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UNIT 1

Part 1: CAD for Additive Manufacturing

● CAD Data Formats: CAD (Computer-Aided Design) data formats refer to

the different file types used to store and communicate design information
within CAD software
○ STEP (STereoLithography) AP214: Versatile format preserving 3D
geometry, product information, and assembly data.
○ IGES (Initial Graphics Exchange Specification): Another widely
used format for exchanging 3D data between different CAD software
programs.
○ ACIS (Spatial ACIS Modeler): A proprietary format used by some
CAD software like SolidWorks.
○ JT (JT Open): Lightweight format for sharing 3D data while
reducing file size.
● Data Translation: Data translation involves converting CAD data from one
format to another to facilitate compatibility between different software or
machines.
● Importance: Ensures that designs can be shared and utilized across various
platforms and equipment.

● Data Loss: Data loss refers to the loss or corruption of information during
the CAD data translation process.
● Importance: Data loss can lead to inaccuracies or errors in the final printed
part, impacting quality and functionality.

● STL (STereoLithography) File Format: STL (STereoLithography) is a

widely used file format for 3D printing. It represents a 3D model as a series
of interconnected triangles.
○ The most common format used for 3D printing.
○ Represents the object's surface geometry as a collection of triangles.
○ Relatively simple format, but loses information about color, texture,
and other CAD data.
 ○ Importance: Easy for most 3D printing software to understand and
widely compatible. However, the triangular mesh representation might
not capture all the details of the original CAD model, potentially
leading to printing issues.

Part 2: 3D Printing (Additive Manufacturing)

● Introduction: 3D printing, or additive manufacturing, is a process of

creating three-dimensional objects by adding material layer by layer based
on a digital model.
● Importance: Enables rapid prototyping, customization, and complex
geometries not easily achievable with traditional manufacturing methods.

● Process:

○ Design: Create a 3D model using CAD software.

○ Slicing: Convert the 3D model into a series of thin layers (slices)
using slicing software.
○ Printing: The 3D printer builds the object layer-by-layer based on the
instructions from the sliced file.
○ Post-Processing: Removing support structures (if used) and finishing
the printed part (e.g., sanding, painting).
● Classification of 3D Printing Technologies: Common classifications
include:
○ Material Deposition (FDM, SLA)
○ Material Jetting (PolyJet)
○ Powder Bed Fusion (SLS, DMLS)
○ Vat Photopolymerization (SLA, DLP)

○ Fused Deposition Modeling (FDM): Uses a heated nozzle to extrude

filament (plastic thread) to build the object.
○ Stereolithography Apparatus (SLA): Uses a laser beam to cure
liquid resin layer-by-layer.
○ Selective Laser Sintering (SLS): Uses a laser beam to sinter
powdered plastic or metal particles together.
 ○ Digital Light Processing (DLP): Similar to SLA but uses a projector
to cure a vat of resin at once.
● Advantages of 3D Printing:

○ Rapid Prototyping: Allows quick iteration and testing of designs.

○ Design Flexibility: Supports complex geometries and customization.
○ Material Efficiency: Reduces material waste compared to subtractive
methods.
○ Rapid Prototyping: Quickly create physical models for testing and
iterating on designs.
○ Complex Geometries: Create intricate shapes difficult or impossible
with traditional manufacturing.
○ Customization: Easily personalize designs for individual needs.
○ Low-Volume Production: Economically produce small batches of
parts.
○ Reduced Waste: Minimize material waste compared to subtractive
manufacturing.
● Additive vs. Conventional Manufacturing Processes: Additive
Manufacturing: Builds objects layer by layer, offering design freedom and
material efficiency.
● Conventional Manufacturing: Involves subtracting material from a solid
block or molding processes.

Feature Additive Manufacturing Conventional Manufacturing

Process Adds material layer-by-layer Removes material from a solid

block

Suitability Prototyping, complex Mass production, simpler

geometries, low-volume shapes
production
Advantages Rapid prototyping, High production speed, lower
customization cost per unit for large volumes

Disadvantag Higher cost per unit for small Limited design freedom for
es volumes, limited material complex geometries, more
selection waste

● Applications of 3D Printing: Used in various industries, including:

○ Prototyping: Used extensively in product development.
○ Aerospace: Manufacturing lightweight components.
○ Healthcare: Producing custom implants and prosthetics.
○ Prototyping: Creating functional prototypes for testing and design
validation.
○ Manufacturing: Producing custom parts, jigs, fixtures, and end-use
components.
○ Medical: Creating prosthetics, implants, and anatomical models.
○ Aerospace: Manufacturing lightweight and complex parts for aircraft
and spacecraft.
○ Consumer Products: Developing custom-made consumer goods.
UNIT 2

Part a: Additive Manufacturing Techniques - Fundamentals

● Process: Additive manufacturing techniques refer to various methods of

creating objects by adding material layer by layer based on digital models.
● Examples: Fused Deposition Modeling (FDM), Stereolithography (SLA),
Selective Laser Sintering (SLS), etc.

● Process Parameters: are specific settings controlled during the additive

manufacturing process to achieve desired results.
● Examples: Layer height, print speed, temperature, material feed rate, laser
power, etc.
● These are critical settings that influence the quality, strength, and accuracy
of the printed part. Common parameters include:

○ Layer Thickness: Affects resolution and printing time (thinner layers

= higher resolution, longer printing time).
○ Infill Density: Percentage of solid material within the part (higher
density = stronger part, more material used).
○ Print Temperature: Melts or cures the material depending on the
technology (affects bonding between layers).
○ Print Speed: Can affect surface quality and accuracy (faster speeds
might lead to imperfections).
● Process Selection for Various Applications: The choice of 3D printing
technology depends on factors like:

○ Material: Different technologies work with different materials (e.g.,

FDM for plastics, SLS for metals).
○ Part Complexity: Some technologies handle complex geometries
better than others.
○ Required Strength and Accuracy: Certain applications require high
strength or precise features.
○ Cost and Production Volume: Consider the cost per part and desired
production volume.
 ○ Examples:
■ FDM for rapid prototyping and low-cost production of
thermoplastic parts.
■ SLS for functional prototypes and production parts with good
mechanical properties.

Part b: Additive Manufacturing Application Domains

3D printing is finding applications in various industries:

● Aerospace: Creating lightweight and complex parts for aircraft and

spacecraft (e.g., brackets, engine components).
● Electronics: Prototyping and producing custom circuit boards and electronic
components.
● Healthcare: Manufacturing prosthetics, implants, and anatomical models
for surgery planning.
● Defense: Developing prototypes for weapons systems, personalized
equipment, and ballistic protection.
● Automotive: Creating prototypes for car parts, custom interiors, and
low-volume production of specialized parts.
● Construction: Printing architectural models, building components, and even
entire structures (in development).
● Food Processing: Developing customized food items and printing molds or
cookie cutters.
● Machine Tools: Creating custom jigs, fixtures, and end-use tooling
components.

Part c: Specific Additive Manufacturing Technologies

● Stereo-Lithography (SLA):Process: Uses a laser to cure layers of resin to

create detailed and accurate parts.
● Application: Ideal for producing high-resolution prototypes and patterns.
○ Process: A laser beam cures liquid resin layer-by-layer to form the
object.
○ Advantages: High resolution, smooth surface finish.
○ Disadvantages: Expensive, limited material selection.
● Laminated Object Manufacturing (LOM): Layers of material (typically
paper or plastic) are bonded together and then cut into the desired shape.
● Application: Used for creating large prototypes and molds
○ Advantages: Good for creating objects with different material
properties layer-by-layer.
○ Disadvantages: Limited resolution, weaker parts compared to some
other technologies.
● Fused Deposition Modeling (FDM): Extrudes thermoplastic material
through a heated nozzle to build layers.
● Application: Widely used for rapid prototyping and low-cost production.
○ Process: The most common technology. Uses a heated nozzle to
extrude filament (plastic thread) to build the object layer-by-layer.
○ Advantages: Easy to use, wide material variety, relatively affordable.
○ Disadvantages: Limited resolution, visible layer lines on the surface
finish.
● Selective Laser Sintering (SLS):.
● Application: Suitable for producing functional parts with high mechanical
strength.
○ Process: A laser beam selectively fuses powdered plastic or metal
particles together to create the object.
○ Advantages: Strong parts, good for functional applications.
○ Disadvantages: Expensive, requires post-processing to remove excess
powder.
● Selective Laser Melting (SLM):

○ Similar to SLS but uses a higher-powered laser to completely melt

metal powder, creating very strong parts.
○ Advantages: Strongest metal parts possible with 3D printing.
○ Disadvantages: Very expensive, requires careful handling due to high
temperatures.
● Binder Jetting Technology: Binds powder particles together using a liquid
binder sprayed through inkjet nozzles.
● Application: Suitable for producing metal, sand, or ceramic parts with
complex geometries.
○ Process: A binder jet applies a liquid bonding agent to powdered
material layer-by-layer, building the object.
○ Advantages: Can use various materials (including sand for casting
molds).
○ Disadvantages: Parts might require post-processing for additional
strength.
UNIT 3
Part a: Material Categories for 3D Printing:

● Polymers: Polymers are a class of materials characterized by long molecular

chains. They are widely used in additive manufacturing due to their
versatility and ease of processing.
● Examples: PLA (Polylactic Acid), ABS (Acrylonitrile Butadiene Styrene),
Nylon, TPU (Thermoplastic Polyurethane).

○ Acrylonitrile Butadiene Styrene (ABS): Strong, durable, and

heat-resistant, often used for functional parts.
○ Polylactic Acid (PLA): Biodegradable, user-friendly, and available in
various colors, ideal for prototyping and hobbyist applications.
○ Nylon: Strong, flexible, and heat-resistant, suitable for demanding
applications (e.g., gears, bearings).
○ High-Temperature Thermoplastics (PEEK, ULTEM): Offer
exceptional heat resistance and strength for high-performance parts.
● Metals: Metal materials used in additive manufacturing are typically in
powder form and include alloys of steel, aluminum, titanium, and
nickel-based superalloys.
● Examples: Stainless Steel (316L), Titanium (Ti6Al4V), Inconel.
● Enable the creation of strong and functional metallic components. Common
options include:

○ Stainless Steel: Versatile metal known for its corrosion resistance,

used for parts requiring strength and durability.
○ Titanium: Lightweight and high-strength metal, ideal for aerospace
and medical applications.
○ Aluminum: Lightweight and good conductor of heat and electricity,
used for prototyping and functional parts.
● Non-Metals: Non-metallic materials used in additive manufacturing include
ceramics, composites, and glass-filled polymers.
● Examples: Carbon fiber-reinforced plastics, ceramic-filled resins.
○ Sand: Used in binder jetting technology to create casting molds.
 ○ Ceramics: Offer high heat resistance and wear resistance, suitable for
specialized applications.
● Ceramics
○ Definition: Ceramics are inorganic, non-metallic materials that exhibit
high-temperature stability and hardness.
○ Examples: Alumina, Zirconia, Silicon Carbide.

Part b: Material Forms and Properties

● Liquid: Some materials are used in liquid form in processes like

Stereolithography (SLA) where a UV laser cures liquid resin layer by layer.
● Examples: Photopolymer resins.

