Write a note on product development by AM?

Product development by Additive Manufacturing (AM), also known as 3D

printing, is a rapidly growing field that offers unique advantages and
opportunities for innovation. AM is a process of creating three-dimensional
objects by layering materials on top of each other using a digital design.

One of the primary advantages of product development by AM is the ability

to produce complex geometries and shapes that may be difficult or
impossible to manufacture using traditional manufacturing methods. This
enables designers to create products with intricate details and precise
features that can meet specific requirements.

Additionally, AM allows for the rapid prototyping of designs, which can

greatly accelerate the product development process. By quickly producing
multiple iterations of a design, engineers and designers can quickly identify
and fix design flaws, reducing the time and cost of development.

Another benefit of product development by AM is the ability to produce

small batch sizes and customize products to meet individual customer
needs. This is particularly advantageous in industries such as healthcare and
aerospace, where personalized products are often required.

However, there are also some challenges associated with product

development by AM. The cost of AM machines and materials can be high,
which can limit the adoption of the technology. Additionally, the quality
and reliability of AM products may vary depending on the materials and
machines used.

In summary, product development by AM offers unique advantages in

terms of design complexity, rapid prototyping, and customization. As the
technology continues to improve and become more affordable, it is likely
to become an increasingly important tool in the product development
process.
2. Classify and Explain of additive manufacturing processes?
Additive Manufacturing (AM) processes can be classified into several
categories based on the type of material used, the method of layering, and
the type of energy source used to fuse the materials. The following are
some of the commonly used AM processes:

1. Material Extrusion: This process involves the extrusion of a

thermoplastic material, which is melted and deposited layer by layer
to form the final object. Fused Deposition Modeling (FDM) is a
popular example of this process.
2. Powder Bed Fusion: This process involves the use of a laser or
electron beam to fuse powdered materials layer by layer. Selective
Laser Sintering (SLS) and Electron Beam Melting (EBM) are examples
of this process.
3. Vat Photopolymerization: This process uses a photopolymer resin
that is cured layer by layer using UV light. Stereolithography (SLA)
and Digital Light Processing (DLP) are examples of this process.
4. Material Jetting: This process involves the use of inkjet printhead to
deposit droplets of liquid or melted material layer by layer. PolyJet
and Drop-on-Demand (DOD) are examples of this process.
5. Binder Jetting: This process involves the deposition of a liquid binder
onto a powder bed, which is then cured layer by layer. This creates a
solid object, which is then sintered or fused to create a final part.
Binder Jetting is commonly used for producing sand molds and metal
parts.

Overall, each AM process has its unique advantages and disadvantages,

and the choice of process depends on the specific application, materials,
and design requirements.
3.Brief about Support structure design?
Support structure design is an important aspect of Additive Manufacturing
(AM) that involves the creation of temporary structures to provide support
for overhanging or delicate features during the printing process. The
support structures are later removed after the printing process is complete.

The design of support structures plays a critical role in the success of an AM

project, as they help to ensure the accuracy and quality of the final part.
Without proper support structures, overhanging features may sag or
deform, resulting in a final part that is not usable.

The support structures are typically generated automatically by the

software based on the geometry of the part being printed. However,
designers may also manually add or modify support structures to optimize
the printing process and minimize material usage.

The key considerations in designing support structures include the type of

AM process, the orientation of the part, the material being used, and the
required level of support. Some common types of support structures
include columns, walls, and lattice structures.

Overall, the design of support structures is an essential part of the AM

process that can greatly impact the quality and accuracy of the final part. By
carefully considering the requirements of the part and the printing process,
designers can create effective support structures that ensure the success of
their AM projects.

What are the advantages of Part orientation?

