Piezoelectric component fabrication using projection-based stereolithography of barium titanate ceramic suspensions

2017 ◽  
Vol 23 (1) ◽  
pp. 44-53 ◽  
Author(s):  
Xuan Song ◽  
Zeyu Chen ◽  
Liwen Lei ◽  
Kirk Shung ◽  
Qifa Zhou ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Ferroelectric Properties ◽  
Tape Casting ◽  
Prototype System ◽  
Ultrasound Transducers ◽  
Post Processing ◽  
Projection System ◽  
Content Type ◽  
Ceramic Suspensions

Purpose Conventional machining methods for fabricating piezoelectric components such as ultrasound transducer arrays are time-consuming and limited to relatively simple geometries. The purpose of this paper is to develop an additive manufacturing process based on the projection-based stereolithography process for the fabrication of functional piezoelectric devices including ultrasound transducers. Design/methodology/approach To overcome the challenges in fabricating viscous and low-photosensitive piezocomposite slurry, the authors developed a projection-based stereolithography process by integrating slurry tape-casting and a sliding motion design. Both green-part fabrication and post-processing processes were studied. A prototype system based on the new manufacturing process was developed for the fabrication of green-parts with complex shapes and small features. The challenges in the sintering process to achieve desired functionality were also discussed. Findings The presented additive manufacturing process can achieve relatively dense piezoelectric components (approximately 95 per cent). The related property testing results, including X-ray diffraction, scanning electron microscope, dielectric and ferroelectric properties as well as pulse-echo testing, show that the fabricated piezo-components have good potentials to be used in ultrasound transducers and other sensors/actuators. Originality/value A novel bottom-up projection system integrated with tape casting is presented to address the challenges in the piezo-composite fabrication, including small curing depth and viscous ceramic slurry recoating. Compared with other additive manufacturing processes, this method can achieve a thin recoating layer (as small as 10 μm) of piezo-composite slurry and can fabricate green parts using slurries with significantly higher solid loadings. After post processing, the fabricated piezoelectric components become dense and functional.

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.

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.

Additive manufacturing of laser cutting nozzles by SLM: processing, finishing and functional characterization

2018 ◽  
Vol 24 (3) ◽  
pp. 562-583 ◽  
Author(s):  
Marco Anilli ◽  
Ali Gökhan Demir ◽  
Barbara Previtali
Keyword(s):  
Functional Analysis ◽  
Additive Manufacturing ◽  
Laser Cutting ◽  
Post Processing ◽  
Production Chain ◽  
Content Type ◽  
Nozzle Geometries ◽  
Finishing Processes ◽  
Cutting Experiments ◽  
Double Chamber

Purpose The purpose of this paper is to demonstrate the use of selective laser melting for producing single and double chamber laser cutting nozzles. The main aim is to assess a whole production chain composed of an additive manufacturing (AM) and consecutive finishing processes together. Beyond the metrological and flow-related characterization of the produced nozzles, functional analysis on the use of the produced nozzles are carried out through laser cutting experiments. Design/methodology/approach SLM experiments were carried out to determine the correct compensation factor to achieve a desired nozzle diameter on steel with known processibility by SLM and using standard nozzle geometries for comparative purposes. The produced nozzles are finished through electrochemical machining (ECM) and abrasive flow machining (AFM). The performance of nozzles produced via additive manufacturing (AM) are compared to conventional ones on an industrial laser cutting system through cutting experiments with a 6 kW fibre laser. The produced nozzles are characterized in terms of pressure drop and flow dynamics through Schlieren imaging. Findings The manufacturing chain was regulated to achieve 1 mm diameter nozzles after consecutive post processing. The average surface roughness could be lowered by approximately 80 per cent. The SLM produced single chamber nozzles would perform similarly to conventional nozzles during the laser cutting of 1 mm mild steel with nitrogen. The double chamber nozzles could provide complete cuts with oxygen on 5 mm-thick mild steel only after post-processing. Post-processing operations proved to decrease the pressure drop of the nozzles. Schlieren images showed jet constriction at the nozzle outlet on the as-built nozzles. Originality/value In this work, the use of an additive manufacturing process is assessed together with suitable finishing and functional analysis of the related application to provide a complete production and evaluation chain. The results show how the finishing processes should be allocated in an AM-based production chain in a broader vision. In particular, the results confirm the functionality for designing more complex nozzle geometries for laser cutting, exploiting the flexibility of SLM process.

