scholarly journals Hybrid Additive Manufacturing - Requirements Engineering Framework for Process Chain Considerations

2019 ◽  
Vol 1 (1) ◽  
pp. 3651-3660 ◽  
Author(s):  
Jan-Henrik Schneberger ◽  
Tobias Häfele ◽  
Jerome Kaspar ◽  
Michael Vielhaber
Keyword(s):  
Additive Manufacturing ◽  
Development Process ◽  
Functional Integration ◽  
Requirements Specification ◽  
Successful Implementation ◽  
Process Chain ◽  
Post Processing ◽  
Hybrid Processes ◽  
User Knowledge ◽  
Design Freedom

AbstractAdditive Manufacturing (AM) provides significant opportunities for design and functional integration of parts and assemblies. Compared to conventional processes, the AM principle increases design freedom notably. Additionally, numerous processible materials and hybrid processes enable the implementation in different industries, spanning from aerospace over automobile until medical applications.However, there are still handicaps to be addressed, arising from the large diversity of AM principles, post-processing and quality assurance issues, partly insufficient user knowledge, and organizational aspects. Coherently, lacking requirements specification hinders a successful consideration of AM in the early stages of development, and its later implementation.To promote knowledge build-up, this contribution presents a requirements specification framework, which supports developers in determining demands throughout the development process, including those resulting from post-processing and testing operations. By incorporating thorough analyses of general organizational and resort overarching limitations, this contribution promotes a successful implementation of suitable AM strategies.

Additive manufacturing a powerful tool for the aerospace industry

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mahyar Khorasani ◽  
AmirHossein Ghasemi ◽  
Bernard Rolfe ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Production Costs ◽  
Process Chain ◽  
Post Processing ◽  
Jet Engine ◽  
Content Type ◽  
Support Optimization ◽  
The Cost

Purpose Additive manufacturing (AM) offers potential solutions when conventional manufacturing reaches its technological limits. These include a high degree of design freedom, lightweight design, functional integration and rapid prototyping. In this paper, the authors show how AM can be implemented not only for prototyping but also production using different optimization approaches in design including topology optimization, support optimization and selection of part orientation and part consolidation. This paper aims to present how AM can reduce the production cost of complex components such as jet engine air manifold by optimizing the design. This case study also identifies a detailed feasibility analysis of the cost model for an air manifold of an Airbus jet engine using various strategies, such as computer numerical control machining, printing with standard support structures and support optimization. Design/methodology/approach Parameters that affect the production price of the air manifold such as machining, printing (process), feedstock, labor and post-processing costs were calculated and compared to find the best manufacturing strategy. Findings Results showed that AM can solve a range of problems and improve production by customization, rapid prototyping and geometrical freedom. This case study showed that 49%–58% of the cost is related to pre- and post-processing when using laser-based powder bed fusion to produce the air manifold. However, the cost of pre- and post-processing when using machining is 32%–35% of the total production costs. The results of this research can assist successful enterprises, such as aerospace, automotive and medical, in successfully turning toward AM technology. Originality/value Important factors such as validity, feasibility and limitations, pre-processing and monitoring, are discussed to show how a process chain can be controlled and run efficiently. Reproducibility of the process chain is debated to ensure the quality of mass production lines. Post-processing and qualification of the AM parts are also discussed to show how to satisfy the demands on standards (for surface quality and dimensional accuracy), safety, quality and certification. The original contribution of this paper is identifying the main production costs of complex components using both conventional and AM.

scholarly journals Novel hybrid method to additively manufacture denser graphite structures using Binder Jetting

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Vladimir Popov ◽  
Alexander Fleisher ◽  
Gary Muller-Kamskii ◽  
Andrei Shishkin ◽  
Alexander Katz-Demyanetz ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Hybrid Method ◽  
Industrial Applications ◽  
Cold Isostatic Pressing ◽  
Post Processing ◽  
Hybrid Processes ◽  
Binder Jetting ◽  
Two Hybrid ◽  
Characterisation Methods

AbstractThis study introduces two hybrid processes integrating an additive manufacturing technique with post-processing treatments namely (i) Binder Jetting Printing (BJP) + Cold Isostatic Pressing (CIP) + cycle and (ii) BJP + cycle where cycle refers to a sequence of Impregnation—Drying—Pyrolysis. These two new processes yielded additively manufactured parts with higher density and reduced defects/porosities. As a testbed, we used these new processes to fabricate graphite structures. The samples produced by both methods were compared with each other and benchmarked to the samples produced by (a) BJP alone and (b) Traditional uniaxial pressing like compaction moulding. Various characterisation methods were used to investigate the microstructure and mechanical properties which showed that the porosity of hybrid manufactured samples reduces from 55% to a record 7%. This technological pathway is expected to create a new avalanche of industrial applications that are hitherto unexplored in the arena of hybrid additive manufacturing with BJP method.

