Additive manufacturing of a metallic optical bench—process development, material qualification and demonstration

Compared to conventional manufacturing processes, additive manufacturing offers a degree of freedom that has the potential to revolutionize the turbine components supply chain. Additive manufacturing facilitates the design and manufacture of highly complex components in high performance materials with features that cannot currently be realized with other processes. In addition, shorter development and manufacturing lead-times are possible due to the flexibility of 3D based processing and the absence of expensive, complicated molds or dies. Having been confined for many years to rapid prototyping or R&D applications, additive manufacturing is now making the move to the factory floor. However, a dearth of manufacturing experience makes the development effort and risk of costly mistakes a deterrent for many organizations that would otherwise be interested in exploring the benefits of additive manufacturing. A former manufacturer of industrial gas turbines recently established an additive manufacturing workshop designed to deliver highly complex engine-ready components that can contribute to increased performance of the gas turbine. A strong emphasis on process validation and implementation of the organization’s best practice Lean and Quality methodologies has laid solid foundations for a highly capable manufacturing environment. This paper describes the approach taken to ensure that the workshop achieves a high level of operational excellence. Process development topics explored in the paper include the following: • Planning of process flow and cell layout to permit the maximum lean performance • Strategy used to determine machine specification and selection method. • Assessment of process capability • Influence of design for manufacture on process efficiency and product quality • Experience gained during actual production of first commercial components

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Process development for additive manufacturing of functionally graded alumina toughened zirconia components intended for medical implant application

Journal of the European Ceramic Society ◽

10.1016/j.jeurceramsoc.2018.09.003 ◽

2019 ◽

Vol 39 (2-3) ◽

pp. 522-530 ◽

Cited By ~ 19

Author(s):

Eric Schwarzer ◽

Stefan Holtzhausen ◽

Uwe Scheithauer ◽

Claudia Ortmann ◽

Thomas Oberbach ◽

...

Keyword(s):

Additive Manufacturing ◽

Process Development ◽

Functionally Graded ◽

Medical Implant

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Additive manufacturing ferromagnetic polymers using stereolithography – Materials and process development

Manufacturing Letters ◽

10.1016/j.mfglet.2019.06.003 ◽

2019 ◽

Vol 21 ◽

pp. 12-16 ◽

Cited By ~ 2

Author(s):

Balakrishnan Nagarajan ◽

Muhammad Arshad ◽

Aman Ullah ◽

Pierre Mertiny ◽

Ahmed Jawad Qureshi

Keyword(s):

Additive Manufacturing ◽

Process Development

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Produktivitätssteigerung durch Hybridisierung im 3D-Druck/Process development for the automated production of plastic parts with integrated functional components. Increased productivity through hybridization in 3D printing

wt Werkstattstechnik online ◽

10.37544/1436-4980-2020-07-08-65 ◽

2020 ◽

Vol 110 (07-08) ◽

pp. 521-525

Author(s):

Michael Baranowski ◽

Markus Netzer ◽

Sven Coutandin ◽

Jürgen Fleischer

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Manufacturing Process ◽

Process Development ◽

Flexible Production ◽

Additive Fertigung ◽

Automated Production ◽

Individualized Production ◽

Plastic Parts ◽

Functional Components

Die additive Fertigung erlaubt eine standortunabhängige sowie de facto individualisierte Produktion von Bauteilen mit nahezu beliebiger Komplexität. Für die flexible Herstellung von hochfunktionalen Hybridbauteilen fehlt es allerdings an entsprechenden Maschinenkonzepten sowie Automatisierungslösungen. Durch ein hier vorgestelltes Anlagenkonzept sollen Funktionskomponenten in den additiven Herstellungsprozess integriert und neue Möglichkeiten der Bauteilhybridisierung erforscht werden.   Additive manufacturing allows a location-independent and de facto individualized production of components of almost any complexity. However, there is a need for appropriate machine concepts and automation solutions for the flexible production of highly functional hybrid components. A plant concept presented here is intended to integrate functional components into the additive manufacturing process and to explore new possibilities for component hybridization.

