ADDITIVE MANUFACTURING

You will get

‘‘maa’’
for Preparation

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Definition Difference between Rapid Prototyping

and Additive Manufacturing
What You See Is What You Build (WYSIWYB) Process
Additive Manufacturing (AM) refers to a process by which • AM, also known as 3D printing, rapid prototyping or free

digital 3D design data is used to build up a component in form fabrication.

layers by depositing material. • Although the terms "3D printing" and "rapid prototyping"

are casually used to discuss additive manufacturing, each

process is actually a subset of additive manufacturing.

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Additive vs Subtractive Manufacturing How does additive manufacturing works? How does additive manufacturing works?

• Additive manufacturing adds material to create an object.
• By contrast, when you create an object by traditional means,
it is often necessary to remove material through milling,
machining, carving, shaping or other means.
• AM technologies grow three-dimensional objects one
• Objects are digitally defined by computer-aided-design
superfine layer at a time.
(CAD) software that is used to create .stl files that essentially
• Each successive layer bonds to the preceding layer of
"slice" the object into ultra-thin layers.
melted or partially melted material.

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 Generic AM Process
1. CAD
How does additive manufacturing works? How does additive manufacturing works? 2. STL Convert (STereoLithography)
• Or, a laser or electron beam selectively melts or partially 3. File transfer to machine
• This information guides the path of a nozzle or print head as 4. Machine setup
melts in a bed of powdered material. As materials cool 5. Build
it precisely deposits material upon the preceding layer.
6. Remove
down or are cured, they fuse together to form a three-
7. Post Processes
dimensional object. 8. Application

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Data path for AM 3D -

MCQ
Modelling
Input of RP data is ______

Data (A) CAM data

preparation
(B) CAPP data

Manufacturing (C) CAD data

on AM
machine (D) All of the above

Note: RP is Rapid Prototyping

Post
process
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MCQ CAD Model into STL Format MCQ

Full form of STL is _____.

Choose the correct sequence

(A) 3D CAD data - CAD solid model - STL file - RP prototype (A) Straight-lithography

(B) CAD solid model - 3D CAD data - RP prototype - STL file (B) Streto-lithography

(C) STL file - 3D CAD data - CAD solid model - RP prototype (C) Stereo-lithography
• STL uses triangles to describe the surfaces to be built. Each
(D) 3D CAD data - STL file - CAD solid model - RP prototype
triangle is described as three points and a facet normal vector (D) Straight-lipsography

indicating the outward side of the triangle.

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Effects of building using different Generation of Geometrical Layer MCQ
layer thicknesses Information on Single Layers
Process of converting STL file model in to layers is called
• To produce three-dimensional models by layer-oriented
________ in RP.
additive manufacturing processes, the 3D CAD solid must
(A) Chopping
be mathematically split into the same layers as those
(B) Slicing
produced physically by the AM machine. This process is
(C) Cutting
known as "slicing."
(D) Trimming
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Generation of Geometrical Layer STL Format STL Format

Information on Single Layers
• The main purpose of the STL file format is to encode the
• STL (STereoLithography) is a file format native to the
• There are two basic methods of doing this:
surface geometry of a 3D object.
stereolithography CAD software.
• 1) Triangulation, which leads to the STL format
• It encodes this information using a simple concept called
• It is widely used for rapid prototyping, 3D printing and
• 2) Direct cutting in the CAD system, which leads to the CL
"tessellation".
computer-aided manufacturing.
(SLI) format

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Tessellation MCQ

STL file converts curved surfaces into_______.

• Tessellation is the process of tiling a surface with one or more

geometric shapes such that there are no overlaps or gaps. (A) Polygons

(B) Lines
• Tessellation can involve simple geometric shapes or very
(C) Surfaces
complicated (and imaginative) shapes.
(D) None of the above

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 ASCII STL File Format Binary STL File Format MCQ
File starts with mandatory line:

solid <name> STL file consists of which of the following format?

• If the tessellation involves many small triangles, the
File ends with mandatory line: (A) ASCII
ASCII STL file can become huge.
endsolid <name>
(B) Binary
• This is why a more compact binary version exists.
The file stores information about the covering
(C) Both A & B
triangles.
(D) Neither A nor B

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MCQ
Special rules for the STL format

STL file format is represented by interaction of ______.

• The STL specification has some special rules for

tessellation and for storing information. (A) lines and hexagons

• The vertex rule: The vertex rule states that each triangle (B) lines and rectangles

must share two vertices with its neighboring triangles. (C) lines and triangles

(D) lines and circles

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Special rules for the STL format

Special rules for the STL format Special rules for the STL format
• The orientation rule: The
orientation rule says that • The triangle sorting rule: The triangle sorting rule
• The all positive octant rule: The all positive octant rule says
the orientation of the facet
recommends that the triangles appear in ascending
(i.e. which way is "in" the that the coordinates of the triangle vertices must all be

3D object and which way is z-value order.

positive.
"out") must be specified in
two ways.