● Solid: Solid materials, such as thermoplastic filaments or metal rods, are

used in processes like Fused Deposition Modeling (FDM) and Wire Arc
Additive Manufacturing (WAAM).
● Examples: PLA filament, titanium wire

● Wire: Used in some metal 3D printing processes where a metal wire is fed
into the system and melted for printing.

● Powder: Powdered materials are used in processes like Selective Laser

Sintering (SLS) and Direct Metal Laser Sintering (DMLS).
● Preparation: Powder is carefully controlled for particle size distribution and
flowability to ensure optimal printing performance.
● Desired Properties: Consistency in particle size, flowability, and chemical
purity are crucial for successful printing.
● The most common form for metal and some polymer 3D printing. A laser or
binder jet selectively fuses or binds the powder particles layer-by-layer.
Powder selection and preparation are crucial for part quality. Desired powder
properties include:

○ Particle size and distribution: Consistent size ensures good flow and
packing during printing.
 ○ Sphericity: Spherical particles generally lead to better flow and
packing density.
○ Material properties: The powder material itself should possess the
desired characteristics for the finished part (e.g., strength, heat
resistance).
● Polymer Properties: Polymers used in additive manufacturing exhibit
characteristics such as flexibility, impact resistance, and chemical resistance.
● Important Properties for Printing: Melting temperature, viscosity, layer
adhesion, and shrinkage are critical for successful printing.
○ Glass Transition Temperature (Tg): The temperature at which the
polymer transitions from a rigid, glassy state to a rubbery state.
Printing temperature should be above Tg for proper material flow.
○ Melting Temperature (Tm): The temperature at which the polymer
completely melts.
○ Thermal Expansion: The amount a polymer expands or contracts
with temperature changes.
○ Strength and Flexibility: The balance between these properties
determines the suitability for a specific application.

Part c: Support Materials

Support materials are temporary structures printed alongside the main object to
provide support for overhangs and complex geometries that would otherwise
collapse during printing. They are typically removed after printing using various
methods depending on the material. Common support materials include:

● Water-Soluble Supports: Dissolve easily in water, ideal for PLA and other
water-soluble filaments.
● Breakaway Supports: Designed to be snapped or broken away from the
printed part. Often used with ABS and other non-water-soluble filaments.
● Gel/Wax Supports: Can be removed manually or with solvents.
UNIT 4
Part a: Additive Manufacturing Equipment
Part a: Process Equipment - Design and Process Parameters, Lasers in
Additive Manufacturing

● Process Equipment Design: 3D printers come in various designs depending

on the technology. However, some common elements include:

○ Build Platform: The lower platform where the object is gradually

built layer-by-layer.
○ Print Head/Extruder: The component that deposits or applies the
material during printing (e.g., nozzle in FDM, laser in SLS/SLM).
○ Material Delivery System: The system that feeds the material
(filament, resin, powder) to the print head.
○ Build Chamber: Enclosed space that might be heated or use a
controlled atmosphere depending on the printing process.
○ Computer Control System: Controls the entire printing process
based on the sliced 3D model and user-defined parameters.
● Process Parameters: As discussed earlier, these parameters significantly
influence the outcome of the 3D print. Common parameters include:

○ Layer Thickness
○ Infill Density
○ Print Temperature
○ Print Speed
○ Laser Power/Scan Speed (for laser-based technologies): These
determine how much energy is delivered to the material and how
quickly the laser scans each layer, impacting melting depth and
bonding between layers.
● Lasers in Additive Manufacturing: Lasers play a crucial role in several 3D
printing technologies like SLA, SLS, and SLM. They provide a focused heat
source to cure resin (SLA) or selectively melt/fuse powdered materials
(SLS/SLM). Key laser characteristics include:
 ○ Wavelength: The specific wavelength of the laser light determines its
interaction with the material.
○ Power: Higher power lasers can melt or cure materials more deeply,
influencing layer thickness and part strength.
○ Scan Speed: The speed at which the laser beam scans across the
powder bed or resin vat affects the size of the melt pool and bonding
between layers.

Part b: Governing Bonding Mechanism

The bonding mechanism between layers varies depending on the 3D printing

technology:

● Fusion bonding (e.g., SLS, DMLS): Melting and solidification of materials.

● Photopolymerization (e.g., SLA, DLP): UV light curing of liquid resins.
● Adhesive bonding (e.g., binder jetting): Binding of powder particles using a
liquid binder.
● FDM: Molten plastic filament fuses together as it cools.
● SLA: A laser beam cures liquid resin, creating a solid layer that bonds to the
previous layer.
● SLS/SLM: A laser beam selectively melts powdered plastic or metal
particles, causing them to fuse together upon cooling.
● Binder Jetting: A liquid binder bonds powder particles together, creating a
solid layer..

Part c: Common Faults and Troubleshooting

● Common Faults
○ Examples: Warping, delamination, layer misalignment, poor surface
finish, nozzle clogging.
○ Causes: Incorrect process parameters, material issues, machine
malfunctions, design flaws.
● Troubleshooting
○ Strategies: Adjusting process parameters (temperature, speed),
optimizing design for additive manufacturing, inspecting and
maintaining equipment, recalibrating machines.
 ● Poor Layer Adhesion: Causes include incorrect temperature settings,
incompatible materials, or dirty print bed/vat. Solutions involve adjusting
parameters, material selection, and cleaning the printing surface.
● Warping: Uneven cooling can cause the part to warp. Solutions include
using a heated bed (FDM), adjusting build orientation, or using support
structures.
● Overhang Curls: Material on unsupported overhangs can curl upwards.
Solutions involve using support structures, adjusting layer thickness, or
reducing print speed.
● Under Extrusion/Over Extrusion (FDM): Incorrect material flow can lead
to gaps or excessive material deposition. Solutions involve calibrating the
extruder and adjusting filament flow settings.
● Laser Power Issues (Laser-based technologies): Incorrect laser power can
lead to incomplete melting/curing or overheating. Solutions involve
calibrating the laser system and adjusting power settings according to the
material.

Part d: Process Design

Process design involves planning and optimizing the entire 3D printing process for
a specific application. Here are some key considerations:

● Design Considerations for Additive Manufacturing

○ Importance: Process design involves optimizing part geometry,
orientation, and support structures for successful printing.
○ Factors: Minimizing overhangs, designing for layer-by-layer
construction, optimizing material usage, considering post-processing
requirements.
● Part Geometry: Analyze the 3D model to identify areas requiring support
structures, potential overhang challenges, and optimal build orientation.
● Material Selection: Choose the material that meets the desired properties
for the final part (strength, flexibility, heat resistance, etc.).
● Process Parameter Optimization: Fine-tune parameters like layer
thickness, infill density, and printing temperature to achieve the best possible
results for the chosen material and part geometry.
● Support Structure Design: Design or utilize pre-designed support
structures to ensure proper support for overhangs and prevent printing
failures.
● Post-Processing Planning: Consider any post-processing steps required,
such as support removal, surface finishing, or heat treatment (for some
materials).
UNIT 5
Post-Processing: Requirement and Techniques

3D printed parts often require post-processing steps to enhance their aesthetics,

functionality, and dimensional accuracy

Needs: Removal of support structures, surface finishing, heat treatment (for

metals), and assembly.

● Requirement for Post-Processing:

○ Removing Support Structures: Temporary structures used during
printing need to be removed carefully to avoid damaging the part.
Techniques include breaking them away, dissolving them
(water-soluble supports), or using specialized tools.
○ Assembly: Joining multiple printed parts, adding inserts, or
integrating electronic components.
○ Improving Surface Finish: 3D printed parts often have visible layer
lines or a rough surface texture. Post-processing techniques can
improve aesthetics and functionality:
■ Sanding: Smoothing the surface with sandpaper of varying
grits.
■ Vapor Smoothing: Exposing the part to solvent vapor to melt
the surface slightly, creating a smoother finish.
■ Polishing: Using polishing compounds or buffing wheels for a
high-gloss finish.
○ Dimensional Accuracy Enhancement: Some technologies might
require post-processing to achieve the desired dimensional accuracy:
■ Infiltration (SLS/SLM): Filling internal pores in metal parts
with a liquid resin to improve strength and density.
■ Heat Treatment (SLS/SLM): Heat treatment can improve the
mechanical properties of metal parts by altering their
microstructure.

Part b: Product Quality

● Inspection and Testing = Inspection ensures that printed parts meet design
specifications and quality standards.
● Techniques:
○ Visual Inspection: Examining for surface defects and dimensional
accuracy.
○ Dimensional Metrology: Using calipers, CMM (Coordinate
Measuring Machine) for precise measurements.
○ Non-Destructive Testing (NDT): X-ray, CT scanning, ultrasonic
testing to detect internal defects.
○ Mechanical Testing: Tensile, compression, and impact testing to
evaluate mechanical properties.
○ Dimensional Accuracy: Using calipers, micrometers, or 3D scanners
to measure critical dimensions and compare them to the design
specifications.
○ Surface Defects: Visually inspecting for any irregularities like cracks,
warping, or incomplete layer bonding.
○ Conformance to Design: Verifying that the overall shape and features
of the part match the intended design.
○ Mechanical Properties: The strength, flexibility, and other
mechanical characteristics of the part, depending on the chosen
material.
○ Functionality: How well the part performs its intended function.

● Testing: Depending on the application, parts might undergo further testing

to assess their performance:

○ Mechanical Testing: Testing for tensile strength, compressive

strength, flexural strength, etc., to ensure the part can withstand
intended loads.
○ Functional Testing: Testing the part's ability to perform its specific
function (e.g., testing a gear for proper meshing or a prototype for its
functionality).
 ○ Non-Destructive Testing (NDT): Techniques like X-ray or CT
scanning to detect internal defects without damaging the part.

Defects and Their Causes

1. Common Defects in Additive Manufacturing

● Warping: Due to residual stresses during cooling.
● Delamination: Layers not bonding properly.
● Surface Roughness: Uneven layer deposition or inadequate
post-processing.
● Porosity: Entrapped air or incomplete fusion of powder particles.
2. Causes of Defects
● Incorrect Process Parameters: Inadequate temperature, speed, or layer
thickness.
● Material Issues: Inconsistent material properties, impurities in
powders.
● Machine Malfunctions: Calibration errors, nozzle clogging, or build
platform misalignment.
● Design Flaws: Unsupported overhangs, sharp corners, inadequate part
orientation.
Mst 1
Q2(a). Define rapid prototyping (RP) by suitable example
Rapid prototyping (RP) is a group of techniques used to quickly fabricate a scale
model or prototype of a physical part or assembly using 3D computer-aided design
(CAD) data.
1. Process = The RP process involves the layer-by-layer addition of material to
create the desired object directly from digital data, bypassing traditional
machining processes.

Key points:

1. Speed: The defining characteristic of RP is its ability to create prototypes

much faster than traditional manufacturing methods (e.g., machining,
casting).
2. Direct from Digital Designs: RP utilizes 3D modeling software to create
digital models, which are then translated into instructions for the 3D printer
to build the physical model.
3. Physical Models: The output of RP is a tangible 3D object that allows for
better visualization, testing, and iteration on designs.
4. Iterative Design: Enables quick iterations and modifications based on testing
and feedback.
5. Design Validation: Facilitates functional testing and validation of concepts
before full-scale production.
6. Example
a. Suppose a design team wants to develop a new smartphone case.
Using rapid prototyping:
i. They create a CAD model of the case.
ii. Utilizing an FDM (Fused Deposition Modeling) 3D printer,
they print a prototype in a matter of hours.
iii. The team tests the prototype for fit, ergonomics, and aesthetic
appeal.
iv. Based on feedback, they iterate on the design, adjusting
dimensions or features as needed.
7. Benefits
 a. Reduced Time to Market: Speeds up product development and
innovation cycles.
b. Cost-Effective: Minimizes material waste and tooling costs associated
with traditional manufacturing processes.
c. Design Flexibility: Allows for complex geometries and customization
without expensive tooling changes.

