The FaaS system using additive manufacturing for personalized production

2018 ◽  
Vol 24 (9) ◽  
pp. 1486-1499 ◽  
Author(s):  
Hyoung Seok Kang ◽  
Sang Do Noh ◽  
Ji Yeon Son ◽  
Hyun Kim ◽  
Jun Hee Park ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Mass Customization ◽  
Dynamic Scheduling ◽  
Numerical Control ◽  
Planning System ◽  
Smart Manufacturing ◽  
3D Printer ◽  
Distributed Manufacturing ◽  
Manufacturing Environment ◽  
Content Type

PurposeIn this paper, a three-dimensional (3D) printer-based manufacturing line and supporting system, which supports personalized/customized manufacturing for individual businesses or start-up companies, was studied to evaluate the practicality of using additive manufacturing for personalization/mass customization.Design/methodology/approachFirst, factory-as-a-service (FaaS) system, which provides factory as a service to customers, was proposed and designed to manufacture various products within a distributed manufacturing environment. This system includes 3D printer-based material extrusion processes, vapor machine/computer numerical control machines as post-processes and assembly and inspection processes with an automated material handling robot in the factory. Second, a virtualization module for the FaaS factory was developed using a simulation model interfaced with a cloud-based order and production-planning system and an internet-of-things-based control and monitoring system. This is part of the system for manufacturing operations, which is capable of dynamic scheduling in a distributed manufacturing environment. In addition, simulation-based virtual production was conducted to verify and evaluate the FaaS factory for the target production scenario. Main information of the simulation also has been identified and included in the virtualization module. Finally, the established system was applied in a sample production scenario to evaluate its practicality and efficiency.FindingsAdditive manufacturing is a reliable, feasible and applicable technology, and it can be a core element in smart manufacturing and the realization of personalization/mass customization.Originality/valueVarious studies on additive manufacturing have been conducted with regard to replacing the existing manufacturing methods or integrating with them, but these studies mostly focused on materials or types of additive manufacturing, with few advanced or applied studies on the establishment of a new manufacturing environment for personalization/mass customization.

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.

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.

Evaluation of smart manufacturing performance using a grey theory-based approach: a case study

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Anilkumar Malaga ◽  
S. Vinodh
Keyword(s):  
Performance Measures ◽  
Manufacturing Systems ◽  
Dynamic Scheduling ◽  
Performance Level ◽  
Self Control ◽  
Raw Material ◽  
Smart Manufacturing ◽  
Grey Theory ◽  
Content Type ◽  
Importance Index

PurposeThe purpose of the article is to report a study on evaluation of smart manufacturing (SM) performance using a grey theory-based approach.Design/methodology/approachIn total, 30 criteria and 79 attributes for SM performance have been developed. A grey theory-based approach has been used for SM performance evaluation. The grey index has been calculated, and weaker areas have been derived. Performance level of SM has been evaluated using the Euclidean distance approach.FindingsThe SM performance index is found to be (3.036, 12.296). The ideal grey performance importance index (GPII) is obtained as (3.025, 4.875). The level of visibility and traceability, vertical integration, lead time and configuration data espionage and control ability are strong performing attributes. Integration abilities of services and manufacturing systems, ability of self-control, worker and raw material productivity, collaboration among buyers and suppliers and dynamic scheduling are identified as weaker areas, and suggestions for improvement have been derived. SM performance level has been identified as “Good.”Research limitations/implicationsAdditional performance measures could be included as a part of evaluation. Practitioners can overcome weaker areas in the early phase. Management achieves confidence and practitioners attain success in implementation of SM in industry through the developed SM performance indexing system.Originality/valueIdentification of SM performance measures and analysis of SM performance is the original contribution of the authors. The developed approach assists practitioners and managers to focus more on specific areas for performance improvement.

