(An Autonomous Institution, Affiliated to Anna University, Chennai)

QUESTION BANK FORMAT

(Questions Should Not Repeat)

NAME OF THE DEPARTMENT Mechatronic Engineering

YEAR / SEMESTER III Year /VI Semester

REGULATION
SUBJECT CODE
SUBJECT NAME Additive Manufacturing
FACULTY NAME S.T.Selvamani Contact Number 9940540221
REVISED BLOOMS TAXONOMY(RBT) :
L1- L2 - L5 - L6 -
L3 - Applying L4 - Analyzing
Remembering Understanding Evaluating Creating

UNIT-I: INTRODUCTION TO DESIGN OF MECHATRONICS SYSTEM

Overview Need Development of Additive Manufacturing (AM) Technology: Rapid Prototyping- Rapid
Tooling Rapid Manufacturing Additive Manufacturing. AM Process Chain ASTM/ISO 52900 Classification
Benefits AM Unique Capabilities AM File formats: STL, AMF Applications: Building Printing, Bio Printing,
Food Printing, Electronics Printing, Automobile, Aerospace, Healthcare. Business Opportunities in AM.
PART-A (2-Marks)

S.NO QUESTIONS CO RBT LEVEL

1. What are the applications of AM? CO1 L1

2. What are the merits of product development? CO1 L1

How is additive manufacturing disrupting traditional manufacturing CO1 L1

3. processes?
Can additive manufacturing be used to create functional end-use CO1 L2
4. products, or is it primarily for prototyping?
5. What is Rapid Prototyping? CO1 L1

6. Write the merits of virtual prototyping. CO1 L2

7. What is Rapid Tooling? CO1 L2

8. What are the applications of rapid tooling? CO1 L2

9. What are the benefits of rapid tooling? CO1 L1

10. What is additive manufacturing? CO1 L1

11. Classify the AM process? CO1 L2

12. What are the applications of AM? CO1 L2

13. What is STL file? CO1 L3

14. What is AM process chain? CO1 L5

15. What are the limitations of AM? CO1 L1

16. How can 3D printing contribute to sustainability and reduce waste in CO1 L2
manufacturing?
What are the challenges and limitations of additive manufacturing? CO1 L1
17.

BT
PART-B (13- Marks Or 16-Marks or 8-Marks) CO Marks
Level
1. Write a note on the need and development of AM systems CO1 L2 13
2. Write a note on the impact of AM on product development CO1 L2 13

3. Explain how AM has influenced the 3D printing technology CO1 L1 13

4. Explain the transition of RP to AM. CO1 L1 13

5. Classify and explain the AM process. CO1 L1 13

6. Explain the AM process chain CO1 L1 13

7. Write a note on the benefits and applications of AM CO1 L2 13

8. What impact does additive manufacturing have on reducing lead times CO1 13
and production costs in the aerospace sector? Elaborate your answer L2
9. State and explain the applications of AM in various sectors.

10. How AM can be useful in electronics printing? Explain in detail.

11. Explain in detail how AM is applied in building printing/ construction
field.

12. Explain the latest advancements and innovations in the field of additive
manufacturing?

13. Briefly explain the potential applications of 3D bioprinting in tissue

engineering and regenerative medicine?

14. Can additive manufacturing reduce the weight of aircraft and improve
fuel efficiency? Justify your answer

15. What are the advancements in additive manufacturing for electronics and
functional devices? Explain in detail

16. Explain in detail how businesses integrate additive manufacturing into

their supply chains?

17. What safety considerations should be taken into account when using 3D
printing in medical applications? Elaborate in detail

18. Explain in detail about the latest advancements in metal 3D printing for
aerospace applications

19. Can 3D printing be used for large-scale manufacturing and construction

projects? Explain in detail with examples

20. How is the automotive industry leveraging 3D printing for customized

components and spare parts?