Q2(b). Describe the functioning of SLA liquid based RP system

Functioning of SLA Liquid-Based RP System

1. Setup
● The SLA system consists of a build platform submerged in a vat filled
with a liquid photopolymer resin.
● Above the vat, a UV laser is mounted on a moving gantry controlled
by computer software.
2. Layer Preparation
● The CAD model of the part to be printed is sliced into thin
cross-sectional layers (typically 0.05 to 0.15 mm thick).
3. Printing Process
● The SLA process begins with the build platform submerged just
below the surface of the liquid resin.
● The UV laser selectively scans the surface of the resin according to
the sliced cross-section from the CAD model.
● Wherever the laser hits the resin, it solidifies and cures the
photopolymer, forming a single layer of the part.
4. Layer-by-Layer Build
● After curing one layer, the build platform lowers by a precise amount
(equal to the layer thickness), and a new layer of liquid resin flows
over the solidified layer.
● The laser then cures the new resin layer according to the next
cross-sectional slice of the part.
5. Building the Part
 ● This process of curing and layering is repeated iteratively until the
entire part is built up layer by layer.
● Each cured layer bonds to the previous layer, gradually forming a
solid three-dimensional object within the resin vat.
6. Post-Processing
● Once the printing is complete, the build platform rises out of the resin
vat, exposing the printed part.
● The part is then cleaned to remove excess resin using solvents and is
often cured further under UV light to fully harden the material.

Key Features and Advantages

● High Resolution: SLA can achieve very fine details and smooth surfaces,
suitable for prototyping intricate parts.
● Accuracy: Offers precise dimensional accuracy and tolerances.
● Wide Range of Materials: Various types of photopolymer resins are
available, including clear, flexible, and tough materials.
● Support Structures: SLA can include automatically generated support
structures that can be removed after printing

Q3. Classify various RP process with examples

RP processes can be classified based on different criteria, but a common approach

focuses on the material state used during building:

1. Liquid-based RP:

● Process: Uses a liquid material (usually a photopolymer resin) that is cured

layer-by-layer using light (SLA) or a projector (DLP).
 ● Example: Stereolithography Apparatus (SLA) - Creates high-resolution
models with smooth surfaces, ideal for detailed prototypes and jewelry.

2. Solid-based RP:

● Process: Uses a solid material, typically filament (FDM) or paper sheets

(LOM), that is deposited or laminated layer-by-layer.
● Examples:
○ Fused Deposition Modeling (FDM): The most common RP process,
uses a heated nozzle to extrude filament, creating functional
prototypes and various end-use parts.
○ Laminated Object Manufacturing (LOM): Uses thin sheets of paper,
metal, or plastic that are bonded together to create layered models,
suitable for rapid concept visualization.

3. Powder-based RP:

● Process: Uses powdered plastic or metal material that is selectively fused or

bound together layer-by-layer using a laser (SLS, SLM) or binder jet.
● Examples:
○ Selective Laser Sintering (SLS): Uses a laser to selectively fuse
powdered plastic particles, creating strong and functional prototypes.
○ Selective Laser Melting (SLM): Similar to SLS but uses a
higher-powered laser to completely melt metal powder, for
high-strength metallic parts.

4. Other RP processes:

● There are additional RP technologies that don't fit neatly into the above
categories, such as:
○ Binder Jetting: Uses a liquid binder to selectively glue powdered
material together, offering flexibility in material selection (e.g., sand
for casting molds).
○ Material Jetting: Jets droplets of liquid photopolymer resin or other
materials to create high-resolution and multi-material models.
Classification of RP Processes
1. Material Extrusion (Fused Deposition Modeling - FDM)
● Process: Thermoplastic filaments are extruded through a heated
nozzle and deposited layer by layer.
● Examples: Ultimaker 3D printers, MakerBot Replicator.
2. Vat Photopolymerization (Stereolithography - SLA)
● Process: Uses a UV laser to solidify layers of liquid photopolymer
resin.
● Examples: Formlabs Form 3, Anycubic Photon.
3. Powder Bed Fusion (Selective Laser Sintering - SLS)
● Process: Uses a laser to sinter (fuse) powdered material (plastic,
metal) layer by layer.
● Examples: EOS P 396, Sinterit Lisa.
4. Material Jetting
● Process: Layers of material (liquid photopolymer or wax) are jetted
and cured using UV light or heat.
● Examples: Stratasys PolyJet technology, 3D Systems ProJet.
5. Binder Jetting
● Process: Powder layers are selectively bonded together using a liquid
binder sprayed through inkjet nozzles.
● Examples: ExOne M-Flex, HP Jet Fusion.
6. Directed Energy Deposition (DED)
● Process: Metal powder or wire is deposited and melted using a
high-energy heat source (laser or electron beam).
● Examples: Optomec LENS systems, DMG MORI LASERTEC.
7. Sheet Lamination (Laminated Object Manufacturing - LOM)
● Process: Layers of adhesive-coated sheets (paper, plastic, metal) are
cut and bonded together to form the part.
● Examples: Mcor IRIS, Voxeljet VX200.
Mst 2
Q2. Explain various forms of raw material and their properties for 3D
printing

1. Form: Liquid

● Material Example: Photopolymer Resin (SLA, DLP) (e.g., acrylic-based,

epoxy-based)
● Properties:
○ High resolution and smooth surface finish due to precise curing by
light.
○ Wide variety of resins with different properties (e.g., rigid, flexible,
castable).
○ Requires careful handling and post-processing to remove excess resin.
● Applications: Commonly used in SLA and DLP printers for high-detail
prototypes and parts.

2. Form: Solid (Filament)

● Material Examples: Thermoplastic polymers (e.g., PLA, ABS, PETG),

Nylon (FDM)
● Properties:
○ Most common form for 3D printing due to ease of use and wide
material variety.
○ Filament is fed through a heated nozzle and extruded layer-by-layer.
○ Offers good strength and dimensional stability for various
applications.
○ Properties vary depending on the material (e.g., ABS is strong and
heat-resistant, PLA is biodegradable and user-friendly).
● Properties:
○ High Strength: Provides good structural integrity.
○ Ease of Use: Widely used in FDM printers due to ease of handling and
wide material selection.
○ Variety: Available in various colors and formulations (e.g., filled with
carbon fiber for added strength).
3. Form: Powder

● Material Examples: Plastic, Metal (SLS, SLM, Binder Jetting) Metals (e.g.,
aluminum, titanium), ceramics (e.g., alumina, zirconia), polymers (e.g.,
nylon).
● Properties:
○ Enables creation of strong and functional parts, especially for metals.
○ Powder particles are selectively fused or bound together
layer-by-layer.
○ Powder selection and preparation are crucial for good part quality
(consistent particle size, sphericity, material properties).
○ Metal powders require careful handling due to high temperatures and
potential hazards.
● Properties:
○ High Strength: Metal powders provide strong, durable parts.
○ Heat Resistance: Ceramic powders can withstand high temperatures.
○ Complex Geometries: Suitable for printing complex and intricate
shapes using SLS and DMLS processes.

4. Form: Wire

● Material Example: Metal (Some Metal 3D Printing)

● Properties:
○ Used in some metal 3D printing processes where a metal wire is fed
into the system and melted for printing.
○ Offers good material utilization and potentially faster printing speeds
compared to powder-based methods.
○ May require post-processing for surface finishing and removal of
support structures.
● Materials: Metals (e.g., aluminum, stainless steel).
● Properties:
○ High Strength: Suitable for producing robust metal parts.
○ Cost-Effective: Wire feedstock is often more affordable than metal
powders.
○ Applications: Used in Wire Arc Additive Manufacturing (WAAM) for
large-scale metal printing.
Properties of 3D Printing Materials

● Melting Point: Determines the suitable printing temperature for the material.
● Viscosity: Influences flow behavior and extrusion in FDM and material
jetting processes.
● Layer Adhesion: Critical for part strength and durability.
● Shrinkage: Some materials may shrink during cooling, affecting dimensional
accuracy.
● Flexibility and Elasticity: Important for materials like TPU used in flexible
parts.

Selection Criteria for Materials

● Mechanical Properties: Strength, stiffness, and impact resistance.

● Thermal Properties: Heat resistance and thermal conductivity.
● Chemical Resistance: Ability to withstand exposure to chemicals.
● Aesthetic Qualities: Color, transparency, and surface finish.

Q3. what do you mean by laser optical instrumentation in Rapid Prototyping,

explain
Laser optical instrumentation in the context of rapid prototyping (RP) refers to the
use of laser-based measurement and monitoring systems to enhance the accuracy,
efficiency, and quality of additive manufacturing processes. These instrumentation
techniques leverage laser technology for various purposes, including process
monitoring, part inspection, and quality control. Here's an explanation of laser
optical instrumentation in RP:

Laser Optical Instrumentation in Rapid Prototyping

1. Process Monitoring
 ● Laser Scanning: High-resolution laser scanners are used to capture
detailed 3D surface information of printed parts during and after
manufacturing.
● In-Process Measurement: Laser sensors can monitor parameters such
as layer height, surface roughness, and dimensions in real-time.
2. Quality Control
● Surface Inspection: Laser-based systems can detect defects,
imperfections, and deviations in part geometry or surface finish.
● Non-Destructive Testing (NDT): Laser techniques like laser
profilometry and interferometry are employed for non-destructive
inspection of internal features and layer quality.
3. Part Verification and Validation
● Dimensional Metrology: Laser-based coordinate measuring machines
(CMMs) and laser trackers are used to verify part dimensions against
CAD specifications.
● Alignment and Calibration: Laser systems assist in aligning and
calibrating additive manufacturing equipment for accurate and
repeatable printing.
4. Material Characterization
● Laser Spectroscopy: Analyzes the composition and properties of
materials used in 3D printing processes, ensuring material quality and
consistency.
● Thermal Imaging: Laser-based thermal cameras monitor temperature
profiles during printing to optimize process parameters and prevent
defects like warping.
5. Advanced Printing Techniques
● Direct Laser Writing: Utilizes focused laser beams to directly write or
ablate materials for microfabrication and high-precision printing.
● Selective Laser Melting (SLM): Laser sintering of metal powders
under controlled conditions for producing complex metal parts with
high accuracy.

Key Benefits of Laser Optical Instrumentation

 ● Precision: Laser systems offer high precision and accuracy in measurements
and inspections.
● Real-Time Monitoring: Enables real-time feedback and adjustments during
printing to ensure quality and consistency.
● Automation: Laser-based systems can be integrated into automated
manufacturing workflows for efficient and reliable operation.
● Quality Assurance: Enhances quality control processes, reducing defects and
ensuring part conformity with design specifications.

