Important Question Bank

with Solutions for MTE

1. What is additive manufacturing, and differentiate between additive, subtractive and formative method of
manufacturing.

Answer:

Additive Manufacturing (AM), also known as 3D printing, is a process of building three-dimensional objects from digital
design files by adding layer upon layer of material until the final product is created. This technology enables the production
of complex geometries and structures that cannot be produced using traditional manufacturing methods.

Subtractive Manufacturing is the process of removing material from a larger block or workpiece to create a final product.
The most common example of this is milling or drilling, where a machine tool is used to cut away unwanted material from a
solid block of material.

Formative Manufacturing is the process of shaping or forming a material without removing any material. This process can
include methods such as forging, casting, or molding, where the material is heated and shaped into the desired form.

The main difference between additive, subtractive, and formative methods of manufacturing is the way in which the final
product is created. Additive manufacturing adds layers of material to create the final product, while subtractive manufacturing
removes material, and formative manufacturing shapes and forms the material without removing any. Each method has its
strengths and weaknesses and is most suitable for specific types of products and manufacturing processes.
2. Explain the Generic steps involved in additive manufacturing.

Answer:

1. Create a CAD model of the design

# Object to be built is modelled using CAD software.
# Solid modellers like ProE yield better results.
# Existing CAD file may also be used

2. Convert the CAD model to STL (Standard Tessellation Language) format

# STL format is the standard of rapid prototyping industry.
# This format represent 3D surface as an assembly of planar triangles and describes only surface geometry. (without any representation of
colour, texture etc.)
2. Explain the Generic steps involved in additive manufacturing.

Answer: In continuation…..

3. Slice the STL file into thin cross-sectional layers

# Several programmes are available for this.
# STL models are sliced into a number of layers (0.01mm to 0.7mm).
# Orientation size and location are adjusted using the software.

4. Construct the model one layer atop another

# RP machine builds one layer at a time from polymers, paper, or powdered metal.
# Fairly autonomous, need little human intervention.

5. Clean and finish the model

# Post processing step.
# Prototype may require minor cleaning and surface treatment.
3. List out the commonly used materials in 3D printing.

Answer:
 3. Highlight the advantages, disadvantages and applications of 3D printing.

Answer:

Advantages of 3D printing:
1.Design flexibility: 3D printing allows for the creation of complex designs that cannot be manufactured using
traditional methods. This can lead to more efficient use of materials and more functional products.
2.Customization: 3D printing allows for the creation of customized products for individual needs or preferences. This
can be useful in medical applications where personalized prosthetics or implants are required.
3.Rapid prototyping: 3D printing allows for the rapid production of prototypes for testing and design verification. This
can reduce the time and cost required for product development.
4.Cost-effectiveness: For small production runs, 3D printing can be a cost-effective alternative to traditional
manufacturing methods.
5.Reduced waste: 3D printing can produce less waste compared to traditional manufacturing methods, as it only
uses the material needed to create the final product.
Disadvantages of 3D printing:
1.Limited materials: The range of materials that can be used for 3D printing is currently limited compared to
traditional manufacturing methods.
2.Quality issues: The quality of 3D printed products can be inconsistent, with surface roughness, layer lines, and
other defects.
3.Limited size: The size of the products that can be 3D printed is currently limited, and larger products may require
printing in sections and then assembly.
4.Slow production times: 3D printing can be slower than traditional manufacturing methods, especially for large or
complex products.
 3. Highlight the advantages, disadvantages and applications of 3D printing.

Answer: In continuation…

Applications of 3D printing:
1.Medical: 3D printing is being used to create customized prosthetics, implants, and surgical models.
2.Aerospace: 3D printing is being used to produce lightweight, complex parts for spacecraft and aircraft.
3.Automotive: 3D printing is being used to produce prototypes, tooling, and low-volume production parts.
4.Education: 3D printing is being used in education to teach design and manufacturing skills.
5.Architecture: 3D printing is being used to create architectural models and prototypes.
3. Give the detail classification of additive manufacturing/ 3D printing and explain any two.

Answer:
3. Explain the mechanism that how bond formation take place between layers in SLA or What is polymerization
process.

Answer:

A photopolymer, also known as light-activated resin, is a polymer that changes its properties when exposed to light, often in
the ultraviolet or visible region of the electromagnetic spectrum, causing its molecules chain to link. Stereolithography (SLA),
the first patented and marketed AM process, is a vat photopolymerization technology.

Vat Photopolymerization is a type of additive manufacturing technology that produces 3D objects by selectively curing
photopolymer liquid resin using light-activated polymerization.

Most 3D printers that use vat photopolymerization keep liquid photopolymer in a container or vat, with the build platform
partially submerged at the liquid’s surface. The printer directs a light source to selectively cure the liquid photopolymer into a
solid layer using information from a CAD file. The build platform is then re-submerged in the leftover resin, and the process is
repeated for the subsequent layers until the design is entirely produced.
3. Describe Stereolithography process.

Answer:

• The basic principle of Stereolithography is the selective curing of a photopolymer (a resin) using a UV laser. A thin layer of
liquid resin (generally 50-100 microns deep) is prepared in the machine’s building space. The Laser draws a pattern on that
layer curing only the shape desired in the first layer of the model. When a layer is completed, a new layer of liquid resin is
created will follow (by moving the part up or the bottom of the building space down) and the process continues.

• There are two types of SLA technology machines, one prints the model upwards (‘bottom-up’), and the other prints the
model downwards (‘top-down’). Furthermore, the UV light source can be either a laser or projector (i.e. DLP). With a DLP
(Digital Light Processing) system the whole model layer pattern can be projected simultaneously instead of drawing the
pattern with the single point of a laser. This means DLP 3D printers are both faster and often cheaper in cost, but have
resolution limitations so are usually limited to smaller build spaces.
Since the part is surrounded by liquid resin in both technologies, both require support structures for overhanging geometry
to prevent those sections from moving out of position from the rest of the model..
 3. Process parameters in SLA.