PART-C (15-Marks) CO CO1 Marks

1. What is bio printing? How AM is useful in biomedical field? CO1 L2 15

2. What are the key challenges and future prospects for industrial CO1 15
L3
applications of additive

3. Can additive manufacturing revolutionize personalized prosthetics and

implants? Explain in detail with examples

4. Are there any successful case studies of using additive manufacturing in

automotive manufacturing? Explain any one case study in detail

5. Are there any successful case studies of using additive manufacturing in

aerospace repair and maintenance? Explain in detail

6. Can additive manufacturing enhance the production of concept cars and

future vehicle designs? Justify your answer
 7. What are the key considerations for ensuring the quality and reliability
of 3D printed aerospace parts? Explain in detail

8. Can additive manufacturing enhance the development of complex and

optimized aircraft structures? If Yes, Explain with a case study

9. What are the challenges and opportunities of using 3D printing in

pharmaceuticals and drug delivery systems? Explain
10.

UNIT-II: VAT POLYMERIZATION AND DIRECTED ENERGY DEPOSITION

Photo polymerization: Stereolithography Apparatus (SLA) Materials -Process top down and bottom up
approach Advantages Limitations Applications. Digital Light Processing (DLP) Process Advantages
Applications.
PART-A (2-Marks)

S.NO QUESTIONS CO RBT LEVEL

1. What do you mean by photo polymerization? CO2 L1

2. Mention the types of photopolymerization processes CO2 L2
3. Differentiate SLA & DLP process CO2 L1
4. Explain the principle of operation in SLA CO2 L1
5. List the important process parameters in SLA process CO2 L1

6. What do you mean by top down approach? How does it differ from CO2 L1
bottom up approach in SL
7. List down the materials used in SLA process CO2 L3
8. Mention the advantages of SLA CO2 L2
9. Mention the disadvantages of SLA CO2 L2
10. List out the specific application of SLA CO2 L2
11. Explain the principle of operation in DLP CO2 L1
List down the materials used in DLP process CO2
12.
L3
13. Mention the advantages of DLP CO2 L2
14. List the important process parameters in DLP process CO2 L2
15. Mention the disadvantages of DLP CO2 L2
16. List out the specific application of DLP CO2 L2
17. Explain the principle of operation in CLIP CO2 L2
18. List down the materials used in CLIP process CO2 L1
19. Mention the advantages of CLIP CO2 L3
20. Mention the disadvantages of CLIP CO2 L2
21. List out the specific applications of CLIP

22. What do you mean by Directed Energy Deposition?

23. Mention the types of Directed Energy Deposition processes

24. Explain the principle of operation in LENS

25. List down the materials used in LENS process

26. Mention the advantages and disadvantages of LENS

27. List out the specific application of LENS

BT
PART-B (13- Marks Or 16-Marks or 8-Marks) CO Marks
Level
You're working on a project that requires intricate and fine details in the CO2
3D printed model. Describe the features of the SLA process that make it
well-suited for reproducing intricate geometries. How does the layer-by-
28. layer process of SLA contribute to achieving high- resolution details? L1 13
Explain the process of DLP in detail. Mention its advantages & CO2 L2 13
29. disadvantages

Describe the challenges and benefits of using DLP for creating larger CO2 L2 13
parts compared to
traditional manufacturing methods. How might you address issues like
30. distortion and accuracy across a larger build area?

31. CO2 L3 13
What is CLIP? Explain the process in detail. Also mention its
 advantages & disadvantages

How can the Laser Engineered Net Shaping (LENS) process be applied CO2 L1 13
to restore the worn section of an erospace component? Describe the
32. steps involved in repairing the part using LENS, including the selection
of appropriate feedstock material and the considerations for achieving a
precise geometry

33. What do you mean by LENS? Explain the process involved in LENS. CO2 L1 13
Also mention its applications
34. Explain in detail the process of Directed Energy Deposition (DED). CO2 L2 13
State the advantages and disadvantages
Explain how CLIP technology could benefit their production process CO2 L2 13
35. compared to traditional methods. Discuss the potential for creating
intricate and highly detailed jewelry pieces using CLIP's features.

