Evaluation of Environmental Sustainability for Additive Manufacturing Batch Production

2017 ◽  
Author(s):  
Yiran Yang ◽  
Lin Li
Keyword(s):  
Additive Manufacturing ◽  
Environmental Sustainability ◽  
Production Method ◽  
Manufacturing Cost ◽  
Layer By Layer ◽  
Batch Production ◽  
Manufacturing Method ◽  
Current State ◽  
Layer Manufacturing ◽  
Batch Sizes

Additive manufacturing (AM), owning to the unique layer-by-layer manufacturing method and its associated advantages, has been implemented in a great number of industries. To further expand the AM applications, the current low throughput of AM system needs to be improved. Consequently, the batch production method, where multiple parts are fabricated in one batch, has gained increasing research interest. In the current state of literature, most research efforts assess the batch production approach based on its manufacturing cost saving potential. Nevertheless, environmental sustainability, serving as a critical part in AM development, is less explored. Environmental sustainability of AM batch production needs to be thoroughly investigated and assessed, due to the potential environmental impacts and human health risks that AM batch production activities might cause. This research aims to advance the state-of-the-art on environmental sustainability evaluation for AM batch production, by experimentally comparing three main environmental sustainability aspects (i.e., energy consumption, emission, and material waste) for batch production processes with different batch sizes. Based on the experimental results, the feasibility of batch production method for AM is discussed. The outcomes of this research will help evaluate the AM batch production method from an environmental sustainability standpoint, and facilitate the development of AM batch production.

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

A review of additive manufacturing applications in ophthalmology

2021 ◽  
pp. 095441192110280
Author(s):  
Arivazhagan Pugalendhi ◽  
Rajesh Ranganathan
Keyword(s):  
Additive Manufacturing ◽  
Treatment Planning ◽  
Physical Object ◽  
Layer By Layer ◽  
Case Examples ◽  
Manufacturing Method ◽  
3D Cad ◽  
Stl File ◽  
Potential Applications ◽  
Manufacturing Applications

Additive Manufacturing (AM) capabilities in terms of product customization, manufacture of complex shape, minimal time, and low volume production those are very well suited for medical implants and biological models. AM technology permits the fabrication of physical object based on the 3D CAD model through layer by layer manufacturing method. AM use Magnetic Resonance Image (MRI), Computed Tomography (CT), and 3D scanning images and these data are converted into surface tessellation language (STL) file for fabrication. The applications of AM in ophthalmology includes diagnosis and treatment planning, customized prosthesis, implants, surgical practice/simulation, pre-operative surgical planning, fabrication of assistive tools, surgical tools, and instruments. In this article, development of AM technology in ophthalmology and its potential applications is reviewed. The aim of this study is nurturing an awareness of the engineers and ophthalmologists to enhance the ophthalmic devices and instruments. Here some of the 3D printed case examples of functional prototype and concept prototypes are carried out to understand the capabilities of this technology. This research paper explores the possibility of AM technology that can be successfully executed in the ophthalmology field for developing innovative products. This novel technique is used toward improving the quality of treatment and surgical skills by customization and pre-operative treatment planning which are more promising factors.

scholarly journals Fabrication of Demineralized Bone Matrix/Polycaprolactone Composites Using Large Area Projection Sintering (LAPS)

2019 ◽  
Vol 3 (2) ◽  
pp. 30 ◽  
Author(s):  
Mohsen Ziaee ◽  
Rebecca Hershman ◽  
Ayesha Mahmood ◽  
Nathan B. Crane
Keyword(s):  
Additive Manufacturing ◽  
Cancellous Bone ◽  
Demineralized Bone Matrix ◽  
Bone Matrix ◽  
Bone Allograft ◽  
Layer By Layer ◽  
Large Area ◽  
Manufacturing Method ◽  
Synthetic Scaffolds ◽  
Demineralized Bone

