Cost modeling and analysis for Mask Image Projection Stereolithography additive manufacturing: Simultaneous production with mixed geometries

PurposeDespite the widespread expectation that additive manufacturing (AM) will become a disruptive technology to transform the spare parts supply chain, very limited research has been devoted to the quantitative modeling and analysis on how AM could fulfill the on-demand spare parts supply. On the other hand, the choice of using AM as a spare parts supply strategy over traditional inventory is a rising decision faced by manufacturers and requires quantitative analysis for their AM-or-stock decisions. The purpose of this paper is to develop a quantitative performance model for a generic powder bed fusion AM system in a spare parts supply chain, thus providing insights into this less-explored area in the literature.Design/methodology/approachIn this study, analysis based on a discrete event simulation was carried out for the use of AM in replacement of traditional warehouse inventory for an on-demand spare parts supply system. Generic powder bed fusion AM system was used in the model, and the same modeling approach could be applied to other types of AM processes. Using this model, the impact of both spare parts demand characteristics (e.g. part size attributes, demand rates) and the AM operations characteristics (e.g. machine size and postpone strategy) on the performance of using AM to supply spare parts was studied.FindingsThe simulation results show that in many cases the AM operation is not as cost competitive compared to the traditional warehouse-based spare parts supply operation, and that the spare parts size characteristics could significantly affect the overall performance of the AM operations. For some scenarios of the arrival process of spare parts demand, the use of the batched AM production could potentially result in significant delay in parts delivery, which necessitates further investigations of production optimization strategies.Originality/valueThe findings demonstrate that the proposed simulation tool can not only provide insights on the performance characteristics of using AM in the spare parts supply chain, especially in comparison to the traditional warehousing system, but also can be used toward decision making for both the AM manufacturers and the spare parts service providers.

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New Hammerstein Modeling and Analysis for Controlling Melt Pool Width in Powder Bed Fusion Additive Manufacturing

ASME Letters in Dynamic Systems and Control ◽

10.1115/1.4050079 ◽

2021 ◽

pp. 1-7

Author(s):

Dan Wang ◽

Xinyu Zhao ◽

Xu Chen

Keyword(s):

Finite Element ◽

Additive Manufacturing ◽

Process Variations ◽

Element Model ◽

Hammerstein Model ◽

Powder Bed Fusion ◽

Modeling And Analysis ◽

Powder Bed ◽

Melt Pool ◽

Linearized Model

Abstract Despite the advantages and emerging applications, broader adoption of powder bed fusion (PBF) additive manufacturing is challenged by insufficient reliability and in-process variations. Finite element modeling and control-oriented modeling have been identified fundamental for predicting and engineering part qualities in PBF. This paper first builds a finite element model (FEM) of the thermal fields to look into the convoluted thermal interactions during the PBF process. Using the FEM data, we identify a novel surrogate system model from the laser power to the melt pool width. Linking a linearized model with a memoryless nonlinear submodel, we develop a physics-based Hammerstein model that captures the complex spatiotemporal thermomechanical dynamics. We verify the accuracy of the Hammerstein model using the FEM and prove that the linearized model is only a representation of the Hammerstein model around the equilibrium point. Along the way, we conduct the stability and robustness analyses and formalize the Hammerstein model to facilitate the subsequent control designs.

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Design and optimization of projection stereolithography additive manufacturing system with multi-pass scanning

Rapid Prototyping Journal ◽

10.1108/rpj-08-2019-0219 ◽

2021 ◽

Vol 27 (3) ◽

pp. 636-642

Author(s):

Qin Qin ◽

Jigang Huang ◽

Jin Yao ◽

Wenxiang Gao

Keyword(s):

Additive Manufacturing ◽

Manufacturing System ◽

Content Type ◽

Design And Optimization ◽

Compensation Algorithm ◽

The Poor ◽

Building Area ◽

Projection Stereolithography ◽

Stitching Errors

Purpose Scanning projection-based stereolithography (SPSL) is a powerful technology for additive manufacturing with high resolution as well as large building area. However, the surface quality of stitching boundary in an SPSL system has been rarely studied, and no positive settlement was proposed to address the poor stitching quality. This paper aims to propose an approach of multi-pass scanning and a compensation algorithm for multi-pass scanning process to address the issue of poor stitching quality in SPSL systems. Design/methodology/approach The process of multi-pass scanning is realized by scanning regions repeatedly, and the regions can be cured simultaneously because of the very short repeat exposure time and very fast scanning. Then, the poor stitching quality caused by the non-simultaneous curing can be eliminated. Also, a compensation algorithm is designed for multi-pass scanning to reduce the stitching errors. The validity of multi-pass scanning is verified by curing depth test, while the performance of multi-pass scanning as well as proposed compensation algorithm is demonstrated by comparing with that of a previous SPSL system. Findings The results lead to a conclusion that multi-pass scanning with its compensation algorithm is an effective approach to improve the stitching quality of an SPSL system. Practical implications This study can provide advice for researchers to achieve the satisfactory surface finish with SPSL technology. Originality/value The authors proposed a process of multi-pass scanning as well as a compensation algorithm for SPSL additive manufacturing (system to improve the stitching quality, which has rarely been studied in previous work.

