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

1.2mm equals approximately 3 nozzle widths at 0.4mm, providing adequate structural integrity for most FDM applications.

Question 2

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

Accepted Answer

45°

Answer

The 45° rule states that overhangs up to 45° from vertical can self-support because each layer only slightly overhangs the previous one.

Question 3

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

Accepted Answer

Topology optimization

Answer

Topology optimization uses algorithms to iteratively remove material from low-stress areas, producing lightweight, organically shaped parts that still meet load requirements.

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

Support structures add print time, waste filament, and must be manually removed in post-processing, often leaving surface blemishes at contact points.

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 living hinge is a thin, flexible region printed integrally with the part, allowing repeated bending without separate fasteners or hardware.

3D Product Practice Test

3D Product Practice Test

3D Product Design for Additive Manufacturing