Nachbearbeitung additiv gefertigter Fräswerkzeuge/Exploiting the full potential by developing seamless process chains

2021 ◽  
Vol 111 (11-12) ◽  
pp. 818-823
Author(s):  
Tobias Kelliger ◽  
Christoph Zachert ◽  
Daniel Schraknepper ◽  
Thomas Bergs
Keyword(s):  
Additive Manufacturing ◽  
Cutting Tools ◽  
Design Guidelines ◽  
Full Potential ◽  
Process Chain ◽  
Post Processing ◽  
Additive Fertigung ◽  
Process Chains ◽  
Individual Design ◽  
Design And Production

Durch additive Fertigung können Zerspanwerkzeuge beanspruchungsgerecht und individuell designt und gefertigt werden. Um das volle ökonomische und ökologische Potenzial dieser Werkzeuge auszuschöpfen, ist eine übergreifende Prozesskettenbetrachtung von der Konstruktion über die Fertigung bis zur spanenden Nachbearbeitung nötig. Dabei müssen übergreifende Lösungen und Gestaltungsrichtlinien entwickelt werden.   Additive manufacturing enables an individual design and production of cutting tools that fulfills the requirements. However, the full economic and ecological potential can only be exploited by considering the entire process chain from design and production to post-processing. General solutions and design guidelines have to be developed.

scholarly journals A Methodical Approach to Support Conceptual Design for Multi-Material Additive Manufacturing

2019 ◽  
Vol 1 (1) ◽  
pp. 659-668 ◽  
Author(s):  
Hagen Watschke ◽  
Sebastian Kuschmitz ◽  
Julius Heubach ◽  
Guido Lehne ◽  
Thomas Vietor
Keyword(s):  
Additive Manufacturing ◽  
Conceptual Design ◽  
Methodological Approach ◽  
Functional Integration ◽  
Innovative Product ◽  
Specific Design ◽  
Design Engineers ◽  
Methodical Approach ◽  
Design Freedom ◽  
Design For Am

AbstractAdditive manufacturing (AM) opens new possibilities for innovative product designs. However, due to a lack of knowledge and restrained creativity because of design fixations, design engineers do not take advantage of AM's design freedom. Especially multi-material AM provides new opportunities for functional integration that hardly considered in ideation. To overcome barriers in the development of solution ideas and utilizing such new design potentials, new design methods and tools are needed. Therefore, in this contribution, a methodological approach for a function-oriented provision of solution principles specific to material extrusion is presented. A tool is developed to facilitate effective guidance in developing solution ideas and to foster a realistic concretization by providing a combination of opportunistic and restrictive AM knowledge. Besides general levers of AM, process-specific design opportunities support the design engineers in exploiting AM's potentials, especially those who are not familiar with Design for AM. Finally, the applicability of the methodological approach is evaluated in an academic study by means of redesigning a hand prosthesis with a grab function.

Fräsbearbeitung von Additivbauteilen*/Milling of additively manufactured parts – post-processing potential for automation of additively manufactured serial parts

2019 ◽  
Vol 109 (06) ◽  
pp. 423-428
Author(s):  
C. Häußinger ◽  
M.F. Zäh
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Processes ◽  
Process Chain ◽  
Post Processing ◽  
High Quality ◽  
Additive Fertigung ◽  
Lightweight Structures ◽  
Laser Beam Melting ◽  
Functional Components ◽  
Efficient Realization

Die Additive Fertigung mittels Laser-Strahlschmelzen eröffnet in Bezug auf Leichtbaukonstruktionen viele Möglichkeiten. Um qualitativ hochwertige Funktionsbauteile zu fertigen, ist jedoch in den meisten Fällen eine spanende Nachbearbeitung erforderlich. Zu deren produktiver Umsetzung wurde im Rahmen des vorliegenden Beitrags eine Prozesskette am Beispiel des Fräsens definiert. Sie wurde zudem auf ihr Automatisierungspotenzial hin analysiert und an ausgewählten Prozessbausteinen wurden Automatisierungsmaßnahmen umgesetzt.   Additive manufacturing processes like laser beam melting enable many possibilities due to lightweight structures. However, a post-processing is necessary in most cases to produce high quality functional components. A process chain was developed for an efficient realization of the post-processing by milling. This process chain was analyzed for automation potentials and selected process modules were automated.

