VALLIAMMAI ENGINEERING COLLEGE

SRM Nagar, Kattankulathur – 603 203

DEPARTMENT OF
MECHANICAL ENGINEERING

QUESTION BANK

II SEMESTER

CC5292 – ADDITIVE MANUFACTURING

AND TOOLING

Regulation – 2017

Academic Year 2017 – 18

Prepared by Mr.J.P.RAMESH, Assistant

Professor/MECHANICAL
 VALLIAMMAI ENGINEERING COLLEGE
SRM Nagar, Kattankulathur – 603
203.

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK
SUBJECT : CC5292 – ADDITIVE MANUFACTURING AND
TOOLING
SEM / YEAR: II / I

UNIT I - I
SYLLABUS
Need - Development of AM systems – AM process chain - Impact of AM on Product Development
- Virtual Prototyping- Rapid Tooling – RP to AM -Classification of AM processes-Benefits-
Applications.
PART - A
Q.No Questions BT Level Competence
1. What is additive manufacturing? BT-1 Remembering
2. Define STL file? BT-1 Remembering
3. What are the advantages of RP? BT-1 Remembering
4. Write a note on product development by AM? BT-6 Creating
5. Define Rapid Tooling? BT-1 Remembering
6. List the applications of AM? BT-1 Remembering
7. Explain the need of AM in current Scenario? BT-4 Analyzing
8. Define AM process chain? BT-1 Remembering
9. Define Rapid Prototyping? BT-1 Remembering
10. Discuss 3D printer? BT-2 Understanding
11. Explain Virtual prototyping? BT-5 Evaluating
12. Explain the benefits of AM? BT-4 Analyzing
13. Classify the AM process? BT-3 Applying
14. List the merits of virtual prototyping. BT-1 Remembering
15. What are basic requirements of product development? BT-1 Remembering
16. Explain the merits of product development? BT-5 Evaluating
17. What are the inputs required for product development? BT-1 Remembering
18. Discuss the benefits of rapid tooling? BT-2 Understanding
19. Formulate the applications of rapid tooling? BT-6 Creating
20. What are the limitations of AM? BT-1 Remembering
PART - B
1. Explain the transition of RP to AM. BT-3 Applying
 2. Classify and explain the AM process. BT-4 Analyzing
3. Write a note on the need and development of AM systems. BT-6 Creating
4. Explain in detail of impact of AM on product development. BT-5 Evaluating
5. Discuss on Virtual prototyping. BT-2 Understanding
6. Explain how AM has influenced the 3D printing technology. BT-4 Analyzing
7. Briefly discuss AM process chain. BT-2 Understanding
8. List out the benefits and applications of AM. BT-1 Remembering
9. Explain how rapid production helped to evolve additive BT-5 Evaluating
manufacturing.
10. List out the benefits and applications of AM. BT-1 Remembering
11. Formulate various new classification of AM processes. BT-6 Creating
12. Discuss about Rapid Tooling. BT-2 Understanding
13. Describe machine setup and build process. BT-2 Understanding
14. Formulate STL file format and post processing of a part. BT-6 Creating

PART - C
1. Evaluate the AM with an example. BT-5 Evaluating
2. Elaborate the application of virtual prototyping with a current BT-5 Evaluating
module.
3. Evaluate the importance of product development in BT-5 Evaluating
concurrent engineering.
4. What is the RP/AM wheel? Explain its four primary aspects. BT-4 Analyzing
UNIT II
SYLLABUS
Basic concept- Digitization techniques – Model reconstruction – Data Processing for Rapid
Prototyping: CAD model preparation, Data requirements – Geometric modeling techniques: Wire
frame, surface and solid modeling – data formats - Data interfacing, Part orientation and support
generation, Support structure design, Model Slicing, Tool path generation-Software for AM- Case
studies.
PART - A
1 What is reverse engineering? BT-1 Remembering
2 Define geometric modeling? BT-1 Remembering
3 Define model reconstruction? BT-1 Remembering
PART - A PART - A
4 What is cad modeling? BT-1 Remembering
5 Define data processing? BT-1 Remembering
6 Classify the digitization techniques. BT-3 Applying
7 Define wire frame modeling? BT-1 Remembering
8 List out few data formats. BT-1 Remembering
9 Discuss data interfacing? BT-2 Understanding
10 Define part orientation? BT-2 Understanding
11 Justify the need of support generation. BT-5 Evaluating
12 Discuss about Support structure design? BT-2 Understanding
13 Explain principle of Model Slicing? BT-4 Analyzing
14 Formulate the software's used for Tool path generation. BT-6 Creating
15 List the software's currently used for AM? BT-1 Remembering
16 Formulate the limitations of Tool path generation? BT-6 Creating
17 What are the advantages of Part orientation? BT-1 Remembering
18 Explain surface modeling? BT-4 Analyzing
19 what is solid modeling? BT-1 Remembering
20 Mention the applications of modeling. BT-5 Evaluating