Q4. explain various types of support materials in 3D printing

In 3D printing, support materials are used to provide temporary structural support
for overhanging or complex features during the printing process. These support
structures are essential for maintaining the integrity of the printed object and can
be removed after printing is complete. Various types of support materials are
available depending on the 3D printing technology and the specific requirements of
the printed part. Here are explanations of different types of support materials used
in 3D printing:

Types of Support Materials

1. Water-Soluble Support Materials

● Material: Typically composed of materials like Polyvinyl Alcohol
(PVA).
● Properties:
● Solubility: Easily dissolves in water, making support removal
straightforward and less labor-intensive.
● Compatibility: Suitable for use with materials that are not
affected by water (e.g., PLA, ABS).
● Applications: Ideal for complex geometries and intricate parts that
require thorough support removal.
2. Breakaway Support Materials
● Material: Similar to the build material (e.g., thermoplastics).
● Properties:
 ● Mechanical Strength: Provides robust support during printing
but can be manually removed after printing.
● Compatibility: Works well with a wide range of 3D printing
materials.
● Applications: Suitable for parts with moderate overhangs or where
support removal by hand is feasible.
3. Dissolvable Support Materials
● Material: Composed of materials that dissolve in specific solvents
(e.g., HIPS - High-Impact Polystyrene).
● Properties:
● Solubility: Requires immersion in a solvent (e.g., limonene) to
dissolve support structures.
● Compatibility: Compatible with materials that are not affected
by the solvent used.
● Applications: Useful for complex geometries and delicate parts where
manual removal of supports may be challenging.
4. Bridging Support Structures
● Material: Generated from the same material used for the build.
● Properties:
● Minimal Contact: Designed to minimize contact points with the
part to ease removal.
● Stability: Offers sufficient support for moderate overhangs
without excessive material usage.
● Applications: Suitable for parts with shallow overhangs or where
minimal support is required.

Considerations for Selecting Support Materials

● Material Compatibility: Ensure that the support material is compatible with

the build material and printing technology being used.
● Ease of Removal: Choose a support material that can be removed efficiently
without damaging the printed part.
● Post-Processing Requirements: Consider the post-processing steps required
(e.g., washing, solvent immersion) for support removal.
● Complexity of Part: Select support structures based on the complexity and
geometry of the printed part to minimize material usage and optimize
printing time.
PYQ Paper 1 april 2023
Q1(a). what do you mean by additive manufacturing process, describe its
classification with suitable examples?

Additive manufacturing (AM), also known as 3D printing, is a manufacturing

process that builds three-dimensional objects by adding material layer by layer
based on a digital model. This contrasts with traditional subtractive manufacturing
methods that involve cutting away material from a solid block. Additive
manufacturing offers unique advantages such as design flexibility, rapid
prototyping, and the ability to create complex geometries with minimal material
waste. Here's a description of additive manufacturing processes along with their
classification and examples:

Classification of Additive Manufacturing Processes:

AM processes can be classified based on the material state used during building
and the way the material is deposited or fused. Here's a breakdown of some
common categories with examples:

1. Liquid-based AM:

● Process: Uses a liquid material (usually a photopolymer resin) that is cured

layer-by-layer using light.
● Example: Stereolithography Apparatus (SLA): A laser beam selectively
cures liquid resin to create high-resolution prototypes with smooth surfaces.

2. Solid-based AM:

● Process: Uses a solid material, typically filament (FDM) or paper sheets

(LOM), that is deposited or laminated layer-by-layer.
● Examples:
○ Fused Deposition Modeling (FDM): The most common AM process,
uses a heated nozzle to extrude filament, creating functional
prototypes and various end-use parts.
○ Laminated Object Manufacturing (LOM): Uses thin sheets of paper,
metal, or plastic that are bonded together to create layered models,
suitable for rapid concept visualization.
3. Powder-based AM:

● Process: Uses powdered plastic or metal material that is selectively fused or

bound together layer-by-layer using a laser (SLS, SLM) or binder jet.
● Examples:
○ Selective Laser Sintering (SLS): Uses a laser to selectively fuse
powdered plastic particles, creating strong and functional prototypes.
○ Selective Laser Melting (SLM): Similar to SLS but uses a
higher-powered laser to completely melt metal powder, for
high-strength metallic parts.

4. Other AM processes:

● There are additional AM technologies that don't fit neatly into the above
categories, such as:
○ Binder Jetting: Uses a liquid binder to selectively glue powdered
material together, offering flexibility in material selection (e.g., sand
for casting molds).
○ Material Jetting: Jets droplets of liquid photopolymer resin or other
materials to create high-resolution and multi-material models.

This classification provides a basic framework for understanding the different

approaches used in AM. The choice of AM process depends on factors like the
desired material properties, resolution, accuracy, and cost.

Benefits of Additive Manufacturing:

● Design Freedom: Enables creation of complex geometries and intricate

features.
● Rapid Prototyping: Allows for quick creation of prototypes for testing and
design iteration.
● Mass Customization: Can be used to produce customized products
on-demand.
● Material Efficiency: Reduces material waste compared to subtractive
manufacturing.
● Lightweighting: Can be used to create lightweight and strong parts for
various applications.
Q1(b). With suitable examples differentiate between additive manufacturing
process and conventional manufacturing process.

● Additive Manufacturing (AM): Builds objects layer-by-layer by adding

material until the desired shape is achieved. (Think of building with Legos!)
● Conventional Manufacturing: Starts with a solid block of material and
removes material through processes like machining, drilling, or cutting to
achieve the final shape. (Think of sculpting with clay)

Material Usage:

● AM: Generally uses less material compared to conventional methods as it

only adds what's necessary.
● Conventional Manufacturing: Often involves significant material waste
due to removal during shaping.

Design Complexity:

● AM: Enables creation of complex geometries and intricate features that

might be difficult or impossible with conventional methods.
● Conventional Manufacturing: May have limitations in creating highly
complex shapes, especially with traditional techniques.

Production Speed:

● AM: Can be faster for producing prototypes or small batches due to the ease
of design iteration and setup.
● Conventional Manufacturing: Generally faster for mass production once
tooling and processes are established.

Examples:

● AM: 3D printing (FDM, SLA, SLS), creating custom prosthetics

● Conventional Manufacturing: Machining engine parts, injection molding
plastic components

Other Considerations:
 ● AM: May require post-processing steps depending on the process used (e.g.,
support structure removal, finishing).
● Conventional Manufacturing: Often involves established processes with
well-defined quality control procedures.

Choosing the Right Method:

The choice between AM and conventional manufacturing depends on various

factors like:

● Product complexity: AM excels at intricate designs.

● Production volume: Conventional methods are often more efficient for
mass production.
● Material properties: Both offer a wide range of materials, but AM might
have limitations in some areas.
● Cost: AM can be cost-effective for prototypes and low-volume production,
while conventional methods might be cheaper for high volumes.

Q1(c). What is .stl file format, what are its defects and how do you remove
these defects.

The .STL (Stereolithography) file format is a widely used file format in 3D

printing that represents the surface geometry of a 3D object using a collection of
triangular facets. It is commonly used for transferring 3D models from
computer-aided design (CAD) software to slicing software, which prepares the
model for 3D printing. However, the .STL file format has certain limitations and
potential defects that can impact the quality of the printed object. Here's an
overview of the .STL file format, its defects, and methods for addressing these
defects:

.STL File Format Overview

 ● Representation: .STL files describe the surface geometry of a 3D object
using a mesh of interconnected triangles (facets).
● Triangle Mesh: The surface of the object is approximated by numerous small
triangles, defining its shape and contours.
● Compatibility: .STL files are compatible with most 3D printing software and
can be easily converted into machine-readable G-code for 3D printers.

Common Defects in .STL Files

1. Facetization
● Issue: Low-resolution .STL files may result in visible facets on curved
surfaces, affecting the smoothness of the printed object.
● Cause: Insufficient number of triangles used to represent the surface
geometry.
2. Non-Manifold Geometry
● Issue: .STL files with non-manifold geometry (e.g., intersecting or
overlapping surfaces) can cause errors during slicing or printing.
● Cause: CAD modeling errors or incomplete surface definitions.
3. Holes and Gaps
● Issue: Gaps or holes in the mesh can lead to missing features or
structural weaknesses in the printed object.
● Cause: Incomplete or improperly closed surfaces in the original CAD
model.

Methods for Removing .STL File Defects

1. Mesh Refinement
● Use software tools to increase the mesh resolution (number of
triangles) to reduce facetization on curved surfaces.
● Example Tools: MeshLab, Autodesk Meshmixer, Blender.
2. Repair Non-Manifold Geometry
● Utilize software tools to identify and repair non-manifold edges,
intersecting surfaces, or overlapping geometry.
● Example Tools: Netfabb, Meshmixer, SolidWorks.
3. Mesh Repair and Healing
 ● Apply automated mesh repair functions to close gaps, fill holes, and
ensure watertight geometry.
● Example Tools: Netfabb, Meshmixer, Simplify3D.
4. Manual Editing
● Manually inspect and edit the .STL file to correct specific defects such
as intersecting surfaces or missing features.
● Example Tools: CAD software (SolidWorks, Autodesk Fusion 360)
with mesh editing capabilities.

Best Practices for .STL File Preparation

● Ensure that the original CAD model is properly defined and closed before
exporting to .STL format.
● Use software tools to inspect and validate the .STL file for errors and defects
before proceeding with slicing and printing.
● Regularly update and optimize the mesh resolution and quality based on the
requirements of the 3D printing project.

Q2(a). Describe any four process parameters of Rapid Prototype process.

In rapid prototyping processes, various parameters are critical for achieving
optimal part quality, dimensional accuracy, and process efficiency. Here are
four important process parameters commonly used in rapid prototyping:

1. Layer Thickness

● Definition: Layer thickness refers to the vertical distance between each

successive layer of material deposited during the printing process.
● Importance: Smaller layer thickness results in finer details and smoother
surface finish but increases printing time.
● Optimization: Balancing layer thickness with print speed and part resolution
is crucial for achieving desired part quality.

2. Printing Speed
 ● Definition: Printing speed refers to the rate at which the printer deposits
material to build up each layer of the part.
● Importance: Faster printing speeds reduce overall printing time but may
compromise part accuracy and surface finish.
● Optimization: Adjusting printing speed based on part complexity and
material properties to achieve the desired balance between speed and quality.

3. Temperature Settings

● Definition: Temperature settings include nozzle temperature (for

extrusion-based processes) and build chamber temperature (for
thermal-based processes).
● Importance: Proper temperature control ensures material flow consistency,
adhesion between layers, and overall part quality.
● Optimization: Optimizing temperature settings based on material
specifications and environmental conditions (e.g., room temperature) to
prevent issues like warping or layer adhesion problems.

4. Support Structure Parameters

● Definition: Support structure parameters include density, pattern, and

material type of support structures generated to support overhangs and
complex geometries.
● Importance: Proper support structure parameters prevent part deformation
and ensure printability of challenging geometries.
● Optimization: Adjusting support density and pattern to minimize material
usage while maintaining part stability and ease of support removal.