Part orientation is an important consideration in Additive Manufacturing
(AM) that refers to the position and orientation of the part on the build
platform. The orientation of the part can have a significant impact on the
success and quality of the printing process. Some of the advantages of part
orientation include:

1. Minimizing support structures: By orienting the part in a way that

minimizes overhangs and unsupported features, the need for support
structures can be reduced. This not only saves material but also
 reduces the time and effort required to remove the support
structures after printing.
2. Improving strength and durability: The orientation of the part can
impact its strength and durability. By orienting the part in a way that
aligns with the direction of the applied forces, the part can be made
stronger and more durable.
3. Reducing warping and distortion: Part orientation can also impact the
amount of warping and distortion that occurs during the printing
process. By orienting the part in a way that minimizes the effect of
thermal stresses and shrinkage, warping and distortion can be
reduced.
4. Improving surface finish: Part orientation can also impact the surface
finish of the final part. By orienting the part in a way that minimizes
the visible layer lines and other imperfections, the surface finish can
be improved.

Overall, part orientation is an important consideration in AM that can

impact the success and quality of the printing process. By carefully
considering the requirements of the part and the printing process,
designers can optimize the part orientation to achieve the best possible
results.

1 a) Write a note on the benefits and applications of AM.

Additive Manufacturing (AM), also known as 3D printing, is a rapidly
growing technology that offers many benefits and applications across
various industries. Some of the key benefits of AM include:

1. Design freedom: AM offers unparalleled design freedom, allowing for

the creation of complex geometries that are difficult or impossible to
produce using traditional manufacturing methods. This enables
designers to optimize parts for performance and functionality,
leading to improved products.
2. Rapid prototyping: AM allows for the rapid prototyping of parts,
enabling designers and engineers to quickly iterate and refine their
designs. This helps to accelerate the product development cycle and
reduce time-to-market.
 3. Cost-effectiveness: AM can be more cost-effective than traditional
manufacturing methods for small batch sizes or low-volume
production runs. This is because AM does not require expensive
tooling and can minimize material waste.
4. Customization: AM enables the production of customized parts to
meet specific customer requirements, which is particularly valuable in
industries such as healthcare, where patient-specific medical devices
and implants can be produced.

Some of the applications of AM include:

1. Aerospace: AM is used in the aerospace industry to produce

lightweight parts with complex geometries, such as turbine blades
and fuel nozzles.
2. Automotive: AM is used in the automotive industry for prototyping,
tooling, and low-volume production of specialized parts.
3. Healthcare: AM is used in the healthcare industry for the production
of patient-specific medical devices and implants, as well as for
surgical planning and training.
4. Architecture and Construction: AM is used in the architecture and
construction industries for the production of complex building
components, such as facades and structural elements.
5. Consumer Products: AM is used in the consumer products industry
for the production of customized and personalized products, such as
jewelry and phone cases.
6. Education and Research: AM is used in education and research for
prototyping, experimentation, and the production of specialized
equipment and tools.

Overall, AM offers many benefits and applications across a wide range of

industries. As the technology continues to evolve, it is expected to play an
increasingly important role in the future of manufacturing.

b) Write a note on the impact of AM on product development. 14 marks

Additive Manufacturing (AM), also known as 3D printing, has had a
significant impact on product development in various industries. Some of
the key ways in which AM has impacted product development include:
 1. Rapid prototyping: AM enables designers and engineers to quickly
produce functional prototypes of parts, allowing for rapid iteration
and refinement of designs. This can significantly accelerate the
product development cycle and reduce time-to-market.
2. Design freedom: AM enables the creation of complex geometries that
are difficult or impossible to produce using traditional manufacturing
methods. This provides designers with greater design freedom,
enabling the creation of optimized parts that improve product
performance and functionality.
3. Customization: AM enables the production of customized parts to
meet specific customer requirements. This is particularly valuable in
industries such as healthcare, where patient-specific medical devices
and implants can be produced.
4. Cost-effectiveness: AM can be more cost-effective than traditional
manufacturing methods for small batch sizes or low-volume
production runs. This is because AM does not require expensive
tooling and can minimize material waste.
5. Supply chain flexibility: AM can provide greater supply chain flexibility
by enabling the production of parts on-demand, eliminating the need
for large inventories or long lead times.
6. Sustainability: AM can be more sustainable than traditional
manufacturing methods by minimizing material waste and energy
consumption.