36. Enumerate the process of SLA with the process specifications involved CO2 L3 13
in it
BT
PART-C (15-Marks) CO Marks
Level
You're designing a load-bearing component using SLA. How would you CO2
ensure that the SLA part has sufficient structural integrity to withstand
1 the required loads? What design considerations and reinforcement L3 15
techniques could you employ to enhance the mechanical strength of the
SLA part?
You're working on a project that involves printing a geometrically CO2
complex part. How would you determine the optimal build orientation
2 L3 15
for this part in the DLP printer? Consider factors such as support
structures, surface quality, and print time.
A dental lab is considering adopting CLIP for producing dental models, CO2
crowns, and bridges. Explain how the continuous motion and surface
3 finish advantages of CLIP could improve the accuracy and quality of L3 15
dental restorations. Discuss the potential for scaling up production in a
dental setting
An automotive manufacturing company needs to modify an existing
tooling mold for a specific component. Describe how the LENS
process can be employed to add material to the mold for the necessary
modifications. Highlight the benefits of using LENS for tooling
applications, such as reducing lead times and extending tool lifespan.
 UNIT-III: POWDER BED FUSION AND MATERIAL EXTRUSION
Powder Bed Fusion: Selective Laser Sintering (SLS): Process Powder Fusion Mechanism- Materials and
Application. Selective Laser Melting (SLM), Electron Beam Melting (EBM): Materials - Process -
Advantages and Applications.
Binder Jetting: Three-Dimensional Printing Materials Process Benefits Limitations Applications
PART-A (2-Marks)

S.NO QUESTIONS CO RBT LEVEL

1. What do you mean byPowder Bed Fusion? CO3 L1

2. Mention the types of Powder Bed Fusion processes CO3 L3
3. Differentiate SLS & SLM process CO3 L2
4. Explain the principle of operation in SLS CO3 L1
5. List the important process parameters in SLS process CO3 L2
6. List down the materials used in SLS process CO3 L2
7. Mention the advantages of SLS CO3 L3
8. Mention the disadvantages of SLS CO3 L2
9. List out the specific application of SLS CO3 L3
10. Explain the principle of operation in SLM CO3 L2
11. List the important process parameters in SLM process CO3 L1
12. List down the materials used in SLM process CO3 L3
13. Mention the advantages of SLM CO3 L3
14. Mention the disadvantages of SLM CO3 L2
15. List down the materials used in EBM process CO3 L1
16. Mention the advantages of EBM CO3 L2
17. Mention the disadvantages of EBM CO3 L3
18. List out the specific applications of EBM CO3 L3
19. List out the specific application of SLM CO3 L1
20. Explain the principle of operation in EBM CO3 L1
21. What do you mean by Material Extrusion process? CO3 L2

22 Explain the principle of operation in FDM CO3 L3

23 List the important process parameters in FDM process CO3 L3

List down the materials used in FDM process CO3 L1
Mention the advantages of FDM CO3 L1
Mention the disadvantages of FDM CO3 L3
List out the specific application of FDM CO3 L1
BT
PART-B (13- Marks Or 16-Marks or 8-Marks) CO Marks
Level

1. Enumerate the process of SLS with the process specifications involved CO3 L1 13
in it
Describe how SLS is used to manufacture lightweight, high-strength CO3 13
aerospace components. What materials are commonly used, and how
does this technology contribute to the aerospace industry's efficiency
2. and performance? L2
Describe the role of SLM in producing high-performance tooling, dies, CO3 13
3. and molds for manufacturing processes. How does SLM contribute to L2
cost-effective tool production and reduced lead times?
4. Explain the process of SLM in detail. Mention its advantages & CO3 13
disadvantages L1

5. What is EBM? Explain the process in detail. Also mention its CO3 13
advantages & disadvantages L2
Describe the use of EBM technology in producing components for the CO3 13
6. marine industry, such as propellers and specialized marine equipment.
What advantages does EBM offer in terms of corrosion resistance and
performance in marine environments? L2

7. What do you mean by FDM? Explain the process involved in FDM. CO3 13
Also mention its applications L2
Discuss the application of FDM in creating customized orthopedic CO3 13
8. braces and supports for patients with musculoskeletal conditions. What
benefits does this technology offer in terms of comfort and support? L2

