It’s time once again for a new article in the #Working3D series, wherein we present the various professions in the additive manufacturing industry. But there would be no material or print without the people who make it. That’s why we’re going to look more closely at their jobs this time. What exactly do engineers who work on materials do? What skills and experience do they bring to the table that make it possible to make 3D printing materials that can be used in a wide range of situations? Markus Lunzer, Team Leader for Materials, helped us answer these questions. What a materials engineer needs to bring to the table and what they do every day were also talked about.
Additive manufacturing, also known as 3D printing, is revolutionizing production across countless industries. As a rapidly evolving field at the forefront of advanced manufacturing, landing a job in additive manufacturing means standing out from the crowd. You need to demonstrate an in-depth understanding of 3D printing technology along with superb problem-solving abilities.
This article will provide you with the 10 most common additive manufacturing interview questions that hiring managers use to assess candidates’ skills. I will explain what employers are looking for in responses and provide sample answers to help you craft strong replies that highlight your expertise. With thorough preparation using these key questions you will be ready to take on interviews and launch an exciting career in additive manufacturing.
1. What experience do you have with different additive manufacturing processes and materials?
This is one of the most frequently asked introductory questions in additive manufacturing interviews. Hiring managers want to understand the breadth and depth of your hands-on experience with 3D printing technologies.
When answering, specify the additive manufacturing processes you are familiar with (e.g. FDM, SLA, SLS, etc.) and particular materials you have worked with for each one. Share examples of projects where you successfully applied your knowledge of the technology and materials to accomplish objectives.
Highlight any experience with process optimization or material innovation. Demonstrate how you keep your knowledge current through continuous learning. This showcases both your technical capabilities and passion for staying at the forefront of developments in the field.
2. How would you go about optimizing a design for additive manufacturing rather than traditional subtractive techniques?
With this question, the interviewer wants to assess your understanding of design principles specific to additive manufacturing. Unlike subtractive techniques 3D printing allows for greater complexity customization, and optimization.
In your response, discuss how additive enables more organic, lightweight shapes with lattice structures and complex internal geometries impossible with subtractive methods. Share examples of how you would redesign a part to reduce weight and material usage while retaining or improving strength and functionality.
Highlight your experience with topology optimization and generative design tools to create organic shapes tailored to load conditions. Demonstrate how such optimizations cut costs and improve performance. Your ability to contrast additive and subtractive techniques will showcase your design engineering skills.
3. What strategies would you use to improve the surface finish and accuracy of additively manufactured parts?
Surface finish and dimensional accuracy are vital in 3D printed parts, especially for end-use components. This question tests your practical knowledge of optimizing print parameters and post-processing methods.
In your answer, provide specific techniques you would use, such as adaptive layer heights, orienting parts to minimize stair-stepping, and adjusting raster angles. Discuss post-processes like vapor smoothing, CNC machining, or annealing to further improve surface finish and achieve precise dimensions. Share examples of how you have successfully enhanced quality and accuracy in your projects.
4. How would you go about qualifying new materials and processes for use in additive manufacturing?
Material and process qualification is critical in 3D printing, especially when implementing new technologies. Hiring managers want to see that you grasp the importance of rigorous testing.
In your response, detail the types of tests you would conduct, including mechanical testing, microstructure analysis, thermal analysis, printability trials, and metrology. Highlight any experience you have with designing test protocols and interpreting results. Share how you would collaborate with suppliers and external labs to validate materials and processes before putting them into production. Demonstrating a methodical approach to qualification will highlight your commitment to quality and safety.
5. How do you optimize print parameters in additive manufacturing to improve part quality and process efficiency?
Process optimization is crucial for repeatable part quality and efficient throughput. With this question, the interviewer will assess your hands-on expertise in refining print parameters.
In your response, discuss techniques you use to dial in settings like layer height, infill patterns, print temperature and speed to achieve desired properties and accuracy. Share specific examples of how you improved quality metrics like surface finish, mechanical properties or dimensional tolerances through parameter tweaking. Also highlight any efforts to reduce print time or material waste through optimization. Convey your analytical approach and how it results in tangible improvements.
6. What quality control practices do you implement for additive manufacturing?
Quality control is imperative for additive manufacturing, especially in regulated industries like aerospace and medical. This question tests your knowledge of QA/QC for 3D printing.
In your answer, describe specific QA procedures like dimensional verification, mechanical testing, metrology, and in-process monitoring you would implement. Share any experience with statistical process control and capability analysis for additive manufacturing. Highlight how you ensure reproducibility through process control. Emphasize how you stay current with industry standards like ASTM F42 for 3D printing. This demonstrates you can ensure high quality and consistency.
7. How do you minimize and handle build failures in additive manufacturing?
Build failures are costly in 3D printing. With this behavioral question, interviewers evaluate your diligence and problem-solving abilities.
In your response, detail strategies you use to prevent failures through machine maintenance, regular calibration, improved process control and inline monitoring tools. Share your debugging process when failures occur – how you would diagnose issues through root cause analysis and correct them. Provide examples of how you implemented solutions to minimize recurring failures. Your thoroughness will showcase your technical aptitude and commitment to continuous improvement.
