1.1 - Manufacturing

What step in the basic AM procedure must engineers or operators complete before creating an STL file and G-code file? Engineers or operators must first:

• Create a 3D CAD model of the part.

• Create a physical prototype.

• Perform a stress analysis.

• Conduct a market survey.

Answer explanation

Before creating an STL file and G-code, engineers or operators must first create a 3D CAD model of the part. This model serves as the digital blueprint for the additive manufacturing process.

What solid modeling tool do engineers use to create 3D part models for AM?

• Computer-aided design (CAD)

• Finite element analysis (FEA)

• Rapid prototyping (RP)

• Material requirement planning (MRP)

Answer explanation

Engineers use Computer-aided design (CAD) tools to create detailed 3D part models for additive manufacturing (AM). CAD software allows for precise modeling and design, essential for successful AM processes.

What removable AM components fortify an AM part as it is built?

• Support structure

• Base plate

• Cooling fins

• Heat sink

Answer explanation

The support structure is crucial in additive manufacturing (AM) as it provides stability during the build process. It is removable after printing, allowing the final part to maintain its intended shape and integrity.

What term refers to manufacturers using AM as an intermediary step during a traditional manufacturing operation?

• Secondary process

• Primary process

• Final assembly

• Quality control

Answer explanation

The term 'Secondary process' refers to the use of additive manufacturing (AM) as an intermediary step in traditional manufacturing, enhancing efficiency and allowing for complex designs before final production.

What additive manufacturing method involves sintering granulated material to create a part?

• Powder bed fusion (PBF)

• Fused deposition modeling (FDM)

• Stereolithography (SLA)

• Laminated object manufacturing (LOM)

Answer explanation

Powder bed fusion (PBF) is an additive manufacturing method that uses a laser to sinter granulated material, typically metal or plastic powders, layer by layer to create a solid part, making it the correct choice.

What AM process did manufacturers develop in the 1990s that allowed them to produce metal parts?

• Direct metal laser sintering (DMLS)

• Selective laser melting (SLM)

• Electron beam melting (EBM)

• Binder jetting

Answer explanation

In the 1990s, manufacturers developed Direct Metal Laser Sintering (DMLS), which enabled the production of metal parts through a layer-by-layer process using a laser to sinter powdered metal, making it a key advancement in additive manufacturing.

What AM material is available in filaments, liquids, and powders and used in material extrusion and selective laser sintering (SLS)?

• Polymer

• Metal

• Ceramic

• Composite

Answer explanation

Polymers are versatile materials available in filaments, liquids, and powders, making them suitable for both material extrusion and selective laser sintering (SLS) processes, unlike metals, ceramics, or composites.

What important information does an AM G-code file contain?

• AM parts divided into layers and machine toolpaths

• Material cost estimates

• Environmental impact assessments

• Supplier contact information

Answer explanation

An AM G-code file contains crucial information about how to construct AM parts, specifically detailing the layers and machine toolpaths required for the additive manufacturing process.

What additive manufacturing method involves depositing droplets of an adhesive material into a powdered material to create a part?

• Binder jetting

• Fused deposition modeling (FDM)

• Stereolithography (SLA)

• Laminated object manufacturing (LOM)

Answer explanation

Binder jetting is an additive manufacturing method that creates parts by depositing adhesive droplets into a powdered material, binding the particles together. This distinguishes it from other methods like FDM and SLA.

What manufacturing process involves stacking layers of material in order to create a finished part?

• Additive manufacturing

• Subtractive manufacturing

• Casting

• Forging

Answer explanation

Additive manufacturing involves stacking layers of material, such as plastic or metal, to create a finished part. This process contrasts with subtractive methods, which remove material, and other techniques like casting and forging.