3D Product Design for Additive Manufacturing

Question 1

What is the generally recommended minimum wall thickness for structural FDM printed parts using a 0.4mm nozzle?

Accepted Answer

1.2mm

Answer

0.2mm

Answer

0.4mm

Answer

5.0mm

Question 2

What is the maximum overhang angle from vertical that typically does NOT require support structures in FDM printing?

Accepted Answer

45°

Answer

15°

Answer

30°

Answer

60°

Question 3

Which computational design technique removes unnecessary material from low-stress regions while maintaining required structural performance?

Accepted Answer

Topology optimization

Answer

Boolean subtraction

Answer

Shell modeling

Answer

Parametric scaling

Question 4

What is the primary reason to minimize support structures in a DfAM design?

Accepted Answer

Supports increase print time, consume material, and require post-processing removal

Answer

Supports reduce nozzle temperature accuracy

Answer

Supports cause layer delamination in the main part

Answer

Supports limit the maximum build height

Question 5

What is a 'living hinge' in the context of 3D printed product design?

Accepted Answer

A thin flexible section integrated into the part that functions as a hinge without hardware

Answer

A hinge joint lubricated during printing

Answer

A motorized hinge powered by a printed mechanism

Answer

A hinge that requires assembly of two separate printed halves

Question 6

Which design strategy best exploits additive manufacturing's unique ability to create complex internal geometries?

Accepted Answer

Integrating internal cooling channels, hollow cavities, or lattice infill

Answer

Simplifying all external profiles to flat planes

Answer

Adding draft angles to every face

Answer

Maximizing solid cross-sections throughout

Question 7

A designer is creating a tall, narrow FDM part with a small footprint. Which printing aid should be considered during design to prevent warping?

Accepted Answer

Adding a brim or raft in the design file or slicer settings to improve bed adhesion

Answer

Reducing infill density to 5%

Answer

Increasing layer height to 0.5mm

Answer

Printing the part on its side to increase footprint