Additive Manufacturing Technologies – Rapid Prototyping to Direct Digital Manufacturing

2012 ◽  
Vol 32 (2) ◽  
Author(s):  
Bernhard Mueller
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Digital Manufacturing ◽  
Direct Digital Manufacturing ◽  
Manufacturing Technologies

A high-speed additive manufacturing approach for achieving high printing speed and accuracy

2019 ◽  
Vol 234 (14) ◽  
pp. 2741-2749 ◽  
Author(s):  
Aamer Nazir ◽  
Jeng-Ywan Jeng
Keyword(s):  
Additive Manufacturing ◽  
Material Property ◽  
High Speed ◽  
Selective Laser Sintering ◽  
High Accuracy ◽  
Digital Manufacturing ◽  
Functional Material ◽  
Direct Digital Manufacturing ◽  
Manufacturing Technologies ◽  
Printing Speed

The primary concern of the Industry 4.0 is the direct digital manufacturing of customized products on demand at high production speed, high accuracy with functional material property. Although the unique capabilities of existing additive manufacturing technologies make it suitable for direct digital manufacturing, there are numerous limitations which include low printing speed, less accuracy and repeatability, and a limited selection of materials for a particular application. Therefore, a high-speed additive manufacturing approach is proposed in this paper, that is capable of achieving high speed of production, high accuracy, and surface finish, and functional material property. For better understanding, authors describe those additive manufacturing technologies that are capable of achieving the aforementioned characteristics. For validation, samples of various dimensions were 3D printed on a selective laser sintering and a high-speed multijet fusion 3D printer. The results were compared in the context of printing speed, surface roughness (Ra), and hardness of printed parts. Results revealed that the multijet fusion process is significantly faster than its counterpart while sacrificing Ra to some extent but the hardness of printed parts is not changed significantly. The selective laser sintering-printed samples had a 15% lower Ra compared with multijet fusion samples. The results also revealed that the multijet fusion process might be able to print composite/multi-materials; however, more research needs to be done.

Complex Sparse-Filled Mechanical Property Prediction Methods for Direct Digital Manufacturing

2013 ◽  
Author(s):  
David N. Kordonowy ◽  
Sydney A. Giblin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Flexible Manufacturing ◽  
Test Methods ◽  
Low Noise ◽  
Digital Manufacturing ◽  
Cycle Times ◽  
Mechanical Property Prediction ◽  
Direct Digital Manufacturing ◽  
And Control

This paper describes how direct digital manufacturing mechanical properties can be analytically estimated for structural use and the associated analytical and test methods used in the design and fabrication of airframes manufactured using additive manufacturing. Complex shape structures, which are now possible using additive manufacturing, and their associated mechanical properties can be predicted in order to allow operationally safe and highly predictive structures to be fabricated. Direct digital manufacturing allows for much greater flexibility and control over the design of airframes, leading to more structurally efficient and capable airframes. These advantages are revealed by application of direct digital manufacturing methods on a series of fixed wing subsonic transport concept wind tunnel scale models that are carried out as a part of the NASA N+3 program, which is paving the way for next generation aircraft that are highly fuel efficient, low-noise, and low-emission. Verification of these methods through test shows excellent correlation that provides reliability in complex sparse filled additive manufacturing design. The outcome of this is a knowledge base, which can then be applied to a system in operation. The combined potential of a flexible manufacturing system and proven predictive analysis tools shorten development time and expand the opportunities for mass customization. These combined benefits enable industry to fabricate affordable highly optimized custom products while concurrently reducing the cycle times required to field new products.

scholarly journals Direct Digital Manufacturing of Nanocomposites

2019 ◽  
Vol 890 ◽  
pp. 92-97
Author(s):  
Saeed D. Mohan ◽  
Meruyert Nazhipkyzy ◽  
Pedro Carreira ◽  
Cyril Santos ◽  
Fred J. Davis ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Carbon Nanotubes ◽  
Additive Manufacturing ◽  
Digital Manufacturing ◽  
Polymer Devices ◽  
Automated Process ◽  
Mechanical Performances ◽  
Direct Digital Manufacturing