8. What are some of the biggest challenges you’ve faced in additive manufacturing projects, and how did you address them?
This question reveals your real-world problem-solving experience. Interviewers look for examples of you overcoming challenges through critical thinking and creativity.
In your answer, share specific difficulties faced, like warping in high-temperature thermoplastics, achieving desired mechanical properties in metals, or surface defects with certain printers. Discuss the systematic approach you took to understand the root causes, such as design analysis or DOE. Share examples of how you solved the problems through tweaks to thermal processing, support structures, print parameters or orientation. Highlight any innovative solutions you came up with. Demonstrate analytical thinking and tenacity in tackling complex issues.
9. How do you stay current with the latest trends and innovations in additive manufacturing?
The 3D printing landscape evolves rapidly. Hiring managers want to see that you are committed to ongoing learning and growth.
Highlight in your answer how you actively stay up-to-date by reading industry publications, engaging in online forums, attending conferences, taking training courses, and networking with experts. Share examples of how you’ve applied cutting-edge knowledge to your work, such as implementing new software, materials, or printer technologies. Convey your enthusiasm for the field and passion to push boundaries and innovate. This will emphasize your dedication to professional development.
10. Where do you see the future of additive manufacturing headed, and how would you contribute to that future?
With this forward-looking question, interviewers want to understand your vision for and continued impact on the 3D printing space.
In your response, provide perspectives on how you see additive technology evolving in terms of expanded applications, new materials like multi-metal alloys or bio-based polymers, improved speed and quality, and increased adoption across industries. Share how you would leverage your skills to help drive these advances as applications engineer, R&D specialist, or technology leader. Convey strategic thinking and your desire to shape the additive manufacturing landscape. This demonstrates leadership potential and your ambition to make a difference.
Preparing responses to these 10 common additive manufacturing interview questions will put you steps ahead in demonstrating your expertise and readiness to join this exciting field. Use these examples as a framework while adding your own experiences and perspectives. With in-depth knowledge and strong communication skills, you will prove you have what it takes to excel in a career in 3D printing and advanced manufacturing. Leverage these insights to ace your next job interview!
3DN: What qualifications and experience are required to work as a Materials Engineer?
The applications of our 2PP technology are extremely exciting as they cover many different scientific and technical fields. Some of our clients print integrated microfluidic devices for IVF, while others make micro-optics or very small parts for medical devices, and still others use hydrogels on 3D cell cultures for pharmaceutical research.
I believe I can use what I learned in all the different subjects I took in college for my job. There are customers for whom printing materials with certain characteristics, such as defined mechanical properties, are important. Others need materials that are as colorless as possible or want parts that are made of glass or ceramic at the end of the process. This requires a great deal of detailed knowledge in material production, as well as in analytics and metrology.
A large proportion of our customers are also top researchers from academia. We are working on a highly innovative technology that is currently the focus of much research. In this respect, it is important to keep abreast of the latest scientific developments in the 2PP field. I wouldn’t want to miss out on scientific work. Many interesting and current research projects are being worked on by our team, ranging from high-precision manufacturing techniques to cancer research and biomedical engineering. By publishing our technology in scientific journals, we can show more people how useful it is and show what 2PP can do.
3DN: How did you discover additive manufacturing?
As part of my master’s thesis, I made molecules that were especially good at starting the process of 2-photon polymerization (2PP) because of the way they were structured. Because it uses a pulsed laser, this 3D printing method has a very high resolution that lets it make parts with resolutions in the sub-micrometer range. When I tested these molecules on university machines that were still being used for research, I realized how exciting this technology is and how useful it could be as a way to make things. So, I chose to focus more on how the technology is used in my dissertation, while still keeping the material development part. Afterwards, I worked on biomedical hydrogels that can be cut with 2PP at a very fine level, for example to make microchannels or expose reactive chemical groups locally.
But the 2PP was slow because each printed part was made up of many tiny voxels, which was a problem with its high resolution. At the same time, though, a research project at the Vienna University of Technology worked on a prototype of a much faster 2PP system. This machine was the basis for the foundation of UpNano GmbH. This made it possible to print much faster and in sizes that had never been possible before, like in the centimeter range and below.
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FAQ
What is the basic knowledge of additive manufacturing?
What are the fundamentals of additive manufacturing?
What is additive manufacturing?
Additive manufacturing creates parts layer by layer, similar to building a house of bricks. This layering process allows parts to have many complex features such as undercuts and blind passages. It can even produce geometries that are impossible to create with the traditional manufacturing processes of milling, drilling, and casting.
How does additive manufacturing create parts that would be impossible?
How does additive manufacturing create parts that would be impossible with any other manufacturing technique? Additive manufacturing creates parts layer by layer, similar to building a house of bricks. This layering process allows parts to have many complex features such as undercuts and blind passages.
How do you understand the potential of additive manufacturing?
Understanding the potential of additive manufacturing requires a deep appreciation for the nuances of the technology. It’s not just about grasping the technical aspects but also about embracing the design philosophy that additive manufacturing demands.
What skills do you need to be an additive manufacturing engineer?
Candidates should demonstrate their analytical skills and practical knowledge of various additive manufacturing processes. When responding, outline a structured decision-making process that begins with a thorough analysis of the project requirements.
