Additive Manufacturing Flashcards
What is Additive Manufacturing?
A process for making 3D products by primarily adding material rather than removing it.
which layers of material are successively built up under computer control to create an object.
What are the various technologies under Additive Manufacturing?
Vat Photopolymerization, Material Extrusion, Materials Jetting, Binder Jetting, Powder Bed Fusion,
Direct Energy Deposition
Stereo lithography is:
a form of 3-D printing technology used for creating models, prototypes, patterns,
and production parts in a layer by layer fashion using photopolymerization, a process by which light
causes chains of molecules to link, forming polymers
What are the advantages of Stereo Lithography?
Advantages: wide range of material; good accuracy, surface finish; possible build larger parts.
What are the disadvantages of Stereo Lithography?
Disadvantages: Only photopolymers; mechanical properties are not stable; materials are
expensive; build process is slow.
Laser Sintering is:
a form of 3-D printing technology that uses a focused laser to sinter powdered
material (typically metal), at points in space defined by a 3D model, binding the material together to
create a solid structure.
What are the advantages of Laser Sintering?
Advantages: Manufacture parts in standard metals high density; a wide set of materials is
available; parts can be further processed; flame retardants and chemical resistant.
What are the disadvantages of Laser Sintering?
Disadvantages: technology is slow and expensive, tolerances and finish limited.
Material Jetting is:
a form of 3-D printing technology that jet drops of liquid photopolymer
onto the build tray, similar to an inkjet document printing, Multiple print heads jet material
simultaneously to create each layer, and UV light is then used to cure the layers. These layers build up
one at a time in an additive process to create a 3D model.
What are the advantages of Material Jetting?
Good accuracy and surface finish; multiples materials in a single build, Digital
materials for customized properties; intricate and accurate parts.
What are the disadvantages of Material Jetting?
Fragile parts; Slow build process
Materials Extrusion (Fused Deposition Modeling) is:
a form of 3-D printing technology that lays down
material in layers; usually a plastic filament or metal wire that is unwound from a coil and supplies
material to produce a part via a heated head unit.
What are the advantages of Material Extrusion?
Good mechanical properties and durable; can build fully functional parts in standard
plastics; parts can be post-processed
What are the disadvantages of Material Extrusion?
Anisotropic properties in z direction (layered); high surface roughness; Ultrafine
details cannot be realized.
AM Prototyping allows for:
Surrogate parts used in form and fit application; application testing (Wind
Tunnel, Bumper and Fascia, Plant Model Change)
Benefits of Additive Manufacturing used as tooling include:
Disruptive time and cost savings, reduced
lead times – enabling iteration, changes, and optimization in design; respond quickly to demand
fluctuations; tailoring of tooling to application; Higher temperature capable materials; lighter weight
designs.
FDM Composite Tooling is:
capable of providing cost effective lay-up tooling in days, not months,
dramatically reduce or eliminate the need for CNC machining. High temp, autoclave-cure compatible –
>350°F, 100 psig; Robust, cost-effective sacrificial tooling for complex geometries, eliminating the
complexity of traditional trapped tooling methods.
Machining, inspection & bonding fixtures, drill guides, masters, and more can be made
What are several key considerations when determining if FDM is right for tooling?
Cure temperature (and pressure), Coefficient of thermal expansion, Accuracy / tolerances, design features, build orientation / design for additive manufacturing (AM), Vacuum bagging, structural integrity, Surface preparation (tool sealing).
In creating a part, what are issues you must account for in the design of the tooling?
Coefficient of Thermal Expansion, tolerances, build orientation impacts, build style impacts, and design
tailored for additive manufacturing.
What are some characteristics of an FDM printed part straight out of the printer?
Inherently porous structure, Perceptible build layers, Surface out of printer is unacceptable for
composite tooling.
