scholarly journals Process and Evaluation of Automated Robotic Fabrication System for In-Situ Structure Confinement

2021 ◽  
pp. 368-379
Author(s):  
B. Bala Murali Kumar ◽  
Yun Chung Hsueh ◽  
Zhuoyang Xin ◽  
Dan Luo
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Rapid Progression ◽  
Additive Process ◽  
Manufacturing Method ◽  
Robotic Fabrication ◽  
Fibre Reinforced Polymer ◽  
3D Printed ◽  
Fabrication Parameters

AbstractThe additive manufacturing process is gaining momentum in the construction industry with the rapid progression of large-scale 3D printed technologies. An established method of increasing the structural performance of concrete is by wrapping it with Fibre Reinforced Polymer (FRP). This paper proposes a novel additive process to fabricate a FRP formwork by dynamic layer winding of the FRP fabric with epoxy resin paired with an industrial scale robotic arm. A range of prototypes were fabricated to explore and study the fabrication parameters. Based on the systemic exploration, the limitations, the scope, and the feasibility of the proposed additive manufacturing method is studied for large scale customisable structural formworks.

History of Additive Manufacturing

2017 ◽  
pp. 1-24 ◽  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Large Scale ◽  
Selective Laser Sintering ◽  
3D Printer ◽  
3D Objects ◽  
History Of ◽  
Pros And Cons ◽  
3D Printed ◽  
The Common

History of additive manufacturing started in the 1980s in Japan. Stereolithography was invented first in 1983. After that tens of other techniques were invented under the common name 3D printing. When stereolithography was invented rapid prototyping did not exists. Tree years later new technique was invented: selective laser sintering (SLS). First commercial SLS was in 1990. At the end of 20t century, first bio-printer was developed. Using bio materials, first kidney was 3D printed. Ten years later, first 3D Printer in the kit was launched to the market. Today we have large scale printers that printed large 3D objects such are cars. 3D printing will be used for printing everything everywhere. List of pros and cons questions rising every day.

scholarly journals Surface Preparation and Treatment for Large-Scale 3D-Printed Composite Tooling Coating Adhesion

Coatings ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 457 ◽  
Author(s):  
Philipp Sauerbier ◽  
James Anderson ◽  
Douglas Gardner
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Lower Cost ◽  
Numerical Control ◽  
Fused Deposition Modelling ◽  
Filler Materials ◽  
Coating Adhesion ◽  
Fused Deposition ◽  
Composite Tooling ◽  
3D Printed

Recent advances in large-scale thermoplastic additive manufacturing (AM), using fused deposition modelling (FDM), have shown that the technology can effectively produce large aerospace tools with common feed stocks, costing 2.3 $/kg, such as a 20% carbon-filled acrylonitrile butadiene styrene (ABS). Large-scale additive manufacturing machines have build-volumes in the range of cubic meters and use commercially available pellet feedstock thermoplastics, which are significantly cheaper (5–10 $/kg) than the filament feedstocks for desktop 3D printers (20–50 $/kg). Additionally, large-scale AM machines have a higher material throughput on the order of 50 kg/h. This enables the cost-efficient tool production for several industries. Large-scale 3D-printed tooling will be computerized numerical control (CNC)-machined and -coated, to provide a surface suitable for demolding the composite parts. This paper outlines research undertaken to review and improve the adhesion of the coating systems to large, low-cost AM composite tooling, for marine or infrastructure composite applications. Lower cost tooling systems typically have a lower dimensional accuracy and thermal operating requirements than might be required for aerospace tooling. As such, they can use lower cost commodity grade thermoplastics. The polymer systems explored in the study included polypropylene (PP), styrene-maleic anhydride (SMA), and polylactic acid (PLA). Bio-based filler materials were used to reduce cost and increase the strength and stiffness of the material. Fillers used in the study included wood flour, at 30% by weight and spray-dried cellulose nano-fibrils, at 20% by weight. Applicable adhesion of the coating was achieved with PP, after surface treatment, and untreated SMA and PLA showed desirable coating adhesion results. PLA wood-filled composites offered the best properties for the desired application and, furthermore, they have environment-friendly advantages.