Comparing environmental impacts of additive manufacturing vs traditional machining via life-cycle assessment

2015 ◽  
Vol 21 (1) ◽  
pp. 14-33 ◽  
Author(s):  
Jeremy Faludi ◽  
Cindy Bayley ◽  
Suraj Bhogal ◽  
Myles Iribarne
Keyword(s):  
Life Cycle Assessment ◽  
Life Cycle ◽  
Additive Manufacturing ◽  
Environmental Impacts ◽  
Surface Finish ◽  
Numerical Control ◽  
Cutting Fluid ◽  
Content Type ◽  
Electricity Use

Purpose – The purpose of this study is to compare the environmental impacts of two additive manufacturing machines to a traditional computer numerical control (CNC) milling machine to determine which method is the most sustainable. Design/methodology/approach – A life-cycle assessment (LCA) was performed, comparing a Haas VF0 CNC mill to two methods of additive manufacturing: a Dimension 1200BST FDM and an Objet Connex 350 “inkjet”/“polyjet”. The LCA’s functional unit was the manufacturing of two specific parts in acrylonitrile butadiene styrene (ABS) plastic or similar polymer, as required by the machines. The scope was cradle to grave, including embodied impacts, transportation, energy used during manufacturing, energy used while idling and in standby, material used in final parts, waste material generated, cutting fluid for CNC, and disposal. Several scenarios were considered, all scored using the ReCiPe Endpoint H and IMPACT 2002+ methodologies. Findings – Results showed that the sustainability of additive manufacturing vs CNC machining depends primarily on the per cent utilization of each machine. Higher utilization both reduces idling energy use and amortizes the embodied impacts of each machine. For both three-dimensional (3D) printers, electricity use is always the dominant impact, but for CNC at maximum utilization, material waste became dominant, and cutting fluid was roughly on par with electricity use. At both high and low utilization, the fused deposition modeling (FDM) machine had the lowest ecological impacts per part. The inkjet machine sometimes performed better and sometimes worse than CNC, depending on idle time/energy and on process parameters. Research limitations/implications – The study only compared additive manufacturing in plastic, and did not include other additive manufacturing technologies, such as selective laser sintering or stereolithography. It also does not include post-processing that might bring the surface finish of FDM parts up to the quality of inkjet or CNC parts. Practical implications – Designers and engineers seeking to minimize the environmental impacts of their prototypes should share high-utilization machines, and are advised to use FDM machines over CNC mills or polyjet machines if they provide sufficient quality of surface finish. Originality/value – This is the first paper quantitatively comparing the environmental impacts of additive manufacturing with traditional machining. It also provides a more comprehensive measurement of environmental impacts than most studies of either milling or additive manufacturing alone – it includes not merely CO2 emissions or waste but also acidification, eutrophication, human toxicity, ecotoxicity and other impact categories. Designers, engineers and job shop managers may use the results to guide sourcing or purchasing decisions related to rapid prototyping.

scholarly journals Numerical simulation and experimental calibration of additive manufacturing by blown powder technology. Part I: thermal analysis

2017 ◽  
Vol 23 (2) ◽  
pp. 448-463 ◽  
Author(s):  
Michele Chiumenti ◽  
Xin Lin ◽  
Miguel Cervera ◽  
Wei Lei ◽  
Yuxiang Zheng ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Additive Manufacturing ◽  
Numerical Model ◽  
High Energy ◽  
Metal Deposition ◽  
Numerical Control ◽  
Experimental Calibration ◽  
Standard Format ◽  
Content Type ◽  
Scanning Pattern

