Lecture 1 Part 1 Flashcards
What are the module 5 learning outcomes ?
- Understand the general principles of AM.
- Differentiate between the major AM
processes & identify the main factors which must be considered when selecting an AM process for a specific application - Appreciate the importance of a broader analysis of suitability for specific applications
- Understand the implications of these technologies in an industrial context
- Demonstrate an understanding of the major research challenges
still to be overcome
History & Context
Still a relatively new technology - approximately how old is it ?
It still needs lots of improvement
~ 25 years old
what are the two main markets for AM systems ?
Industrial systems (commercial)
&
Personal systems (desktop)
Additive Manufacturing is AKA 6 other names, what are these ?
- 3D Printing
- Layer Manufacturing
- Freeform Fabrication
- Solid Freeform Fabrication
- Tool-less Manufacture
- Digital Manufacturing
What is the American society for testing materials (ASTM International) definition of AM ?
A process of jooining material using 3D model data , usually layer upon layer, as opposed to subtractive manufcaturing technologies.
What are Marshal Burns’ 3 manufacturing processes?
Subtractive - Material removed from a solid block until the desired shape is reached (e.g machining)
Additive - Material manipulated so that successive pieces of it combine to make the desired object
Formative - Mechanical forces applied to a material to form it into the desired shape (includes bending and moulding)
Fill in the missing words
AM is an ……….. process, whereby parts are
built, …… by …….., directly from a …. …….
Eliminates requirement for ……..
Range of different processing ………. &………. etc.
- Additive
- layer by layer
- CAD file
- Tooling
- Methods & Materials
Generic AM process chain 1
What are the 3 steps of file preparation ?
- Create 3D CAD model
- Generate .stl file
- Check and repair the .stl file
Generic AM process chain 2
What are the 3 steps to build Set-up ?
- Orientate parts
- Generate supports*
- Slice the parts horizontally*
*Process specific
Generic AM process chain 3
What are the 3 steps to the physical side of this process ?
- Build the part layer by layer*
- Remove the support structures*
- Post-processing*
*Process specific
What file type do most AM machines build from ?
What does this file do ?
How is accuracy lost ?
What can’t you do with these files?
- .stl files
- These files approximate the surface of the CAD model into a series of tessellated triangles
- accuracy is lost during triangulation - depends on the resolution of your triangulation
- Very difficult to edit these .stl files once made ‘ dumb data’
Support Structures
What are these and what are they used for ?
(Fill in the missing words)
powder-polyer systems are …. - ……….
other processes are ….- ………. up to a certain …..
There are also water-……. supports
These are temporary thin lattices made of the or weaker material to suporrt overhanging geometries
self-supporting
self-supporting
angle
soluable
Post-processing
The often ‘overlooked’ side of AM
what are 6 post processing procedures ?
- post curing
- infiltration
- support removal
- bead blasting
- machining
- polishing
What is the classification of an AM system based on ?
there are 5 points
- materials
- processing method (e.g laser based , photo-cure,jetting etc.)
- Speed
- Size
- Cost
It isn’t always appropriate to use AM. Not all processes are suitable for all applications.
Choice of AM is affected by …. (7 factors)
what are these ?
- Accuracy required
- Mechanical properties
- Application
- Surface finish
- Number of parts required
- Component size and complexity
- Cost
