Additive Manufacturing Flashcards
Name 4 Benefits of 3d Printing to other Manufacturing Processes
More Complex Geometries
Rapid Prototyping
Print on Demand
Minimises Waste
Explain what a .stl File does?
Explain what a .sli file does?
Software Generates a Tesselated Object Description
File Consists of XYZ coords of each triangle/patern of the Tesselated object
Produces a series of 2d cross sections of a .sti file.
What are the 7 Major Sectors of 3D Printing
Material Extrusion
Vat Polymerisation
Powder Bed Fusion
Material Jetting
Binder Jetting
Directed Energy Deposition
Sheet Lamination
Describe Material Extrusion.
What Materials can be Used
What its Dimensional Accuracy
Fused Deposition Modelling (FDM)
Material is extruded through a nozzle
Plastics,Metals, Foods, Concrete
+- 0.5% (Lower limit +- 0.5mm)
Name the Strengths and Weaknesses with Material Extrusion
Lowest cost 3d printing method
Can create parts with multiple materials.
Lower Strength
Lower Durability
Low Dimensional Accuracy
Describe Vat Polymerisation.
What Materials can be Used
What its Dimensional Accuracy
Streolithography
Liquid photopolymer is selectively cured by light-activated polymerization
Photopolmer Resins
+-0.5% (lower limit +-0.15mm)
What are the Design Considerations with Vat Polymerisation
Orientation & Placement of support Structures
Poor Surface Quality (Rough)
Trapped Liquid
Bubble Formation
Limit on Feature Size
Describe Powder Bed AM .
What Materials can be Used
What its Dimensional Accuracy
SLS & SLM (Selective Laser Sintering and Melting)
Create Solid products using Laser & Material Powders.
Plastic, Metallic and Ceramic Powders
+-0.3% (Lower limit +-0.3mm)
Explain the Difference Between Electron beam Melting and Selective Laser Melting
Which is Faster at Part Production?
SLM
Contains High Energy Laser
Laser is directed by a Mirror
EBM
Contains High Energy Electron Beam
Beam Directed by Magnetic Field
EBM , Electron beams can change direction faster
Name the Strengths and Weaknesses with Powder Bed AM
Higher Strength
Higher Durability
Complex Geometries
Wider Range of Materials
High Machine Cost
Low Build Rate
Post Processing Required
Varing Mechanical properties in different directions (Anisotropic)
Trapped Powder
Residual Stresses and Porosity
Requires Support Strucuture
Describe Material jetting .
What Materials can be Used
What its Dimensional Accuracy
Droplets of material, selectively applied inkjet print heads. Then Cured and Solidified with UV Light
Photopolymer Resin
+-0.1mm
Name the Strengths and Weaknesses with Material Jetting
Can Create Parts with Multi-Materials
Frabrication of parts with varing Light Absorption Levels
Not Suitible for Mechanical Parts
Expensive System.
what process is this
what process is this?
FDM
Fused deposition modelling
What process is this?
Powder bed fusion
What process is this
DED
Metallic object
Doesn’t require as much infrastructure as powder bed fusion
Material Jetting
Sheet Lamination
SLS
Powder Bed Fusion
Directed Energy Deposition
Made from Ceramic
Powder Bed Fusion
Describe Binder jetting .
What Materials can be Used
What its Dimensional Accuracy
Liquid Bonding Agent Selectively deposited onto powder materials which fuses the particles
Sand, Polymers, Metal , Cermaics
+-0.2mm (Metal), +-0.3mm (Sand)
Name the Strengths and Weaknesses of Binder Jetting
High Print Speed
Low Cost
Large Build Volumes
Support free Design
Colour Reproduction
Limited Materials Can be Used
Non Durable Polymer Parts
Multi Step Process for Metals
Trapped Powder causing Defects
Describe Directed Energy Deposition .
What Materials can be Used
What its Dimensional Accuracy
Focused Thermal energy fuses feedstock material by melting, as its being deposited
Metals or ceramics in wire or powder form
+-0.1mm
Name the Strengths and Weaknesses of Directed Energy Deposition
Excellent Physical Properties (Very Dense)
Wide Range of Processing Materials
Can produce produce products with varying microstructures
Can Produce Products with Embedded Sensors
Cannot complex shapes that require supoorts
Poor Surface finish
Difficult to Control
Describe Sheet Lamination .
What Materials can be Used
What its Dimensional Accuracy
Sheets of material are bonded together to form a larger part.
In a Adhesive or Welding Process
Paper, Polymers, Metals in Sheet Form
+-0.1mm
Name the Strengths and Weaknesses of Sheet Lamination
Inexpesnive Materials
Ability to Add COlour
Quick Production
Composite Materials
Restricted Functionality
Low Mechanical Strength
Expensive System in some cases