PART-C (15-Marks) CO BT Marks

 Level

How does SLS contribute to the production of intricate patterns for CO3
1. investment casting processes, especially in the jewelry and aerospace
L3 15
industries? What advantages does it offer in terms of design complexity
and lead times?
Explain the role of SLM in producing efficient heat exchangers for CO3
2. various industrial applications. What materials are suitable for heat L3 15
exchangers, and how does SLM enhance their performance?
Explore how EBM is used in the automotive industry to produce CO3
3. customized, high- performance parts like exhaust manifolds and
L3 15
suspension components. What benefits does EBM offer in terms of rapid
prototyping and optimization of automotive designs?
Explain how FDM technology is used to produce customized wearables,
4. such as hearing aids and sports equipment. What materials and design
capabilities make FDM suitable for these applications?

UNIT-IV: MATERIAL JETTING AND DIRECTED ENERGY DEPOSITION

Material Jetting: MultiJet Modeling- Materials Process Benefits Applications. Directed Energy Deposition:
Laser Engineered Net Shaping (LENS) Process Material Delivery Materials-Benefits -Applications.

PART-A (2-Marks)

S.NO QUESTIONS CO RBT LEVEL

1. Define Material Jetting and explain its working principle briefly. CO4 L1
What are the main advantages of Material Jetting over traditional CO4
2. manufacturing processes? L1
List two common materials used in Material Jetting and their typical CO4
3. applications. L3
4. Describe the process of material delivery in Material Jetting CO4 L1
Explain the concept of Directed Energy Deposition and how it differs CO4
5. from other additive manufacturing techniques. L2
6. What are the key benefits of using Directed Energy Deposition for CO4 L2
 repairing components?

Name two materials commonly used in Directed Energy Deposition and CO4
7. describe their properties. L1
Compare the process monitoring and control in Material Jetting and CO4
8. Directed Energy Deposition. L2
Discuss two challenges associated with post-processing parts produced CO4
9. by Material Jetting and Directed Energy Deposition. L3
How do the mechanical properties of parts produced by Material Jetting CO4
and Directed Energy Deposition compare to traditional manufacturing
10. methods? L3
11. What is the primary method of material delivery in Material Jetting? CO4 L1

12. How does Directed Energy Deposition differ from Material Jetting in CO4
terms of energy source? L3
13. Name one common application of Material Jetting in the medical field. CO4 L2

14. Describe one advantage of using Directed Energy Deposition for CO4
repairing components. L2
15. What is the key benefit of using support structures in Material Jetting? CO4 L2

16. How does the surface finish of parts produced by Directed Energy CO4
Deposition compare to parts produced by Material Jetting? L2
17. Name one environmental consideration associated with Material Jetting. CO4 L2

18. What software is commonly used for designing parts in Directed Energy CO4
Deposition L3
BT
PART-B (13- Marks Or 16-Marks or 8-Marks) CO Marks
Level
How does the Material Jetting process work, and what are its key CO4
1. advantages over traditional manufacturing methods? L3 13
What are the main materials used in Material Jetting and how do their CO4 13
2. properties affect the final printed parts? L2

3. What are the limitations of Material Jetting in terms of part size, CO4 13
complexity, and resolution? L3

4. How does Directed Energy Deposition (Laser Engineered Net Shaping) CO4 13
L2
differ from other additive manufacturing processes, such as powder bed
 fusion?

What are the advantages of using Directed Energy Deposition (Laser CO4 13
5. Engineered Net Shaping) for repairing and adding material to existing
components? K5

6. What materials can be used in Directed Energy Deposition, and how do CO4
they impact the mechanical properties of the deposited parts?

7. How does the process control and monitoring differ between Material CO4 13
Jetting and Directed Energy Deposition? L3

8. What are the key challenges in post-processing parts produced by

Material Jetting and Directed Energy Deposition
How do the material properties of parts produced by Material Jetting and
9. Directed Energy Deposition compare to traditionally manufactured
parts?
BT
PART-C (15-Marks) Marks
Level
What are some of the most common applications of Material Jetting and CO4
1. Directed Energy Deposition in industries such as aerospace, automotive, L3 15
and medical?

