MF 8071 - Additive Manufacturing | Review Questions | Revised

May 2023

UNIT – I :: PART - A

1. Why is the term “Rapid Prototyping” not suitable for additive manufacturing anymore?
In earlier days additive manufacturing is only used to create prototypes quickly. So, at that
time the term rapid prototyping is suitable for the AM process.
In these modern days rapid tooling, manufacturing, and prototyping are all possible in AM.
So, the term “Rapid Prototyping” is not suitable for additive manufacturing anymore.
(Currently, rapid-prototyping is a subset of the additive manufacturing process.)

2. Find the newest definition for Additive Manufacturing by the ASTM F42 Committee.
Additive Manufacturing (AM) refers to a process by which digital 3D design data is
used to build up a component in layers by layer depositing of material.

3. Mention the importance of AM in the tooling industry.

✓ Improved tool design facilitates more functional final products
✓ Removes Limits on Design
✓ Customized tools for customized end products
✓ Optimizing tooling improves ergonomics and bottom-line performance
✓ Lead time is shortened
✓ Costs can be reduced

4. Are 3D printed goods as good as those Manufactures “traditionally”?

✓ 3D printed parts are typically 1/3 weaker than traditionally manufactured parts,
however, 3D printing can make parts that cannot be easily made by traditional
processes.
✓ There are processes involving heat that can improve the strength of the 3D printed
product, however, it cannot improve the strength of the product sufficiently when
compared to traditionally made products.

5. Can chocolate be 3D printed? Provide appropriate reasons for it.

Yes, We can print some types of Chocolates using the material Extrusion Process.

In the extrusion process instead of filament, a syringe, which contains the chocolate is
loaded, and then it keeps the chocolate at temperature as it prints.

The extruder head moves around and lays down the melted chocolate with the shape
desired in layers. The chocolate eventually cools and becomes solid. The syringe loading
system is food-safe, clean, efficient, and keeps the chocolate fresh. If the operating
temperatures are followed, the chocolate shouldn’t dry up in the syringe at all.

Also, note that we cannot print all types of chocolates using 3D printing

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6. List out the most advanced components that are manufactured using 3D printing.
✓ Aerospace
Environmental control systems (ECS) ducting, custom cosmetic aircraft interior components,
rocket engines components, combustor liners, tooling for composites, oil and fuel tanks, and
UAV components.
✓ Medical
Orthopedic implant devices, dental devices, pre-surgery models from CT scans, custom saw
and drill guides
✓ Transportation
resilient prototypes, elastomeric models, grilles, custom interior features, and large paneling.
✓ Energy
rotors, stators, turbine nozzles, down-hole tool components, and models, fluid/water flow
analysis, flow meter parts, mud motor models, pressure gauge pieces, control-valve
components and pump manifolds

7. What is the need for Additive Manufacturing?

AM allows for mass customization, reduced material waste, lower costs, and increased
efficiency compared to injection moulding, extrusion, or subtractive manufacturing
processes. and also for making geometries that cannot be achieved using traditional
manufacturing methods.

8. How do Solid Images and Functional Prototypes differ from each other?
A Functional Prototype is a sample or model of a product built to test whereas the solid
image is a geometric model in the computer.

9. Why can AM delivered parts have almost unlimited complex geometries?

The AM is an additive process in which the part is built by layer-by-layer addition of the
materials, so the production of the complex geometry is the main advantage of AM process.
Or
As any imaginable part can be sliced (at least virtually), any part can be composed by its
slices, regardless of what geometry it shows.

10. List one company that produces Additive Manufacturing machines and associated
products such as materials and also list one of their products.
✓ 3D Systems
✓ FormLabs
✓ Stratasys
✓ HP
✓ Desktop Metal

Eg.: General Electric makes nozzles for the new Leap jet engines using AM only. The
printers can make the nozzles in one metal piece and the finished product is stronger and
lighter than the ones made in the traditional assembly line.
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PART - B
1. Describe the process chain of AM.
2. Explain Rapid Prototyping and Rapid Tooling.
3. Classify Additive Manufacturing processes. (Or) Based on the state of input
material/raw material classify the AM processes.
4. Describe which specific characteristics of the part are better produced due to the
general AM manufacturing steps than traditional steps.
5. Name the materials (category wise) used in AM processes.
PART - C

1. Summarize the general steps for an Additive Manufacturing process, and give a good
example of a part that will be better fabricated by AM than traditional manufacturing.
2. Make a list of different characteristics of AM technologies as a means to compare with
CNC machining. Under what circumstances does AM have the advantage and under
what would CNC?

