Name – Shivam Singh
Student ID- SVU34050026
Branch- Mechanical Engineering
Subject- Additive Manufacturing
(IME - 704) – 7th Semester
Unit – Assignment no: 1
Objective Type Questions-(1Marks each)
1. Plastic used in additive manufacturing..
a. Nylon
b. PLA
c. TPU
d. Both of the above
Ans : d. Both of the above
2. Metals used in additive manufacturing
a. Copper
b. H13 tool steel
c. Both of the above
d. None of the above
Ans : c. Both of the above
3. Which of the following is typically the cheapest type of 3D printer?
a. FDM
b. SLA
c. Powder based
d. SLM
Ans : a. FDM
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4. Which of the following is typically the most expensive type of 3D printer?
a.SLA
b.SLM
c.FDM
d.None
Ans : b.SLM
5. What printer melts metal?
a. SLS
b.SLM
c. SLA
d.FDM
Ans : b.SLM
Short Answer Type Questions-(2 Marks each)
1. Define additive manufacturing.
Additive manufacturing is a modern manufacturing process where materials are added layer by
layer to create a 3D object.
It is based on a digital 3D model and contrasts with subtractive methods like machining.
This technology allows for the creation of complex shapes that are difficult or impossible to
achieve using traditional methods.
Materials commonly used include plastics, metals, and ceramics.
It reduces waste as only the required material is used.
It supports rapid prototyping and small-scale production efficiently.
Common applications include aerospace, medical implants, and automotive components.
It is also known as 3D printing in many applications.
2. Define 3D printing.
3D printing is a type of additive manufacturing where objects are built layer by layer from a
digital file.
It involves slicing a 3D design into horizontal layers and printing each layer using materials like
plastic or metal.
The process starts with CAD (Computer-Aided Design) software for modeling.
Printers use materials like PLA, ABS, or resin to create physical items.
3D printing is used in education, prototyping, healthcare, and consumer goods.
It allows quick design validation and customization.
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It is cost-effective for low-volume production.
3D printing helps reduce lead times and material wastage.
3. What is PLA?
PLA stands for Polylactic Acid, a biodegradable thermoplastic derived from renewable
resources like corn starch or sugarcane.
It is one of the most commonly used materials in 3D printing.
PLA is environmentally friendly and emits a sweet smell during printing.
It melts at a lower temperature (around 180–220°C), making it user-friendly.
PLA is ideal for beginners due to minimal warping and easy handling.
It offers good surface finish and is used in models, toys, and prototypes.
However, it is less heat-resistant compared to ABS.
It’s suitable for decorative or non-functional prints.
4. Give the example of plastics used in additive manufacturing.
Several types of plastics are used in additive manufacturing depending on the application.
Common examples include PLA (Polylactic Acid), which is biodegradable and easy to print.
ABS (Acrylonitrile Butadiene Styrene) is known for strength and durability.
PETG (Polyethylene Terephthalate Glycol) is a tough, impact-resistant plastic.
Nylon (Polyamide) is flexible and strong, used in engineering applications.
TPU (Thermoplastic Polyurethane) is a flexible rubber-like material.
Polycarbonate (PC) offers high strength and heat resistance.
Each plastic type offers unique properties suited to different industrial and functional uses.
5. What is the function of Copper in additive manufacturing?
Copper is used in additive manufacturing primarily for its excellent electrical and thermal
conductivity. It is suitable for producing complex components like heat exchangers, induction
coils, and electrical connectors. 3D printing of copper allows for intricate internal geometries
that improve heat transfer. Traditional methods may not offer such design flexibility.
Copper-based printing requires specialized printers due to its reflective surface.
Laser Powder Bed Fusion and Binder Jetting are often used for copper. It supports lightweighting
and efficient cooling systems in electronics and aerospace. Copper’s inclusion in AM expands
design possibilities for high-performance component
Long Question- Answers (7 Marks each)
1. What do you understand by additive manufacturing . Write down the differences
between additive manufacturing and 3D printing.
Additive Manufacturing (AM) is a process of creating a three-dimensional object by building it
layer by layer from a digital model. Unlike traditional manufacturing techniques that involve
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subtracting material from a solid block (e.g., cutting, drilling, or milling), AM adds material only
where needed, leading to minimal waste and the ability to create complex and intricate shapes.
It is widely used in aerospace, automotive, medical, and prototyping industries.
Additive manufacturing can utilize a variety of materials including plastics, metals, ceramics,
and composites. It enables faster prototyping, customization, and on-demand production.
