Foam additive manufacturing technology: main characteristics and experiments for hull mold manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Elodie Paquet ◽  
Alain Bernard ◽  
Benoit Furet ◽  
Sébastien Garnier ◽  
Sébastien Le Loch
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Process ◽  
Manufacturing Industry ◽  
Pressure Head ◽  
Manufacturing Technology ◽  
Cnc Machining ◽  
Numerical Control ◽  
Content Type ◽  
Additive Manufacturing Technology

Purpose The purpose of this paper is to present a novel methodology to produce a large boat hull with a foam additive manufacturing (FAM) process. To respond to shipping market needs, this new process is being developed. FAM technology is a conventional three-dimensional (3D) printing process whereby layers are deposited onto a high-pressure head mounted on a six-axis robotic arm. Traditionally, molds and masters are made with computer numerical control (CNC) machining or finished by hand. Handcrafting the molds is obviously time-consuming and labor-intensive, but even CNC machining can be challenging for parts with complex geometries and tight deadlines. Design/methodology/approach The proposed FAM technology focuses on the masters and molds, that are directly produced by 3D printing. This paper describes an additive manufacturing technology through which the operator can create a large part and its tools using the capacities of this new FAM technology. Findings The study shows a comparison carried out between the traditional manufacturing process and the additive manufacturing process, which is illustrated through an industrial case of application in the manufacturing industry. This work details the application of FAM technology to fabricate a 2.5 m boat hull mold and the results show the time and cost savings of FAM in the fabrication of large molds. Originality/value Finally, the advantages and drawbacks of the FAM technology are then discussed and novel features such as monitoring system and control to improve the accuracy of partly printed are highlighted.

Preliminary design of 3D printed fittings for UAV

2019 ◽  
Vol 91 (5) ◽  
pp. 756-760 ◽  
Author(s):  
Jacek Mieloszyk ◽  
Andrzej Tarnowski ◽  
Michal Kowalik ◽  
Rafal Perz ◽  
Witold Rzadkowski
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Technology ◽  
Ease Of Use ◽  
Printing Technology ◽  
Content Type ◽  
3D Printing Technology ◽  
Additive Manufacturing Technology ◽  
3D Printed ◽  
Reduction Cost

Purpose Additive manufacturing technology, also commonly called as 3D printing technology, is entering rapidly into the aerospace world and seems to be its future. Many manufacturing processes are replaced by this technology because the ease of use, low costs and new possibilities to make complicated parts. However, there are only few solutions which present manufacturing of structurally critical parts. Design/methodology/approach Complete process of deriving loads, design of fitting geometry, numerical validation, manufacturing and strength testing was presented. The emphasis was made to show specific features of 3D technology in printed fittings for UAV. Findings The research confirms that the technology can be used for the application of fittings manufacturing. Attention needs to be paid, during the design process, to account for specific features of the 3D printing technology, which is described in details. Practical implications Without a doubt, additive manufacturing is useful for manufacturing complicated parts within limited time and with reduction cost. It was also shown that the manufactured parts can be used for highly loaded structures. Originality/value The paper shows how additive manufacturing technology can be used to produce significantly loaded parts of airplanes’ structure. Only few such examples were presented till now.

scholarly journals Impact of 3D Printing on Automotive Parts

2020 ◽  
Vol 5 (3) ◽  
pp. 79-84
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Process ◽  
Manufacturing Technology ◽  
Automotive Components ◽  
Additive Manufacturing Technology ◽  
Engine Part ◽  
Automotive Parts ◽  
3D Printed ◽  
The Impact

The impact of 3D Printing on automotive parts is investigated. 3D printing is an additive manufacturing technology to rapidly create prototypes by laying down a broad range of material onto successive layers of surfaces. In the automotive parts generally metal or alloy materials are used in the manufacturing. In this research we tested effect of 3D Printing on different automotive components. For the testing purpose we used Front Hub, Rear Hub, Knuckle, Calliper, CAM (engine part) and Steering pedal. After manufacturing in FDM printer using PLA material, the different properties were checked, and compare the result of existing manufactured components with the 3D printed one. The results showed that the 3D printed components having lesser weight up-to 35% to 40% with better geometric finishing. It also allows the complex geometric in the manufacturing process.

Optimal space filling for additive manufacturing

2016 ◽  
Vol 22 (4) ◽  
pp. 660-675 ◽  
Author(s):  
Sajan Kapil ◽  
Prathamesh Joshi ◽  
Hari Vithasth Yagani ◽  
Dhirendra Rana ◽  
Pravin Milind Kulkarni ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Layered Manufacturing ◽  
Closed Curve ◽  
Numerical Control ◽  
Surface Finishing ◽  
Content Type ◽  
Single Pass ◽  
Connected Area ◽  
Area Filling

