Additive Manufacturing: Current State, Future Potential, Gaps and Needs, and Recommendations

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Yong Huang ◽  
Ming C. Leu ◽  
Jyoti Mazumder ◽  
Alkan Donmez
Keyword(s):  
Additive Manufacturing ◽  
Research University ◽  
Three Dimensional ◽  
Cost Effective ◽  
Layer By Layer ◽  
Current State ◽  
Future Potential ◽  
Traditional Manufacturing ◽  
Research And Education ◽  
Complicated Geometries

Additive manufacturing (AM), the process of joining materials to make objects from three-dimensional (3D) model data, usually layer by layer, is distinctly a different form and has many advantages over traditional manufacturing processes. Commonly known as “3D printing,” AM provides a cost-effective and time-efficient way to produce low-volume, customized products with complicated geometries and advanced material properties and functionality. As a result of the 2013 National Science Foundation (NSF) Workshop on Frontiers of Additive Manufacturing Research and Education, this paper summarizes AM's current state, future potential, gaps and needs, as well as recommendations for technology and research, university–industry collaboration and technology transfer, and education and training.

scholarly journals Environment and Safety Impacts of Additive Manufacturing: A Review

2019 ◽  
Vol 27 (44) ◽  
pp. 9-20
Author(s):  
Eva Buranská ◽  
Ivan Buranský ◽  
Ladislav Morovič ◽  
Katarína Líška
Keyword(s):  
Additive Manufacturing ◽  
Energy Use ◽  
Three Dimensional ◽  
Cost Effective ◽  
Liquid Sheet ◽  
Raw Material ◽  
Layer By Layer ◽  
Environmental Implications ◽  
Subtractive Manufacturing ◽  
Complicated Geometries

Abstract The paper is focused on additive manufacturing (AM) which is the process of producing objects from a three-dimensional (3D) model by joining materials layer by layer, as opposed to the subtractive manufacturing methodologies [1], directly from raw material in powder, liquid, sheet, or a filament form without the need for moulds, tools, or dies. The article demonstrates potential environmental implications of additive manufacturing related to the key issues including energy use, occupational health, waste and lifecycle impact. AM provides a cost-effective and time-efficient way to fabricating products with complicated geometries, advanced material properties and functionality. Based on this review, we identified that additive manufacturing will have a significant societal impact in the near future. A critical technical review of the promises and potential issues of AM is beneficial for advancing its further development.

scholarly journals Additive Manufacturing in the Construction Industry: The Comparative Competitiveness of 3D Concrete Printing

2021 ◽  
Vol 11 (9) ◽  
pp. 3865
Author(s):  
Siavash H. Khajavi ◽  
Müge Tetik ◽  
Ashish Mohite ◽  
Antti Peltokorpi ◽  
Mingyang Li ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Construction Industry ◽  
Positive Impact ◽  
Three Dimensional ◽  
Cost Effective ◽  
Robotic Arm ◽  
Process Time ◽  
Current State ◽  
The Cost ◽  
The Impact

The construction industry is facing increasing pressure to improve productivity and decrease its environmental impact. Additive manufacturing (AM) technologies, especially three-dimensional concrete printing (3DCP) technology, have provided many benefits for construction. However, holistic comparative studies of the competitiveness of 3DCP and conventional methods, from cost and time perspectives, are lacking. Choosing between the methods is difficult for practitioners. In this study, we investigated the current state of 3DCP in the construction industry using seven distinct scenarios. Our analysis was performed to illustrate the impact of design and supply chain configurations on performance. The results prove the notable competitiveness of 3DCP. In contrast to the conventional construction method, the more complex round design had a positive impact on the cost and process time in 3DCP scenarios. Additionally, we show that on-site 3DCP using a robotic arm was more cost-effective than off-site 3DCP.

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

Animal orthosis fabrication with additive manufacturing – a case study of custom orthosis for chicken

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Wiktoria Maria Wojnarowska ◽  
Jakub Najowicz ◽  
Tomasz Piecuch ◽  
Michał Sochacki ◽  
Dawid Pijanka ◽  
...  
Keyword(s):  
Veterinary Medicine ◽  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Fused Deposition ◽  
Secondary Objective ◽  
Traditional Manufacturing ◽  
Aided Design