Differences between Additive Manufacturing and 3D Printing
Basis Additive Manufacturing (AM) 3D Printing
A subset or commonly used term for AM,
Broad industrial process of layer-
Definition especially in consumer-level
wise manufacturing
applications
Mostly used in industrial, high- Often used in hobbyist, education, and
Usage
precision sectors consumer applications
Technical and used in professional Popular and general-purpose term for
Terminology
manufacturing contexts any layer-based printing process
Includes multiple advanced
Technology Typically refers to FDM, SLA, or basic
technologies (e.g., SLM, EBM,
Scope printing methods
DMLS)
Metals, ceramics, polymers,
Material Range Mostly polymers (like PLA, ABS, TPU)
composites
Accuracy and High accuracy and industrial-grade Moderate accuracy, less suitable for
Tolerance tolerances critical components
Application Aircraft parts, medical implants,
Prototypes, models, toys, learning kits
Examples tooling
2. What is the working of additive manufacturing? Write down the steps such as Software
hardware used in additive manufacturing.
Additive Manufacturing (AM) is a process where 3D objects are built layer by layer directly from a
digital model. It is used to manufacture prototypes, tools, and end-use products with complex
geometries that would be difficult or impossible using traditional methods.
Working Principle of Additive Manufacturing:
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Additive manufacturing works by depositing material layer-by-layer based on a CAD model.
Each layer is fused together until the final part is completed. The process includes both
software and hardware components to ensure accurate printing.
Steps Involved in Additive Manufacturing:
1. Designing the 3D Model (Software):
• The first step is to create a 3D model of the object using CAD (Computer-Aided
Design) software like:
o AutoCAD
o SolidWorks
o Fusion 360
• The design is then exported to a compatible format, usually .STL
(Stereolithography).
2. Slicing the Model (Software):
• The STL file is imported into slicing software, such as:
o Cura
o PrusaSlicer
o Simplify3D
• This software slices the model into horizontal layers and generates G-code, which
instructs the printer how to build each layer.
3. Machine Setup (Hardware):
• Load the 3D printer with the required material (filament, resin, powder, etc.).
• Level the build platform and ensure the extruder or laser is calibrated.
• Set parameters like temperature, print speed, and layer height.
4. Printing Process (Hardware):
• The printer starts depositing or curing material layer by layer:
o FDM printers extrude melted filament.
o SLA printers cure liquid resin using UV light.
o SLM/DMLS printers melt metal powder with a laser.
• The build continues until all layers are complete.
5. Post-Processing:
• After printing, parts may require:
o Support removal
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o Surface finishing (sanding, polishing)
o Curing (for resins)
o Sintering (for metal parts)
• These steps improve appearance, accuracy, and strength.
Software Used in Additive Manufacturing:
• CAD Software: AutoCAD, CATIA, SolidWorks.
• Slicing Software: Cura, Slic3r, Repetier-Host.
• Simulation Software: ANSYS Additive, Autodesk Netfabb (for stress and thermal
analysis).
Hardware Used in Additive Manufacturing:
1. 3D Printer (based on technology used):
2. FDM (Fused Deposition Modeling)
3. SLA (Stereolithography)
4. SLS (Selective Laser Sintering)
5. DMLS/SLM (for metal printing)
6. Print Head/Extruder or Laser
7. Build Platform
8. Motion Control System
9. Cooling Fans or Heaters
10. Electronic Controller Unit
3. What are the materials used in additive manufacturing.
Additive manufacturing (AM), commonly known as 3D printing, uses a variety of materials
depending on the process type, application, and end-use requirement. The materials used
are broadly classified into plastics, metals, ceramics, and composites. Each category has
unique properties making them suitable for specific purposes.
1. Plastics/Polymers:
o PLA (Polylactic Acid): A biodegradable plastic, widely used in FDM printers due
to its low melting point and ease of use.
o ABS (Acrylonitrile Butadiene Styrene): Stronger and more heat-resistant than
PLA, used in durable consumer products.
o Nylon (Polyamide): Offers flexibility, strength, and chemical resistance, ideal for
functional parts.
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o TPU (Thermoplastic Polyurethane): A flexible, rubber-like plastic used for seals,
gaskets, and phone cases.
o Photopolymers: Used in SLA and DLP printers, they harden when exposed to UV
light.
2. Metals:
o Stainless Steel: Offers strength and corrosion resistance; used in aerospace and
medical devices.
o Aluminum: Lightweight and strong; ideal for automotive and aerospace parts.
o Titanium: High strength-to-weight ratio and biocompatibility; used in aerospace
and implants.
o H13 Tool Steel: Used in high-temperature tooling applications.
o Copper and Nickel Alloys: Used for their electrical and thermal conductivity.
3. Ceramics:
o Used in industries where high-temperature resistance is required such as
aerospace and biomedical applications.
o Materials include alumina, zirconia, and silica.
4. Composites:
o These are materials reinforced with fibers such as carbon fiber, glass fiber, or
Kevlar to enhance strength and stiffness.
o Often used in automotive, aerospace, and sporting goods.
5. Other Emerging Materials:
o Bio-inks: Used in bioprinting to create tissues and organs.
o Concrete and construction materials: Used in large-scale 3D printing for
building structures.