UNIT – II :: PART - A

1. Explain in detail about the CAD model preparation for AM.

✓ The design of the part to be built is drafted as CAD 3D models by using any one of
the CAD software like Catia, Creo, etc.

✓ After the creation of the 3d model, it is converted into STL file format.

✓ STL file is a defacto file format that has been followed by AM systems.

2. Why do AM parts show stair-stepping effects?

3D printing uses a layer-by-layer technique that creates
a staircase effect when an object is printed. This effect is
caused by the offset between an object's printed layers
when its curves vary, and it is more noticeable on
oblique and curved surfaces. This effect can be reduced
by reducing the layer thickness.

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3. With neat sketch explain Support structure generation.

Support structures are elements of
a build that are made to properly
support parts during the printing
process to ensure a stable and
successful print. Without them,
prints are subject to failure.

4. Explain the model slicing.

Slicing is a software operation that creates thin, horizontal cross-sections of the STL file.
Basically, the slicing software takes the drawing and cuts it into horizontal cross-sections
of the required thickness.

5. Define Tessellation and explain about the chordal error in the tessellation process.
• It is a process of converting the 3D CAD model into an STL file
• The maximum deviation between an original surface of a CAD model and a triangle
of the tessellated model is termed as chordal error

6. Name some of the software used in STL repair.

✓ Meshmixer
✓ Meshlab
✓ Magics
✓ Blender

7. Name some of the software used in slicing.

✓ Cura
✓ Astroprint
✓ Netfabb
✓ Slic3r

8. Name a few data formats involved in the process of AM.

9. Differentiate between geometry and topography.

10. What is data interfacing?

PART - B
1. Briefly explain the concepts and objectives of DfAM.
2. What are the unique capabilities of AM? Explain in detail.
3. Differentiate Uniform slicing and Adaptive slicing.

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4. How part orientation will affect the Additive manufactured model. Explain in detail.
5. Explain about Tool path generation. Summarize the considerations during Tool path
generation.
PART - C

1. How the part quality can be improved using DfAM concepts. Also, Illustrate the points
to consider for design and fabrication for medical applications.
2. Explain the importance of support structure generation and the possible design in
detail.

UNIT – III :: PART - A

1. Define polymerization.
Polymerization is the process in which small molecules, called monomers, join
chemically to produce a very large chain-like or network molecule, called a polymer.

2. When VPP is preferable?

Vat polymerization processes are excellent at producing parts with fine details and a
smooth surface finish. So VPP is preferable for jewelry, investment casting, and many
dental and medical applications.

3. Name a few photocurable materials and their industrial applications.

Photocurable Materials:
✓ Monomers,
✓ oligomers,
✓ Prepolymers etc.
Industrial Application:
✓ Aircraft Coatings
✓ Corrosion-Protection Coatings
✓ Stereolithography
✓ Optics and Electronics,etc.

4. What materials can be processed with metal laser sintering or laser melting
processes?
✓ Stainless Steel
✓ Titanium
✓ Aluminum
✓ Cobalt Chrome
✓ Steel

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5. Name typical materials used in PBF processes and also state their specific industrial
application.

Materials:
SHS,SLS: Nylon
DMLS, SLM: Stainless Steel, Titanium, Aluminium, Cobalt Chrome, Steel.
EBM: titanium, Cobalt Chrome, ss, al, and copper.

Applications:
Automotive, electrics, desalination industries, corrosion- and wear-resistant alloys,
cemented carbides, industrial machinery, etc.

6. Differentiate between direct and indirect SLS.

selective laser melting (SLM), is the same as direct metal laser melting (DMLM), but the
difference is on a molecular level only.

SLM DMLS
SLM heats the metal powder until it DMLS does not melt the metal
fully melts into a liquid powder, the powder is only sintered
SLM is porous the DMLS Less porous when compared to SLM
it's a complex procedure to print Easily printing alloy of a different
alloys of a different metal. melting point is possible
As it heats until melting more energy Less energy is only required as it only
is required. sinters the powder
A combination of metal and plastic is Even combining metal and plastic is
not possible. possible.
eg. Alumide (mixture of nylon
powder and aluminum powder

7. Why post-processing is required in powder-based AM processes?

To achieve the right properties such as surface quality, geometrical accuracy, and
mechanical properties, nearly all AM components need post-processing. This can include
heat treatment, separating the components from the support structure and build plate,
surface finishing procedures, as well as testing and certification.
PART - B
1. Describe the VAT photo-polymerization and its capability.
2. Explain why VPP is a good process to use to fabricate patterns for investment casting of
metal parts.
3. Explain about Vat Photo Polymerization Process and its working principle. Also,
summarize the benefits and limitations of the process.
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4. Explain about Powder Bed Fusion Process and its working principle. Also, summarize
the benefits and limitations of the process.
5. Explain about Electron Beam Melting Process and its working principle. Also,
summarize the benefits and limitations of the process.
PART - C
1. With a basic understanding of PBF based processes, what is an application you can think
of where PBF could be used? Explain how.
2. Summarize the working principle of the process (in AM) used for making scaffolds for
tissue engineering and custom anatomical models.

