is utilized. Can also be used for “Encapsulation”

Answer 18

PLASTIC CASTING

Question 19

Which type of plastic is usually utilized in PLASTIC CASTING

Answer 19

EPOXY URETHANE

Question 20

Plastic process that resembles some aspects of metal rolling and other aspects of glass sheet manufacturing. The
process is different from the one used in the textiles and paper industries, and is employed in the mass production of
plastic sheet or film

Answer 20

CALENDERING

Question 21

What are the products of CALENDERING?

Answer 21

Plastic sheet or film
Embossed sheet
Laminated sheet

Question 22

Natural formation found inside bee hives and are used by
the colony to hatch eggs and store food (honey)
This shape is made up of interlocking hexagonal cells which results in a very efficient use of space.

Answer 22

HONEYCOMBS

Question 23

Examples of materials in the man-made HONEYCOMB structures:

Answer 23

paper
cardboard
plastic foil
metal foil

Question 24

HONEYCOMBS are combined with rigid cover sheets. They are LIGHT and STIFF and used within aerospace/ commercial aviation (flooring).

Answer 24

STRUCTURAL HONEYCOMBS

Question 25

GRP

Answer 25

Glass Reinforced Plastic

Question 26

CFRP (used for military aircraft flooring)

Answer 26

Carbon Fiber Reinforced Plastic

Question 27

General term for a number of individual additive manufacturing methods.

Answer 27

3D PRINTING

Question 28

Categories of 3D PRINTING:

Answer 28

1. Material Extrusion – FDM, FFF 2. Vat Polymerization – SLA, DLP, MSLA (or LCD) 3. Powder Bed Fusion (Polymers) – SLS 4. Material Jetting – MJ, DOD 5. Binder Jetting – BJ 6. Powder Bed Fusion (Metals) –DMLS, SLM, EBM

Question 29

3D Printing competitor technique. Beginning to emerge as a faster option, although not quite ready for “prime time” just yet

Answer 29

VOLUMETRIC PRINTING

Question 30

1. MATERIAL EXTRUSION- typically used 3D Modeling technique, commercially available and the cheapest. Most common material is PLA, poor surface finish.

Answer 30

FDM- Fused Deposition Modeling FFF- Fused Filament Fabrication

Question 31

2. VAT POLYMERIZATION-The method essentially uses a laser to photo-polymerize a special light sensitive liquid polymer. Brittle plastic and translucent, smooth finish.

Answer 31

SLA- Stereo Lithography (first type of 3D printing method invented) DLP- Digital Light Processing LCD- Liquid Crystal Display

Question 32

SLA technique where a projector casts a light over the entire layer to cure it all at once

Answer 32

DLP- Digital Light Processing

Question 33

SLA technique where a screen masks a projector's light or uses its own light to cure a layer

Answer 33

LCD- Liquid Crystal Display

Question 34

3. POWDER BED FUSION (Polymers)- Can use multiple plastics, commonly Nylon. Different colors can be used.

Answer 34

SLS (Selective Laser Sintering) The polymer used is normally NYLON 6, NYLON 11, or NYLON 1

Question 35

method where a laser selectively switches on and off as it is scanned across a layer of material. The material is a very fine powder.

Answer 35

SLS (Selective Laser Sintering)

Question 36

4. MATERIAL JETTING- The parts are used for investment casting patterns.

Answer 36

works in a very similar way to an inkjet printer, except that droplets of photopolymer are deposited rather than ink.

Question 37

DOD

Answer 37

Drop On Demand

Question 38

Hybrid between SLS and BJ. A bed of powder is used for the part body, but the particles are locally bound together not by laser fusion, but instead by a print head depositing droplets of a liquid binder (adhesive).

Answer 38

BINDER JETTING (can also be used for building of molds and cores for metals casting by using sand instead of metal)

Question 39

Last step of BINDER JETTING

Answer 39

SINTERING OVEN

Question 40

6. POWDER BED FUSION (Metals)

Answer 40

DMLS (Direct Metal Laser Sintering) SLM (Selective Laser Melting) (Currently very expensive)

Question 41

Basically the same as SLS except that the build powder is of metal, and the laser is powerful enough to melt the metal.

Answer 41

DMLS, SLM

Question 42

Where an electron beam is used instead of the laser the process is called ------------------- which is a faster process due to superior energy density of the beam, but the need for a vacuum limits the size of parts that can be made.

Answer 42

EBM (Electron Beam Melting)