Week 2: Assignment 2 Due date: 2025-03-05, 23:59 IST.

1. What is the primary function of a recoater in Powder Bed Fusion?

Answer: Depositing new powder layers Explanation: The recoater spreads a fresh layer of powder
material across the build platform after each layer is fused.
2. Which material is commonly used in Electron Beam Powder Bed Fusion (EB PBF)?
Answer: Titanium Explanation: Titanium and its alloys are popular in EB PBF due to their excellent
conductivity and mechanical properties.
3. What is the typical layer thickness range for EB PBF?
Answer: 50–200 µm Explanation: EB PBF typically operates in this range, offering a good balance of
detail and build speed.
4. Which AM technology uses a vacuum environment to reduce impurities?
Answer: Electron Beam Powder Bed Fusion Explanation: EB PBF operates in a vacuum to prevent
oxidation and improve material quality.
5. What is the role of the deflection lens in EB PBF?
Answer: Guides the electron beam Explanation: The deflection lens steers the electron beam to
precisely fuse the powder.
6. Which of the following is NOT a limitation of Powder Bed Fusion?
Answer: Minimum material waste Explanation: PBF is efficient, as unused powder can often be
recycled.
7. What is a major advantage of DED over PBF?
Answer: High deposition rates Explanation: Direct Energy Deposition (DED) is faster at depositing
materials compared to the layer-by-layer approach in PBF.
8. What are the operations included in build preparation in AM?
Answer: STL fixing, support generation, and nesting Explanation: These steps are vital for preparing a
design for 3D printing.
9. What is the main purpose of the Build Processor in AM?
Answer: To slice models into layers Explanation: The Build Processor converts 3D models into
printable slices for the AM machine.
10. Which deposition method allows blank production of legacy parts?
Answer: Friction Energy Deposition Explanation: Friction Energy Deposition is useful for repairing or
producing legacy components.
11. What does the process simulation stage in AM focus on?
Answer: Predicting distortions and residual stresses Explanation: Process simulation minimizes issues
during printing by predicting such effects.
12. What is the key focus of the Quality Control stage in AM?
Answer: Residual stress detection Explanation: Quality control aims to ensure structural integrity and
performance.
13. What is a limitation of Sheet Lamination?
 Answer: Poorer surface quality Explanation: Sheet Lamination struggles with achieving fine surface
finishes compared to other AM methods.
14. What is the main benefit of CAD modeling in AM?
Answer: Providing precise design for printing Explanation: CAD modeling ensures accuracy and
customization for AM processes.
15. What is the key limitation of Cold Spray technique?
Answer: Limited deposition rates Explanation: While Cold Spray offers low thermal impact, its
deposition rates can be slower.
16. Which material property is critical for the success of Electron Beam Powder Bed Fusion?
Answer: Conductivity Explanation: Conductivity is crucial for the material to interact effectively with
the electron beam.
17. What is the function of inert gas in Direct Energy Deposition?
Answer: Preventing contamination Explanation: The inert gas shields the molten material from
oxidation and impurities.
18. Which technology is used for RF applications due to its ability to align magnetic particles in
resins?
Answer: DCM by Fortify Explanation: DCM (Digital Composite Manufacturing) specializes in
aligning magnetic particles for RF applications.
19. Which step in additive manufacturing involves generating accurate tool paths?
Answer: Build Processor Explanation: The Build Processor converts the digital model into precise tool
paths for printing.
20. What is the role of post-processing in AM technologies like Powder Bed Fusion?
Answer: Ensuring surface quality and removing residual stresses Explanation: Post-processing refines
the part and enhances its mechanical properties.
21. In which process is pressure used to bond the layers?
Answer: Sheet Lamination Explanation: Sheet Lamination bonds layers using heat and pressure.
22. Which step in the AM workflow ensures efficient part nesting and orientation?
Answer: Build Preparation Explanation: Efficient nesting and orientation reduce material waste and
optimize build volume.
23. Which AM process is best suited for high thermal conductivity requirements?
Answer: Direct Energy Deposition Explanation: DED is effective for applications needing high thermal
conductivity.
24. What is the key consideration for monitoring systems in PBF?
Answer: All of the above Explanation: Powder uniformity, layer thickness, and defect detection are all
crucial for consistent PBF quality.
25. How does process simulation help in AM?
Answer: Minimizes distortion Explanation: Process simulation predicts and mitigates distortions for
more reliable builds.
26. What is the purpose of lattice structures in AM?
Answer: Improve strength while reducing weight Explanation: Lattice structures are designed for
lightweight strength, commonly used in aerospace.
27. How does a build processor enhance AM efficiency?
Answer: Generates precise tool paths Explanation: Accurate tool paths minimize errors and improve
efficiency during printing.
28. What factors influence powder selection in DED?
Answer: All of the above Explanation: Particle size, melting temperature, and oxidation resistance are
all vital considerations.
29. How can AI enhance generative design in AM?
Answer: All of the above Explanation: AI helps simulate stress, optimize material usage, and create
innovative geometries.
30. Does Powder Bed Fusion (PBF) use a laser or electron beam to selectively fuse powdered
materials?
Answer: Yes Explanation: Both laser and electron beams are used in PBF depending on the specific
variant.
31. Is Direct Energy Deposition (DED) suitable for producing high surface-quality parts without post-
processing?
Answer: No Explanation: DED usually requires post-processing for high surface quality.
32. Can Electron Beam Powder Bed Fusion (EB PBF) work with non-conductive materials?
Answer: No Explanation: EB PBF requires conductive materials to interact with the electron beam.
33. Is support generation required in Sheet Lamination processes?
Answer: No Explanation: Sheet Lamination does not typically require support structures during
production.
34. Is defect identification part of process simulation in AM?
Answer: Yes Explanation: Process simulation involves identifying potential defects to optimize the
build.
35. Are lattice structures created to reduce material usage while maintaining strength?
Answer: Yes Explanation: Lattice structures balance material efficiency and mechanical strength.
 Week-2 Assignment Answers
1. Depositing new powder layers
2. Titanium
3. 50–200 µm
4. Electron Beam Powder Bed Fusion
5. Guides the electron beam
6. Minimum material waste
7. High deposition rates
8. STL fixing, support generation, and nesting
9. To slice models into layers
10. Digital Composite Manufacturing
11. Predicting distortions and residual stresses
12. Residual stress detection
13. Poorer surface quality
14. Providing precise design for printing
15. Limited deposition rates
16. Conductivity
17. Preventing contamination
18. DCM by Fortify
19. Build Processor
20. Ensuring surface quality and removing residual stresses
21. Sheet Lamination
22. Build Preparation
23. Electron Beam Powder Bed Fusion
24. All of the above
25. Minimizes distortion
26. Improve strength while reducing weight
27. Generates precise tool paths
28. All of the above
29. All of the above
30. Yes
31. No
32. No
33. No
34. Yes
35. Yes