Manufacturing Techniques Flashcards
What is the feedstock of material extrusion?
Plastic filament
What is the material extrusion process (hint: 4 main steps)
- filament is heated and forced through fine nozzle
- plastic pattern build on platform and solidifies
- build platform moves down
- additional layers deposited on top
three pros for material extrusion
relatively cheap
common materials
widely used
three design considerations of material extrusion
- resolution of product vs printer abilities
- orientation
- support structures and pos-processing
What is kerf when referring to laser cutting?
excess material that is removed after cutting
What will the amount of kerf depend on?
laser spot size, focal length of the laser, workpiece thickness and material properties
two design considerations of laser cutting:
- only 2D cutting
- internal holes will be slightly bigger, external perimeter slightly smaller due to KERF
What is feedstock for material jetting? and what is another name for this process?
Ink as a solution, suspension or melt
Inkjet printing
how does material jetting work (4 main steps)
Drops of ink deposited on build platform in pattern
ink solidifies from liquid state
build platform moves down
additional layers are deposited on top
pros and cons of material jetting (two pros, one con)
Pros:
- capable of fine detail
- many different colours
Cons:
- Limited material properties
What is the feedstock for binder jetting?
Polymers, ceramics
How does binder jetting work? (3 main steps)
A layer of powder is coated on build platform
A binder liquid is deposited to bond the powder together
Build platform moves down to be recoated
Pros and cons of binder jetting (2 pros, 1 con)
Pros:
- no support material needed
- Can be further processed to improve properties (firing)
con:
Part properties are limit by binder
feedstock of powder bed fusion
polymers, metals
Powder bed fusion process (3 main steps)
- Layer of powder is coated on build platform
- a focus energy source (laser) is scanned over powder surface to heat and fuse powder together
- build platform moves down and is recoated
pros and cons of powder bed fusion (2 pros, 1 con)
Pros:
- no support material required
- produces high quality parts
Con:
- requires high energy beam (higher safety risk, higher cost)
Feedstock of vat polymerisation
liquid UV resin
Vat polymerisation process (2 two mins steps)
Resin selectively exposed to UV light
surface recoated in resin but dipping or raising platform
cycle repeats
one pro and one con to do with vat polymerisation
pro:
very fine resolution
con: must be UV resin
Feedstock of laminated object manufacturing
paper, metal foil, wood
Process of laminated object manufacturing (3 main steps
sheet is stuck to build platform
sheet layer is cut to desired pattern by blade or laser
build platform moves down
repeats
pros and cons of laminated object manufacturing
materials are cheap, but limited
no internal holes or overhangs
moulding vs subtractive manufacturing vs additive manufacturing
moulding vs subtractive manufacturing vs additive manufacturing
costing in subtractive manufacturing vs additive manufacturing (hint: when applying the equation for const analysis, which factors are increased/decreased depending on these manufacturing methods - energy, data, materials)
Subtractive manufacturing:
- energy and data increased the more complex the part
Additive manufacturing:
- each cost if fixed, but materials tend to be more costly overall
costing in additive manufacturing vs moulding (hint: when applying the equation for const analysis, which factors are increased/decreased depending on these manufacturing methods - energy, data, materials)
Moulding:
- Processes are cheaper but cost of mould often expensive
Additive manufacturing:
- no cost of mould but other costs great per part