Purpose This paper aims to address the numerical simulation of additive manufacturing (AM) processes. The numerical results are compared with the experimental campaign carried out at State Key Laboratory of Solidification Processing laboratories, where a laser solid forming machine, also referred to as laser engineered net shaping, is used to fabricate metal parts directly from computer-aided design models. Ti-6Al-4V metal powder is injected into the molten pool created by a focused, high-energy laser beam and a layer of added material is sinterized according to the laser scanning pattern specified by the user. Design/methodology/approach The numerical model adopts an apropos finite element (FE) activation technology, which reproduces the same scanning pattern set for the numerical control system of the AM machine. This consists of a complex sequence of polylines, used to define the contour of the component, and hatches patterns to fill the inner section. The full sequence is given through the common layer interface format, a standard format for different manufacturing processes such as rapid prototyping, shape metal deposition or machining processes, among others. The result is a layer-by-layer metal deposition which can be used to build-up complex structures for components such as turbine blades, aircraft stiffeners, cooling systems or medical implants, among others. Findings Ad hoc FE framework for the numerical simulation of the AM process by metal deposition is introduced. Description of the calibration procedure adopted is presented. Originality/value The objectives of this paper are twofold: firstly, this work is intended to calibrate the software for the numerical simulation of the AM process, to achieve high accuracy. Secondly, the sensitivity of the numerical model to the process parameters and modeling data is analyzed.

Validation of design and materials for additive manufacturing of endocavitary mechanical distractor

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jose Manuel Sierra ◽  
Maria del Rocio Fernandez ◽  
Jose Ignacio Ignacio Rodriguez Garcia ◽  
Jose Luis Cortizo ◽  
Marta María Villazon
Keyword(s):  
Additive Manufacturing ◽  
Low Income ◽  
High Performance ◽  
Design Methodology ◽  
Three Dimensional ◽  
3D Printer ◽  
Validation Process ◽  
Content Type ◽  
Endoscopic Microsurgery ◽  
Optimal Material

Purpose This paper describes the evolution of the design of a mechanical distractor fabricated using additive manufacturing (AM) technology for use in surgical procedures, such as transanal endoscopic microsurgery (TEM). The functionality of the final device was analysed and the suitability of different materials was determined. Design/methodology/approach Solid modelling and finite element modelling software were used in the design and validation process to allow the fabrication of the device by AM. Several prototypes were manufactured and tested in this study. Findings A new design was developed to greatly simplify the existing devices used in TEM surgery. The new design is easy to use, more economical and does not require pneumorectum. Different AM materials were investigated with regard to their mechanical properties, orientation of parts in the three-dimensional (3D) printer and cytotoxicity to select the optimal material for the design. Social implications The device designed by AM can be printed anywhere in the world, provided that a 3D printer is available; the 3D printer does not have to be a high-performance printer. This makes surgery more accessible, particularly in low-income regions. Moreover, patient recovery is improved and pneumorectum is not required. Originality/value A suitable mechanical distractor was designed for TEM, and different materials were validated for fabrication by AM.

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.

Design an intelligent real-time operation planning system in distributed manufacturing network

2017 ◽  
Vol 117 (4) ◽  
pp. 742-753 ◽  
Author(s):  
Yaqiong Lv ◽  
Danping Lin
Keyword(s):  
Real Time ◽  
Planning System ◽  
Operation Planning ◽  
Distributed Manufacturing ◽  
Content Type ◽  
Manufacturing Networks ◽  
Time Operation ◽  
Time Modeling ◽  
Real Time Operation ◽  
Manufacturing Network

Purpose With the new generation Industry 4.0 coming, as well as globalization and outsourcing, products are fabricated by different parties in the distributed manufacturing network and enterprises face the challenge of consistent planning of semi-finished product in each manufacturing process in different geographical locations. The purpose of this paper is to propose a real-time operation planning system in the distributed manufacturing network to intelligently control/plan the manufacturing networks. Design/methodology/approach The feature of the proposed system is to model and simulate large distributed manufacturing networks to streamline the mechanical and production engineering processes with radio frequency identification (RFID) technology, which can keep track of process variants. To deal with concurrency and synchronization, the hierarchical timed colored Petri net (HTCPN) formalism for modeling is selected in this study. This method can help to model graphically and test the discrete events of concurrent operations. Fuzzy inference system can help for knowledge representation, so as to provide knowledge-based decision assistance in distributed manufacturing environment. Findings In this proposed system, there are two main sub-systems: one is the real-time modeling system, and the other one is intelligent operation planning system. These two systems are not parallel in the whole systems while the intelligent operation planning system should be embedded in any stage of the real-time modeling system as needed. That means real time modeling system provides the holistic structure of the studied distributed manufacturing system and realize real-time data transfer and information exchange. At the same time the embedded intelligent operation planning system fulfill operation plan function. Originality/value This new intelligent real-time operation system realizes real-time modeling with RFID-based HTCPN and smart fuzzy engine to fulfill intelligent operation planning which is highly desirable in the environment of Industry 4.0. The new intelligent manufacturing architecture will highly reduce the traditional planning workload and improve the planning results without manual error interference. The new system has been applied in a practical case to demonstrate its feasibility.