Role of process parameters during additive manufacturing by direct metal deposition of Inconel 718

2017 ◽  
Vol 23 (5) ◽  
pp. 919-929 ◽  
Author(s):  
Bo Chen ◽  
Jyoti Mazumder
Keyword(s):  
Additive Manufacturing ◽  
Cooling Rate ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Inconel 718 ◽  
Processing Parameters ◽  
Forming Quality ◽  
Content Type ◽  
Forming Characteristics ◽  
The Relationship

Purpose The aim of this research is to study the influence of laser additive manufacturing process parameters on the deposit formation characteristics of Inconel 718 superalloy, the main parameters that influence the forming characteristics, the cooling rate and the microstructure were studied. Design/methodology/approach Orthogonal experiment design method was used to obtain different deposit shape and microstructure using different process parameters by multiple layers deposition. The relationship between the processing parameters and the geometry of the cladding was analyzed, and the dominant parameters that influenced the cladding width and height were identified. The cooling rates of different forming conditions were obtained by the secondary dendrite arm spacing (SDAS). Findings The microstructure showed different characteristics at different parts of the deposit. Cooling rate of different samples were obtained and compared by using the SDAS, and the influence of the process parameters to the cooling rate was analyzed. Finally, micro-hardness tests were done, and the results were found to be in accordance with the micro-structure distribution. Originality/value Relationships between processing parameters and the forming characteristics and the cooling rates were obtained. The results obtained in this paper will help to understand the relationship between the process parameters and the forming quality of the additive manufacturing process, so as to obtain the desired forming quality by appropriate parameters.

scholarly journals An optimisation framework for designs for additive manufacturing combining design, manufacturing and post-processing

2021 ◽  
Vol 27 (11) ◽  
pp. 90-105
Author(s):  
Anton Wiberg ◽  
Johan Persson ◽  
Johan Ölvander
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Manufacturing Cost ◽  
Design For Additive Manufacturing ◽  
Post Processing ◽  
Process Selection ◽  
Content Type ◽  
Post Process ◽  
Alternative Designs

Purpose The purpose of this paper is to present a Design for Additive Manufacturing (DfAM) methodology that connects several methods, from geometrical design to post-process selection, into a common optimisation framework. Design/methodology/approach A design methodology is formulated and tested in a case study. The outcome of the case study is analysed by comparing the obtained results with alternative designs achieved by using other design methods. The design process in the case study and the potential of the method to be used in different settings are also discussed. Finally, the work is concluded by stating the main contribution of the paper and highlighting where further research is needed. Findings The proposed method is implemented in a novel framework which is applied to a physical component in the case study. The component is a structural aircraft part that was designed to minimise weight while respecting several static and fatigue structural load cases. An addition goal is to minimise the manufacturing cost. Designs optimised for manufacturing by two different AM machines (EOS M400 and Arcam Q20+), with and without post-processing (centrifugal finishing) are considered. The designs achieved in this study show a significant reduction in both weight and cost compared to one AM manufactured geometry designed using more conventional methods and one design milled in aluminium. Originality/value The method in this paper allows for the holistic design and optimisation of components while considering manufacturability, cost and component functionality. Within the same framework, designs optimised for different setups of AM machines and post-processing can be automatically evaluated without any additional manual work.

Development of a deposition framework for implementation of a region-based adaptive slicing strategy in arc-based metal additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nitish P. Gokhale ◽  
Prateek Kala
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Complex Geometry ◽  
Dimensional Accuracy ◽  
Successful Implementation ◽  
Mathematical Function ◽  
Adaptive Slicing ◽  
Content Type ◽  
Metal Additive Manufacturing ◽  
Metal Additive

Purpose This study aims to develop and demonstrate a deposition framework for the implementation of a region-based adaptive slicing strategy for the Tungsten Inert Gas (TIG) welding-based additive manufacturing system. The present study demonstrates a deposition framework for implementing a novel region-based adaptive slicing strategy termed as Fast Interior and Accurate Exterior with Constant Layer Height (FIAECLH). Design/methodology/approach The mentioned framework has been developed by performing experiments using the design of experiments and analyzing the experimental data. Analysis results have been used to obtain the mathematical function to integrate customization in the process. The paper, in the end, demonstrates the FIAECLH framework for implementing region-based adaptive slicing strategy on the hardware level. Findings The study showcase a new way of implementing the region-based adaptive slicing strategy to arc-based metal additive manufacturing. The study articulating a new strategy for its implementation in all types of wire and arc additive manufacturing processes. Originality/value Wire-arc-based technology has the potential to deliver cost-effective solutions for metal additive manufacturing. The research on arc welding-based processes is being carried out in different dimensions. To deposit parts with complex geometry and better dimensional accuracy implementation of a novel region-based adaptive slicing strategy for the arc-based additive manufacturing process is an essential task. The successful implementation of an adaptive slicing strategy would ease the fabrication of complex geometry in less time. This paper accomplishes this need of implementing a region-based adaptive slicing strategy as no experimental investigation has been reported for the TIG-based additive manufacturing process.

