Additive Manufacturing Technician
Level II Exam With Actual Questions &
Verified Answers, Plus Explained
Rationales/Expert Verified For
Guaranteed 100% Pass 2026/Latest
Update/Instant Download Pdf
1. In powder bed fusion processes, which parameter most directly
affects part density?
A. Chamber humidity
B. Scan speed
C. Build orientation
D. Part color
Answer: B
Rationale: Scan speed controls energy input per unit length;
improper speed leads to lack of fusion or porosity, directly
affecting density.
2. Which defect is most commonly caused by insufficient laser
power in metal AM?
A. Keyholing
B. Balling
C. Warping
D. Over-curing
Answer: B
Rationale: Insufficient laser power prevents proper melt pool
, formation, causing molten metal to ball up instead of forming
continuous tracks.
3. Support structures in metal additive manufacturing primarily
serve which function?
A. Improve surface color
B. Reduce laser power needs
C. Anchor parts and manage heat
D. Increase build speed
Answer: C
Rationale: Supports anchor the part to the build plate and
dissipate heat, reducing distortion and residual stress.
4. Which non-destructive testing method is most suitable for
detecting internal porosity in AM metal parts?
A. Visual inspection
B. Ultrasonic testing
C. Radiographic testing
D. Dye penetrant testing
Answer: C
Rationale: Radiographic testing can detect internal voids and
porosity without damaging the part.
5. In directed energy deposition (DED), material is typically supplied
in which form?
A. Sheet metal only
B. Resin
C. Powder or wire
D. Filament only
Answer: C
Rationale: DED systems commonly use metal powder or wire fed
into a melt pool created by a focused energy source.
,6. What is the primary cause of residual stresses in metal AM parts?
A. Poor CAD modeling
B. Rapid heating and cooling cycles
C. Excessive support structures
D. Improper slicing
Answer: B
Rationale: Rapid thermal gradients during melting and
solidification introduce residual stresses in the part.
7. Which post-processing step is most effective for relieving residual
stress in metal AM parts?
A. Sandblasting
B. Heat treatment
C. Machining
D. Polishing
Answer: B
Rationale: Heat treatment allows stress relaxation by controlled
heating and cooling.
8. What is the main advantage of lattice structures in additive
manufacturing?
A. Increased material use
B. Higher build time
C. Weight reduction with maintained strength
D. Improved color quality
Answer: C
Rationale: Lattice structures reduce weight while maintaining
structural performance, a key AM advantage.
9. Which software function converts a CAD model into layer-by-layer
instructions?
A. Simulation
, B. Meshing
C. Slicing
D. Rendering
Answer: C
Rationale: Slicing software converts 3D models into toolpaths
and layers for the printer.
10. In polymer AM, which material property most affects layer
adhesion?
A. Color
B. Melt temperature
C. Density
D. Transparency
Answer: B
Rationale: Proper melt temperature ensures sufficient bonding
between layers.
11. Which AM process uses ultraviolet light to cure liquid resin?
A. FDM
B. SLS
C. SLA
D. DED
Answer: C
Rationale: Stereolithography (SLA) uses UV light to cure
photopolymer resin.
12. What is a common cause of warping in FDM parts?
A. Excessive infill
B. Uneven cooling
C. High resolution settings
D. Slow print speed
Answer: B
Level II Exam With Actual Questions &
Verified Answers, Plus Explained
Rationales/Expert Verified For
Guaranteed 100% Pass 2026/Latest
Update/Instant Download Pdf
1. In powder bed fusion processes, which parameter most directly
affects part density?
A. Chamber humidity
B. Scan speed
C. Build orientation
D. Part color
Answer: B
Rationale: Scan speed controls energy input per unit length;
improper speed leads to lack of fusion or porosity, directly
affecting density.
2. Which defect is most commonly caused by insufficient laser
power in metal AM?
A. Keyholing
B. Balling
C. Warping
D. Over-curing
Answer: B
Rationale: Insufficient laser power prevents proper melt pool
, formation, causing molten metal to ball up instead of forming
continuous tracks.
3. Support structures in metal additive manufacturing primarily
serve which function?
A. Improve surface color
B. Reduce laser power needs
C. Anchor parts and manage heat
D. Increase build speed
Answer: C
Rationale: Supports anchor the part to the build plate and
dissipate heat, reducing distortion and residual stress.
4. Which non-destructive testing method is most suitable for
detecting internal porosity in AM metal parts?
A. Visual inspection
B. Ultrasonic testing
C. Radiographic testing
D. Dye penetrant testing
Answer: C
Rationale: Radiographic testing can detect internal voids and
porosity without damaging the part.
5. In directed energy deposition (DED), material is typically supplied
in which form?
A. Sheet metal only
B. Resin
C. Powder or wire
D. Filament only
Answer: C
Rationale: DED systems commonly use metal powder or wire fed
into a melt pool created by a focused energy source.
,6. What is the primary cause of residual stresses in metal AM parts?
A. Poor CAD modeling
B. Rapid heating and cooling cycles
C. Excessive support structures
D. Improper slicing
Answer: B
Rationale: Rapid thermal gradients during melting and
solidification introduce residual stresses in the part.
7. Which post-processing step is most effective for relieving residual
stress in metal AM parts?
A. Sandblasting
B. Heat treatment
C. Machining
D. Polishing
Answer: B
Rationale: Heat treatment allows stress relaxation by controlled
heating and cooling.
8. What is the main advantage of lattice structures in additive
manufacturing?
A. Increased material use
B. Higher build time
C. Weight reduction with maintained strength
D. Improved color quality
Answer: C
Rationale: Lattice structures reduce weight while maintaining
structural performance, a key AM advantage.
9. Which software function converts a CAD model into layer-by-layer
instructions?
A. Simulation
, B. Meshing
C. Slicing
D. Rendering
Answer: C
Rationale: Slicing software converts 3D models into toolpaths
and layers for the printer.
10. In polymer AM, which material property most affects layer
adhesion?
A. Color
B. Melt temperature
C. Density
D. Transparency
Answer: B
Rationale: Proper melt temperature ensures sufficient bonding
between layers.
11. Which AM process uses ultraviolet light to cure liquid resin?
A. FDM
B. SLS
C. SLA
D. DED
Answer: C
Rationale: Stereolithography (SLA) uses UV light to cure
photopolymer resin.
12. What is a common cause of warping in FDM parts?
A. Excessive infill
B. Uneven cooling
C. High resolution settings
D. Slow print speed
Answer: B