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 Disadvantages of STL File Format MCQ
Advantages of STL File Format
STL files plague several problems as they contain no
• Provides a simple method of representing 3D CAD data • The STL file is many times larger than the original CAD
_______ data.
data file
• A de facto standard has been used by most CAD systems and
• The geometric flaws exist in the STL file (A) geographical
RP systems
• The subsequent slicing of large STL files can take many (B) analytical
• It can provide small and accurate files for data transfer for hours
(C) topological
certain shapes
(D) all of the above
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Powder Materials

Powder Materials

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Liquid Materials

Liquid
Extrusion Polymerization or
Processes Stereolithographic
Laminated Process
Object
Manufacturing 43 44 45
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 MCQ
Liquid Polymerization or Additive Manufacturing Technologies
Stereo-lithographic Process • Selective laser sintering (SLS) or Direct metal laser sintering From following, the alternative name for RP is ________.
(DMLS)
(A) Additive Manufacturing
• Stereo-lithography (SLA)
(B) Layer Manufacturing
• Fused deposition modeling (FDM)
(C) Direct CAD Manufacturing
• 3D printing
(D) All of the above
• Laminated object manufacturing (LOM) etc.
e
Stereo-lithography Note: RP is Rapid Prototyping

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Direct metal laser sintering (DMLS) Selective laser sintering (SLS)

Direct metal laser sintering (DMLS)

• Nearly 0.1 mm thick layers

• A laser sinters each layer of metal powder so that the metal
particles adhere to one another. • The part building takes place inside an enclosed chamber

• DMLS machines produce high-resolution objects with filled with nitrogen gas to minimize oxidation and
desirable surface features and required mechanical
degradation of the powdered material;
properties.

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Selective laser sintering (SLS) Selective laser sintering (SLS)

• The powder in the building platform is maintained at an • A focused CO2 laser beam is moved on the bed in such a way
elevated temperature just below the melting point and/or that it thermally fuses the material to form the slice cross-
glass transition temperature of the powdered material. section.
• Infrared heaters are used to maintain an elevated • Surrounding powders remain loose and serve as support for
temperature around the part being formed. subsequent layers.

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 3D printing 3D printing

• The operation is repeated until parts are produced, which shall

• The 3D printing process is an indirect process in two steps.
be then removed carefully from the powder bed, as they are in

• After applying a powder layer on the build platform, the a « green » stage.
Powder
powder is agglomerated tanks to a binder fed through the • The metal part solidification takes place in a second step, Layers
during a debinding and sintering operation, sometimes
printer nozzle.
followed by an infiltration step.

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3D printing MCQ Stereolithography (SLA)

• Stereolithography (SLA) uses photopolymerization to print

• The 3D printing technology is more productive than laser In 4D printing, which one is the fourth dimension?

(A) Time ceramic objects. Stereolithography is also called

beam melting and requires no support structure. Besides it
(B) Material Photopolymerization.
provides a good surface quality by using one of several post
(C) Sound
processing techniques. • The process employs a UV laser selectively focused into a vat of
(D) Light
photopolymer resin.

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Stereolithography (SLA) Stereolithography (SLA)

• The UV-curable resins produce torque-resistant parts that can
withstand extreme temperatures.
• The source supplies the energy that is needed to induce a
chemical reaction (curing reaction), bonding large number of
small molecules and forming a highly cross-linked polymer
• The UV light comes from a laser, which is controlled to scan
across the surface according to the cross-section of the part
that corresponds to the layer.
• The laser penetrates into the resin for a short distance that
corresponds to the layer thickness.

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 Facts About SLA
Stereolithography (SLA) Part Build Time in SLA
• Time to complete a single layer :
• The first layer is bonded to a platform, which is placed just • Each layer is 0.076 mm to 0.50 mm thick
below the surface of the resin container.
Ai
Ti = + Td
• Starting materials are liquid monomers vD
• The platform lowers by one layer thickness and the Where Ti = time to complete layer i;
• Polymerization occurs on exposure to UV light produced by
scanning is performed for the next layer. Ai = area of layer i;
laser scanning beam
v = average scanning speed of the laser beam at the surface;
• This process is continued until the part has been
Scanning speeds – 0.5 to 2.5 m/s D = diameter of the "spot size", assumed circular;
completed.
and Td = delay time between layers to reposition the worktable
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Part Build Time in SLA MCQ NAT