4. What are the advantages and disadvantages of additive manufacturing.
Additive Manufacturing (AM), also known as 3D printing, is a process of creating three-
dimensional objects by adding material layer by layer. It has revolutionized modern
manufacturing by offering unique capabilities that traditional methods lack. However, like any
technology, it has both advantages and disadvantages.
Advantages of Additive Manufacturing:
1. Design Flexibility:
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o Complex geometries, internal features, and lightweight structures (like lattice
designs) can be easily created which are difficult or impossible with traditional
methods.
2. Customization:
o Each part can be uniquely designed without requiring changes in tooling or
setup. It’s highly beneficial for prosthetics, dental implants, and custom-fit
components.
3. Reduced Waste:
o Material is added layer by layer, leading to minimal waste, especially compared
to subtractive processes like machining.
4. Rapid Prototyping:
o Designers can quickly turn ideas into prototypes, allowing for faster design
iterations and product development cycles.
5. Lower Tooling Costs:
o No need for expensive molds or tooling, making low-volume production more
affordable.
6. On-Demand Manufacturing:
o Parts can be printed as needed, reducing the need for large inventories and
enabling localized production.
7. Shorter Lead Times:
o Faster setup and production times help reduce time-to-market.
Disadvantages of Additive Manufacturing:
1. Limited Material Selection:
o Although growing, the variety of materials available for 3D printing is still limited
compared to traditional manufacturing.
2. Lower Strength and Surface Finish:
o Printed parts often have inferior mechanical properties and surface finishes
compared to those made with conventional processes.
3. High Initial Cost:
o High-end industrial 3D printers and materials can be expensive, especially for
metal additive manufacturing.
4. Slow Production Speed:
o AM is generally slower for mass production compared to methods like injection
molding or CNC machining.
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5. Post-Processing Required:
o Many parts require support removal, sanding, or heat treatment after printing,
which adds time and labor.
6. Size Limitations:
o Most 3D printers have size constraints, making the production of large parts
challenging.
7. Regulatory and Quality Challenges:
o In industries like aerospace or medical, certification of AM parts can be difficult
due to variations in properties and lack of standardization
5. Write short notes on
a. Binder Jetting and Material Jetting
b. Material Extrusion and Sheet Lamination
Binder Jetting
Binder Jetting is an additive manufacturing process where a liquid binding agent is selectively
deposited onto a powder bed to join the powder particles together layer by layer. It is similar to
inkjet printing but uses a binder instead of ink.
• Working Principle:
o A layer of powdered material (like metal, sand, or ceramic) is spread across the
build platform.
o A print head moves over the bed and deposits binder droplets in specific
locations, fusing the powder particles.
o The platform is lowered, and a new layer of powder is added.
o The process is repeated until the entire part is built.
• Applications:
o Metal casting molds and cores, architectural models, full-color prototypes.
• Advantages:
o Fast printing speed.
o Ability to produce complex shapes.
o No support structures needed during printing.
• Limitations:
o Post-processing like sintering or infiltration is often required to strengthen the
parts.
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Material Jetting
Material Jetting involves the deposition of droplets of build material (usually photopolymers or
waxes) onto a build platform, which are then cured using UV light.
• Working Principle:
o Tiny droplets of material are jetted through multiple nozzles onto the build
platform.
o UV light instantly cures the material.
o Layer by layer, the part is built with very high accuracy and smooth surface
finish.
• Applications:
o Dental models, jewelry, anatomical models, high-resolution prototypes.
• Advantages:
o Excellent surface finish and dimensional accuracy.
o Multi-material and color printing is possible.
• Limitations:
o Expensive materials.
o Parts may be brittle and not suitable for functional use.
b. Material Extrusion
Material Extrusion, commonly represented by Fused Deposition Modeling (FDM), is the most
widely used additive manufacturing method, especially in desktop 3D printing.
• Working Principle:
o A thermoplastic filament is fed through a heated nozzle where it is melted.
o The molten material is extruded layer by layer onto a build platform.
o The material solidifies and bonds as it cools.
• Applications:
o Prototypes, jigs and fixtures, educational models, simple functional parts.
• Advantages:
o Low cost of equipment and materials.
o Easy to operate and maintain.
• Limitations:
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o Lower surface finish and accuracy compared to other AM processes.
o Limited material selection.
Sheet Lamination
Sheet Lamination is an additive manufacturing process that involves stacking and bonding
sheets of material (such as paper, metal, or plastic) to create a 3D object.
• Working Principle:
o Thin sheets are cut to shape using a laser or blade.
o Each layer is bonded using adhesive or ultrasonic welding.
o The sheets are stacked to form the complete object.
• Applications:
o Visual prototypes, laminated tooling, decorative objects.
• Advantages:
o Fast and relatively inexpensive process.
o Material waste is minimal.
o Colored and paper-based models are possible.
• Limitations:
o Mechanical properties are generally lower.
o Layer bonding may not be strong, depending on material and application.
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