Additional Considerations

● Material Properties: Parameters such as material type, feed rate, and cooling
settings are tailored based on the specific material used in the rapid
prototyping process.
● Environmental Factors: Humidity, ambient temperature, and ventilation can
influence process parameters and should be considered during printing.
Q2 EXTRA Q2(c). Describe LOM

Laminated Object Manufacturing (LOM) Explained:

LOM, or Laminated Object Manufacturing, is an additive manufacturing process

that utilizes thin sheets of material to create 3D objects layer-by-layer. Here's a
breakdown of its key aspects:

Process:

1. Preparation: A 3D model is created in CAD software and sliced into thin

layers.
2. Material: LOM uses sheets of adhesive-coated paper, plastic, or even metal
as the building material.
3. Layer Bonding: Each layer sheet is fed from a roll and bonded to a platform
using a heated roller.
4. Shape Definition: A laser cutter or knife precisely cuts the desired shape
from the bonded sheet according to the sliced model data.
5. Layer Stacking: The platform with the completed layer lowers down, and a
fresh sheet is rolled into position for the next layer.
6. Iteration: Steps 3-5 are repeated for each layer until the entire object is
built.

Key Points:

● LOM offers a relatively fast and inexpensive way to create prototypes,

especially compared to some other 3D printing technologies.
● The layer thickness is determined by the material sheet used, typically
ranging from the thickness of a few sheets of paper to a thin sheet of plastic.
This limits resolution compared to some other AM processes.
● LOM is a versatile process; the choice of material (paper, plastic, metal)
allows for creating prototypes with different properties and functionalities.

Advantages:
 ● Fast Prototyping: Suitable for rapid creation of concept models and
functional prototypes.
● Low Cost: Generally less expensive compared to other 3D printing methods
due to readily available materials and simpler equipment.
● Material Versatility: Offers flexibility in choosing paper, plastic, or even
metal for building prototypes with varying properties.
● No Support Structures: Unlike some other AM processes, LOM often
doesn't require complex support structures for overhangs.

Disadvantages:

● Limited Resolution: Layer thickness restricts the level of detail achievable

in the final object.
● Surface Finish: The visible layers on the finished part might require
additional finishing for a smoother appearance.
● Material Properties: Paper-based LOM prototypes may not be very durable
and are not suitable for functional applications requiring high strength.

Applications:

● LOM is often used for concept modeling, rapid prototyping, and creating
visual aids due to its speed and affordability.
● It can be used in various industries, including automotive, aerospace, and
consumer product design, for early-stage design validation and visualization.
● Advancements in LOM technology are exploring the use of metal laminates
for creating functional prototypes with improved strength.

Q2 EXTRA Describe SLA

Stereolithography Apparatus (SLA) Explained:

SLA, or Stereolithography Apparatus, is a 3D printing process that utilizes a vat of

liquid photopolymer resin and a laser to create high-resolution and accurate
prototypes. Here's a breakdown of its key aspects:

Process:
 1. Preparation: A 3D model is created in CAD software.
2. Material: SLA uses a photosensitive liquid resin cured by a specific
wavelength of light. Different resins offer various properties like rigidity,
flexibility, and transparency.
3. Laser Curing: A computer-controlled laser beam focuses on specific areas
of the resin vat surface according to the sliced model data.
4. Layer-by-Layer Building: The laser light cures (solidifies) the exposed
resin, corresponding to a thin layer of the object.
5. Platform Lowering: The build platform, which holds the partially built
object, lowers slightly into the vat.
6. Recoating: A blade sweeps across the vat, distributing a fresh layer of liquid
resin over the previous cured layer.
7. Iteration: Steps 3-6 are repeated for each layer of the sliced model, building
the object layer-by-layer.
8. Post-Processing: Once printing is complete, the platform rises out of the vat
with the completed object. The object undergoes cleaning to remove excess
resin and possible support structures. Depending on the material, post-curing
with UV light might be necessary for optimal strength.

Key Points:

● SLA offers exceptional resolution and smooth surface finish due to the
precise laser curing process, making it ideal for creating detailed prototypes,
jewelry, and other parts requiring high accuracy.
● A wide variety of resins with different properties is available, expanding the
applications of SLA beyond just visual models.
● SLA printers can have a limited build volume compared to some other 3D
printing technologies.

Advantages:

● High Resolution and Smooth Finish: Produces highly detailed and visually
appealing prototypes with smooth surface finishes.
● Wide Material Variety: Offers a diverse range of resins with varying
properties for different applications.
 ● Accuracy: SLA is known for its dimensional accuracy, making it suitable
for creating precise parts.
● Isotropic Parts: The properties of the printed part are consistent in all
directions due to the layer-by-layer curing process.

Disadvantages:

● Limited Build Volume: Build volumes of SLA printers can be smaller

compared to other methods, restricting the size of printable objects.
● Resin Cost: Resins used in SLA can be more expensive compared to some
materials used in other 3D printing processes.
● Post-Processing: Requires careful handling and post-processing steps to
remove excess resin and support structures.

Applications:

● SLA is widely used in various industries for applications such as:

○ Prototyping: Creating high-resolution prototypes for design
validation and functional testing.
○ Jewelry Design and Manufacturing: Producing intricate and
detailed jewelry pieces with smooth finishes.
○ Medical Prototyping: Creating medical models and surgical guides
for improved planning and visualization.
○ Dental Applications: Manufacturing dental crowns, bridges, and
other dental prosthetics requiring high accuracy.

Q2(b). With neat sketch explain working principle of Fused Deposition

Modeling. How it is differ from Laminated Object Modeling.

Fused Deposition Modeling (FDM) vs. Laminated Object Modeling (LOM):

Working Principles and Differences

Fused Deposition Modeling (FDM):

Working Principle:
 1. Preparation: A 3D model is created in CAD software and sliced into thin
layers.
2. Material: FDM uses a filament, typically a thermoplastic material like ABS
or PLA.
3. Extrusion and Deposition: The filament is fed through a heated nozzle that
melts the material.
4. Movement and Patterning: A computer-controlled system precisely moves
the nozzle along a predetermined path, depositing the molten filament
layer-by-layer to create the desired shape according to the sliced model data.
5. Layer Solidification: As the extruded filament cools, it solidifies, bonding
to the previous layer and building the object.
6. Support Structures: For overhangs or complex geometries, additional
support material might be printed alongside the main object. This support
material is removed after printing.

Key Points:

● FDM is the most widely used 3D printing technology due to its relative ease
of use, affordability, and wide range of filament materials.
● The resolution and surface finish of FDM prints depend on the layer
thickness and nozzle size.
● FDM offers a good balance between affordability, speed, and material
options for creating functional prototypes and end-use parts.

Laminated Object Manufacturing (LOM):

Working Principle:

1. Preparation: A 3D model is created in CAD software and sliced into thin

layers.
2. Material: LOM uses sheets of adhesive-coated paper, plastic, or even metal
as the building material.
3. Sheet Bonding: Each layer sheet is fed from a roll and bonded to a platform
using a heated roller.
 4. Shape Definition: A laser cutter or knife precisely cuts the desired shape
from the bonded sheet according to the sliced model data. This cutting
process removes unwanted material from the sheet.
5. Layer Stacking: The platform with the completed layer lowers down, and a
fresh sheet is rolled into position for the next layer.
6. Iteration: Steps 3-5 are repeated for each layer until the entire object is
built.

Key Points:

● LOM offers a relatively fast and inexpensive way to create prototypes,

especially compared to some other 3D printing technologies.
● The layer thickness is determined by the material sheet used, typically
limiting resolution compared to FDM.
● LOM provides material versatility, allowing for paper, plastic, or even metal
prototypes with varying properties.

Key Differences:

Feature Fused Deposition Modeling Laminated Object Modeling

(FDM) (LOM)

Material Form Filament (thermoplastics) Sheets (paper, plastic, metal)

Material Wide range of thermoplastics Limited options based on

Choice sheet type

Process Material extrusion and layering Sheet bonding and selective

cutting

Resolution Moderate (depends on layer Lower (limited by sheet

thickness) thickness)
Surface Finish Good, but visible layer lines Stepped layers visible on
surfaces

Speed Moderate Relatively fast

Cost Generally affordable Can be cost-effective

Support Required for overhangs Not typically needed

Structures

Applications Prototyping, functional parts Prototyping, concept models

Choosing Between FDM and LOM:

● FDM: If you need high material versatility, good resolution for functional
parts, and a balance of affordability and speed, FDM is a strong choice.
● LOM: If rapid creation of concept models or low-cost paper prototypes is
the priority, and high resolution is less critical, LOM can be a suitable option

Q2 (c). Describe with examples any four applications of Rapid Prototyping.

Four Applications of Rapid Prototyping with Examples:

Rapid prototyping (RP) plays a crucial role in various industries, accelerating the
design and development process. Here are four key applications with examples:

1. Product Development and Design Validation:

● Example: An automotive company creates a rapid prototype of a new car

dashboard using FDM printing. This allows them to test the ergonomics, fit
and finish of the design with physical buttons and knobs before investing in
expensive tooling for mass production.

2. Custom Medical and Dental Implants:

 ● Example: Doctors use SLA printing to create a custom-sized jaw implant
for a patient undergoing facial reconstruction surgery. The high resolution
and accuracy of SLA allow for a perfect fit, improving surgical outcomes
and patient recovery.

3. Aerospace Component Testing:

● Example: Engineers in the aerospace industry use SLS printing to create

wind tunnel models of new aircraft wings. This allows them to test the
aerodynamic performance of the design quickly and iterate on it before
manufacturing full-scale prototypes.

4. Architectural Models and Prototypes:

● Example: An architect uses LOM to create a scale model of a new building

design with different colored paper sheets representing various building
materials. This allows for better visualization of the design for client
presentations and communication with stakeholders.

Q3(a). What material is used for Selective Laser Sintering RP process, give its
two properties, how do you prepare this material explain.

Selective Laser Sintering (SLS): A Layered Approach to 3D Printing

Selective Laser Sintering (SLS) is an additive manufacturing (AM) process that

utilizes a high-powered laser to create complex 3D objects from powdered plastic
or metal materials. Here's a breakdown of the key steps involved:

1. Preparation:

● 3D Model Creation: A digital 3D model of the desired object is created

using CAD software.
● Slicing: The model is sliced into thin virtual layers using specialized slicing
software. This software generates instructions for the SLS machine, defining
the laser path for each layer.
 ● Material Selection: A suitable powdered material like nylon (PA12) or
metal is chosen based on the desired properties of the final part (strength,
flexibility, etc.).

2. Printing Process:

● Powder Bed Preparation: A layer of powder is evenly distributed across

the build platform inside the SLS machine. This layer thickness typically
ranges from 50 to 200 microns.
● Selective Laser Sintering: A high-powered laser beam (e.g., CO2 laser)
scans across the powder bed according to the sliced model data. The laser
selectively melts and fuses the powder particles in designated areas, creating
a solid representation of the first layer of the object.
● Layer-by-Layer Building: The build platform lowers slightly, and a fresh
layer of powder is deposited across the previous sintered layer. The laser
then scans and selectively fuses this new layer, bonding it to the previous
one. This process repeats for each layer in the sliced model, gradually
building the entire object layer-by-layer.

3. Post-Processing:

● Part Removal: Once printing is complete, the build platform lowers

completely, and the remaining loose powder is carefully removed. The
printed part remains embedded within the unsintered powder.
● Excavation and Cleaning: The printed part is carefully excavated from the
powder bed. Depending on the complexity, support structures might have
been printed alongside the part to prevent overhangs from collapsing. These
supports are removed, and the part might undergo additional cleaning
procedures.
● Post-Curing (Optional): For some materials, heat treatment might be
applied as a post-processing step to improve the strength and mechanical
properties of the final part.

Key Advantages of SLS:

● High Resolution and Accuracy: SLS offers exceptional resolution and

dimensional accuracy, enabling the creation of intricate and detailed parts.
 ● Functional Prototypes and End-Use Parts: The printed parts can be strong
and functional, suitable for prototyping and even some end-use applications
depending on the material.
● Wide Material Variety: A range of powdered plastic and metal materials
are available, offering options for various strength, flexibility, and heat
resistance requirements.
● Minimal Material Waste: Unsintered powder can be recycled and reused in
subsequent prints, minimizing material consumption.

Applications of SLS:

● Prototyping: Creating functional prototypes for testing form, fit, and

functionality of designs.
● Manufacturing: Producing end-use parts in low-volume or customized
applications where SLS offers advantages over traditional manufacturing
methods.
● Medical and Dental Applications: Manufacturing custom prosthetics,
implants, and surgical models.
● Aerospace Industry: Creating lightweight and functional prototypes for
aircraft components.

Limitations of SLS:

● Cost: SLS machines and materials can be relatively expensive compared to

some other 3D printing technologies.
● Build Volume: Build volumes of SLS machines can be limited, restricting
the size of printable objects.
● Post-Processing: The process can involve post-processing steps like support
structure removal and cleaning, adding extra time and effort.

Selective Laser Sintering (SLS) Material and Preparation

Material:
The primary material used in SLS is powdered plastic. However, some variations
can also utilize metal powders.

Two Key Properties of SLS Material (Plastic Powders):

1. Particle Size and Distribution: The powder particles need to be consistent

in size and have a good size distribution for optimal flow and packing during
the printing process. This ensures proper laser interaction and sintering
between particles.
2. Thermal Properties: The material needs to have a well-defined melting
point and good thermal conductivity. The laser beam should be able to melt
the targeted particles without significantly affecting surrounding powder.
Additionally, the material should cool rapidly after laser exposure to allow
for proper layer bonding.

Material Preparation for SLS:

Here's a breakdown of the typical material preparation steps for SLS using plastic
powders:

1. Material Selection: Choose a powder material with properties suitable for

your desired application (e.g., strength, flexibility, heat resistance). Nylon
(PA12) is a common and versatile choice for SLS.
2. Pre-heating: The powder bed in the SLS machine might be pre-heated
slightly to improve powder flow and ensure consistent material properties
throughout the printing process.
3. Powder Coating: A roller mechanism spreads a thin layer of powder evenly
across the build platform.
4. Selective Laser Sintering: The laser beam selectively melts the powder
particles according to the sliced model data, creating a solid layer
corresponding to a single slice of the 3D model.
5. Re-coating: After each layer is sintered, a fresh layer of powder is deposited
for the next round of laser melting and bonding.
6. Post-Processing: Once printing is complete, the build platform lowers, and
the remaining loose powder is removed. The printed part might require
additional cleaning and post-processing steps depending on the material
 used. This might involve heat treatment for improved strength or removal of
support structures (if needed for complex geometries).

Additional Considerations:

● Material Recycling: Unsintered powder from the build chamber can often
be recycled and reused in subsequent prints, minimizing waste and material
costs.
● Material Handling: SLS powder can be fine and might have slight
electrostatic properties. Proper handling procedures and personal protective
equipment (PPE) might be necessary to avoid inhalation risks or dust
explosions.

Q3(b). How do you take care of overhanging parts in model while building on
RP process, what are four properties explain with examples

Overhangs are features in a 3D model that extend horizontally without any

underlying support. These can be challenging to print in some RP processes as the
material being deposited might not have anything to adhere to, causing them to
droop or collapse. Here's how to address overhangs and four key properties to
consider:

Approaches to Overhangs:

1. Support Structures:
● This is the most common approach. The RP machine generates additional
temporary structures made from the same or a different material that support
overhangs during printing. These supports are removed after printing is
complete.
○ Example: In FDM printing, support structures are typically made
from a breakaway material that can be snapped off or dissolved with a
solvent.
2. Model Orientation:
 ● Repositioning the model during the slicing process can sometimes minimize
or eliminate overhangs altogether. This might not always be feasible
depending on the desired final orientation of the part.
○ Example: Tilting a model with a long, unsupported bridge feature at
an angle can allow for printing without needing support structures.
3. Design for Manufacturability (DFM):
● Incorporating design modifications during the initial modeling stage can
often eliminate the need for complex support structures altogether. This
might involve adding angled features, fillets, or reducing the overhang angle.
○ Example: Instead of a sharp 90-degree overhang, redesigning the
model with a 45-degree angle might allow for successful printing
without supports.

Four Key Properties to Consider When Addressing Overhangs:

1. Material Properties:
● The printability of overhangs depends on the material used in the RP
process. Some materials, like certain high-temperature thermoplastics in
FDM, offer better natural overhang capabilities due to their ability to bridge
small gaps before solidifying.
○ Example: Nylon in FDM can handle steeper overhang angles
compared to PLA due to its higher melting temperature and slower
cooling rate.
2. Layer Thickness:
● Thicker layers can be more challenging for printing overhangs as they
provide less surface area for the deposited material to adhere to. Using
thinner layers generally improves overhang printability.
○ Example: Reducing the layer thickness in your slicing software can
help create smoother and more supported overhangs.
3. Print Orientation:
● The orientation of the model on the print bed can significantly impact
overhang printability. Minimizing the angle of the overhang relative to the
build plate can improve support and reduce the risk of drooping.
 ○ Example: Printing a model with a large overhang flat on the bed will
require more support material compared to printing it at an angle that
minimizes the overhang angle.
4. Cooling Settings:
● In some RP processes, adjusting the cooling settings can influence overhang
printability. Slower cooling can allow the deposited material to solidify and
bridge small gaps more effectively.
○ Example: Reducing fan speed in FDM printing might improve
overhang quality by allowing the filament to cool slightly slower and
improve layer adhesion.

Q3(c). How do you use Ceramic as a RP materials, explain any one RP process
that uses Ceramic as a raw material

While ceramics aren't as widely used in rapid prototyping (RP) as some other
materials due to challenges, they do offer advantages for specific applications.
Here's an explanation of how ceramics can be used in RP and a specific process
that utilizes them:

Challenges of Using Ceramics in RP:

● Brittleness: Ceramics are inherently brittle and prone to cracking or

breaking, especially during handling and post-processing steps.
● High Processing Temperatures: Sintering ceramics often requires very
high temperatures, which can limit the choice of compatible RP technologies
and add complexity to the process.
● Material Limitations: Not all ceramic compositions are readily available or
suitable for RP applications.

Despite these challenges, ceramics offer unique benefits for certain

applications:

● High-Temperature Resistance: Ceramics can withstand extremely high

temperatures, making them ideal for prototyping parts intended for high-heat
environments.
 ● Wear Resistance: Certain ceramics exhibit excellent wear resistance,
valuable for prototyping components that experience friction and abrasion.
● Electrical Properties: Some ceramics offer specific electrical properties
like insulation or conductivity, useful for creating functional prototypes in
electronics.

RP Process Using Ceramics: Stereolithography (SLA) with Ceramic Resins:

1. Preparation: A 3D model is created in CAD software and sliced into thin

layers.
2. Material: A specialized SLA resin containing ceramic particles suspended
in a photopolymer base is used. The resin composition can be formulated to
achieve desired final properties after sintering.
3. Laser Curing: A computer-controlled laser beam selectively cures
(solidifies) the resin layers according to the sliced model data, building the
object layer-by-layer. This process is similar to standard SLA using
photopolymers.
4. Debinding: Once printing is complete, the printed part needs to undergo a
debinding process to remove the uncured resin binder material. This might
involve chemical or thermal treatments.
5. Sintering: The debound part is then subjected to high temperatures (often
exceeding 1000°C) in a furnace. This sintering process fuses the ceramic
particles together, creating a strong and dense ceramic object with the
desired final properties.

Applications of Ceramic RP:

● Prototyping for Engines and Turbines: Creating high-temperature

resistant prototypes for components used in engines and turbines.
● Functional Prototyping in Electronics: Manufacturing electrical insulators
or other functional prototypes requiring specific electrical properties.
● Biomedical Applications: Prototyping biocompatible ceramic implants or
scaffolds for medical research.

Alternative RP Processes for Ceramics:

 ● Binder Jetting: This process uses a liquid binder to selectively inkjet a
ceramic powder bed, creating a 3D object layer-by-layer. The part then
undergoes debinding and sintering similar to SLA with ceramic resins.
● Direct Inkjet Printing (DIJ): This method utilizes an inkjet system to
deposit a ceramic slurry (ink) containing ceramic particles and a binder onto
a build platform. The part undergoes debinding and sintering for finalization.

Q4(a). What is the role of Laser in Rapid Prototyping, explain with block
diagram.

Lasers play a critical role in several Rapid Prototyping (RP) technologies by

providing a precise and controlled method for shaping and solidifying materials
layer-by-layer to create 3D objects. Here's a breakdown of how lasers are utilized
in different RP processes:

Selective Laser Sintering (SLS):

● A high-powered laser selectively melts and fuses powdered plastic or metal

materials, bonding them together to create each layer of the desired object.

Stereolithography (SLA):

● A laser beam cures (solidifies) photosensitive liquid resin according to the

sliced model data. The laser selectively exposes specific areas of the resin
vat, building the object layer-by-layer.

Selective Laser Melting (SLM):

● A high-power laser beam melts and fuses metal powder particles to create
complex 3D metallic objects. Similar in principle to SLS but with higher
laser power to achieve full melting of metal particles.

Laser Cutting/Engraving (Used in some RP systems):

● In some RP processes like Laminated Object Manufacturing (LOM), a laser

cutter precisely cuts the desired shape from a sheet of material (paper,
 plastic, metal) based on the sliced model data. This cutting process defines
the geometry of each layer before it's bonded to the previous layer.

Advantages of Using Lasers in RP:

● High Precision and Accuracy: Lasers offer a highly focused and

controllable beam, enabling the creation of intricate details and precise
geometries in the printed parts.
● Wide Range of Materials: Lasers can be used with various materials,
including plastics, metals, and even some ceramics (through specialized
resins or processes).
● Speed and Efficiency: The laser curing or sintering process can be
relatively fast, allowing for rapid creation of prototypes compared to
traditional manufacturing methods.
● Minimal Material Waste: In some laser-based RP processes, unused
material (e.g., unsintered powder) can be recycled and reused, minimizing
waste.

Examples of RP Technologies Not Using Lasers:

● Fused Deposition Modeling (FDM): This method uses a heated nozzle to

extrude and deposit molten filament material layer-by-layer.
● Binder Jetting: A liquid binder selectively inkjet onto a powder bed to
create the object. The powder itself is not melted or fused by a laser.

Q4(b). For an FDM process, a wire with a diameter of 1.75 mm is utilized and
7 fed at a speed of 0.86 mm/s. The deposited bead area is 0.091 mm². In order
to maintain no slip between the pinch rollers and the wire, what would be the
appropriate travel speed of extruder relative to its build platform?

Q4(c). Describe FDM with free hand sketch. Describe any two major faults
and their trouble shooting in Fusion Deposition Modeling, RP process.
Fused Deposition Modeling (FDM) Explained:
FDM, or Fused Deposition Modeling, is one of the most widely used rapid
prototyping (RP) technologies. It utilizes a continuous filament of thermoplastic
material to create 3D objects layer-by-layer. Here's a breakdown of its key aspects:

Process:

1. Preparation: A 3D model is created in CAD software and sliced into thin

layers.
2. Material: FDM uses a filament, typically a thermoplastic material like ABS
(Acrylonitrile Butadiene Styrene) or PLA (Polylactic Acid).
3. Extrusion and Deposition: The filament is fed through a heated nozzle that
melts the material.
4. Movement and Patterning: A computer-controlled system precisely moves
the nozzle along a predetermined path, depositing the molten filament
layer-by-layer to create the desired shape according to the sliced model data.
5. Layer Solidification: As the extruded filament cools, it solidifies, bonding
to the previous layer and building the object.
6. Support Structures: For overhangs or complex geometries, additional
support material might be printed alongside the main object. This support
material is removed after printing.

Two Major Faults and Troubleshooting in FDM:

1. Under-extrusion:

● Symptoms: Gaps between filament lines, missing layers, poor overall print
quality.
● Possible Causes:
○ Clogged Nozzle: Blockage in the nozzle due to burnt filament or
debris.
○ Incorrect Filament Diameter: Filament diameter not properly
configured in the slicer software, leading to under-extrusion.
○ Insufficient Tension: Loose filament tension can cause feeding issues
and under-extrusion.
○ Low Extrusion Temperature: Filament temperature set too low,
preventing proper melting and flow.
 ● Troubleshooting:
○ Clean the Nozzle: Use the appropriate cleaning tools and procedures
to remove any blockage.
○ Calibrate Filament Diameter: Ensure the slicer software is set to the
correct filament diameter you're using.
○ Adjust Filament Tension: Increase the tension on the filament spool
to improve feeding consistency.
○ Raise Extrusion Temperature: Increase the printing temperature
within the recommended range for your filament material.

2. Stringing or Blobbing:

● Symptoms: Thin strands of filament oozing from the nozzle between

printing positions, creating unwanted string-like connections or blobs on the
printed object.
● Possible Causes:
○ Excessive Retraction: Too much retraction distance or speed can
cause the filament to retract too far, leading to stringing upon
resumption of extrusion.
○ High Printing Temperature: Filament temperature set too high,
causing excessive melting and dripping from the nozzle.
○ Incorrect Print Speed: Printing speed too high can limit proper
filament cooling and solidification, leading to stringing.
● Troubleshooting:
○ Reduce Retraction Settings: Lower the retraction distance or speed
in your slicer software to minimize filament oozing during travel
moves.
○ Lower Printing Temperature: Decrease the printing temperature
slightly while maintaining good layer adhesion for your material.
○ Adjust Print Speed: Reduce the overall printing speed to allow for
better filament cooling and solidification between printing positions.

Additional Tips:
 ● Proper Slicer Settings: Optimizing slicer settings like layer height, infill
density, and printing temperature for your specific filament and desired print
quality is crucial.
● Material Compatibility: Ensure you're using filament compatible with your
FDM printer and adjust settings accordingly.
● Regular Maintenance: Regular cleaning and maintenance of the nozzle and
extruder system can help prevent clogging and ensure smooth filament flow.

Q5(a). What do you mean by post processing of Rapid Prototype part, explain

In Rapid Prototyping (RP), post-processing refers to the additional steps performed

on a 3D printed part after it's finished printing on the machine. While the RP
machine builds the object layer-by-layer, the final part might require some
additional work to achieve its desired form, functionality, and surface finish. Here's
a breakdown of what post-processing typically entails:

1. Support Removal:

● Many RP processes, such as Fused Deposition Modeling (FDM) and

Stereolithography (SLA), utilize support structures during printing. These
temporary structures are necessary to hold up overhangs or complex
geometries that would otherwise collapse without support.
● Post-processing involves removing these support structures carefully.
Depending on the material and type of support used, this might involve:
○ Manual removal: Using tools like pliers or tweezers for larger
support structures.
○ Chemical baths: Soaking the part in a solvent solution that dissolves
the support material (applicable for specific materials).
○ Breaking away: For some materials, support structures are designed
to be snapped off manually.

2. Cleaning:
 ● Depending on the RP process and material used, the printed part might have
some residual material or debris on its surface. This could be uncured resin
in SLA or excess filament wisps in FDM.
● Post-processing might involve cleaning the part with:
○ Solvents: For SLA prints, specific solvents might be used to remove
uncured resin depending on the resin type.
○ Brushes and compressed air: Removing dust, debris, or loose
filament strands from the surface.

3. Surface Finishing:

● The surface finish of a 3D printed part directly out of the machine might
have visible layer lines or imperfections depending on the RP technology
and settings used.
● Post-processing can involve techniques to improve the surface aesthetics or
functionality of the part:
○ Sanding and polishing: Smoothing out the surface with sandpaper or
polishing techniques for a better visual finish.
○ Painting or coating: Applying paint or coatings for aesthetic
purposes or to enhance functional properties like wear resistance.
○ Vapor smoothing: Exposing the part to a solvent vapor bath to melt
the surface slightly, creating a smoother finish (applicable for specific
materials).

4. Debinding and Sintering (for specific materials):

● Some RP processes, like those using ceramic materials, might involve

additional post-processing steps like debinding and sintering:
○ Debinding: Removing any leftover binding material that held the
ceramic particles together during printing.
○ Sintering: Subjecting the part to high temperatures in a furnace to
fuse the ceramic particles and create a strong, dense final object.

Importance of Post-Processing:

● Post-processing plays a crucial role in transforming a freshly printed part

into a functional or visually appealing prototype.
 ● It can significantly impact the final quality, dimensional accuracy, surface
finish, and functionality of the rapid prototype.

Q5 (b). What is Green Strength and Curl effect in Rapid Prototype build part
explain with sketches.

Green Strength and Curl Effect in Rapid Prototyping

Green Strength:

● Definition: Green strength refers to the initial handling strength of a 3D

printed part immediately after the printing process is complete. The part is
still uncured or in a partially cured state and might be fragile.

● Importance: While not the final strength, green strength is crucial for
handling the part during post-processing steps like support removal or
cleaning without causing damage.

● Factors Affecting Green Strength:

○ Material: Different materials inherently possess varying degrees of

green strength. For example, FDM parts printed with ABS might have
higher green strength compared to PLA due to differences in material
properties.
○ Layer Thickness: Thicker layers generally provide more structural
integrity and contribute to higher green strength.
○ Infill Density: A higher infill density within the part (more material
filled inside the printed shell) increases green strength by offering
more material for handling.
○ Printing Temperature: For some materials, adjusting the printing
temperature can influence green strength. In FDM, slightly lower
printing temperatures can sometimes improve green strength by
allowing for better layer bonding before solidification.

Sketch of Green Strength:

Imagine a freshly printed FDM part with a medium infill density. The individual
layers are visible, but the part has enough inherent strength to be carefully picked
up and moved without breaking due to its green strength.

Curl Effect:

● Definition: Curl effect refers to the warping or deformation of a 3D printed

part, typically along its edges or base, during the printing process.

● Causes:

○ Thermal Expansion and Contraction: As the material in each layer

heats up during printing and then cools down after deposition, it can
undergo thermal expansion and contraction. This can lead to uneven
shrinkage and warping in the part, especially for parts with large flat
areas.
○ Warping Stress: Internal stresses can build up within the part as
layers are deposited and cool. These stresses can cause the part to curl
or warp, particularly at areas with significant changes in geometry.
● Minimizing Curl Effect:

○ Build Platform Adhesion: Using a heated build platform or applying

a suitable adhesive to the platform can help improve adhesion and
reduce warping.
○ Support Structures: Strategic placement of support structures can
help counteract warping forces and minimize curling.
○ Print Orientation: Reorienting the model during slicing can
sometimes minimize the impact of warping on critical features.
○ Adjusting Print Settings: Reducing printing temperature (within
material limitations) or adjusting cooling settings might help manage
thermal expansion and contraction, minimizing curl.

Sketch of Curl Effect:

Imagine an FDM printed rectangular plate. Due to the curl effect, the edges of the
plate might be slightly warped upwards, creating a curved shape instead of a
perfectly flat surface.

Q5(c). Describe various techniques of post processing of RP part.

Post-Processing Techniques for Rapid Prototypes

After the magic of 3D printing builds your object layer by layer, your RP part
might not be quite ready for its close-up (or its functional purpose) just yet.
Post-processing steps are crucial for transforming a freshly printed part into its
final form. Here's an overview of various techniques used in post-processing RP
parts:

1. Support Removal:

This is a common step for RP processes like FDM and SLA that utilize support
structures during printing. These temporary structures are necessary to uphold
overhangs and complex geometries. However, once the printing is complete, they
need to be removed carefully:

● Manual Removal: Using tools like pliers, tweezers, or hobby knives, you
can carefully break away or cut off larger support structures.
● Chemical Baths: For specific materials like SLA resins, the part might be
submerged in a solvent solution that dissolves the support material.
● Breakaway Supports: Some materials are designed with breakaway
supports that can be snapped off manually without requiring tools.

2. Cleaning:

Depending on the RP process and material used, the printed part might have some
residual material or debris on its surface:

● Solvents: For SLA prints, specific solvents might be used to remove

uncured resin depending on the resin type.
 ● Brushes and Compressed Air: This is a simple yet effective way to remove
dust, debris, or loose filament strands from the surface, especially for FDM
parts.

3. Surface Finishing:

The surface finish of a 3D printed part straight out of the machine might have
visible layer lines or imperfections:

● Sanding and Polishing: Smoothing out the surface with sandpaper or

polishing techniques like buffing wheels for a better visual finish. This is
commonly used for FDM parts.
● Painting or Coating: Applying paint or coatings can enhance aesthetics or
add functional properties like wear resistance. This can be used for various
RP processes.
● Vapor Smoothing: Exposing the part to a solvent vapor bath can slightly
melt the surface, creating a smoother finish. This is applicable for specific
materials like ABS in FDM.

4. Debinding and Sintering (for Ceramic RP):

These additional steps are specific to RP processes using ceramic materials:

● Debinding: Removing any leftover binding material that held the ceramic
particles together during printing.
● Sintering: Subjecting the part to high temperatures in a furnace to fuse the
ceramic particles and create a strong, dense final object.

5. Advanced Finishing Techniques:

For specific applications or high-quality prototypes, even more advanced

techniques might be employed:

● Electroplating: Depositing a thin layer of metal onto the printed part for
improved conductivity or aesthetics.
● Infiltration: Filling the pores of a printed part with a different material to
enhance strength or other properties.
 ● CNC Machining: Using a computer numerically controlled machining
process for very high precision and surface finish requirements.

Choosing the Right Technique:

The specific post-processing techniques used will depend on several factors:

● RP Process: The type of 3D printing technology used (FDM, SLA, SLS,

etc.) will determine the initial state of the part and the available support
removal methods.
● Material: Different materials respond differently to post-processing
techniques. Some materials might be more prone to warping during sanding,
for example.
● Desired Outcome: Are you prioritizing a smooth surface finish, improved
functionality, or simply removing support structures?
PYQ Paper 2 April 2023
Q1(a). What is IGES file format, Explain?