Purpose In additive manufacturing (AM) process, the physical properties of the products made by fractal toolpaths are better as compared to those made by conventional toolpaths. Also, it is desirable to minimize the number of tool retractions. The purpose of this study is to describe three different methods to generate fractal-based computer numerical control (CNC) toolpath for area filling of a closed curve with minimum or zero tool retractions. Design/methodology/approach This work describes three different methods to generate fractal-based CNC toolpath for area filling of a closed curve with minimum or zero tool retractions. In the first method, a large fractal square is placed over the outer boundary and then rest of the unwanted curve is trimmed out. To reduce the number of retractions, ends of the trimmed toolpath are connected in such a way that overlapping within the existing toolpath is avoided. In the second method, the trimming of the fractal is similar to the first method but the ends of trimmed toolpath are connected such that the overlapping is found at the boundaries only. The toolpath in the third method is a combination of fractal and zigzag curves. This toolpath is capable of filling a given connected area in a single pass without any tool retraction and toolpath overlap within a tolerance value equal to stepover of the toolpath. Findings The generated toolpath has several applications in AM and constant Z-height surface finishing. Experiments have been performed to verify the toolpath by depositing material by hybrid layered manufacturing process. Research limitations/implications Third toolpath method is suitable for the hybrid layered manufacturing process only because the toolpath overlapping tolerance may not be enough for other AM processes. Originality/value Development of a CNC toolpath for AM specifically hybrid layered manufacturing which can completely fill any arbitrary connected area in single pass while maintaining a constant stepover.

Manufacture of Lenses and Diffraction Gratings Using DLP As an Additive Manufacturing Technology

2018 ◽  
Author(s):  
Laura Daniela Vallejo Melgarejo ◽  
Jose García ◽  
Ronald G. Reifenberger ◽  
Brittany Newell
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Diffraction Grating ◽  
Diffraction Gratings ◽  
Optical Microscope ◽  
Manufacturing Technology ◽  
Manufacturing Processes ◽  
Digital Light Processing ◽  
Additive Manufacturing Technology ◽  
Potential Use

This document condenses the results obtained when 3D printing lenses and their potential use as diffraction gratings using Digital Light Processing (DLP), as an additive manufacturing technique. This project investigated the feasibility of using DLP additive manufacturing for producing custom designed lenses and gratings. DLP was identified as the preferred manufacturing technology for gratings fabrication. Diffraction gratings take advantage of the anisotropy, inherent in additive manufacturing processes, to produce a collated pattern of multiple fringes on a substrate with completely smooth surfaces. The gratings are transmissive and were manufactured with slit separations of 10, 25 and 50 μm. More than 50 samples were printed at various build angles and mechanically treated for maximum optical transparency. The variables of the irradiance equation were obtained from photographs taken with an optical microscope. These values were used to estimate theoretical irradiance patterns of a diffraction grating and compared against the experimental 3-D printed grating. The resulting patterns were found to be remarkably similar in amplitude and distance between peaks when compared to theoretical values.

scholarly journals Additive Manufacturing in Vascular Stent Fabrication

2019 ◽  
Vol 253 ◽  
pp. 03003
Author(s):  
Lei Yang ◽  
Xin Chen ◽  
Lei Zhang ◽  
Lei Li ◽  
Shuangzhu Kang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Personalized Medicine ◽  
High Efficiency ◽  
Structural Characteristics ◽  
Manufacturing Technology ◽  
Vascular Stent ◽  
Additive Manufacturing Technology ◽  
Vascular Scaffolds ◽  
And Personalized Medicine

High-efficiency formation of personalized stent by additive manufacturing (3D printing) has gained deal of attention and research in interventional and personalized medicine. In this article, the structural characteristics of vascular scaffolds and the application and innovation of additive manufacturing technology in the process of angioplasty are reviewed. In the future, with the continuous maturity of additive manufacturing technology, it is expected to be an important part of interventional precision medicine to manufacture personalized vascular stent.

Rethinking reverse logistics: role of additive manufacturing technology in metal remanufacturing

2019 ◽  
Vol 31 (1) ◽  
pp. 124-144 ◽  
Author(s):  
Danielle Strong ◽  
Michael Kay ◽  
Thomas Wakefield ◽  
Issariya Sirichakwal ◽  
Brett Conner ◽  
...  
Keyword(s):  
Supply Chain ◽  
Additive Manufacturing ◽  
Facility Location ◽  
Reverse Logistics ◽  
Small And Medium Enterprises ◽  
Real Data ◽  
Cnc Machining ◽  
Numerical Control ◽  
Content Type ◽  
The Usa