2. How do the cost considerations of Material Jetting and Directed Energy CO4
L3 15
Deposition compare to traditional manufacturing methods?

3. What are the current research trends and future developments in Material CO4
L3 15
Jetting and Directed Energy Deposition?

UNIT-V: SHEET LAMINATION AND DIRECT WRITE TECHNOLOGY

Sheet Lamination: Laminated Object Manufacturing (LOM)- Basic Principle- Mechanism: Gluing or
Adhesive Bonding – Thermal Bonding – Materials – Application and Limitation. Ink-Based Direct Writing
(DW): Nozzle Dispensing Processes, Inkjet Printing Processes, Aerosol DW – Applications of Dw.

PART-A (2-Marks)

S.NO QUESTIONS CO RBT LEVEL

How does LOM differ from traditional subtractive manufacturing

1. processes? CO5 L1
2. State one advantage of using LOM for rapid prototyping. CO5 L2
3. Describe one post-processing step often required after LOM. CO5 L1
4. What role does a laser play in the LOM process? CO5 L3
5. Name one industry where LOM is commonly used. CO5 L2
6. What types of material can be used in Ink based direct writing(DW)? CO5 L2
How does the resolution of inkjet printing in DW compare to other CO5
7. nozzle dispensing processes? L3
8. Name one application where Aerosol DW is particularly useful. CO5 L2
9. Describe one method to control the deposition of ink in DW processes. CO5 L2
State one advantage of using Ink-Based Direct Writing (DW) over CO5
10. traditional printing methods. L3
BT
PART-B (13- Marks Or 16-Marks or 8-Marks) CO Marks
Level
Explain the basic principle of Laminated Object Manufacturing (LOM). CO5
How does the LOM process differ from other additive manufacturing
1. techniques? L2 13
Describe the mechanism of LOM in detail, focusing on the two main CO5
bonding methods: gluing or adhesive bonding, and thermal bonding.
2. Discuss the advantages and limitations of each bonding method.
L2 13
Compare and contrast the materials used in LOM with those used in CO5
other additive manufacturing processes. Discuss the key properties of
3. these materials and their suitability for LOM. L2 13
4. State one limitation of using gluing or adhesive bonding in LOM. CO5 L2 13
5. What is the basic principle of Laminated Object Manufacturing (LOM)? CO5 L2 13
6. Name two bonding methods used in LOM for joining layers of material. CO5 L2 13
7. Mention one advantage of using thermal bonding in LOM.

8. Give an example of a material commonly used in LOM.

9. What is the primary function of nozzles in Ink-Based Direct Writing

(DW)?
10. Name one nozzle dispensing process used in DW.

11. Briefly explain the working principle of inkjet printing in DW.

12. State one advantage of using Aerosol DW over traditional DW

processes.

13. Provide one example of an application where Ink-Based Direct Writing

(DW) is used.
Explain the different nozzle dispensing processes used in Ink-Based
14. Direct Writing (DW). Compare the advantages and limitations of each
process, considering factors such as resolution, speed, and material
compatibility.

15. Discuss the concept of Aerosol DW in detail, including the mechanism

of aerosol deposition and its advantages over traditional DW processes.
BT
PART-C (15-Marks) CO Marks
Level
Describe the working principle of inkjet printing processes in DW. How CO5
1. does inkjet printing differ from other nozzle dispensing processes?
L3 15
Discuss the key features of inkjet printing that make it suitable for DW
applications
Discuss the applications of LOM in various industries. Provide examples CO5
2. of how LOM is used to create complex parts or prototypes, and explain L3 15
the advantages it offers over traditional manufacturing methods
Provide examples of applications where Ink-Based Direct Writing (DW) CO5
3. is used. Discuss the unique capabilities of DW processes that make them
L3 15
suitable for these applications, such as biofabrication, electronics
manufacturing, or 3D printing of functional materials