• Time to build a part ranges from one hour for small parts of Which of the following is used as base material in • A prototype of a tube with a square cross-section is to be
simple geometry up to several dozen hours for complex parts fabricated using stereolithography. The outside dimension of
Stereolithography (SLA) process?
• SLA Build Cycle Time : the square = 100 mm and the inside dimension = 80 mm (wall
nI (A) Thermoplastics, Metals powders thickness = 10 mm except at corners). The height of the tube
Tc = å Ti (B) Thermoplastics, Eutectic metals. (z-direction) = 100 mm. Layer thickness = 0.25 mm. The
i =1
diameter of the laser beam (“spot size”) = 0.2 mm, and the
(C) Photopolymer
Where Tc = STL build cycle time; and nI = number of layers used beam is moved across the surface of the photopolymer at a
to approximate the part (D) Titanium alloys velocity of 1 m/s.
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NAT
Fused deposition modeling (FDM)
Calculate the time required to build the part, if 25 s are lost • FDM uses a heating chamber to liquefy polymer that is fed

each layer to lower the height of the platform that holds the into the system as a filament.

part. Neglect the time for post curing.

• The filament is pushed into the chamber by a tractor wheel

arrangement and it is this pushing that generates the

extrusion pressure.

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 MCQ
Fused deposition modeling (FDM)

• The major strength of FDM is in the range of materials and Which of the process is using the extrusion concept?

the effective mechanical properties of resulting parts made (A) SLA

using this technology. (B) SLS

(C) FDM
• Parts made using FDM are amongst the strongest for any
(D) MJM
polymer based additive manufacturing process.

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MCQ
Laminated Object Manufacturing (LOM)
Laminated Object Manufacturing (LOM)
Ultrasonic Additive Manufacturing(UAM)
Ultrasonic Additive Manufacturing(UAM)
• Laminated object manufacturing (LOM) and ultrasonic Which material is NOT available for LOM process?

additive manufacturing (UAM) are two sheet lamination

• LOM excels at creating objects ideal for visual or aesthetic (A) Paper
methods. (B) Plastic
modeling.
(C) Metal
• LOM uses alternate layers of paper and adhesive, while • UAM is a relatively low-temperature, low-energy process used
with various metals, including titanium, stainless steel and (D) Glass
UAM employs thin metal sheets conjoined through
ultrasonic welding. aluminum.

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MCQ Electron Beam Melting MCQ

In laminated object manufacturing (LOM), which of the • The EBM process utilizes a high-power electron beam that Which of the following RP system is not developed by 3D

following cutting strategy is preferable? generates the energy needed for high melting capacity and systems?

(A) Directional scanning high productivity. The hot process allows you to produce parts (A) Selective Laser Sintering (SLS)

(B) Zigzag tool paths (B) Multi-Jet Modeling System (MJM)

with no residual stress and the vacuum ensures a clean and
(C) Contouring and spiral paths (C) Paper Lamination Technology (PLT)
controlled environment. (D) Stereolithography Apparatus (SLA)
(D) Boundary cutting tool paths

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 Selective Laser Melting (SLM)
or Direct Metal Laser Melting (DMLM)
or Laser Powder Bed Fusion (LPBF)
• Materials are fully melted in the DMLM and EBM processes.
• With DMLM, a laser completely melts each layer of metal.
• Ideal for manufacturing dense, non-porous objects.
Selective Laser Melting (SLM)
or Direct Metal Laser Melting (DMLM)
or Laser Powder Bed Fusion (LPBF)
• A powder layer is first applied on a building platform with a
Powder
Layers recoater (blade or roller) and a laser beam selectively melts
the layer of powder. Then the platform is lowered by 20 μm to

100 μm and a new powder layer is applied.

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Different Additive Manufacturing Powder Bed Fusion

Selective Laser Melting (SLM) Processes
or Direct Metal Laser Melting (DMLM) • This technology is used in a variety of AM processes,
• Powder Bed Fusion
or Laser Powder Bed Fusion (LPBF)
• Material Extrusion including direct metal laser sintering (DMLS), selective laser
• The laser beam melting operation is repeated.
• Directed Energy Deposition sintering (SLS), selective heat sintering (SHS), electron beam
• After a few thousand cycles (depending on height of the part), • Material Jetting
melting (EBM) and direct metal laser melting (DMLM).
the built part is removed from the powder bed. • Binder Jetting

• Sheet Lamination

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Powder Bed Fusion Material Extrusion

• Spooled polymers are extruded, or drawn through a heated

• These systems use lasers, electron beams or thermal print
nozzle mounted on a movable arm.
heads to melt or partially melt ultra-fine layers of material
in a three-dimensional space. • The nozzle moves horizontally while the bed moves
• As the process concludes, excess powder is blasted away
vertically, allowing the melted material to be built layer
from the object.
after layer.