Overall, AM has had a significant impact on product development by

enabling designers and engineers to produce parts that are optimized for
performance, functionality, and customization. As the technology continues
to evolve, it is expected to play an increasingly important role in the future
of product development.

12. a) Write a note on the need and development of AM systems. (14

marks)
Additive Manufacturing (AM), also known as 3D printing, has been rapidly
evolving since its inception in the 1980s. AM systems have been developed
to meet the growing demand for the technology and to address the
limitations of early systems. Some of the key factors driving the need for
AM systems include:
 1. Design freedom: The need for greater design freedom has led to the
development of AM systems that can produce complex geometries
with high precision.
2. Material diversity: The need for AM systems to work with a wider
range of materials, including metals, ceramics, and composites, has
led to the development of new systems that can handle these
materials.
3. Production volume: The need for AM systems to produce parts in
larger volumes has led to the development of systems that can print
multiple parts simultaneously or in a continuous process.
4. Speed and efficiency: The need for AM systems to produce parts
quickly and efficiently has led to the development of systems with
faster print speeds, improved automation, and greater reliability.
5. Cost-effectiveness: The need for AM systems to be cost-effective has
led to the development of systems that can minimize material waste,
reduce energy consumption, and streamline production processes.

The development of AM systems has been driven by advancements in

materials science, computer-aided design (CAD), and automation
technology. For example, the development of new materials that can be
used in AM has enabled the production of parts with improved mechanical
properties and greater durability. Similarly, the use of CAD software has
enabled designers to create more complex and intricate geometries that
can be printed with greater precision.

The development of AM systems has also been driven by the needs of

specific industries, such as aerospace, healthcare, and automotive. These
industries have specific requirements for parts that can be produced using
AM, such as the need for lightweight and high-strength materials in
aerospace, or the need for patient-specific medical devices in healthcare.

Overall, the need for greater design freedom, material diversity, production
volume, speed and efficiency, and cost-effectiveness has driven the
development of AM systems. As the technology continues to evolve, it is
expected to play an increasingly important role in the future of
manufacturing.

a) Write a note on the need and development of AM systems. (14 marks)

Additive Manufacturing (AM), also known as 3D printing, has been rapidly
evolving since its inception in the 1980s. AM systems have been developed
to meet the growing demand for the technology and to address the
limitations of early systems. Some of the key factors driving the need for
AM systems include:

1. Design freedom: The need for greater design freedom has led to the
development of AM systems that can produce complex geometries
with high precision.
2. Material diversity: The need for AM systems to work with a wider
range of materials, including metals, ceramics, and composites, has
led to the development of new systems that can handle these
materials.
3. Production volume: The need for AM systems to produce parts in
larger volumes has led to the development of systems that can print
multiple parts simultaneously or in a continuous process.
4. Speed and efficiency: The need for AM systems to produce parts
quickly and efficiently has led to the development of systems with
faster print speeds, improved automation, and greater reliability.
5. Cost-effectiveness: The need for AM systems to be cost-effective has
led to the development of systems that can minimize material waste,
reduce energy consumption, and streamline production processes.

The development of AM systems has been driven by advancements in

materials science, computer-aided design (CAD), and automation
technology. For example, the development of new materials that can be
used in AM has enabled the production of parts with improved mechanical
properties and greater durability. Similarly, the use of CAD software has
enabled designers to create more complex and intricate geometries that
can be printed with greater precision.

The development of AM systems has also been driven by the needs of

specific industries, such as aerospace, healthcare, and automotive. These
industries have specific requirements for parts that can be produced using
AM, such as the need for lightweight and high-strength materials in
aerospace, or the need for patient-specific medical devices in healthcare.

