1. Introduction to additive processes

Question 1

Def.: Production process

Answer 1

process to transform raw material into a complex part with tools (and energy)

Question 2

Def.: subtractive production process

Answer 2

part is manufactured by material removal

Exp.: milling, electrical discharge machining, electrochemical machining

Question 3

Def.: replicative production process

Answer 3

part is manufactured by material addition/deformation in/on a shape tool

Exp.: plastic injection, sand casting, deep drawing, classical sintering

Question 4

Classification based on nature of base material

Answer 4

photo resist
extruded solid
powder deposited in a thin bed
powder delivered by a nozzle

Question 5

Different consolidation processes

Answer 5

chemical reactions (cross-linking of PR)
liquid phase bonding (FDM)
indirect bonding/brazing for powders

Question 6

What have SLA, Polyjet, SGC, Envisionec, BIS in common?

Answer 6

Base material liquid
Consolidation principal UV-curing
Material is a thermoset

Question 7

What have FDM, LMWD, BPM in common?

Answer 7

base material extruded solid, amorphous thermoplastic, metal wire, wax binds by liquid phase bonding

Question 8

What have 3dP SLS, SLM in common?

Answer 8

liquid phase bonding of metals, ceramics in a powder bed

Question 9

Advantages of AM

Answer 9

directly from CAD to part
geometrical complexity for free
integrated functions
faster, less waste

Question 10

Disadvantages of AM

Answer 10

material choice limited, difficult to control processes, poor density/resistance
expensive equipment, slow for large series

Question 11

Classes of Prototypes

Answer 11

models or dimensional proto
conceptual proto
functional proto

Question 12

models/ dimensional prototypes

Answer 12

Identify design flaws,

obstruction, disassembly, packaging

Question 13

conceptual proto

Answer 13

Assess the business impact of the design

Question 14

Functional proto

Answer 14

Perform functional tests

Question 15

Expendable shape tool

Answer 15

tool for a replicative process which has to be destroyed to recover the part
(Sand casting, Galvanic holding)

Question 16

(master) model

Answer 16

positive of the final part, negative of the needed mild, can be lost pattern or master model

Question 17

Polymer material

Answer 17

chain molecules with double bonds between carbons

thermosets and elastomers

Question 18

Photopolymer

Answer 18

Curable by light

Question 19

Example: thermosets

Answer 19

Polyester, epoxy

Question 20

Example: Elastomer

Answer 20

rubber, polyurethane

Question 21

Example thermoplastics

Answer 21

polycarbonate, polystyrene

Question 22

Galvanic molding

Answer 22

Manu of parts by electroplating of counter-parts