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 Directed Energy Deposition Material Jetting
Material Extrusion
• An electron beam gun or laser mounted on a four- or five-axis • With material jetting, a print head moves back and forth,
• Proper adhesion between layers occurs through precise
arm melts either wire or filament feedstock or powder. much like the head on a 2D inkjet printer.
temperature control or the use of chemical bonding agents.
• DED is similar to material extrusion, although it can be used • However, it typically moves on x-, y- and z-axes to create 3D
• Material extrusion is one of the most well-known additive
with a wider variety of materials, including polymers, objects.
manufacturing processes.
ceramics and metals. • Layers harden as they cool or are cured by ultraviolet light.

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Binder Jetting Sheet Lamination Sheet Lamination

• Laminated object manufacturing (LOM) and ultrasonic

• LOM excels at creating objects ideal for visual or aesthetic
• The binder jetting process is similar to material jetting, additive manufacturing (UAM) are two sheet lamination
methods. modeling. UAM is a relatively low-temperature, low-energy
except that the print head lays down alternate layers of
• LOM uses alternate layers of paper and adhesive, while UAM process used with various metals, including titanium,
powdered material and a liquid binder.
employs thin metal sheets conjoined through ultrasonic
stainless steel and aluminum.
welding.

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Vat Polymerization Additive Manufacturing Materials Benefits of AM Technology

• Vat photopolymerization, an object is created in a vat of a • Thermoplastics • Freedom to design and innovate without penalties
liquid resin photopolymer. • Metals
• Rapid iteration through design permutations
• Ceramics
•A process called photopolymerization, cures each
• Biochemicals • Excellent for mass customization
microfine resin layer using ultraviolet (UV) light precisely
• Composites • Elimination of tooling
directed by mirrors.

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 Benefits of AM Technology Limits of AM technology Limits of AM technology

• Green manufacturing • Unexpected pre- and post-processing requirements • Inconsistent Materials

• Minimal material wastage • High process cost • Limited number of materials

• Energy efficient • Lack of industry standards • High equipment cost for high-end manufacturing

• Enables personalized manufacturing • Low speed, not suitable for mass production • Porosity (99.9% density achieved)

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AM - Applications 3D PRINTING MCQ

• Aerospace Rapid Prototyping Additive Manufacturing (AM)
Rapid Manufacturing Additive Layer Manufacturing (ALM)
• Medical Full form of LENS is______
• Manufacturing
Free Form Fabrication (FFF)
Laser Beam Melting (LBM)
• Automotive Solid Freeform Fabrication (SFF) (A) Lamination Electron Net Sintering
Selective Laser Melting (SLM)
• Lifestyle Selective Laser Sintering (SLS)
(B) Laminated Engineered Net Shaping
Direct Metal Laser Sintering (DMLS)
• Oil & Gas Direct Metal Laser Melting (DMLM)

• Food & Beverage Electron Beam melting (EBM) Laser Metal Deposition (LMD) (C) Laser Engineered Net Shaping
Powder Bed Fusion (PBF) Laser Cladding
• Consumer Electronics Direct Energy Deposition (DED) (D) Laser Engineered Net Sintering
Direct Metal Deposition (DMD)
Powder fed fusion
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Binder Jetting

MCQ

Which material can be efficiently used as a support

material?

(A) ABS

(B) PLA

(C) Nylon

(D) INF
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 Powder Metallurgy: Answers with Explanations
MCQ Page No. 2 Slide No. 15 Ans. (c)
MCQ Page No. 2 Slide No. 16 Ans. (a)
MCQ Page No. 2 Slide No. 18 Ans. (c)
MCQ Page No. 3 Slide No. 21 Ans. (b)
MCQ Page No. 3 Slide No. 27 Ans. (a)
MCQ Page No. 4 Slide No. 30 Ans. (c)
MCQ Page No. 4 Slide No. 33 Ans. (c)
MCQ Page No. 5 Slide No. 39 Ans. (c)
MCQ Page No. 6 Slide No. 48 Ans. (d)
MCQ Page No. 7 Slide No. 59 Ans. (a)
MCQ Page No. 8 Slide No. 68 Ans. (c)
MCQ Page No. 9 Slide No. 75 Ans. (c)
MCQ Page No. 9 Slide No. 78 Ans. (d)
MCQ Page No. 9 Slide No. 79 Ans. (d)
MCQ Page No. 9 Slide No. 81 Ans. (c)
MCQ Page No. 12 Slide No. 105 Ans. (c)
MCQ Page No. 12 Slide No. 106 Ans. (b)

ABS – Acrylonitrile Butadiene Styrene

PLA – Polylactic Acid ( It will be removed by immersion in a solution of isopropyl alcohol and potassium
hydroxide)

1|P a g e