Hybrid Additive Manufacturing Method for Selective Plating of Freeform Circuitry on 3D Printed Plastic Structure

2018 ◽  
Vol 4 (2) ◽  
pp. 1800529 ◽  
Author(s):  
Ji Li ◽  
Yang Wang ◽  
Gengzhao Xiang ◽  
Handa Liu ◽  
Jiangling He
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Method ◽  
Plastic Structure ◽  
3D Printed ◽  
Selective Plating

3D Printing for Manufacturing Antique and Modern Musical Instrument Parts

2016 ◽  
Author(s):  
Frank Celentano ◽  
Nicholas May ◽  
Edward Simoneau ◽  
Richard DiPasquale ◽  
Zahra Shahbazi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Cloud Model ◽  
Low Cost ◽  
Sound Quality ◽  
Musical Instrument ◽  
Original Design ◽  
Manufacturing Method ◽  
3D Print ◽  
3D Printed

Professional musicians today often invest in obtaining antique or vintage instruments. These pieces can be used as collector items or more practically, as performance instruments to give a unique sound of a past music era. Unfortunately, these relics are rare, fragile, and particularly expensive to obtain for a modern day musician. The opportunity to reproduce the sound of an antique instrument through the use of additive manufacturing (3D printing) can make this desired product significantly more affordable. 3D printing allows for duplication of unique parts in a low cost and environmentally friendly method, due to its minimal material waste. Additionally, it allows complex geometries to be created without the limitations of other manufacturing techniques. This study focuses on the primary differences, particularly sound quality and comfort, between saxophone mouthpieces that have been 3D printed and those produced by more traditional methods. Saxophone mouthpieces are commonly derived from a milled blank of either hard rubber, ebonite or brass. Although 3D printers can produce a design with the same or similar materials, they are typically created in a layered pattern. This can potentially affect the porosity and surface of a mouthpiece, ultimately affecting player comfort and sound quality. To evaluate this, acoustic tests will be performed. This will involve both traditionally manufactured mouthpieces and 3D prints of the same geometry created from x-ray scans obtained using a ZEISS Xradia Versa 510. The scans are two dimensional images which go through processes of reconstruction and segmentation, which is the process of assigning material to voxels. The result is a point cloud model, which can be used for 3D printing. High quality audio recordings of each mouthpiece will be obtained and a sound analysis will be performed. The focus of this analysis is to determine what qualities of the sound are changed by the manufacturing method and how true the sound of a 3D printed mouthpiece is to its milled counterpart. Additive manufacturing can lead to more inconsistent products of the original design due to the accuracy, repeatability and resolution of the printer, as well as the layer thickness. In order for additive manufacturing to be a common practice of mouthpiece manufacturing, the printer quality must be tested for its precision to an original model. The quality of a 3D print can also have effects on the comfort of the player. Lower quality 3D prints have an inherent roughness which can cause discomfort and difficulty for the musician. This research will determine the effects of manufacturing method on the sound quality and overall comfort of a mouthpiece. In addition, we will evaluate the validity of additive manufacturing as a method of producing mouthpieces.

Design and Fabrication of Structural Connections Using Bi-Directional Evolutionary Structural Optimization and Additive Manufacturing

2016 ◽  
Vol 846 ◽  
pp. 571-576 ◽  
Author(s):  
Hamed Seifi ◽  
Mike Xie ◽  
James O’Donnell ◽  
Nicholas Williams
Keyword(s):  
Additive Manufacturing ◽  
Structural Optimization ◽  
Large Scale ◽  
Limited Area ◽  
Complex Structures ◽  
Evolutionary Structural Optimization ◽  
3D Printed ◽  
Structural Connections ◽  
Definition Of ◽  
Processing Steps

The need to simplify the construction issues of complex structures leads to definition of SmartNodes project as a research which aims to confine the complexity of structure to a limited area (nodes) in order to decrease processing steps and labor intensity by application of additive manufacturing (AM) techniques. Bi-Directional Evolutionary Structural Optimization (BESO) is used to design efficient and elegant nodal connections of large scale spatial structures and minimise the volume of nodes to be printed and to ultimately replace welded, forged and cast connections by 3D printed connections. The prototypes discussed in this paper demonstrate BESO design process through two generic cases.

