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Unit 45: Additive Manufacturing Processes
Assignment 3: Design and manufacture of a component using Additive
manufacturing
Learning Aim C: Develop a component using additive manufacturing processes safely
,Designing and manufacturing the product 4
Form/ Complexity of the product 4
Material suitability 5
Mechanical property suitability 5
Heat resistance 5
Biodegradability 5
Adhesion 6
Fumes 6
Surface finish and post processing 6
Accuracy 6
Availability 6
Variety of colours 6
Structural integrity of the component 7
Shrinkage allowance 7
Cooling 7
Support of overhangs 7
Functionality of the product 7
Characteristics of FDM 3D printer (Material Extruding) 7
Printer Parameters 7
Build size and layer height 8
Warping 8
Layer Adhesion 8
Support Structure 9
Infill & Shell Thickness 10
Creating the product drawing 11
Transferring data 25
Positioning of the datam 26
Product orientation 27
Physical size 27
Scale 27
Carrying out the AM process 27
PPE and guarding 27
Setting up the AM System parameters 27
Infill 27
Layer height 28
Speed 28
Temperature 28
Resolution 28
Optimising AM parameters 28
Layer heights 28
Changes impacting the processing time and mass 28
, Infill 29
Capacity of the machine 29
Machine resolution 29
Using appropriate finishing processes 29
Quality control checks 29
, Designing and manufacturing the product
Form/ Complexity of the product
My product is a small table incorporating a tray and two cup holders. It is assembled in one piece
using 3D printing technology. The base is mostly hollow but has a low density infill. There are four
small indents located on the base to support the cylinders better. The cylinders are hollow and hold the
top section of the table. There are temporary supports in place during the manufacture to prevent the
top section collapsing. It allows the product to maintain its shape and increases the adhesion between
layers. The additional contact with the top layers from the support reduce warping. Although the
supports provide additional strength for the product it is no longer necessary once the product is
complete. Below is the completed product with the supports removed.
The image below shows how the supports are positioned and their function in the manufacturing
stage.
The image below shows the CAD drawing and the cross section of the hollow cylinders before and
during assembly. The purpose of having hollow cylinders is to reduce weight and material.
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