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Optimisation procedure for additive manufacturing processes based on mask image projection to improve Z accuracy and resolution

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2018.01.004 ◽

2018 ◽

Vol 31 ◽

pp. 689-702 ◽

Cited By ~ 8

Author(s):

J. Bonada ◽

A. Muguruza ◽

X. Fernández-Francos ◽

X. Ramis

Keyword(s):

Additive Manufacturing ◽

Manufacturing Processes ◽

Image Projection ◽

Optimisation Procedure

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3D Printing Temporary Crown and Bridge by Temperature Controlled Mask Image Projection Stereolithography

Procedia Manufacturing ◽

10.1016/j.promfg.2018.07.134 ◽

2018 ◽

Vol 26 ◽

pp. 1023-1033 ◽

Cited By ~ 8

Author(s):

Xiangjia Li ◽

Benshuai Xie ◽

Jie Jin ◽

Yang Chai ◽

Yong Chen

Keyword(s):

3D Printing ◽

Image Projection ◽

Temperature Controlled ◽

Projection Stereolithography

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Additive Manufacturing of Bi-Continuous Piezocomposites With Triply Periodic Phase Interfaces for Combined Flexibility and Piezoelectricity

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4044708 ◽

2019 ◽

Vol 141 (11) ◽

Cited By ~ 2

Author(s):

Xuan Song ◽

Li He ◽

Wenhua Yang ◽

Zhuo Wang ◽

Zeyu Chen ◽

...

Keyword(s):

Additive Manufacturing ◽

Load Transfer ◽

Piezoelectric Materials ◽

Phase Interface ◽

Ferroelectric Ceramic ◽

Ceramic Phase ◽

Flexible Polymer ◽

Triply Periodic ◽

Load Transfer Efficiency ◽

Projection Stereolithography

Abstract An additive manufacturing-enabled bi-continuous piezocomposite architecture is presented to achieve mechanical flexibility and piezoelectricity simultaneously in piezoelectric materials. This architecture comprises an active ferroelectric ceramic phase and a passive flexible polymer phase, which are separated by a tailorable phase interface. Triply periodic minimal surfaces were used to define the phase interface, due to their excellent elastic properties and load transfer efficiency. A suspension-enclosing projection-stereolithography process was used to additively manufacture this material. Postprocesses including polymer infiltration, electroding, and poling are introduced. Piezoelectric properties of the piezocomposites are numerically and experimentally studied. The results highlight the role of tailorable triply periodic phase interfaces in promoting mechanical flexibility and piezoelectricity of bi-continuous piezocomposites.

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Evaluation Method and Collaborative Study of Sustainable Additive-Manufacturing

10.20944/preprints202107.0436.v1 ◽

2021 ◽

Author(s):

Haishang Wu

Keyword(s):

Additive Manufacturing ◽

Cost Reduction ◽

Manufacturing Industry ◽

Evaluation Method ◽

Dominant Role ◽

Sustainable Manufacturing ◽

Collaborative Study ◽

Divide And Conquer ◽

Cost Modeling ◽

Efficient Production

It has been commonly recognized that additive manufacturing (AM) enables cost-effective and efficient production towards sustainability. A rigorous evaluation method is required to further investigate the measurement method and efficiency before AM can be well-positioned in sustainable manufacturing and become the industry mainstream. Cost reduction plays key role in manufacturing industry. Compared to conventional manufacturing (CM), cost of AM is volume independent. In contrary, CM production requires a certain volume to share initial tooling cost to achieve cost reduction. This constraint limits CM from service on demand, and leave ambiguity behind. Invisibility of AM advantage in cost factors blocks AM technologies from appropriate process and affects its applications. The major issues AM encountering are the scaling, speed and size of products. Enhancement in scaling threshold and cost modeling are the novelty of this study and a breakthrough of AM issues. Through this study, generic equations are derived by using Convergence Effect and Buy-to-Fly (BTF) ratio. The Divide-and-Conquer approach further supports scaling factors and dependencies of conventional manufacturing (CM) cost modeling as well as AM methods. Consequently, appropriate AM technologies and CM convergence threshold can enhance standardization, decision support, and pre-pilot of AM society through this rigorous benchmarking. Advantages of AM are identified, and a collaboration pattern is proposed to connect large enterprise (LE), SME, and home-based-business (HBB) into an AM society. Through this society, advantages of AM can be fully utilized, scaling and speed issues can be resolved, and AM’s dominant role in sustainable manufacturing becomes feasible.

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