Additive manufacturing has surged in popularity as a route to designing and preparing functional parts. Depending on the parts function, certain attributes such as high mechanical performances may be desired. We develop a route for improving the mechanical properties of polymer devices, fabricated through additive manufacturing by combining electrospinning and stereo-lithography into one automated process. This process utilises the impressive mechanical properties of carbon nanotubes by encapsulating and aligning them in electrospun fibres. Composite fibres will be incorporated into polymer resins prepared with stereo-lithography, thereby providing resins that benefit from the composite fibres properties, enhancing their overall mechanical properties.

The Manufacturing of Rapid Tooling by Stereo Lithography

2010 ◽  
Vol 102-104 ◽  
pp. 578-582
Author(s):  
Ya Li Hou ◽  
Ting Ting Zhao ◽  
Chang He Li ◽  
Y.C. Ding
Keyword(s):  
Rapid Prototyping ◽  
Casting Process ◽  
Rapid Tooling ◽  
Rapid Manufacturing ◽  
Digital Manufacturing ◽  
Geometrical Properties ◽  
Production Complex ◽  
Manufacturing Technologies ◽  
The Cost

The development and manufacturing speed of products have become the focus of competition, at the same time the manufacturing not only has to meet user’s constantly changing needs, but also has to have a relatively strong flexibility of manufacturing technologies. Additive processes can be defined as rapid prototyping, which generate parts (prototyping) in a layered way, is gaining progress by rapid tools (RT) and rapid manufacturing (RM) for production of functional parts in small quantity and even one product without adding the cost becomes more and more critical. The paper describes which mechanism of stereo lithography (SLA) rapid prototyping can be applied to rapid tooling for production complex geometries for long-term consistency. Moreover, the paper demonstrates the application examples of rapid tooling fulfilling the required physical, mechanical and geometrical properties in precision deformation and casting process. The most notable advantage is the integration of production design and digital manufacturing within the product development period.

An alternative method to produce metal/plastic hybrid components for orthopedics applications

2016 ◽  
Vol 231 (1-2) ◽  
pp. 179-186 ◽  
Author(s):  
M Silva ◽  
A Mateus ◽  
D Oliveira ◽  
C Malça
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Computer Aided Design ◽  
Optimization Procedure ◽  
Well Being ◽  
Laser Melting ◽  
Metal Mesh ◽  
Recovery Times ◽  
Direct Digital Manufacturing ◽  
Manufacturing Technologies

The demand for additive processes that provide components with high technological performance became overriding regardless of the application area. For medical applications, the orthopedics field—multimaterial orthoses and splints—can clearly benefit from direct additive manufacturing using a hybrid process instead of the traditional handmade manufacturing, which is slow, expensive, inaccurate, and difficult to reproduce. The ability to provide faster better orthoses, using innovative services and technologies, resulting in lower recovery times, reduced symptoms, and improved functional capacity, result in a significant impact on quality of life and the well-being of citizens. With these purposes, this work presents an integrate methodology, that includes the tridimensional (3D) scanning, 3D computer-aided design modeling, and the direct digital manufacturing of multimaterial orthoses and splints. Nevertheless, additive manufacturing of components with functional gradients, multimaterial components, e.g. metal/plastic is a great challenge since the processing factors for each one of them are very different. This paper proposes the addition of two advanced additive manufacturing technologies, the selective laser melting and the stereolithography, enabling the production of a photopolymerization of the polymer in the voids of a 3D metal mesh previously produced by selective laser melting. Based on biomimetic structures concept, this mesh is subject to a previous design optimization procedure in order to optimize its geometry, minimizing the mass involved and evidencing increased mechanical strength among other characteristics. A prototype of a hybrid additive manufacturing device was developed and its flexibility of construction, geometrical freedom, and different materials processability is demonstrated through the case study—arm orthosis—presented in this work.

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