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3D Printing and Design

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Module 3: Solid Based 3D Printing Processes

  1. Q1(c). In FDM, the material is typically: (i) Liquid resin (ii) Powdered metal (iii) Thermoplastic filament (iv) Ceramic slurry2025?m

    Module 3: Solid Based 3D Printing Processes

    In FDM, the material is typically:

    (i) Liquid resin
    (ii) Powdered metal
    (iii) Thermoplastic filament
    (iv) Ceramic slurry

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    Worked Solution

    Answer: (iii) Thermoplastic filament

    FDM generally uses thermoplastic polymers supplied as a filament, such as PLA, ABS, PETG, or nylon. The filament is heated above its softening/melting temperature and extruded through a nozzle. It cools and solidifies to build the component layer by layer.

  2. Q1(g). Which stage in the Fused Deposition Modeling (FDM) process is directly responsible for bonding a newly deposited layer to the previous layer? (i) Liquefaction (ii) Extrusion (iii) Solidification and Bonding (iv) G-Code Interpretation2025?m

    Module 3: Solid Based 3D Printing Processes

    Which stage in the Fused Deposition Modeling (FDM) process is directly responsible for bonding a newly deposited layer to the previous layer?

    (i) Liquefaction
    (ii) Extrusion
    (iii) Solidification and Bonding
    (iv) G-Code Interpretation

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    Worked Solution

    Answer: (iii) Solidification and Bonding

    In FDM, the extruded thermoplastic is deposited while hot. As the new material contacts the previous layer, heat and molecular diffusion allow interlayer adhesion. Subsequent cooling produces solidification and establishes the bond between layers. Therefore, solidification and bonding is the best answer.

  3. Q4(b). Describe the working principle of Fused Deposition Modeling (FDM) and Stereo Lithography (SLA) with suitable diagrams.20257m

    Module 3: Solid Based 3D Printing Processes

    Describe the working principle of Fused Deposition Modeling (FDM) and Stereo Lithography (SLA) with suitable diagrams.

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    Worked Solution

    FDM and SLA: Working Principles

    1. Fused Deposition Modeling (FDM)

    FDM is a material-extrusion process that normally uses thermoplastic filament.

    Working:

    1. Filament is fed from the spool into a heated extrusion head.
    2. The filament is heated until it becomes sufficiently soft or molten.
    3. The nozzle deposits the material along the programmed path of the current layer.
    4. The deposited material cools and bonds with the previous layer.
    5. The build platform or print head moves by one layer height.
    6. The process repeats until the complete part is formed.

    Advantages: relatively simple equipment, low material cost for common polymers, and easy prototyping.

    2. Stereo Lithography (SLA)

    SLA is a vat photopolymerization process that uses liquid photosensitive resin.

    Working:

    1. A build platform is positioned in a vat of photopolymer resin.
    2. A UV laser or projected UV light selectively exposes the resin according to the current layer.
    3. The exposed resin polymerizes and becomes solid.
    4. The platform moves by the layer thickness and fresh resin covers the next layer region.
    5. Exposure is repeated until the part is complete.
    6. The printed part is removed, washed and normally post-cured.

    Comparison: FDM deposits melted/softened filament, whereas SLA selectively cures liquid resin using light. SLA generally provides finer details and smoother surfaces, while FDM is often simpler and economical for many prototype applications.

  4. Q6(a). What are the steps involved in cost estimation of an FDM 3D printed component? Mention the key factors affecting cost.20257m

    Module 3: Solid Based 3D Printing Processes

    What are the steps involved in cost estimation of an FDM 3D printed component? Mention the key factors affecting cost.

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    Worked Solution

    Cost Estimation of an FDM 3D Printed Component

    A practical FDM cost estimate can be divided into material, machine, labor, energy and post-processing costs.

    Steps

    1. Determine material consumption: Obtain filament mass or volume from the slicer, including model material and support material.
    2. Calculate material cost: Multiply consumed mass by the material cost per unit mass.
    3. Determine machine time: Estimate printing time from the slicer.
    4. Calculate machine cost: Multiply machine operating time by the machine hourly rate, including depreciation, maintenance and overhead.
    5. Calculate electricity cost: Estimate energy consumption and multiply by the electricity tariff.
    6. Add labor cost: Include setup, bed preparation, filament loading, monitoring and part removal where applicable.
    7. Add post-processing: Include support removal, sanding, finishing, washing or other required operations.
    8. Add overhead and profit: For commercial production, include facility overhead, reject allowance and desired profit margin.

    Simplified formula

    Total cost = Material + Machine time + Electricity + Labor + Post-processing + Overhead

    Key cost factors

    Material type and quantity, infill percentage, layer height, support volume, print duration, machine depreciation, electricity, labor, failure rate and finishing requirements all influence the final cost.

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