Purpose Although the adoption of metal additive manufacturing (AM) for production has continuously grown, in-house access to production grade metal AM systems for small and medium enterprises (SMEs) is a major challenge due to costs of acquiring metal AM systems, specifically powder bed fusion AM. On the other hand, AM technology in directed energy deposition (DED) has been evolving in both: processing capabilities and adaptable configuration for integration within existing traditional machines that are available in most SME manufacturing facilities, e.g. computer numerical control (CNC) machining centers. Integrating DED with conventional processes such as machining and grinding into Hybrid AM is well suited for remanufacturing of metal parts. The paper aims to discuss these issues. Design/methodology/approach Classical facility location models are employed to understand the effects of SMEs adopting DED systems to offer remanufacturing services. This study identifies strategically located counties in the USA to advance hybrid AM for reverse logistics using North American Industry Classification System (NAICS) data on geographical data, demand, fixed and transportation costs. A case study is also implemented to explore its implications on remanufacturing of high-value parts on the reverse logistics supply chain using an aerospace part and NAICS data on aircraft maintenance, repair and overhaul facilities. Findings The results identify the candidate counties, their allocations, allocated demand and total costs. Offering AM remanufacturing services to traditional manufacturers decreases costs for SMEs in the supply chain by minimizing expensive new part replacement. The hubs also benefit from hybrid AM to repair their own parts and tools. Originality/value This research provides a unique analysis on reverse logistics through hybrid AM focused on remanufacturing rather than manufacturing. Facility location using real data is used to obtain results and offers insights into integrating AM for often overlooked aspect of remanufacturing. The study shows that SMEs can participate in the evolving AM economy through remanufacturing services using significantly lower investment costs.

The Trends and Challenges of 3D Printing

2019 ◽  
pp. 415-423
Author(s):  
Edna Ho Chu Fang ◽  
Sameer Kumar
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Rapid Prototyping ◽  
Industrial Design ◽  
Consumer Products ◽  
Manufacturing Technology ◽  
3D Object ◽  
Additive Manufacturing Technology ◽  
Human Organs ◽  
Traditional Manufacturing

3D printing is a type of additive manufacturing technology where a 3D object is created by laying down subsequent layers of material at the mm scale. It is also known as rapid prototyping. 3D printing is now applied in various industries such as footwear, jewelry, architecture, engineering and construction, aerospace, dental and medical industries, education, consumer products, automotive, and industrial design. Some claim that 3D printing will put an end to traditional manufacturing, primarily since 3D printing imposes a tool-less process. Though 3D printing technology is used in weapon manufacturing, it is also being used to improve the lives of mankind. In the future, 3D printing will most probably be used to print human organs. The chapter discusses the trends and challenges faced by this exciting technology.

scholarly journals Elements of additive manufacturing technology adoption in small- and medium-sized sized companies

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Praveen Kulkarni ◽  
Arun Kumar ◽  
Ganesh Chate ◽  
Padma Dandannavar
Keyword(s):  
Additive Manufacturing ◽  
Technology Adoption ◽  
New Technologies ◽  
Negative Impact ◽  
Manufacturing Technology ◽  
Research Approach ◽  
Content Type ◽  
Additive Manufacturing Technology ◽  
Design Engineers ◽  
The Difference

Purpose This study aims to examine factors that determine the adoption of additive manufacturing by small- and medium-sized industries. It provides insights with regard to benefits, challenges and business factors that influence small- and medium-sized industries when adopting this technology. The study also aims to expand the domain of additive manufacturing by including a broader range of challenges and benefits of additive manufacturing in literature. Design/methodology/approach Using data collected from 175 small- and medium-sized industries, the study has examined through Mann–Whitney test to understand the difference between owners and design engineers on additive manufacturing technology adoption in small- and medium-sized companies. Findings This study suggests contribution to academic discussion by providing associated factors that have significant impact on the adoption of additive manufacturing technology. Related advantages of additive manufacturing are reduction in inventory cost, lowering the wastage in production and customization of products. The study also indicates that factors such as cost of machinery, higher level of cost in integrating metal components have a negative impact on the adoption of this technology in small- and medium-sized industries. Research limitations/implications Because of the chosen research approach, the research results may lack generalizability. Therefore, researchers are encouraged to test the proposed propositions further in the field of challenges and growth in other areas of application of additive manufacturing, for instance, medical sciences, fabric and aerospace. Practical implications The study provides important implications that are of interest for both research and practitioners, related to technology management in small- and medium-sized industries, e.g. foundry and machining industries. Social implications This work/study fulfills an identified need of the small- and medium-sized companies in adopting new technologies and contribute to their growth by understanding the need to accept and implement technology. Originality/value This paper fulfills an identified need to study how small- and medium-scale companies accept new technologies and factors associated with implementation in the manufacturing process of the organization.

The Trends and Challenges of 3D Printing

2018 ◽  
pp. 4382-4389
Author(s):  
Edna Ho Chu Fang ◽  
Sameer Kumar
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Rapid Prototyping ◽  
Industrial Design ◽  
Consumer Products ◽  
Manufacturing Technology ◽  
3D Object ◽  
Additive Manufacturing Technology ◽  
Human Organs ◽  
Traditional Manufacturing

3D printing is a type of additive manufacturing technology where a 3D object is created by laying down subsequent layers of material at the mm scale. It is also known as rapid prototyping. 3D printing is now applied in various industries such as footwear, jewelry, architecture, engineering and construction, aerospace, dental and medical industries, education, consumer products, automotive and industrial design. Some claim that 3D printing will put an end to traditional manufacturing primarily since 3D printing imposes a tool-less process. Though 3D printing technology is used in weapon manufacturing, it is also being used to improve the lives of mankind. In the future, 3D printing will most probably be used to print human organs. The article discusses the trends and challenges faced by this exciting technology.

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