Question 1: Applications of additive manufacturing [18 points] For each of the m

Question

Question 1: Applications of additive manufacturing [18 points] For each of the manufactured objects listed below, say whether or not you think the use of an additive manufacturing process could be justified, as opposed to using a "traditional" process such as machining, injection molding, casting, stamping, etc. If you think additive manufacturing would be appropriate, briefly explain why (you can use the list of possible motivations for using additive processing in the lecture notes). Then suggest which additive process technology of the ones we have studied in lecture would be most appropriate, and why. If you think an additive process would not be warranted, briefly say why not. [3 points per object below] a) Pair of sneakers b) Aluminum drink can c) Smartphone case d) Tire for motor vehicle e) Computer keyboard f) Birthday cake

Explanation / Answer

a) Pair of sneakers

Yes – could be justified. Possible grounds: mass customization to give optimal fit to each individual’s foot size; graded material properties to optimize shock-absorbing properties of sole; aesthetic enhancement through graded or complex color patterns.

b) Aluminum drink can

No – hard to see how this could be justified. A drink can is a very standardized geometry – different people do not need different drinks can designs. The cost would be vastly increased by switching to additive manufacturing.

c) Smartphone case

Additive manufacturing would be convenient for phone cases because it's customizable for all the different phone sizes and shapes. Since you’d want phone cases to be as cheap as possible, you’d probably use fused deposition modelling (FDM) because it’s versatile and it would add customizable.

d) Tire for motor vehicle

Probably no , tires are produced in large volumes and are composed of multiple materials (rubber with embedded reinforcement) and subjected to extreme severe conditions. The materials have highly developed specialist properties that are currently not possible to replicate additively. The expense of producing tires additively would be enormous relative to conventionally manufactured tires. The one conceivable argument for additive manufacturing would be to reduce replacement lead-time – say you go to a garage with an unusual make of car for which the correct size of tire is not available – could it be printed on the spot? Almost certainly not with current technology, but perhaps in a few years.

e) Computer keyboard

Additive manufacturing would be good for the computer keyboard because of its versatility. Keyboards have a lot of components that would be good to print using Stereolithography (SLA) because using a vat to create the model would be easier than FDM printing it.

f) Birthday cake

Additive manufacturing would be bad for a birthday cake because assuming that it's possible to create the cake with it’s components, it would be hard to apply the fine details such as frosting and decor on the cake because every cake is going to be different and extremely intricate.

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