Purpose Chicken orthoses that cover the ankle joint area are not commercially available. Therefore, the main purpose of this study is to fabricate a customised temporary Ankle–Foot Orthosis (AFO) for a chicken with a twisted ankle using computer-aided design (CAD) and three-dimensional (3D) printing. The secondary objective of the paper is to present the specific application of Additive Manufacturing (AM) in veterinary medicine. Design/methodology/approach The design process was based on multiple sketches, photos and measurements that were provided by the owner of the animal. The 3D model of the orthosis was made with Autodesk Fusion 360, while the prototype was fabricated using fused deposition modelling (FDM). Evaluation of the AFO was performed using the finite element method. Findings The work resulted in a functional 3D printed AFO for chicken. It was found that the orthosis made with AM provides satisfactory stiffen and a good fit. It was concluded that AM is suitable for custom bird AFO fabrication and, in some respects, is superior to traditional manufacturing methods. It was also concluded that the presented procedure can be applied in other veterinary cases and to other animal species and other parts of their body. AM provides veterinary with a powerful tool for the production of well-fitted and durable orthoses for animals. Research limitations/implications The study does not include the chicken's opinion on the comfort or fit of the manufactured AFO due to communication issues. Evaluation of the final prototype was done by the researchers and the animal owner. Originality/value No evidence was found in the literature on the use of AM for chicken orthosis, so this study is the first to describe such an application of AM. In addition, the study demonstrates the value of AM in veterinary medicine, especially in the production of devices such as orthoses.

An Assessment on the Benefits of Additive Manufacturing Regarding New Swirler Geometries for Gas Turbine Burners

2018 ◽  
Author(s):  
Fabrice Giuliani ◽  
Nina Paulitsch ◽  
Daniele Cozzi ◽  
Michael Görtler ◽  
Lukas Andracher
Keyword(s):  
Additive Manufacturing ◽  
Gas Turbine ◽  
Inconel 718 ◽  
Advanced Materials ◽  
Gas Turbine Combustor ◽  
Engineering Research ◽  
Know How ◽  
Current State ◽  
Research And Education ◽  
Near Future

In the near future, combustion engineers will shape the burner according to the flame, and not the opposite way anymore. In this contribution, this idea is explored with the help of additive manufacturing (AM). The focus is put on the design and the production of swirlers using advanced materials with the least possible efforts in terms of manufacturing. The material chosen for this study is Inconel 718. There are three motivations to this project. The first one is to design new shapes and assess these in comparison to conventional ones. The second motivation is to be able to manufacture them using additive manufacturing, and to gather know-how on selective laser melting. The third motivation is to elaborate a methodology involving engineering, research and education to promote — only if and when this is desirable — the production of series of premium parts such as high-end components of gas turbine combustor using AM. First-of-a-kind swirler shapes are explained and designed. These are unlikely to be produced using conventional manufacturing. They are then successfully produced in Inconel 718 using AM. The raw parts are directly submitted for testing with no surface post-processing. The paper states why at current state-of-the-art the raw surface quality still needs improvement, and highlights the benefits of the new swirler shape versus conventional.

Increasing Part Accuracy in Additive Manufacturing Processes Using a k-d Tree Based Clustered Adaptive Layering

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Neeraj Panhalkar ◽  
Ratnadeep Paul ◽  
Sam Anand
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Adaptive Slicing ◽  
Stl File ◽  
Build Time ◽  
Standard File Format ◽  
Aided Design ◽  
Profile Errors

Additive manufacturing (AM) is widely used in aerospace, automobile, and medical industries for building highly accurate parts using a layer by layer approach. The stereolithography (STL) file is the standard file format used in AM machines and approximates the three-dimensional (3D) model of parts using planar triangles. However, as the STL file is an approximation of the actual computer aided design (CAD) surface, the geometric errors in the final manufactured parts are pronounced, particularly in those parts with highly curved surfaces. If the part is built with the minimum uniform layer thickness allowed by the AM machine, the manufactured part will typically have the best quality, but this will also result in a considerable increase in build time. Therefore, as a compromise, the part can be built with variable layer thicknesses, i.e., using an adaptive layering technique, which will reduce the part build time while still reducing the part errors and satisfying the geometric tolerance callouts on the part. This paper describes a new approach of determining the variable slices using a 3D k-d tree method. The paper validates the proposed k-d tree based adaptive layering approach for three test parts and documents the results by comparing the volumetric, cylindricity, sphericity, and profile errors obtained from this approach with those obtained using a uniform slicing method. Since current AM machines are incapable of handling adaptive slicing approach directly, a “pseudo” grouped adaptive layering approach is also proposed here. This “clustered slicing” technique will enable the fabrication of a part in bands of varying slice thicknesses with each band having clusters of uniform slice thicknesses. The proposed k-d tree based adaptive slicing approach along with clustered slicing has been validated with simulations of the test parts of different shapes.