Design and Manufacturing of a Metal 3D Printed kW Scale Axial Turboexpander

2019 ◽  
Author(s):  
Vaclav Novotny ◽  
Monika Vitvarova ◽  
Michal Kolovratnik ◽  
Barbora Bryksi Stunova ◽  
Vaclav Vodicka ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Surface Quality ◽  
High Efficiency ◽  
Cost Effective ◽  
Manufacturing Cost ◽  
Machining Processes ◽  
Manufacturing Method ◽  
Design And Manufacturing ◽  
3D Printed

Abstract Greater expansion of distributed power and process systems based on thermodynamic cycles with single to hundred kW scale power output is limited mainly there are not available cost-effective expanders. Turboexpanders have a perspective of high efficiency and flexibility concerning operating parameters even for the micro applications. However, they suffer from a high manufacturing cost and lead time in the development of traditional technologies (such as casting and machining processes). Additive manufacturing provides a possibility to overcome some of the issues. Manufacturing parts with complicated shapes by this technology, combining multiple components into a single part or rapid production by 3D printing for development purposes are among the prospective features with this potential. On the other hand, the 3D printing processes come with certain limitations which need to be overcome. This paper shows a design and manufacturing process of a 3 kW axial impulse air turbine working with isenthalpic drop 30 kJ/kg. Several samples to verify printing options and the turbine itself has been manufactured from stainless steel by the DMLS additive manufacturing method. Manufactured are two turbine variations regarding blade size and 3D printer settings while maintaining their specific dimensions. The turboexpanders testing method and rig is outlined. As the surface quality is an issue, several methods of post-processing of 3D printed stator and rotor blading to modify surface quality are suggested. Detailed experimental investigation is however subject of future work.

Additive Manufacturing of Polymer Nanocomposites With In-Situ Strain Sensing Capability

2018 ◽  
Author(s):  
Mohammad Abshirini ◽  
Mohammad Charara ◽  
Yingtao Liu ◽  
Mrinal C. Saha ◽  
M. Cengiz Altan
Keyword(s):  
Additive Manufacturing ◽  
Cyclic Loading ◽  
Flexible Structures ◽  
Strain Sensing ◽  
Load Sensing ◽  
Additional Layer ◽  
Sensing Applications ◽  
3D Printed ◽  
High Flexibility

This paper presents the additive manufacturing of electrically conductive polydimethylsiloxane (PDMS) nanocomposites for in-situ strain sensing applications. A straight line of pristine PDMS was first 3D printed on a thin PDMS substrate using an in-house modified 3D printer. Carbon nanotubes (CNTs) were uniformly sprayed on top of uncured PDMS lines. An additional layer of PDMS was then applied on top of CNTs to form a thin protective coating. The 3D printed PDMS/CNT nanocomposites were characterized using a scanning electron microscope (SEM) to validate the thickness, CNT distribution, and microstructural features of the sensor cross-section. The strain sensing capability of the nanocomposites was investigated under tensile cyclic loading at different strain rates and maximum strains. Sensing experiments indicate that under cyclic loading, the changes in piezo resistivity mimic, both, the changes in the applied load and the measured material strain with high fidelity. Due to the high flexibility of PDMS, the 3D printed sensors have potential applications in real-time load sensing and structural health monitoring of complex flexible structures.

scholarly journals In-Situ Thermal Imaging for Single Layer Build Time Alteration in Large-Scale Polymer Additive Manufacturing

2019 ◽  
Vol 34 ◽  
pp. 482-488
Author(s):  
Michael Borish ◽  
Brian K. Post ◽  
Alex Roschli ◽  
Phillip C. Chesser ◽  
Lonnie J. Love ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Thermal Imaging ◽  
Large Scale ◽  
Single Layer ◽  
Polymer Additive ◽  
Build Time

scholarly journals Analytical modelling of in situ layer-wise defect detection in 3D-printed parts: additive manufacturing

2020 ◽  
Vol 111 (7-8) ◽  
pp. 2311-2321
Author(s):  
Oluwole K. Bowoto ◽  
Bankole I. Oladapo ◽  
S. A. Zahedi ◽  
Francis T. Omigbodun ◽  
Omonigho P. Emenuvwe
Keyword(s):  
Additive Manufacturing ◽  
Defect Detection ◽  
Analytical Modelling ◽  
3D Printed
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