UNIT – IV :: PART – A
1. What processes can be used to join the metal sheets when using LLM for metal parts.
The bonding of adjacent layers is done by glue, ultrasonic, soldering, or diffusion
welding.

2. What is the typical layer thickness of AM parts made of plastics?

Process Printer Thickness

Professional fused deposition Stratasys 0.17 mm to 0.33 mm
modeling
Office fused deposition modeling Makerbot, 0.10 mm to 0.33 mm
Ultimaker
Selective laser sintering (SLS) EOS, 3D System 0.060mm to 0.150 mm
Material jetting Stratasys Polyjet 0.016mm to 0.028 mm
Binding Jetting 3D Systems 0.089 - 0.203 mm
ZPrinter
Stereolithography Formlabs 0.05 mm to 0.15 mm
3. List the various materials used in FDM
✓ ABS - Acrylonitrile Butadiene Styrene,
✓ polyamide,
✓ polycarbonate,
✓ polyethylene, and
✓ polypropylene.

4. Why FDM is most commonly used?

✓ FDM can print Thermoplastics that endure heat, chemicals, and mechanical
stress, which makes them an ideal material for printing prototypes that must
withstand testing

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✓ FDM is a relatively accurate and cost-effective solution for most parts.

✓ The materials for FDM printers are inexpensive and widely available

4. List out the process parameters of the FDM/ material extrusion process.
layer thickness air gap layer height
take up unit speed print speed die temperature
build orientation extrusion rate die temperature
raster width nozzle diameter screw speed,
raster orientation mean barrel temperature.

5. What is LOM?
Laminated Object Manufacturing(LOM) is one of the additive manufacturing processes
where an object is created by successively layering sheets of build material, bonding them
through heat and pressure, and then cutting them into the desired shape using either a
blade or a carbon laser

6. List the most commonly used materials in LOM.

LOM technology uses the following as a 3D printing medium.
✓ adhesive-coated paper,
✓ plastic, or
✓ metal laminates
or
UAM: aluminum, copper, stainless steel, and titanium
LOM: Effectively any sheet material capable of being rolled. Paper, plastic, and some sheet
metals. The most commonly used material is A4 paper

PART - B
1. Briefly explain about the material extrusion process. Also state their benefits, limitations,
and applications.
2. Briefly explain about the sheet lamination process. Also state their benefits, limitations,
and applications.
3. Write a short note on Gluing, Adhesive bonding and Thermal bonding.
4. Explain with a neat sketch about Thermal bonding.

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5. Explain the process and principle of Bio-extrusion. Also state their benefits,
limitations, and applications.

Principle:
Extrusion-based bioprinting involves the extrusion of bio-inks through nozzles to
create three-dimensional structures. The bio-ink contains living organisms with biological
relevance for emerging applications such as tissue scaffolds, organs-on-a-chip,
regenerative medicine, and drug delivery systems.

Application:
✓ Tissue engineering and regenerative medicine.
✓ Bioprinting for tissue transplantation.
✓ Pharmaceutical and high throughput screening.
✓ Bioprinting cancer research
Advantages:
✓ High speed,
✓ availability,
✓ low cost,
✓ greater than85% cell viability

Limitations
✓ Lack of precision in droplet placement and size,
✓ need for low viscosity bio-link

PART - C

1. Describe an additive manufacturing process that fabricates multi-material parts (largest

install base and inexpensive machines). Also, discuss about the various materials used in
the process with their benefits and applications.
2. Describe the LLM and its capability. Also, explain the two approaches used in the
process.

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UNIT – V :: PART – A
1. Why should a 3D printing part (made of binder jetting process) not be taken for a
structural test?
✓ Due to the method of binding, the material characteristics are not always
suitable for structural parts
✓ The binder jetting process uses two materials; a powder-based material and a
binder. The binder acts as an adhesive between powder layers.
✓ The binder is usually in liquid form and the build material in powder form.

2. What industry branch preferably uses directed energy deposition?

✓ aerospace,
✓ oil & gas,
✓ defense,
✓ marine, and
✓ architecture.