Additive Manufacturing of Porous Ceramics with Foaming Agent

2021 ◽  
pp. 1-21
Author(s):  
Zipeng Guo ◽  
Lu An ◽  
Sushil Lakshmanan ◽  
Jason Armstrong ◽  
Shenqiang Ren ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Ambient Pressure ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Cost Effective ◽  
Tensile Tests ◽  
Porous Ceramics ◽  
Foaming Agent ◽  
Printing Quality ◽  
And Control

Abstract The macro-porous ceramics has promising durability and thermal insulation performance. As porous ceramics find more and more applications across many industries, a cost-effective and scalable additive manufacturing technique for fabricating macro-porous ceramics is highly desirable. Herein, we reported a facile additive manufacturing approach to fabricate porous ceramics and control the printed porosity. Several printable ceramic inks were prepared, the foaming agent was added to generate gaseous bubbles in the ink, followed by the direct ink writing and the ambient-pressure and room-temperature drying to create the three-dimensional geometries. A set of experimental studies were performed to optimize the printing quality. The results revealed the optimal process parameters for printing the foamed ceramic ink with a high spatial resolution and fine surface quality. Varying the concentration of the foaming agent enables the controllability of the structural porosity. The maximum porosity can reach 85%, with a crack-free internal porous structure. The tensile tests showed that the printed macro-porous ceramics possessed enhanced durability with the addition of fiber. With a high-fidelity 3D printing process and the precise controllability of the porosity, we showed that the printed samples exhibited a remarkably low thermal conductivity and durable mechanical strength.

The Current State and Future Potential of Virtual Worlds

2011 ◽  
pp. 2535-2543
Author(s):  
John M. Artz
Keyword(s):  
Information Technology ◽  
Virtual Worlds ◽  
Second Life ◽  
Virtual World ◽  
Three Dimensional ◽  
Social Implications ◽  
Application Technology ◽  
Current State ◽  
Future Potential

Virtual worlds, while not a new phenomenon, have come to the foreground of information technology in the past few years largely due to the growth of Second Life, a three dimensional, global virtual world that has captured the imagination of millions. This article provides some background on this virtual world phenomenon providing both a history and a classification of virtual world technology. It then focuses on Second Life discussing the application, technology, and social implications. Included in the discussion are some current initiatives such as the open source client and server projects and the implications of those initiatives. Finally, we provide some speculation on the future potential of virtual world technology as an extrapolation of the current trajectory.

Advancements in Manufacturing Technology With Additive Manufacturing and Its Context With Industry 4.0

2021 ◽  
pp. 1-24
Author(s):  
Ganzi Suresh
Keyword(s):  
Additive Manufacturing ◽  
Industry 4.0 ◽  
Industrial Revolution ◽  
Three Dimensional ◽  
Metal Alloys ◽  
Layer By Layer ◽  
Post Processing ◽  
Clear Insight ◽  
Am Processes ◽  
Insight Into

Additive manufacturing (AM) is also known as 3D printing and classifies various advanced manufacturing processes that are used to manufacture three dimensional parts or components with a digital file in a sequential layer-by-layer. This chapter gives a clear insight into the various AM processes that are popular and under development. AM processes are broadly classified into seven categories based on the type of the technology used such as source of heat (ultraviolet light, laser) and type materials (resigns, polymers, metal and metal alloys) used to fabricate the parts. These AM processes have their own merits and demerits depending upon the end part application. Some of these AM processes require extensive post-processing in order to get the finished part. For this process, a separate machine is required to overcome this hurdle in AM; hybrid manufacturing comes into the picture with building and post-processing the part in the same machine. This chapter also discusses the fourth industrial revolution (I 4.0) from the perspective of additive manufacturing.

Scalable submicrometer additive manufacturing

Science ◽  
2019 ◽  
Vol 366 (6461) ◽  
pp. 105-109 ◽  
Author(s):  
Sourabh K. Saha ◽  
Dien Wang ◽  
Vu H. Nguyen ◽  
Yina Chang ◽  
James S. Oakdale ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Design Space ◽  
Three Dimensional ◽  
Complex Structures ◽  
Layer By Layer ◽  
Promising Candidate ◽  
Single Digit ◽  
Cross Sectional ◽  
Two Photon ◽  
Nanoscale Features

High-throughput fabrication techniques for generating arbitrarily complex three-dimensional structures with nanoscale features are desirable across a broad range of applications. Two-photon lithography (TPL)–based submicrometer additive manufacturing is a promising candidate to fill this gap. However, the serial point-by-point writing scheme of TPL is too slow for many applications. Attempts at parallelization either do not have submicrometer resolution or cannot pattern complex structures. We overcome these difficulties by spatially and temporally focusing an ultrafast laser to implement a projection-based layer-by-layer parallelization. This increases the throughput up to three orders of magnitude and expands the geometric design space. We demonstrate this by printing, within single-digit millisecond time scales, nanowires with widths smaller than 175 nanometers over an area one million times larger than the cross-sectional area.

Sign in / Sign up

Export Citation Format

Share Document