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.

scholarly journals Additive manufacturing revolution in ceramic microsystems

2020 ◽  
Vol 37 (2) ◽  
pp. 79-85 ◽  
Author(s):  
Witold Nawrot ◽  
Karol Malecha
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Electronic Device ◽  
Dielectric Parameters ◽  
Content Type ◽  
Electronic Manufacturing ◽  
Dielectric Performance ◽  
In The Beginning ◽  
Ceramic Stereolithography

Purpose The purpose of this paper is to review possibilities of implementing ceramic additive manufacturing (AM) into electronic device production, which can enable great new possibilities. Design/methodology/approach A short introduction into additive techniques is included, as well as primary characterization of structuring capabilities, dielectric performance and applicability in the electronic manufacturing process. Findings Ceramic stereolithography (SLA) is suitable for microchannel manufacturing, even using a relatively inexpensive system. This method is suitable for implementation into the electronic manufacturing process; however, a search for better materials is desired, especially for improved dielectric parameters, lowered sintering temperature and decreased porosity. Practical implications Relatively inexpensive ceramic SLA, which is now available, could make ceramic electronics, currently restricted to specific applications, more available. Originality/value Ceramic AM is in the beginning phase of implementation in electronic technology, and only a few reports are currently available, the most significant of which is mentioned in this paper.

Automated post machining process planning for a new hybrid manufacturing method of additive manufacturing and rapid machining

2018 ◽  
Vol 24 (7) ◽  
pp. 1077-1090 ◽  
Author(s):  
Niechen Chen ◽  
Prashant Barnawal ◽  
Matthew Charles Frank
Keyword(s):  
Additive Manufacturing ◽  
Process Planning ◽  
Manufacturing Process ◽  
Machining Process ◽  
Hybrid Manufacturing ◽  
High Quality ◽  
Content Type ◽  
Machining Process Planning ◽  
Quality Surface ◽  
High Quality Surface

PurposeThe purpose of this paper is to present a new method for automated post machining process planning for a hybrid manufacturing process. The manufacturing process is expected to generate complex functional parts by taking advantage of free form surface creation from additive manufacturing and high-quality surface finishing from CNC milling. Design/methodology/approachThe hybrid process starts with additive manufacturing to generate a near net shape part with pre-defined machining allowances on surfaces requiring high quality surface or tight tolerances, along with integrated fixture geometry. The next step is to conduct automated machining process planning to determine critical parameters such as setup angle, tool selection, depth, tool containment, and consequently, the NC code to machine the part. FindingsThis method is shown to be a feasible solution for rapidly creating functional parts. The tests have been conducted to validate the method developed in this paper. Originality/valueThis paper introduces a new automated post machining process planning method for integrating additive manufacturing with a rapid milling process.

Ultrasound Transducer Array Fabrication Based on Additive Manufacturing of Piezocomposites

2012 ◽  
Author(s):  
Hamid Chabok ◽  
Chi Zhou ◽  
Yong Chen ◽  
Arash Eskandarinazhad ◽  
Qifa Zhou ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Ultrasound Transducer ◽  
Prototype System ◽  
Sintering Process ◽  
Projection System ◽  
Complex Shapes ◽  
Transducer Arrays ◽  
Ceramic Components ◽  
Digital Micromirror Devices ◽  
Future Work

Conventional methods for fabricating ultrasound imaging transducer arrays, especially for high frequency range (>20 MHz), are expensive, time consuming and limited to relatively simple geometries. In this paper, the development of an additive manufacturing (AM) process based on digital micromirror devices (DMDs) is presented for the fabrication of piezoelectric devices such as ultrasound transducer arrays. Both green-part fabrication and the sintering of fabricated green-parts have been studied. A novel two-channel design in the bottom-up projection system is presented to address the piezo-composite fabrication challenges including a small curing depth and viscous ceramic slurry recoating. A prototype system has been developed for the fabrication of green-parts with complex shapes and small features. Based on the fabricated green-parts, the challenges in the sintering process for achieving desired functionality are discussed. Various approaches for increasing the density of sintered components are presented. Dielectric and piezoelectric properties of the fabricated samples are measured and compared with those of bulk PZT samples. Based on the identified challenges in the DMD-based AM process, future work for achieving fully functional piezoelectric ceramic components is discussed.

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