Overall, the need for greater design freedom, material diversity, production
volume, speed and efficiency, and cost-effectiveness has driven the
development of AM systems. As the technology continues to evolve, it is
expected to play an increasingly important role in the future of
manufacturing.

b) Classify and explain the AM process (14 marks Text book answers)
Additive Manufacturing (AM), also known as 3D printing, is a process of
creating a physical object from a digital design by adding successive layers
of material. There are several types of AM processes, each with its own
advantages and limitations. The most common types of AM processes are
as follows:

1. Fused Deposition Modeling (FDM): FDM is a process in which a

thermoplastic material is heated and extruded through a nozzle to
create a 3D object. The material is deposited layer by layer until the
final object is formed. This process is commonly used for prototyping
and low-volume production.
2. Stereolithography (SLA): SLA is a process in which a laser is used to
cure a liquid photopolymer resin layer by layer to create a 3D object.
This process is commonly used for creating highly detailed and
complex geometries.
3. Selective Laser Sintering (SLS): SLS is a process in which a laser is used
to sinter powdered material layer by layer to create a 3D object. This
process is commonly used for creating objects from metal, plastic,
and ceramic powders.
4. Binder Jetting: Binder Jetting is a process in which a liquid binder is
selectively deposited onto a powdered material layer by layer to
create a 3D object. This process is commonly used for creating
objects from sand, metal, and ceramic powders.
5. Material Jetting: Material Jetting is a process in which a material is
deposited layer by layer using a print head to create a 3D object. This
process is commonly used for creating highly detailed and accurate
objects with multiple materials and colors.
6. Direct Energy Deposition (DED): DED is a process in which a focused
energy source, such as a laser or electron beam, is used to melt and
deposit material layer by layer to create a 3D object. This process is
commonly used for creating large-scale metal objects.
Each AM process has its own advantages and limitations. The choice of
process depends on the application and the requirements of the final
product. Some factors to consider when selecting an AM process include
the materials that can be used, the level of detail required, the size and
complexity of the object, and the production volume. As the technology
continues to evolve, new AM processes are likely to emerge, each with its
own unique set of advantages and limitations.

13. a) Explain about data formats and data interfacing? (14 marks Text book
answer)
In Additive Manufacturing (AM), data formats and data interfacing play a
critical role in the process of converting a digital design into a physical
object. The following are the important aspects of data formats and data
interfacing in AM:

1. Data Formats: Data formats are the file types used to store and
transfer the digital design data between different software
applications and machines. Some of the common data formats used
in AM include STL (STereoLithography), AMF (Additive Manufacturing
Format), and 3MF (3D Manufacturing Format).
• STL is a file format that describes the surface geometry of a 3D object
as a collection of interconnected triangles. It is the most commonly
used file format in AM.
• AMF is a newer file format that includes information about the
material properties, color, and texture of the object in addition to its
geometry.
• 3MF is a newer file format that provides more comprehensive data
than STL and AMF, including information about the internal structure,
orientation, and support structures of the object.
2. Data Interfacing: Data interfacing is the process of converting the
digital design data from one file format to another to ensure
compatibility with different software applications and machines. The
following are the important aspects of data interfacing in AM:
• Pre-processing: Pre-processing involves preparing the digital design
data for printing. This includes tasks such as repairing the geometry,
optimizing the orientation and support structures, and slicing the
design into layers.
 • CAM (Computer-Aided Manufacturing): CAM is the process of
generating toolpaths based on the digital design data. This involves
converting the sliced design into machine-specific code that can be
executed by the AM machine.
• Post-processing: Post-processing involves removing the support
structures, cleaning and finishing the printed object, and performing
any necessary secondary operations such as painting, plating, or
machining.