PART - B
1 Explain about data formats and data interfacing. BT-5 Evaluating
2 What is part orientation? Explain with illustrations. BT-4 Analyzing
3. Explain the need of support generation with flow charts. BT-4 Analyzing
4. What are the steps involved in model slicing? BT-6 Creating
5. Discuss various aspects of tool path generation. BT-2 Understanding
6. Formulate the procedure followed for digitization technique. BT-6 Creating
7. Briefly discuss the concept of reverse engineering? BT-2 Applying
8. Describe in detail of data processing for RP. BT-1 Remembering
9. Explain the wireframe modeling techniques? BT-5 Evaluating
10. What are the techniques used in Tool path generation? BT-1 Remembering
11. Discuss about surface modeling. BT-2 Understanding

12. Describe the concepts and procedures involved in solid BT-1 Remembering
modeling.
13. Formulate the procedures for CAD model preparation. BT-6 Creating
14. Analyse reverse engineering technique with respect to BT-4 Analyzing
digitization and explain
PART -C
1. Find the geometric modifiers available on your CAD BT-6 Creating
system. What is their syntax? How do you use them? What
is the default modifier?
2. Briefly explain about the data processing of RP and the BT-4 Analyzing
problems associated with it.
3. Evaluate the importance of digitization in AM with case BT-5 Evaluating
study.
4. Analyze the functions of support structure. BT-4 Analyzing

UNIT III
 SYLLAUS
Stereolithography Apparatus (SLA): Principle, pre-build process, part-building and post-build
processes, photo polymerization of SL resins, part quality and process planning, recoating issues,
materials, advantages, limitations and applications. Solid Ground Curing (SGC): working principle,
process, strengths, weaknesses and applications. Fused deposition Modeling (FDM): Principle, details
of processes, process variables, types, products, materials and applications. Laminated Object
Manufacturing (LOM): Working Principles, details of processes, products, materials, advantages,
limitations and applications - Case studies.

PART - A
1. Define SLA? BT-1 Remembering
2. Justify the pre-build process is required in SLA? BT-5 Evaluating
3. Discuss the part-building steps in SLA? BT-2 Understanding
4. Explain what are the steps in post-build processes? BT-4 Analyzing
5. Explain photo polymerization in SLA? BT-4 Analyzing
6. What is the role of process planning in SLA? BT-6 Creating
7. Define SGC? BT-1 Remembering
8. Explain what are the strengths of SGC? BT-5 Evaluating
9. Explain what are the weaknesses of SGC? BT-4 Analyzing
10. List out the applications of SGC? BT-1 Remembering
11 Define FDM? BT-1 Remembering
12 Define FDM process. BT-1 Remembering
13 Discuss what are the process variables in FDM? BT-2 Understanding
14 Demonstrate the products of FDM? BT-3 Applying
15 Discuss the limitations of FDM? BT-2 Understanding
16 Define LOM? BT-1 Remembering
17 Explain the LOM process. BT-4 Analyzing
18 List out the limitations of FDM? BT-1 Remembering
19 What are the recoating issues in SLA? BT-6 Creating
20 What are the applications of FDM? BT-6 Creating
PART -B
1 Explain the working principle of SLA. BT-5 Evaluating
2 What are the part building and post building process BT-6 Creating
involved in SLA.
3 Briefly discuss recoating issues in SLA. BT-2 Understanding
4 Explain the working principle of SGC. BT-4 Analyzing
5 Briefly discuss about strength, Weakness and applications of BT-2 Understanding
SGC.
 6 Discuss in detail about working principle of FDM. BT-2 Understanding
7 Explain the process variables of FDM. BT-4 Analyzing
8 Explain the working principle of LOM. BT-5 Evaluating
9 What are the steps in pre build and post-build process for BT-6 Creating
LOM.
10 Compare the liquid based and solid based AM systems. BT-5 Evaluating
11 Discuss about various FDM materials and applications of BT-2 Understanding
FDM.
12 Describe about various SLA materials, advantages and BT-2 Understanding
applications.
13 Explain about various LOM materials, advantages, BT-4 Analyzing
limitations and applications.
14 Formulate the process of photopolymerisation of SL resin and BT-6 Creating
write about the process variables in FDM
PART-C
1 Meiko co., Ltd produces the LC and LCV series for jewelry BT-4 Analyzing
prototyping. By comparing the machine specifications with
other vendors, discuss what you think are the important
specifications that will determine their suitability for jewelery
prototyping.
2 Evaluate the photo polymerization in liquid based additive BT-5 Evaluating
manufacturing.
3 Compare and construct the laser-based LOM process and the BT-5
Evaluating
FDM systems.
4 Compare and construct Cubic’s LOM process with Kira BT-5 Evaluating
corporations PLT and Ennex corporations offset Fabber.
What are the advantages and disadvantages for each of the
systems
UNIT IV
SYLLAUS