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Towards the Possibility of Additive Manufacturing of XNA-Based Devices Using Molecular Engineering Principles

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1037.84 ◽

2021 ◽

Vol 1037 ◽

pp. 84-104

Author(s):

Oleg V. Gradov ◽

Irina A. Maklakova ◽

Margaret A. Gradova ◽

Andrey Ivanovich Sergeev ◽

Yu.K. Naganovskiy

Keyword(s):

Additive Manufacturing ◽

Process Development ◽

Molecular Engineering ◽

Molecular Devices ◽

3D Printer ◽

Technical Process ◽

Electron Beam Processing ◽

Novel Approach ◽

Multiparametric Characterization

This paper considers a novel approach for integration between molecular engineering of XNA-based structures and additive manufacturing of XNA-based devices based on multiparametric characterization of XNAs by different functional descriptors (such as physical properties of XNA-based materials and precursors of XNA-based molecular devices) and the possibility of thermal or electron-beam processing as a prerequisite of the industrial technical process development for such device implementation. This can be performed in the framework of additive manufacturing by connecting the output of the XNA synthesizer or nucleic acid synthesizer with 3D-printer nozzles in such a way that oligos / AGCTX products are supported into the nozzles separately.

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Additive Manufacturing of Single-Crystal Superalloy CMSX-4 Through Scanning Laser Epitaxy: Computational Modeling, Experimental Process Development, and Process Parameter Optimization

Metallurgical and Materials Transactions A ◽

10.1007/s11661-016-3571-y ◽

2016 ◽

Vol 47 (8) ◽

pp. 3845-3859 ◽

Cited By ~ 35

Author(s):

Amrita Basak ◽

Ranadip Acharya ◽

Suman Das

Keyword(s):

Additive Manufacturing ◽

Computational Modeling ◽

Single Crystal ◽

Parameter Optimization ◽

Process Development ◽

Process Parameter ◽

Single Crystal Superalloy ◽

Scanning Laser ◽

Process Parameter Optimization ◽

Experimental Process

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Process Development for a Robotized Laser Wire Additive Manufacturing

Volume 2: Additive Manufacturing; Materials ◽

10.1115/msec2017-2951 ◽

2017 ◽

Cited By ~ 2

Author(s):

Meysam Akbari ◽

Yaoyu Ding ◽

Radovan Kovacevic

Keyword(s):

Additive Manufacturing ◽

Process Parameters ◽

Process Development ◽

Laser Scanner ◽

Travel Speed ◽

Main Process ◽

Feed Speed ◽

Wire Feed Speed ◽

Deposition Processes ◽

Complicated Geometries

Additive manufacturing has attracted the attention of industries such as aerospace and automotive as well as the medical technology sectors in recent years. Among all metal-based additive techniques, laser metal wire deposition offers some advantages like shorter processing time, more efficient material usage, and a larger buildup envelop. It has been found that robotized laser/wire additive manufacturing (RLWAM) is a demanding process. A plethora of process parameters must be controlled compared to other laser-based metal deposition processes. The influence of main process parameters such as laser power, stepover increment, wire feed speed, travel speed and z-increment was investigated in this study to find the optimal values. Droplet formation, wire dripping, irregular deposition in the first layer, and deviation of the wire tip were also found to be the main obstacles throughout the process and practical solutions were proposed to deal with these issues. In this study, an 8-axis robot (6-axis arm robot with a 2-axis positioner) and a 4 kW fiber laser along with a wire feeder were integrated to print the different geometrical shapes in 3D. In order to verify the geometrical accuracy of the as-built part, the buildup was scanned using a portable 3D laser scanner. The 3D representation, the Standard Tessellation Language (STL) format obtained from the buildup, was compared with the original CAD model. The results show that RLWAM can be successfully applied in printing even complicated geometries.

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