In summary, data formats and data interfacing play a crucial role in the AM
process by ensuring that the digital design data can be accurately and
efficiently converted into a physical object. The use of standardized data
formats and robust data interfacing processes is critical for ensuring the
compatibility and reliability of AM systems.

b) What is part orientation? Explain with illustrations?(14 marks Text book

answers with reference)
Part orientation refers to the placement of a 3D object in the build volume
of an Additive Manufacturing (AM) machine. It plays a crucial role in
determining the quality, accuracy, and mechanical properties of the printed
object. The following are the important aspects of part orientation in AM:

1. Build Orientation: The build orientation refers to the orientation of

the object relative to the build plate. In general, the build orientation
should be chosen to minimize the amount of support material
needed and to maximize the strength and durability of the printed
object.
2. Support Structures: Support structures are temporary structures that
are added to the printed object to provide additional stability and
prevent deformation or collapse during printing. The support
structures are removed after printing and can leave surface defects
on the printed object. Therefore, the part orientation should be
chosen to minimize the amount of support material needed while
ensuring that the object is stable during printing.
3. Mechanical Properties: The part orientation can significantly affect the
mechanical properties of the printed object, such as strength,
stiffness, and toughness. The part orientation should be chosen to
 maximize the desired mechanical properties while minimizing any
negative effects on the mechanical properties.

Illustration of part orientation:

For example, consider the case of a cylindrical object that needs to be

printed using an AM machine. The following figure shows the different part
orientations that can be used for printing the object.

In the first orientation (A), the object is printed horizontally, which requires
a large amount of support material to prevent the object from collapsing.
This can result in surface defects and reduced mechanical properties of the
printed object.

In the second orientation (B), the object is printed vertically, which requires
less support material and results in a higher quality and more accurate
printed object.

In the third orientation (C), the object is printed at an angle, which can
result in a higher strength and stiffness of the printed object. However, this
orientation may require more support material than the vertical orientation.

In summary, part orientation is a critical aspect of AM that can significantly

affect the quality, accuracy, and mechanical properties of the printed object.
The choice of part orientation should be based on the specific requirements
of the printed object and should consider factors such as support
structures, mechanical properties, and build orientation.

4. a) Explain the need of support generation with flow charts?(14 marks Text
book answers with reference)
Support structures are essential in Additive Manufacturing (AM) for
ensuring the successful printing of complex parts with overhanging
features. The support structures provide temporary support during the
printing process and are removed after printing. The following flowchart
illustrates the need for support generation in AM:
As shown in the flowchart, the need for support generation arises when a
part contains overhanging features or complex geometries that cannot be
printed without additional support structures. The need for support
structures can be determined based on the following criteria:

1. Overhang angle: The overhang angle refers to the angle of the

overhanging feature with respect to the vertical axis. If the overhang
angle is greater than a specific value, then support structures are
required.
2. Aspect ratio: The aspect ratio is the ratio of the height of the
overhanging feature to its base width. If the aspect ratio is greater
than a specific value, then support structures are required.
3. Geometrical complexity: If the part contains complex geometries,
such as internal cavities or intricate features, then support structures
may be required to ensure successful printing.

Once the need for support structures is determined, the next step is to
generate the support structures. The support generation process involves
adding temporary structures to the model to provide additional support
during printing. The support generation process can be divided into the
following steps:

1. Analysis of the part geometry: The first step in support generation is

to analyze the part geometry and identify the areas that require
support structures.
2. Placement of support structures: Once the areas requiring support
are identified, the support structures are placed in the model. The
placement of the support structures should be optimized to minimize
the amount of support material needed while ensuring the stability of
the printed object.
3. Generation of support structures: The support structures are
generated based on the placement and geometry of the support
areas. The support structures should be designed to provide
sufficient support to the overhanging features without damaging the
printed object.
In conclusion, the need for support generation in AM arises when parts
contain overhanging features or complex geometries. The support
generation process involves analyzing the part geometry, placing the
support structures, and generating the support structures. The support
structures are essential for ensuring the successful printing of complex
parts and should be optimized to minimize the amount of support material
needed while ensuring the stability of the printed object.

b) What are the steps involved in model slicing? (14 marks Text book
answers with reference)
Model slicing is the process of converting a 3D digital model into a series of
2D layers that can be printed layer-by-layer in an additive manufacturing
(AM) process. The following are the steps involved in model slicing:

1. Model preparation: The first step in model slicing is to prepare the 3D

digital model for slicing. This may involve tasks such as repairing any
mesh errors, scaling the model, and orienting the model for printing.
2. Setting printing parameters: The next step is to set the printing
parameters, such as the layer thickness, printing speed, and
temperature. These parameters will affect the quality and accuracy of
the printed object.
3. Slicing software: The 3D model is then imported into the slicing
software, which converts the 3D model into a series of 2D layers. The
slicing software also generates the tool path for the 3D printer to
follow during printing.
4. Layer thickness: The user sets the layer thickness based on the
printing parameters and the desired quality of the printed object.
Thicker layers can be printed faster but may result in a lower quality
print, while thinner layers produce higher quality prints but take
longer to print.
5. Support structures: If the model contains overhangs or other features
that require support structures, the slicing software will generate
these structures based on the user's settings.
6. Export sliced file: Once the slicing process is complete, the user can
export the sliced file in the appropriate format for the specific 3D
printer being used.
7. Printing: The final step is to print the sliced file using an AM process
such as Fused Deposition Modeling (FDM), Stereolithography (SLA),
 or Selective Laser Sintering (SLS). The 3D printer follows the tool path
generated by the slicing software and prints each layer sequentially
until the object is complete.

In conclusion, model slicing is a crucial step in the additive manufacturing

process that converts a 3D digital model into a series of 2D layers that can
be printed layer-by-layer. The steps involved in model slicing include model
preparation, setting printing parameters, using slicing software to convert
the 3D model into 2D layers, setting layer thickness and support structures,
exporting the sliced file, and printing the sliced file using an AM process.

b) Explain the working principle and process variables of FDM. (14 marks
Text book answers with reference)
Fused Deposition Modeling (FDM) is an additive manufacturing process
that uses a thermoplastic filament to create 3D objects. The following are
the working principle and process variables of FDM:

Working Principle:

1. Filament feeding: The FDM process begins with feeding the

thermoplastic filament into the extruder. The extruder is a motorized
device that heats the filament to its melting point and forces it
through a nozzle.
2. Extrusion and deposition: As the filament exits the nozzle, it is
deposited in a specific pattern to create the first layer of the 3D
object. The extruder moves along the X, Y, and Z axes, depositing the
filament layer by layer until the object is complete.
3. Cooling: After each layer is deposited, the filament is allowed to cool
and solidify before the next layer is added.

Process Variables:

1. Extruder temperature: The temperature of the extruder is a critical

process variable in FDM. If the temperature is too low, the filament
will not melt properly, resulting in poor adhesion between layers. If
the temperature is too high, the filament can burn or degrade,
resulting in poor quality prints.
 2. Layer height: The layer height is the thickness of each layer of
filament that is deposited during the printing process. This process
variable affects the surface finish of the printed object, with smaller
layer heights resulting in a smoother surface finish but longer
printing times.
3. Print speed: The print speed is the rate at which the extruder moves
along the X, Y, and Z axes. This process variable affects the printing
time and the quality of the printed object, with slower print speeds
resulting in a higher quality print but longer printing times.
4. Bed temperature: The bed temperature is the temperature of the
build plate on which the object is printed. This process variable
affects the adhesion between the object and the build plate, with
higher bed temperatures resulting in better adhesion but longer
printing times.
5. Filament type: The type of thermoplastic filament used in the FDM
process is another critical process variable. Different types of
filaments have different melting points, physical properties, and
adhesion characteristics, affecting the quality and properties of the
printed object.

In conclusion, Fused Deposition Modeling (FDM) is an additive

manufacturing process that uses a thermoplastic filament to create 3D
objects. The working principle of FDM involves feeding the filament into an
extruder, extruding and depositing the filament in a specific pattern layer
by layer, and allowing it to cool and solidify before the next layer is added.
The process variables of FDM include extruder temperature, layer height,
print speed, bed temperature, and filament type, all of which affect the
quality and properties of the printed object.