Selective Laser Sintering (SLS): Principle, process, Indirect and direct SLS- powder structures,
materials, post processing, surface deviation and accuracy, Applications. Laser Engineered Net
Shaping (LENS): Processes, materials, products, advantages, limitations and applications– Case
Studies. PART-A
1 Define LENS. BT-1 Remembering
2 Explain what are the materials used in LENS. BT-4 Analyzing
3 Define SLS? BT-1 Remembering
4 List out what are the advantages and limitations of LENS. BT-1 Remembering
5 What are the advantages and limitations of SLS. BT-6 Creating
6 What are the materials used in SLS. BT-6 Creating
7 Discuss about the post processing types of SLS. BT-2 Understanding
8 Why surface deviation occurs in SLS. BT-2 Understanding
9 Why is accuracy important in SLS. BT-2 Understanding
10 List out the applications of SLS. BT-1 Remembering
11 Explain post processing types of LENS. BT-5 Evaluating
12 Why surface deviation occurs in LENS. BT-2 Understanding
13 Why is accuracy important in LENS. BT-2 Understanding
14 What are the applications of LENS. BT-6 Creating
15 Why case studies are analyzed for sintering. BT-2 Understanding
16 Define direct SLS? BT-1 Remembering
17 What is indirect SLS. BT-6 Creating
18 Explain merits of direct SLS. BT-4 Analyzing
19 Explain merits of indirect SLS. BT-4 Analyzing
20 List out applications of direct SLS. BT-1 Remembering

PART-B
1 Define LENS? Explain the same. BT-1 Remembering
2 What are the processing techniques used in LENS. BT-6 Creating
3 Define SLS? Explain the same. BT-1 Remembering
4 What are the advantages and limitations of LENS? Explain BT-5 Evaluating
with examples.
5 Demonstrate the applications of SLS and its processing BT-3 Applying
techniques.
6 Briefly discuss post processing types of LENS. Explain each BT-2 Understanding
with suitable example.
7 Explain the effect of surface deviation in LENS. BT-5 Evaluating
8 Briefly discussed indirect SLS and direct SLS. BT-2 Understanding
9 Explain in detail about post processing techniques of direct BT-4 Analyzing
SLS.
10 Explain in detail about post processing techniques of direct BT-4 Analyzing
SLS.
11 Discuss about powder structure and materials in SLS. BT-2 Understanding
12 Describe about the materials and product in LENS. BT-2 Understanding
13 Formulate the post processing, surface deviation and accuracy BT-6 Creating
in SL.
14 Explain the LENS process with the aid of an example. BT-4 Analyzing
PART- C
1 Explain the case studies of following commercial version BT-4 Analyzing
(a)Z-corporation 3DP (b) Optomec’s LEN’s.
2 Analyze the importance of powder structure in SLS BT-4 Analyzing
3 Evaluate the working process of Muskless Mesoscale material BT-5 Evaluating
deposition.
4 Compare and construct EOS, s EOSINTM system with BT-5 Evaluating
optomec, s LEN’s system.
UNIT V
 SYLLABUS

Classification, Soft tooling, Production tooling, Bridge tooling, direct and indirect tooling,
Fabrication processes, Applications Case studies automotive, aerospace and electronics
industries.

