Lecture 4 part 2

Question 1

What did everybody had? #leastgramaticallycorrectcardaward2013

Answer 1

Matching towels

Question 2

What should be considered when designing in support structures?

Answer 2

Process type
Manual or automatic generation
Placement and Removal (could be Water/chemical soluble)

Question 3

Support structures should be ____-__________ and _________ through design and ____________ .

For a complex shape, a _______ angle is better than a ______ angle.

Answer 3

self supporting
minimsed
orientation

smaller
larger

Question 4

Support structures can be used to bridge gaps. What are 3 elementary rules when doing this?

Answer 4

No curves.
Same layer (exactly horizontal)
gaps no larger than 39.999…mm or else sagging can occur

Question 5

Name 2 methods for aiding powder removal

Answer 5

Question 6

4 main elements in process selection?

Answer 6

Build materials (functional/aesthenic/engineering grade)

Build volume (can split up large parts and glue)

Resolution and Accuracy (layer height, feature size)

Costs

Question 7

WHAT DOES STL STAND FOR? AND WHAT EXACTLY IS ITS PURPOSE?

Answer 7

Standard Triangulation Language
Slice files are generated from STL data, which are then directly built, forming the port.

Question 8

STL files are built within what 3 major parameters?

(odds are 3 to one its a re_olution)

Answer 8

Cord deviation
Angle tolerance
Resolution (trade off between fidelity and file size)

Question 9

What does build orientation depend on?

Answer 9

Speed (minimise z-axis height)
 Surface finish (visualise with stepping)
 Mechanical properties (weakest in z-akis)

Question 10

What is key when you are going through your ‘build file’ setup?

Answer 10

Seperation of parts

Question 11

Temperature and Feed rate are common machine parameters across all manufacturing processes. Give a couple of examples of AM specific parameters.

Answer 11

Laser power/scan strategy
 Layer height (resolution)

Question 12

What are 4 common post processing jobs

Answer 12

Part removal
 clean up (support structure / powder removal (LS))
 Surface finish (rub/chemical/vapour)
 colour (dye (LS)/ prime and paint)

Question 13

There are 5 types of core RP/AM system. Which _ are more suitable for prototyping? IN COST ORDER (high to low)

Answer 13

Jetting based / Powder based / Polymerisation based / Extrusion based

Question 14

EXAMPLE! powder based. go:

(design strengths) _________ parts and ___________ complexity
(major consideration) ______ removal

(LS!) for _______/_____ (material)

Answer 14

Question 15

EXTRUSION!
(FDM)
material?
design strengths?
major considerations?

Answer 15

Question 16

JETTING!
(CONNEX)
material?
design strengths?
major considerations?

Answer 16

Question 17

PLOYMERISATION.
(SL)
material?
design strengths?
major considerations?

Answer 17