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3D Printing and Design

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Module 2: 3D Printing Materials

  1. Q1(e). Which Additive Manufacturing process primarily utilizes raw material in the form of a wire/filament? (i) Selective Laser Sintering (SLS) (ii) Stereo Lithography (SLA) (iii) Fused Deposition Modeling (FDM) (iv) Binder Jetting2025?m

    Module 2: 3D Printing Materials

    Which Additive Manufacturing process primarily utilizes raw material in the form of a wire/filament?

    (i) Selective Laser Sintering (SLS)
    (ii) Stereo Lithography (SLA)
    (iii) Fused Deposition Modeling (FDM)
    (iv) Binder Jetting

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    Worked Solution

    Answer: (iii) Fused Deposition Modeling (FDM)

    FDM commonly uses thermoplastic material in filament form. The filament is fed into a heated extrusion head, melted or softened, and deposited through a nozzle according to the programmed toolpath.

  2. Q1(f). When choosing a material for a medical device that will be surgically implanted, which performance requirement is the absolute primary consideration? (i) High Shore Hardness (ii) Excellent Surface Finish (iii) Biocompatibility (iv) Low Cost2025?m

    Module 2: 3D Printing Materials

    When choosing a material for a medical device that will be surgically implanted, which performance requirement is the absolute primary consideration?

    (i) High Shore Hardness
    (ii) Excellent Surface Finish
    (iii) Biocompatibility
    (iv) Low Cost

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    Worked Solution

    Answer: (iii) Biocompatibility

    For an implantable medical device, the material must be biocompatible, meaning it should not produce an unacceptable toxic, inflammatory, allergic, or other harmful biological response. Cost, hardness, and surface finish can matter, but biological safety is the primary requirement for an implanted device.

  3. Q5(a). Discuss the four primary forms of 3D printing raw material.20257m

    Module 2: 3D Printing Materials

    Discuss the four primary forms of 3D printing raw material.

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    Worked Solution

    Four Primary Forms of 3D Printing Raw Material

    The major forms of raw material used in additive manufacturing are:

    1. Liquid: Used mainly in vat photopolymerization processes such as SLA. The liquid photopolymer is selectively cured by light.
    2. Solid: Includes thermoplastic filaments, pellets and sheets. FDM commonly uses filament, while some extrusion systems use pellets.
    3. Wire: Metal wire is used as feedstock in wire-based additive manufacturing and some directed-energy-deposition systems. The wire is melted by a heat source and deposited layer by layer.
    4. Powder: Powder is used in processes such as SLS, selective laser melting and binder jetting. Particle size, distribution, flowability and other powder properties strongly influence the process.

    Selection

    The appropriate feedstock depends on the manufacturing process, required mechanical properties, accuracy, surface finish, production rate and cost.

  4. Q5(b). Explain the properties of polymers used in FDM and SLA processes. How do these properties affect the final product performance?20257m

    Module 2: 3D Printing Materials

    Explain the properties of polymers used in FDM and SLA processes. How do these properties affect the final product performance?

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    Worked Solution

    Properties of Polymers Used in FDM and SLA

    Polymers in FDM

    FDM uses thermoplastics such as PLA, ABS, PETG and nylon. Important properties include:

    • Melting/softening behavior: determines extrusion temperature and processing window.
    • Viscosity in the molten state: affects flow through the nozzle and layer deposition.
    • Interlayer adhesion: strongly affects strength in the build direction.
    • Shrinkage and thermal expansion: influence warping and dimensional accuracy.
    • Toughness and strength: determine functional performance.
    • Moisture sensitivity: some polymers absorb moisture, which can degrade print quality.

    Polymers in SLA

    SLA uses photosensitive liquid resins. Important properties include:

    • Photosensitivity: determines how effectively the resin cures under the selected wavelength.
    • Viscosity: affects resin recoating and flow between layers.
    • Cure depth and conversion: influence dimensional accuracy and mechanical properties.
    • Shrinkage: can affect dimensions during and after curing.
    • Mechanical properties: determine stiffness, strength, toughness and durability of the finished part.

    Effect on final performance

    Material properties influence dimensional accuracy, surface quality, layer adhesion, strength, flexibility, heat resistance and durability. Therefore, polymer selection must match the functional requirements of the component.

Previous moduleModule 1: Additive Manufacturing Introduction and CAD-CAM for 3D PrintingNext moduleModule 3: Solid Based 3D Printing Processes