Efficient volumetric error compensation technique for additive manufacturing machines

2016 ◽  
Vol 22 (1) ◽  
pp. 2-19 ◽  
Author(s):  
Carlos Cajal ◽  
Jorge Santolaria ◽  
David Samper ◽  
Jesus Velazquez
Keyword(s):  
Additive Manufacturing ◽  
Error Compensation ◽  
Error Reduction ◽  
Error Model ◽  
Measurement Process ◽  
Optimization Process ◽  
3D Printer ◽  
Volumetric Error ◽  
Content Type ◽  
Final Error

Purpose – This paper aims to present a methodology for volumetric error compensation. This technique is applied to an Objet Eden350V 3D printer and involves a custom measurement strategy. Design/methodology/approach – The kinematic model of the printer is explained, and its error model is simplified to 18 independent error functions. Each error function is defined by a cubic Legendre polynomial. The coefficients of the polynomials are obtained through a Levenberg–Marquardt optimization process. This optimization process compares, in an iterative algorithm, nominal coordinates with actual values of the cloud of points. The points are built in the faces of a gauge artefact as conical sockets defining one unique point for each socket. These points are measured by a coordinate measuring machine self-centring measurement process. Findings – Most of the errors of the 3D printer are systematic. It is possible to obtain an improvement of 70 per cent in terms of global mean error reduction in single points within a volume of 120 × 120 × 40 mm. The forecast of the final error compensation fully matches the actual final error. Practical implications – This methodology can be used for accuracy improvement in additive manufacturing machines. Originality/value – Unlike the calculation of geometric errors, the proposed parametric determination through optimization of the error model allows global error reduction, which decreases all sort of systematic errors concurrently. The proposed measurement strategy allows high reliability, high speed and operator independence in the measurement process, which increases efficiency and reduces the cost. The proposed methodology is easily translated to other rapid prototyping machines and allows scalability when replicating artefacts covering any working volume.

Investigation of Delta Robot 3D Printer for a Good Quality of Printing

2017 ◽  
Vol 870 ◽  
pp. 164-169 ◽  
Author(s):  
Cheng Tiao Hsieh
Keyword(s):  
3D Printing ◽  
Low Cost ◽  
Standard Procedure ◽  
Smart Manufacturing ◽  
The Internet ◽  
3D Printer ◽  
Printing Industry ◽  
Manufacturing Environment ◽  
3D Printers

Within this couple of years, a group of skilled people called “Maker” are interested in building everything by themselves. They attempt to develop a small manufacturing environment where allows people to execute a low cost fabrication task. In order to achieve this goal, they utilized flexible and smart manufacturing machines like 3D printers, laser cutter and small CNC. Especially 3D printer, its excellent performances had grasped many government administrators’ attention and developing 3D printing industry has become an important policy of many countries. Some of 3D printing patents have been expired within recent years. This event makes opens sources of 3D printers grow very fast. The Kossel Mini, Rostock and Prusa i3 are the typical examples. All of development kits of the above printers can be freely obtained from the Internet. This event makes a low cost fabrication become possible. However, the quality of their printed parts is dependent on a series of calibrations. The calibrations include defining the dimensions of hard frame of the printer, configuring firmware and setting building parameters of software. In order to let users to go through entire calibrating process, this paper proposed a standard procedure to calibrate Kossel Mini as well as make it print a good quality part.

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