Answer:

1.Layer thickness: The layer thickness determines the resolution and smoothness of the printed object. Thinner
layers result in a smoother surface finish but increase the print time.
2.Exposure time: The exposure time determines the amount of UV light exposure the resin receives, which affects
the curing depth and strength of the printed object.
3.Laser power: The laser power determines the intensity of the laser beam and affects the curing speed and
accuracy of the printed object.
4.Scanning speed: The scanning speed of the laser beam affects the accuracy and quality of the printed object.
Slower speeds result in better accuracy but increase the print time.
5.Resin type: The type of resin used in SLA affects the properties of the printed object, such as strength, flexibility,
and color.
6.Build platform temperature: The temperature of the build platform affects the adhesion of the printed object to the
platform and the curing of the resin.
3. Parts Manufactured by SLA with the detailed steps.

Answer:

• The process begins with a 3D CAD file.

• The file is digitally sliced into a series of parallel horizontal cross- sections which are
then provided to a StereoLithography Apparatus (SLA) one at a time.
• A radiation source draws the cross-section onto a bath of
photopolymer resin which solidifies the cross-section.
• The part is lowered a layer thickness into the bath and additional resin is swept onto
the surface (typically about 0.1 mm) .
• The radiation source then solidifies the next cross-section.
• This process is repeated until the part is complete.
• Once the model is complete, the platform rises out of the vat and the excess resin is
drained.
• The model is then removed from the platform, washed of excess resin, and then placed
in a curing light oven for a final curing.
3. Materials for SLA.

Answer:

Materials used in most liquid based RP systems are photopolymers

that are cured when exposed to light. They are composed of three
components:

1.Photo-initiator that generates free radicals upon exposure

to UV
2. Epoxcy- (or Acrylate-) based Monomers
3. A reactive acrylic diluents to lower the vicousity of the
polymer
3. What is LOM Process? State its Importance and working
principle.

Answer:

• LOM is actually more of a hybrid between subtractive and

additive process.
• In that models are built up with layers of cross section of the part.
Hence as layers are been added, the excess material is not
required for that cross section is being cut away.
• LOM is one of the fastest RP processes for parts with longer cross
sectional areas which make it ideal producing large parts.
• Solid physical model made by stacking layers of sheet stock,
each an outline of the cross-sectional shape of a CAD model
that is sliced into layers
• Starting sheet stock includes paper, plastic, cellulose,
metals, or fiber-reinforced materials
• The sheet is usually supplied with adhesive adhesive
backing as rolls that are spooled between two reels.
• After cutting, excess material in the layer remains in place
to support the part during building
3. Process parameters in LOM.

Answer:

• Laser Power:
• It is the percentage of total laser output wattage. For e.g. LOM
1015 is operated at a laser power of about 9% of maximum 25W
laser or approximately 2.25 W. This value will be different for
various materials or machines but essentially it is set to cut
through only one sheet of build material.
• Heater Speed:
• It is the rate at which hot roller passes across the top of the part.
The rate given in inches/second. It is usually 6”/sec for initial pass
and 3”/sec for returning pass of heater. The heater speed effects
the lamination of the sheet so it must be set low enough to get a
good bond between layers. 1 Foil supply. 2 Heated roller. 3 Laser beam. 4.
• Material Advance:
Scanning prism. 5 Laser unit. 6 Layers. 7 Moving
platform. 8 Waste.
It is the distance the paper is advanced in addition to length of the
part.
• Support Wall Thickness:
It controls the outer support box walls throughout a part. The
support wall thickness is generally set 0.25” in the Margin X and Y
direction, although this value can be changed by operator.
3. Bond formation in FDM Process.

Answer:

The machine fabricates prototypes by extruding a semi-molten filament through a heated nozzle in a prescribed
pattern onto a platform. As the material is deposited, it cools, solidifies, and bonds with the surrounding material.
The formation of the bonding in the FDM process is driven by the thermal energy of the semi-molten material

Bond formation process through

sintering: (1) surface contact; (2) neck
growth; (3) neck growth and
molecular diffusion at the interface
3. Process parameters in FDM Process.

Answer:
1. The nozzle diameter:
• It is the diameter of the extruder tip and
depends on the type of nozzle used.

• The extruder nozzle diameter has an

impact on the extruded melt flow
behavior. The selection of an optimal
nozzle diameter is critical for maintaining a
proper and consistent flow of the
extruding material.

• The decrease in the nozzle diameter

contributes to better resolutions with low
layer thickness, which in turn provides a
good surface quality.

P.T.O
3. Process parameters in FDM Process.

Answer: In continuation

2. Extrusion and bed temperature

• The extrusion temperature is the temperature used to convert the solid filament into a molten state before the
extrusion process and depends on the material type and printing speed. It should be set based on the melting point of
the filament material.

3. Print speed
The print speed is the distance travelled by the nozzle tip per unit time (mm/s) during the printing process. The optimum
printing speed in FDM is determined by the material, extrusion temperature and resolution used.

4. Build orientation
The build orientation is defined as the mode position part that is placed on the platform in respect of the X, Y and Z axes
and can be presented as a quantitative parameter (angle of axis) or a categorical parameter (ZX-upright, XZ-edgewise and
XY-flatwise).

5. Layer thickness
The layer thickness is defined as the vertical resolution and depends on the material, nozzle diameter and type of nozzle
and can influence the surface quality, dimensional accuracy, mechanical strength and build time.
3. Comparison between 3D printing processes.

Answer: