R038 Engineering Design Topic 4.2 - Additive manufacturing

​ (a)   is the process of joining material together layer by layer to create a component or product.  This is often referred to as ​ (b)   , which can use a range of different materials, inc. plastic, metal and concrete.

​ (c)   builds up 3D objects by adding layers of material under the control of a computer.  ​ (d)   is first used to design and create the component, which is then used to program and control the ​ (e)   machine.

• Additive manufacturing
• 3D printing
• CAD software
• Laser Cutting
• CNC Milling
• CAM software
• additive manufacturing

Identify the different parts on a 3D printer.

a

b

c

d

e

Build plate

Power supply

Extruder

Hot end

Control display

Organise these options into the right categories

Groups:

(a) 3D printed

,

(b) Not 3D printed

• 
• 
• 
• 
• 
• 

While this process has commonly been used to quickly produce prototype components, it is now being used in the manufacture of actual components for use on finished products.  Airbus uses additive manufacture for high volume production of components for its aircraft and helicopters. What is this process also known as?

3D printers construct a ‘model’ by building up layer upon layer of PLA, Nylon or ABS, fed from spool, usually at the back of the printer. Each layer is a fraction of a millimetre and building even a small model can take sometime. The PLA / ABS is purchased in the form of ​ (a)   on open ​ (b)   . ​ (c)   tend to be 2.85mm diameter and rolled on to a ​ (d)   . The ​ (e)   fits on a roller, normally on the back of the 3D printer.

• filaments
• Filaments
• spool
• spools
• string
• rod
• pipe
• Pipes

Which material is commonly used in 3D printing?

Answer explanation

Plastic is commonly used in 3D printing due to its versatility, affordability, and ease of use.

Which 3D printing technology uses a laser to cure liquid resin into hardened plastic?

Answer explanation

Stereolithography (SLA) technology uses a laser to cure liquid resin into hardened plastic.

What is a critical design consideration when creating a model for 3D printing?

• The color of the material

• The size of the print bed

• The layer thickness of the print

• The ambient temperature of the room

Answer explanation

The critical design consideration when creating a model for 3D printing is the size of the print bed, as it determines the maximum dimensions of the object that can be printed.

Which of the following is an advantage of additive manufacturing?

• High production speed for large volumes

• Ability to create complex and customised designs

• Lower material costs compared to traditional manufacturing

• Less post-processing required

Which industry has widely adopted 3D printing for creating prototypes and custom parts?

• Agriculture

• Fashion

• Automotive

• Oil and Gas