3D-Print-Cloud Baden-Württemberg*/3D-Print-Cloud Baden-Württemberg. An open platform for the process chain of Additive Manufacturing

2018 ◽  
Vol 108 (07-08) ◽  
pp. 537-542
Author(s):  
S. Merz ◽  
W. Maier ◽  
F. Baumann ◽  
Q. Spiller ◽  
H. Möhring ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Service Providers ◽  
Quality Service ◽  
Process Chain ◽  
Post Processing ◽  
Online Platform ◽  
3D Print ◽  
Entire Process ◽  
Open Platform ◽  
Required Quality

Mit der 3D-Print-Cloud BW entsteht eine zunächst vorwettbewerbliche, offene Online-Plattform für die Gesamtprozesskette der Additiven Fertigung – von der Konstruktion, über die Simulation und Fertigung bis hin zur Nachbearbeitung der gedruckten Teile. Die Nutzer der Onlineplattform sind einerseits Firmen, die diese Dienstleistungen anbieten, und andererseits Kunden, die nach einer Dienstleistung im Bereich der Additiven Fertigung suchen und diese über die Onlineplattform finden und beauftragen können. Den Dienstleistern erschließen sich neue Kunden. Den Kunden steht eine große Anzahl an Dienstleistungen unterschiedlicher Firmen zur Verfügung. Durch die Abdeckung der gesamten Prozesskette sparen die Nutzer Zeit und Kosten. Mit der 3D-Print-Cloud BW ist es möglich, von der Konstruktion ausgehend schnell das gewünschte Bauteil in der geforderten Qualität zu erhalten.   In the project 3D-Print-Cloud BW a pre-competitive, open online-platform for the entire process chain of Additive Manufacturing – from design, through simulation and production to post-processing is developed. Users have access to a large number of service providers and save time because the platform covers the entire process chain. By using the platform users quickly get from the design to the desired component in the required quality. Service providers gain new customers.

scholarly journals Design And Validation of A Sheet Metal Clamping System For Additive Manufacturing and Post-Processing

2021 ◽  
Author(s):  
Julian Ferchow ◽  
Marvin Bühler ◽  
Marcel Schlüssel ◽  
Livia Zumofen ◽  
Christoph Klahn ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Sheet Metal ◽  
Process Chain ◽  
Post Processing ◽  
Powder Bed ◽  
Fundamental Investigation ◽  
Clamping System ◽  
Universal Interface ◽  
Sheet Metal Profiles ◽  
Milling Tools

Abstract Automated clamping for post-processing of mass-customized parts is a challenging step in the laser powder bed fusion (LPBF) process chain. In this study, a novel modular sheet metal clamping system was developed that uses disposable sheet metal profiles as a universal interface for the LPBF, robotic handling, and milling processes. Based on a fundamental investigation of hybrid additive manufacturing, the sheet metal clamping system was designed to use the same interface for the LPBF and milling processes. Subsequent an end-to-end validation was performed for the entire process chain. The concept of the sheet metal clamping system gives milling tools access to a part on five to six sides. Further, the part can be accessed from the top and bottom sides, and simplifying the removal of LPBF supports. No clamping forces are induced in the LPBF part, which is especially important for filigree structures. The sheet metal clamping system’s underlying concept could be adapted to automating the LPBF process chain for applications such as prosthetic dentistry.

Preventing and Detecting Cyber Attacks (Stl & Amf) on Additive Manufacturing (Am) Process Chain

2018 ◽  
Author(s):  
Anil Lamba ◽  
Satinderjeet Singh ◽  
Balvinder Singh ◽  
Natasha Dutta ◽  
Sivakumar Sai Rela Muni
Keyword(s):  
Additive Manufacturing ◽  
Cyber Attacks ◽  
Process Chain

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

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