IGES File Format Explained

IGES stands for Initial Graphics Exchange Specification. It's a vendor-neutral

file format used to exchange product definition data between different
Computer-Aided Design (CAD) software applications.

Here's a breakdown of key characteristics of IGES files:

● Purpose: Facilitate the transfer of 2D or 3D models, including geometry,

wireframes, surface information, and even circuit diagrams, between
different CAD programs.
● Format: ASCII text-based format with each line containing a maximum of
80 characters. This format originated from the limitations of punched cards
used in early computer systems.
● Structure: Divided into five sections identified by specific letters in the
73rd column of each line:
○ Start (S) - Header information
○ Global (G) - Global settings and units
○ Data Entry (D) - Geometric data definitions
○ Parameter Data (P) - Additional parameters associated with the
geometry
○ Terminate (T) - End of file marker
● Complexity: Due to its text-based nature and historical origins, IGES files
can be quite complex and challenging to interpret directly. Specialized
software is often used to view and edit IGES files.

Benefits of IGES:

● Vendor Neutrality: Allows data exchange between different CAD

programs, promoting collaboration.
● Supports 2D & 3D Data: Can handle both two-dimensional drawings and
three-dimensional model information.
Limitations of IGES:

● Complexity: The text-based format can be cumbersome to work with and

prone to errors.
● Data Loss: During translation between different CAD programs, some data
might be lost or misinterpreted due to variations in how software interprets
IGES specifications.
● Limited Functionality: Less advanced than newer file formats like STEP
(STereoLithography) when it comes to representing complex design features
and annotations.

Use Cases for IGES:

● Sharing 2D drawings or 3D models with collaborators using different CAD

software.
● Importing legacy CAD data into newer software applications.
● Manufacturing workflows where data needs to be transferred between design
and production software.

Alternatives to IGES:

● STEP (STereoLithography): A more modern and comprehensive format

for exchanging product data, offering better support for complex geometries
and annotations.
● JT Open: Another vendor-neutral format specifically designed for
lightweight data exchange and visualization of 3D models.

Q1(c). Compare the product development in CAD and conventional

methodology

Product Development: CAD vs. Conventional Methodology

Here's a comparison of product development using Computer-Aided Design

(CAD) and conventional methods:

Concept & Design:

 ● CAD:

○ Digital sketches and 3D modeling allow for rapid exploration of

design ideas and variations.
○ Easier visualization and manipulation of designs from different
angles.
○ Built-in features for simulating product performance and functionality.
● Conventional:

○ Relies on physical sketches and 2D drawings, making design changes

time-consuming.
○ Physical prototypes needed for visualization and testing, increasing
costs and lead times.
○ Limited ability to simulate product performance without physical
prototypes.

Documentation & Communication:

● CAD:

○ Electronic files easily shared with collaborators and manufacturers.

○ Automated generation of bills of materials (BOM) and assembly
instructions.
○ Improved version control and tracking of design changes.
● Conventional:

○ Paper-based drawings prone to errors and miscommunication during

handoffs.
○ Manual creation of BOMs and assembly instructions, increasing risk
of errors.
○ Difficulty in tracking design revisions and ensuring everyone has the
latest version.

Analysis & Iteration:

 ● CAD:

○ Integrated analysis tools for stress, heat flow, and other engineering
factors.
○ Faster design iterations based on analysis results.
○ Easier optimization of designs for performance and manufacturability.
● Conventional:

○ Relies on physical prototypes and manual testing for analysis, which

is time-consuming and expensive.
○ Design changes often require rebuilding physical prototypes, slowing
down iteration cycles.
○ Limited ability to optimize designs beyond what can be achieved
through physical testing.

Prototyping & Manufacturing:

● CAD:

○ Direct generation of data for 3D printing or CNC machining,

facilitating rapid prototyping.
○ Improved accuracy and consistency in parts created through digital
manufacturing.
○ Easier communication of design intent to manufacturers through
digital models.
● Conventional:

○ Relies on skilled craftspeople to create prototypes, which can be

time-consuming and expensive.
○ Potential for errors or inconsistencies during manual prototype
creation.
○ Re-creation of design intent for manufacturing can lead to errors in
translation.

Overall Advantages of CAD:

 ● Faster design cycles and time-to-market
● Improved design accuracy and quality
● Enhanced collaboration and communication
● Reduced prototyping costs
● Increased design iteration and optimization

Q3(a). What are post-processing techniques used to improve the surface finish
of 3D printed objects, Explain?

3D printing brings objects to life layer-by-layer, but the surface finish straight out
of the machine might not always be perfect. Here are some post-processing
techniques used to enhance the surface finish of 3D printed parts:

Mechanical Techniques:

● Sanding and Polishing: This is a common approach for FDM prints (ABS,
PLA) and involves using sandpaper of varying grits (rough to fine) to
progressively smooth out the layer lines and imperfections. Polishing with
abrasive compounds or buffing wheels can further enhance the shine.

● Abrasive Blasting: A more aggressive technique using a pressurized stream

of abrasive particles like sand or glass beads to remove material and achieve
a smoother surface. This is suitable for materials like metal or some
high-temperature thermoplastics but requires proper equipment and safety
precautions.

● Tumbling: Parts are placed in a rotating drum with abrasive media (ceramic
tumbling media, etc.) to create a smooth and even finish. This is effective for
small parts and can be used for various materials depending on the media
chosen.

Chemical Techniques:
 ● Vapor Smoothing: Exposing the printed part to a solvent vapor (often
acetone for ABS) melts the surface slightly, fusing the layer lines and
creating a smoother finish. This requires a controlled environment and
proper ventilation.

● Chemical Smoothing: Certain materials might be compatible with specific

chemical baths that can achieve a smoother surface. This approach requires
careful selection of chemicals and safety protocols depending on the
material.

Other Techniques:

● Electroplating: A thin layer of metal can be deposited on the printed part

through an electroplating process, improving surface aesthetics and
potentially adding conductivity.

● Infiltration: For porous printed parts, a different material can be infiltrated

to fill the pores and enhance strength or other properties. This can also
improve the surface finish depending on the infiltrant used.

Choosing the Right Technique:

The most suitable post-processing technique depends on several factors:

● Material: Different materials respond differently to various techniques. For

example, some materials might be more susceptible to warping during
sanding.
● Desired Outcome: Are you aiming for a high-gloss finish, a smoother
surface for painting, or simply a more polished look?
● Complexity of the Part: Some techniques like sanding might be
challenging for intricate parts with tight spaces.
Q5(a). What is Rapid Tooling, explain Tafa Metal Gun used in rapid tooling
system with free hand sketch

Rapid Tooling Explained

Rapid tooling refers to a group of techniques that allow for the rapid creation of
molds, jigs, fixtures, and other tooling components used in manufacturing
processes. These tools are typically used for low-volume production runs or
prototyping stages before full-scale manufacturing begins.

Benefits of Rapid Tooling:

● Reduced Lead Times: Compared to traditional tool manufacturing

methods, rapid tooling offers significantly faster turnaround times,
accelerating the product development process.
● Lower Costs: For low-volume production runs, rapid tooling can be more
cost-effective than traditional tooling methods.
● Design Iteration: The ability to quickly create and modify tools allows for
greater flexibility in design exploration and refinement.
● Complex Geometries: Rapid tooling techniques can handle complex
geometries that might be challenging or expensive to produce using
traditional methods.

Common Rapid Tooling Techniques:

● Fused Deposition Modeling (FDM): Can be used to create molds and

casting patterns for limited production runs.
● Stereolithography (SLA): High-resolution SLA prints can be used for
creating master patterns for casting molds.
● Selective Laser Sintering (SLS): SLS is suitable for creating functional
tools from metal or nylon powders.
● Machining: CNC machining can be used for rapid tool creation from metal
or plastic stock.

TAFA Metal Gun Used in Rapid Tooling System

Unfortunately, there isn't a widely recognized rapid tooling system referred to
specifically as a "TAFA Metal Gun." It's possible this term might be specific to a
certain brand or proprietary technology.

Here are some possibilities:

● Metal Deposition Systems: There are additive manufacturing technologies

using directed energy deposition to create metal tools. These systems might
involve a "gun" metaphor referring to the deposition head that melts and
extrudes metal powder or wire to build the tool.

● Tooling Fabrication Techniques: Some rapid tooling techniques might

utilize equipment with a "gun-like" form factor for specific purposes. For
instance, directed energy deposition or cold spray metal technologies might
have handheld or robotic deposition tools

Q5(b). Provide an explanation of the imperfections that exist in the WAAM

method that involves the use of MIG technology

Wire Arc Additive Manufacturing (WAAM), especially when using MIG (Metal
Inert Gas) welding technology, offers a versatile and efficient approach to 3D
printing metal parts. However, there are certain imperfections you might encounter
with this method. Here's a breakdown of some common challenges:

1. Porosity:

● Description: Porosity refers to air pockets or voids trapped within the

deposited metal during the WAAM process.
● Causes: Several factors can contribute to porosity, including:
○ Insufficient shielding gas: Improper shielding gas flow around the
welding arc can allow air to contaminate the molten metal, leading to
trapped gas pockets.
○ Moisture on the wire or in the shielding gas: Moisture can cause
similar issues as insufficient shielding gas, creating porosity during
solidification.
 ○ Travel speed and wire feed rate: Incorrect settings can lead to
incomplete fusion between layers, trapping air pockets.

2. Surface Roughness:

● Description: WAAM-printed parts can exhibit a rough surface texture due

to the inherent nature of the welding process.
● Causes: The visible layer lines and spatter from the welding arc contribute
to a rougher surface finish compared to some other 3D printing methods.

3. Warping and Distortion:

● Description: Uneven heating and cooling during the WAAM process can
cause warping or distortion in the printed part.
● Causes: The concentrated heat source from the welding arc can lead to
localized thermal expansion and contraction. This can result in warping,
especially in parts with significant overhangs or thin features.

4. Residual Stress:

● Description: The rapid solidification of molten metal during WAAM can

introduce residual stresses within the printed part.
● Causes: As the deposited metal cools quickly, it can shrink and create
internal stresses. These stresses can affect the part's dimensional stability and
potentially lead to cracking in extreme cases.

5. Limited Material Compatibility:

● Description: While WAAM offers compatibility with various metal alloys,

it might not be suitable for all materials.
● Causes: Some materials with high vaporization points or sensitivity to rapid
heating and cooling might not be ideal for the WAAM process due to
challenges in achieving proper fusion and controlling distortion.

Minimizing Imperfections in WAAM:

 ● Optimizing Process Parameters: Fine-tuning parameters like travel speed,
wire feed rate, and welding current can minimize porosity and improve layer
fusion.
● Preheating and Post-heating: Controlled heating before and after printing
can help manage thermal gradients and reduce warping.
● Support Structures: Strategic use of support structures can help counteract
warping forces during printing.
● Stress Relieving Techniques: Post-processing techniques like heat
treatment can help alleviate residual stresses within the printed part.

Conclusion:

Despite these imperfections, WAAM remains a valuable 3D printing technology

for metal parts due to its advantages in speed, material selection, and build volume.
By understanding these limitations and implementing proper process control
strategies, users can minimize these imperfections and achieve high-quality metal
parts using WAAM with MIG technology.