Unit 45 - Additive Manufacturing Processes Assignment 3 - Distinction Grade contains all the crucial information that is required in the assignment brief set out by BTEC. In the images, you can see the quality work put out which also highlights that I got a distinction grade for it.
Assignment 3 – Develop a Component Using Additive Manufacturing Processes Safely
During this report I will clarify every process I have carried out from coming up with an idea of
component to manufacture to the selection of suitable material to fit for the purpose of part, To the
last section of setting up the 3D printer and manufacturing the component.
As it can be seen in the two images the router attachment has some simple features that are easy to
3D print, the only issue that we might have is with the curved center hollow piece because if we do
not support it properly it might start to cave in or deform if we do not pay attention when we are
, removing it from the printer bed. Besides that simple issue the part should be fairly easy to make on
a MAKERBOT printer that we have access to in the college.
There are many different material types that can be used for 3D printing with different mechanical
properties these are some of the examples:
PLA:
• PLA stands for Polylactic Acid, PLA is the most popular and the most commonly used within
the 3D printing industry due to its low price and due to being highly available in large
quantities but mainly due to its ease of use and versatility.
• One of the main physical properties of PLA is that it has a high stiffness which makes it very
beneficial for those projects that require stability or structural integrity throughout the
component.
• Compared to other filament materials PLA is much more brittle and it has a low impact
resistance which makes it prone to cracking which also means that it cannot withstand large
loads or forces acting upon it.
• PLA got a very low melting point (glass transition temperature) at around 60 degrees Celsius
however at around 40 degrees Celsius it becomes so soft that the layers start to deform and
separate meaning that its not a desirable material for a high temperature environment.
ABS:
• ABS stands for Acrylonitrile Butadiene Styrene, and it is the 2nd most common filament
material used, however it is the most common material used for industrial applications.
• As previously stated, ABS is used for industrial applications this is mainly due to its great
strength and well distributed toughness throughout the part, ABS is suitable for parts that
require durability and the ability to withstand mechanical forces acting upon it from different
directions.
• ABS has a higher glass transition temperature compared to PLA of 100 degrees Celsius and
by this allowing it to be used in environments that require withstand to heat, ABS can
provide resistance to deformation even under temperatures up to 80 degrees Celsius
because after that it will enter the amorphous region which causes the glass transition within
the material and making it much softer.
• The main downside of ABS is that it emits a strange odor/smoke when printed and by this it
requires an environment with good ventilation to ensure the safety of others and this
smoke/odor contains toxic gases.
PETG:
• PETG stands for Polyethylene Terephthalate Glycol, PETG is a specially made filament that
combines the physical and mechanical properties of PLA and ABS.
• Because it has the physical and mechanical properties of PLA and ABS combined it allows it
to have a good strength and flexibility and also it has a great impact resistance, the
combination of the two materials allows PETG to shine in all aspects and to become an
almost perfect material.
• PETG has a glass transition temperature of 80 degrees Celsius which is lower that ABS but its
much higher that PLA, PETG has a great heat resistance which is taken from ABS and by this it
allows it to be used in high temperature environment applications.
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