BTEC HND Level 3 Unit 45: Additive Manufacturing Processes Assignments Answers

Additive manufacturing, or 3D printing, is the process of making three-dimensional solid objects from a digital model. The term “3D printing” encompasses a variety of technologies that build objects by depositing material layer by layer. While the technology has been around for more than 25 years, it has only recently become commercially available and affordable for consumers and small businesses. There are several different types of additive manufacturing processes, each with its own advantages and disadvantages. This blog post will explore the most common additive manufacturing processes and discuss their suitability for various applications.

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Assignment Activity 1: Examine the technology and characteristics of additive manufacturing processes as used in industry.

The most common additive manufacturing processes are fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), and polymer jet printing (PJP).

1. Fused Deposition Modeling (FDM) is the most commonly used additive manufacturing process. It works by heating thermoplastic filament and depositing it layer by layer in the desired pattern. This process is relatively cheap and easy to use, making it a popular choice for home users and small businesses.
2. Stereolithography (SLA) is a process that uses a laser to cure photopolymer resin into a solid object. SLA produces high-quality objects with smooth surfaces, making it a popular choice for medical and dental implants, eyeglasses, and other precision parts.
3. Selective Laser Sintering (SLS) is a process that uses lasers to fuse powder particles together. This process produces strong and durable objects with intricate details, making it a popular choice for manufacturing tools, medical implants, and other high-end products.
4. Polymer Jet Printing (PJP) is a process that uses a UV laser to solidify liquid polymer resin. This process is relatively fast and can produce large objects with high detail, making it a popular choice for manufacturing prototypes and small runs of products.

Each of these additive manufacturing processes has its own advantages and disadvantages, so it’s important to choose the process that is best suited for the application. For example, FDM is a good choice for making simple objects with few details, while SLA is a good choice for making high-quality objects with smooth surfaces. SLS is a good choice for manufacturing durable and intricate objects, and PJP is a good choice for manufacturing large objects with high detail.

Assignment Activity 2: Investigate component design considerations and finishing processes required to effectively use additive manufacturing processes.

When designing components for additive manufacturing, there are several things to consider.

• First, the component must be designed in such a way that it can be manufactured using one of the common additive manufacturing processes.
• Second, the component must be designed with appropriate tolerances to ensure a good fit and finish.
• Third, the component must be designed to withstand the heat and stress of the manufacturing process.
• Fourth, the component must be designed with appropriate draft angles to facilitate removal from the build platform.
• Fifth, the component must be designed with appropriate supports to ensure proper alignment and stability during the printing process.
• Sixth, the component must be designed with a finish that is compatible with the additive manufacturing process.

For example, FDM is a good choice for components with a simple finish, while SLA is a good choice for components with a smooth finish. SLS is a good choice for components with a durable finish, and PJP is a good choice for components with a glossy finish.

Finishing processes are also important when using additive manufacturing processes. In many cases, the component must be finished after printing to remove excess material and/or to achieve the desired finish. Common finishing processes include sanding, drilling, machining, and painting.

It is also important to note that not all additive manufacturing processes are compatible with all materials. For example, FDM only works with thermoplastic filaments, while SLA only works with photopolymer resins. SLS only works with metal powders, and PJP only works with liquid polymer resins.

Assignment Activity 3: Develop a component using additive manufacturing processes safely.

When additive manufacturing (3D printing) processes are used to produce components, there is a risk of inhaling or ingesting particulates that may be released during the manufacturing process.

In order to reduce the risk of exposure to these particles, it is important to use certified safety equipment, such as respirators and masks, when working with additive manufacturing processes. Additionally, it is important to keep the work area clean and free of debris and to avoid eating or drinking in the work area.

If you are exposed to any particles released during the additive manufacturing process, it is important to immediately wash your hands and face thoroughly with soap and water. If you experience any symptoms such as shortness of breath, chest pain, or nausea, seek medical attention immediately.

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