Unit 1: Introduction to Additive Manufacturing (AM)
Q: What is Additive Manufacturing (AM)?
A: AM, or 3D printing, is a process that creates objects layer-by-layer from digital models,
contrasting with subtractive manufacturing, which removes material.
Q: How does AM differ from traditional manufacturing?
A: Traditional manufacturing involves subtractive processes (like machining) and formative
processes (like casting), while AM adds material layer-by-layer.
Q: What is reverse engineering?
A: Reverse engineering involves scanning an existing object to create a digital CAD model, often for
replication or improvement.
Q: Explain the AM process chain.
A: The AM process chain includes: Design (CAD modeling), Slicing (converting the model into
layers), Printing (layer-by-layer build), and Post-Processing (finishing operations).
Q: Name and describe any two application levels of AM.
A: Rapid Prototyping: Quickly creates prototypes for design verification. Rapid Tooling: Produces
tools or molds rapidly using AM techniques.
Unit 2: Materials Science for AM
Q: What types of materials are used in AM?
A: Polymers (e.g., PLA, ABS), metals (e.g., titanium, aluminum), ceramics, and composites are
commonly used in AM.
Q: Why is the solidification rate important in AM?
A: The solidification rate affects the microstructure and mechanical properties of the printed part.
Faster cooling can create unique non-equilibrium structures.
Q: What is meant by multifunctional and graded materials?
A: Multifunctional materials have different properties within the same part, while graded materials
gradually change properties across the part.
Q: How does AM control grain structure and microstructure?
A: By adjusting parameters like cooling rates and laser power, AM can control grain growth,
orientation, and phase formation.
Unit 3: AM Technologies
Q: Describe Selective Laser Sintering (SLS).
A: SLS uses a laser to fuse powdered materials (usually polymers or metals) layer-by-layer to create
a solid object.
Q: What is Electron Beam Melting (EBM)?
A: EBM uses a high-energy electron beam to melt and fuse metal powder in a vacuum environment,
suitable for aerospace and biomedical applications.
Q: How does Fused Deposition Modeling (FDM) work?
A: FDM extrudes thermoplastic filaments through a heated nozzle, depositing material layer-by-layer
to build the object.
Q: What is Stereolithography (SLA)?
A: SLA uses UV lasers to selectively harden photopolymer resin, creating highly detailed parts with
smooth surface finishes.
Unit 4: Mathematical Models for AM
Q: What are transport phenomena in AM?
A: Transport phenomena refer to heat transfer, fluid flow, and material composition during the AM
process, influencing part quality.
Q: Why is residual stress analysis important in AM?
A: Residual stress, caused by uneven heating and cooling, can lead to deformations and defects.
Simulations help predict and minimize these stresses.
Q: What is numerical modeling in AM?
A: Numerical modeling involves simulating the AM process to predict outcomes like temperature
distribution, stress formation, and defect occurrence.
Unit 5: Process Selection, Planning, and Control
Q: What factors affect the selection of an AM process?
A: Material type, part geometry, mechanical properties, surface finish, and cost are key factors.
Q: What are common defects in AM, and how are they controlled?
A: Common defects include porosity, residual stress, and warping. In-situ monitoring and parameter
optimization help control defects.
Q: Explain the importance of post-processing in AM.
A: Post-processing enhances surface finish, mechanical strength, and dimensional accuracy.
Methods include polishing, heat treatment, and coating.