PART
1 Classify Rapid tooling A BTL-3 Applying
2 Write down the significance of RTV tools BTL-1 Remembering

3 BTL-4 Analyzing
Compare direct and indirect fabrication processes.
4 BTL-2 Understanding
Distinguish between soft tooling and production tooling.
5 BTL-4 Analyzing
Classify bridge tooling.
6 What is meant by rapid tooling? BTL-6 Creating
7 Distinguish between rapid tooling and conventional tooling. BTL-2 Understanding
8 What is meant by production tooling? BTL-6 Creating
9 BTL-2 Understanding
Distinguish between direct and indirect fabrication processes
using rapid tooling.
10 BTL-1 Remembering
Sketch the advantages of break-away support system.
11 How does aerospace technology make use of rapid tooling BTL-1 Remembering
applications?
12 BTL-6 Creating
What is soft tooling?

13 What is bridge tooling? BTL-6 Creating

14 State classification of rapid tooling. BTL-3
15 Remembering
How does aerospace technology make use of soft tooling BTL-1
applications?
16 Compare direct and indirect tooling. BTL-4 Analyzing

17 How does automotive technology make use of rapid tooling BTL-1 Remembering
applications?
18 Write down any two application in Rapid tooling process. BTL-1 Remembering
19 What is indirect tooling? BTL-6 Creating
20 Discuss any one type of finishing processes adopted for rapid Remembering
prototypes. BTL-1
PART B
1 (i) Compare the role of direct and indirect methods in rapid
tool production. BTL-2 Understanding
(ii) Give a brief account on various fabrication processes.
2 Explain in detail about the following
(i) Metal Deposition tools BTL-4 Analyzing
(ii) Epoxy tools
3 Explain the role of rapid tooling in aerospace industry with a
case study BTL-5 Evaluating
4 Give some short notes about the following :
BTL-1
 (i) Direct fabrication process Remembering
(ii) Indirect fabrication process.
5 Briefly explain soft tooling, production tooling and
bridge tooling. BTL-1 Remembering
6 Describe the applications of rapid tooling in automotive and
aerospace industries. BTL-1 Remembering
7 (i) Discuss the process of making a rapid tool for blow moulding.
Assume your own example as product. BTL-2 Understanding
(ii) Compare ‘Direct’ and ‘Indirect tooling’ with classic
examples.
8 (i) Discuss any four types of finishing processes adopted for BTL-1 Remembering
rapid prototypes.
(ii) Write notes on the applications of RP&T in the following
fields :
(1) Medical field
(2) Automotive engineering
(3) Electronic industries
(4) Architecture.
9 (i) Distinguish between direct and indirect rapid tooling. BTL-2 Understanding
(ii) Write down two automotive applications of Rapid tooling.
10 Write short notes on the following :
(i) Production tooling. BTL-1 Remembering
(ii) Rapid tolling application of Electronic industries.
11 Explain the concept of Bridge tooling with a case study. BTL-4 Analyzing
12 Discuss how RPT can be used for the production of rapid tooling BTL-2 Understanding
for aerospace and electronic industries.
13 Explain the role of rapid tooling in Electronic industries
industry with a case study BTL-4 Analyzing
14 Briefly explain direct and indirect tooling.
BTL-6 Creating

PART C
1 Explain the concept of Production tooling with a case study. BTL-4 Analyzing
2 Explain the role of rapid tooling in automotive industries
BTL-5 Evaluating
industry with a case study
3 Write short notes on the following :
(i) Fabrication processes BTL-2 Understanding
(ii) Rapid tolling application of aerospace industries.
4 Describe the applications of rapid tooling in electronics and
BTL-1 Remembering
aerospace industries.