Table of Contents

Q1: 1.1 3
Q1:1.2 4
Q1:1.3 6
Q2 7
Q3 8
References 9

2
Q1)

1.1

1st Dimension: Production Method

● Layered Manufacturing: Formlabs Form 2

● Laminated Object Manufacturing: Autodesk Ember
● Directed Energy Deposition: Concept Laser XLine 1000R

2nd Dimension: Material Transformation Physics

● Material Extrusion: Ultimaker S5

● Material Jetting: HP Jet Fusion 580
● Binder Jetting: Carbon M1
● Powder Bed Fusion: EOS M400-4
● Sheet Lamination: Mcor Matrix 300+
● Vat Photopolymerization: EnvisionTEC Perfactory Micro
● Directed Energy Deposition: Concept Laser XLine 1000R

3rd Dimension: Machine Architecture

● 1-1-1: Laminated Object Manufacturing (LOM) using Polymer and Vat

Photopolymerization (VPP): Formlabs Form 2
● 1-1-2: Laminated Object Manufacturing (LOM) using Metal and Sheet Lamination
(SHL): Desktop Metal Studio System
● 1-1-3: Laminated Object Manufacturing (LOM) using Ceramic and Directed Energy
Deposition (DED): Markforged X7
● 1-2-1: Stereolithography (SLA) using Polymer and Vat Photopolymerization (VPP):
Formlabs Form 2
● 1-2-2: Stereolithography (SLA) using Metal and Powder Bed Fusion (PBF): EOS
M400
● 1-2-3: Stereolithography (SLA) using Ceramic and Directed Energy Deposition
(DED): Markforged X7
● 1-3-1: Fused Deposition Modeling (FDM) using Polymer and Material Extrusion
(MEX): Ultimaker S5
● 1-3-2: Fused Deposition Modeling (FDM) using Metal and Material Extrusion
(MEX): Markforged X7

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 ● 1-3-3: Fused Deposition Modeling (FDM) using Ceramic and Directed Energy
Deposition (DED): Markforged X7

1.2

Formlabs Form 2: A photopolymerization-based high-resolution professional 3D printer that can

produce parts for both prototyping and final application.

Figure 1: Formlabs Form 2

Desktop Metal Studio System: A metal 3D printing technology that allows production-level
speed and quality through the use of the novel Bound Metal Deposition (BMD) technique.

Figure 2: Desktop Metal Studio System

4
Markforged X7: A direct energy deposition (DED) industrial 3D printer that can create items out
of metal, carbon fiber, and other high-tech materials.

Figure 3: Markforged X7

EOS M400: A Powder Bed Fusion (PBF)-based high-performance metal 3D printer created for
demanding industrial applications.

Figure 4: EOS M400

5
Ultimaker S5: A multifunctional and dependable desktop 3D printer that uses Fused Deposition
Modeling (FDM) technology and a variety of materials.

Figure 5: Ultimaker S5

1.3

System Process Material Machine Pos. Dim. Surface Support Post-Proc Volumetr
Type Architect Accuracy Accuracy Roughne Structure essing ic Work
ure ss (0-3) space(m
m)

Formlaba LOM Polymer VPP 25 +/-0.1 <1 Yes 1 145 X

Form 2 145 X
175

Desktop LOM Metal SHL 50 +/-0.2 <2 Yes 2 300 X

Metal 300 X
Studio 300
System

Markforg LOM/SL Ceramic DED 50 +/-0.2 <2 Yes 3 330 X

ed X7 A/FDM 330 X
250

EOS SLA Metal PBF 20 +/-0.1 <2 Yes 2 400 X

M400 400 X
400

Ultimake FDM Polymer MEX 20 +/-0.1 <1 No 1 330 X

r S5 240 X
300
Table 1

6
Q2)

Temperature:
The importance of temperature in a control extrusion is 9. The ideal circumstance would be to
keep the melt inside the reservoir at a constant temperature. The pressure should gradually
decrease as the heat rises in order to keep the flow rate constant. The extrusion force is inversely
correlated with the metal's deformation resistance, however this relationship is not linear because
temperature and metal composition are not homogeneous. The deformation resistance of the
metal diminishes as the temperature rises, as does the extrusion force. However, because
localized temperatures must be considerably below any potential melting temperature, the
maximum extrusion speed is also decreased. The current experiment focuses on how the
temperature in the billet changes over time, starting at upset and continuing until the extrusion
cycle is completed. The pressure-displacement trace, as well as the events that occur in the
deformed material throughout the extrusion process, are anticipated along with the extrusion
pressure and temperature rise.

Nozzle Diameter:
This is constant for a particular build, but many MEX systems do allow for interchangeable
nozzles that can be used to offset speed against precision. Nozzle diameter is a printing
characteristic that receives little attention. Many users never give the idea of changing their
normal nozzle for one with a narrower or wider diameter because the majority of printers come with
a .4 mm nozzle as standard equipment, and this kind of nozzle works well for the majority of print tasks.
The X-Y plane can be printed with considerably finer details using small nozzles, whereas the X-Y plane
can be printed with significantly quicker printing speeds using large nozzles. Additionally significant is the
link between nozzle diameter and layer height. Layer height is somewhat influenced by the size of the
nozzle installed on the printer, and while the two can be modified separately, it can be useful to take into
account both factors at once. Thus, while .2 layers high, although 4 nozzle diameter may be preferred
setup for FDM printing, there are many situations in which you would wish to change both values. To
conclude the nozzle diameter level of importance in control extrusion would be 7.

Gravity:
The mass of the molten material inside the reservoir creates a pressure head, which may cause material to
flow even if no pressure is applied to it. If the reservoir is sealed, a buildup of gaseous pressure could
make things worse. This effect might be delayed by drag forces at the internal surfaces of the nozzle and
surface tension of the melt. Extrusion into empty space cannot occur without sagging, which necessitates
the usage of support material to avoid. Extrusions into free space that would typically droop can proceed
unhindered in a microgravity environment, enabling the construction of structures that are not possible in
a gravity environment. The importance level of gravity to control the extrusion in a material extrusion
the AM process is a 4.

7
Input Pressure:
The output flow rate changes in direct proportion to the input pressure. However, a few other factors can
have a minor impact on the flow. The pressure that is applied to the material when it is fed into the extruder
is known as the input pressure. Its job is to keep the flow rate steady and avoid obstructions in the extruder.
Its relevance can be rated at a 9 out of 10, as it is crucial that the material passes through the extruder
continuously and without pause.

Q3

8
References

. “Extrusion Temperature.” Extrusion Temperature - an Overview | ScienceDirect Topics,

https://www.sciencedirect.com/topics/engineering/extrusion-temperature.

. “Nozzle Diameter and Layer Height Explained.” Wevolver,

https://www.wevolver.com/article/nozzle-diameter-and-layer-height-explained.

. “Materials: Additive Manufacturing Research Group: Loughborough University.

” Materials | Additive Manufacturing Research Group | Loughborough University,
https://www.lboro.ac.uk/research/amrg/about/materials/.