3. Name two AM processes that deliver colored parts

✓ Binder jetting,
✓ Material Jetting,
✓ Material Extrusion

4. Write a short note on Bio-plotter.

➢ The 3D Bioplotter is a registered trademark of Envisiontec, Marl, Germany, allows the
processing of a wide variety of materials from plastics to bone materials and drugs and
even organ printing or soft tissue fabrication.
➢ Up to five materials can be processed using either a heated or a cooled dispenser unit
that is operated by a 3-axis plotter.
➢ Depending on the material, the system uses different hardening processes such as
precipitation, phase transition (liquid to solid), or two-component reaction.
➢ Some materials need post-processing such as sintering.

5. What is the significance of the 3D printing process? Explain.

✓ Majorly, 3D printing can create intricate, and complex shapes using less material
than subtractive manufacturing processes.
✓ Colored parts
✓ Mass customization
✓ Speed
✓ Flexibility and Cost benefits in prototyping

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6. Explain the 3DP process and its process parameters.

3DP is also known as Binder Jetting. It is one of the Additive Manufacturing processes
in which a Liquid Bonding agent is selectively deposited to join powder materials.

Process Parameters:
✓ Particle packing. ( The spreading of powder causes low powder packing.)
✓ Green strength.
✓ Particle size distribution.
✓ Powder flowability.
✓ Powder wet ability.
7. What are the materials that can be processed via metal 3D printing?
✓ Acrylic photopolymers (thermoset)
✓ ABS
✓ Polyamide
✓ PBA

8. State the application of LENS.

✓ Repair and reconditioning
✓ Aircraft frame and structures
✓ Marine propulsion
✓ Refractory metal components.

9. Name a few materials used in the DED process.

✓ titanium,
✓ aluminum,
✓ stainless steel
✓ copper

10. What is Bio-Additive Manufacturing?

Bio - Additive Manufacturing can be defined as the use of a 3D printer for printing in the
medical Industries.
or
Bio- Additive Manufacturing (Bio-AM) is defined as the use of 3D printing for medical
purposes or non-therapeutic "human enhancement", whether they involve the production
of biological material or not. It includes any application for rehabilitating, supporting, or
augmenting biological functionality.

11. List a few medical applications of AM process.

✓ bio-printing,
✓ Tissue Engineering,
✓ Dentistry,
✓ printing patient-specific customized implants,

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✓ Medical devices/Surgical tools,

✓ orthopedics and prosthesis,
✓ Drug delivery
✓ virtual surgical planning

12. What are the various AM processes used in medical applications?

✓ Powder bed fusion, material extrusion, and VAT photopolymerization are utilized
in all categories.
✓ Material jetting is not used for implants and biomanufacturing, and
✓ binder jetting is not utilized for tools, instruments, and parts for medical devices.
✓ sheet lamination is rarely for medical models or phantoms.
✓ directed energy deposition is utilized rarely only in implants.

13. What is the most commonly used AM material(s) in a medical application?

PART - B

1. Explain various droplet formation technologies in Material Jetting.

The Main modes of inkjet technology used for the deposition of material in the material
jetting process are continuous stream inkjet (CIJ) and drop-on-demand (DOD) techniques.
The difference between the continuous stream and DOD is the timing of droplet
generation.

continuous stream inkjet (CIJ):

➢ In the continuous stream, the droplets are generated by breaking up the continuous
stream of droplets through an ejection nozzle.
➢ In continuous stream technique ejection of droplet stream and its corresponding
recycling via gutter continues even in the non-working state of the printer.

Drop-On-Demand (DOD):
➢ In DOD droplets are generated whenever required.
➢ In a DOD inkjet printer, the printer is supposed to eject an ink droplet only when
commanded for the same and not continuous.
2. With a neat sketch explain the working principle of the material jetting process. Also,
state its advantages, limitations, and applications. (or) Write the working principle of
polyjet/MJM.
3. With a neat sketch explain the working principle of the binder jetting process. Also, state
its advantages, limitations, and applications. (or) Enumerate the basic process,

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capabilities, and types of printing in 3D Printing. What are the materials that can be
processed via metal 3D printing?
4. With a neat sketch explain the working principle of the DED process. Also, state its
advantages, limitations, and applications. (or) Explain the entire process of LENS and list
its advantages, limitations, and applications with a case study.
PART - C
1. With a basic understanding of AM technologies, prepare a comparative table for basic
principles, materials, advantages, limitations, typical build volumes, and manufacturer
of additive manufacturing processes categorized as per ASTM (VPP, PBF, MEX, SL, MJ,
BJ, DED).
2. Find three parts that were created via three differing Additive Manufacturing
Technologies. Present the picture of the part, the process used for production, the
material used, and what is it about the part that gives an idea of the process used to create
it.

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