Additive Manufacturing

Question 1

What is Additive Manufacturing?

Answer 1

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.

Question 2

What are the various technologies under Additive Manufacturing?

Answer 2

Vat Photopolymerization, Material Extrusion, Materials Jetting, Binder Jetting, Powder Bed Fusion,
Direct Energy Deposition

Question 3

Stereo lithography is:

Answer 3

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

Question 4

What are the advantages of Stereo Lithography?

Answer 4

Advantages: wide range of material; good accuracy, surface finish; possible build larger parts.

Question 5

What are the disadvantages of Stereo Lithography?

Answer 5

Disadvantages: Only photopolymers; mechanical properties are not stable; materials are
expensive; build process is slow.

Question 6

Laser Sintering is:

Answer 6

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.

Question 7

What are the advantages of Laser Sintering?

Answer 7

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.

Question 8

What are the disadvantages of Laser Sintering?

Answer 8

Disadvantages: technology is slow and expensive, tolerances and finish limited.

Question 9

Material Jetting is:

Answer 9

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.

Question 10

What are the advantages of Material Jetting?

Answer 10

Good accuracy and surface finish; multiples materials in a single build, Digital
materials for customized properties; intricate and accurate parts.

Question 11

What are the disadvantages of Material Jetting?

Answer 11

Fragile parts; Slow build process

Question 12

Materials Extrusion (Fused Deposition Modeling) is:

Answer 12

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.

Question 13

What are the advantages of Material Extrusion?

Answer 13

Good mechanical properties and durable; can build fully functional parts in standard
plastics; parts can be post-processed

Question 14

What are the disadvantages of Material Extrusion?

Answer 14

Anisotropic properties in z direction (layered); high surface roughness; Ultrafine
details cannot be realized.

Question 15

AM Prototyping allows for:

Answer 15

Surrogate parts used in form and fit application; application testing (Wind
Tunnel, Bumper and Fascia, Plant Model Change)

Question 16

Benefits of Additive Manufacturing used as tooling include:

Answer 16

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.

Question 17

FDM Composite Tooling is:

Answer 17

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

Question 18

What are several key considerations when determining if FDM is right for tooling?

Answer 18

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).

Question 19

In creating a part, what are issues you must account for in the design of the tooling?

Answer 19

Coefficient of Thermal Expansion, tolerances, build orientation impacts, build style impacts, and design
tailored for additive manufacturing.

Question 20

What are some characteristics of an FDM printed part straight out of the printer?

Answer 20

Inherently porous structure, Perceptible build layers, Surface out of printer is unacceptable for
composite tooling.