Cadaveric decellularized bone tissue is utilized as an allograft in many musculoskeletal surgical procedures. Typically, the allograft acts as a scaffold to guide tissue regeneration with superior biocompatibility relative to synthetic scaffolds. Traditionally these scaffolds are machined into the required dimensions and shapes. However, the geometrical simplicity and, in some cases, limited dimensions of the donated tissue restrict the use of allograft scaffolds. This could be overcome by additive manufacturing using granulated bone that is both decellularized and demineralized. In this study, the large area projection sintering (LAPS) method is evaluated as a fabrication method to build porous structures composed of granulated cortical bone bound by polycaprolactone (PCL). This additive manufacturing method utilizes visible light to selectively cure the deposited material layer-by-layer to create 3D geometry. First, the spreading behavior of the composite mixtures is evaluated and the conditions to attain improved powder bed density to fabricate the test specimens are determined. The tensile strength of the LAPS fabricated samples in both dry and hydrated states are determined and compared to the demineralized cancellous bone allograft and the heat treated demineralized-bone/PCL mixture in mold. The results indicated that the projection sintered composites of 45–55 wt %. Demineralized bone matrix (DBM) particulates produced strength comparable to processed and demineralized cancellous bone.

A Short Glance on Metal 3D AM

2018 ◽  
Vol 786 ◽  
pp. 348-355
Author(s):  
Terho Iso-Junno ◽  
Kimmo Mäkelä ◽  
Kari Mäntyjärvi ◽  
Tero Jokelainen
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Future Development ◽  
Cost Efficiency ◽  
Holistic Approach ◽  
Production Method ◽  
Digital Manufacturing ◽  
Laser Melting ◽  
Manufacturing Method ◽  
Manufacturing Methods

Metal 3D AM (Additive Manufacturing) has been becoming a more common production method for larger variety of parts. In this review the current situation and future development trends of the 3D metal AM are presented, concentrating on the SLM (Selective Laser Melting) technology. A holistic approach to the AM as a digital manufacturing method is presented and different manufacturing aspects of the AM production are identified. The most promising aspects for the future development are the automatization of the AM design tasks and automatization of the production. With the development of these aspects the production and cost efficiency of the metal AM can be increased to a more competitive level compared with other manufacturing methods.

Design and Manufacturing of a Metal 3D Printed kW Scale Axial Turboexpander

2019 ◽  
Author(s):  
Vaclav Novotny ◽  
Monika Vitvarova ◽  
Michal Kolovratnik ◽  
Barbora Bryksi Stunova ◽  
Vaclav Vodicka ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Surface Quality ◽  
High Efficiency ◽  
Cost Effective ◽  
Manufacturing Cost ◽  
Machining Processes ◽  
Manufacturing Method ◽  
Design And Manufacturing ◽  
3D Printed

Abstract Greater expansion of distributed power and process systems based on thermodynamic cycles with single to hundred kW scale power output is limited mainly there are not available cost-effective expanders. Turboexpanders have a perspective of high efficiency and flexibility concerning operating parameters even for the micro applications. However, they suffer from a high manufacturing cost and lead time in the development of traditional technologies (such as casting and machining processes). Additive manufacturing provides a possibility to overcome some of the issues. Manufacturing parts with complicated shapes by this technology, combining multiple components into a single part or rapid production by 3D printing for development purposes are among the prospective features with this potential. On the other hand, the 3D printing processes come with certain limitations which need to be overcome. This paper shows a design and manufacturing process of a 3 kW axial impulse air turbine working with isenthalpic drop 30 kJ/kg. Several samples to verify printing options and the turbine itself has been manufactured from stainless steel by the DMLS additive manufacturing method. Manufactured are two turbine variations regarding blade size and 3D printer settings while maintaining their specific dimensions. The turboexpanders testing method and rig is outlined. As the surface quality is an issue, several methods of post-processing of 3D printed stator and rotor blading to modify surface quality are suggested. Detailed experimental investigation is however subject of future work.

Modelling of Cusp Geometry in Additive Manufacturing Parts Using a Piece-Wise Polynomial

2015 ◽  
Author(s):  
Farzaneh Kaji ◽  
Ahmad Barari
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
High Surface ◽  
3D Models ◽  
Critical Issue ◽  
Layer By Layer ◽  
Layer Manufacturing ◽  
Surface Angle ◽  
Good Agreement

The final dimensional and geometric inaccuracies, and the resulting high surface roughness of the products have been the major problems in employing Additive Manufacturing (AM) technologies. Most of commonly used Additive manufacturing (AM) technologies are developed based on a layer-based manufacturing process to fabricate 3D models. The main critical issue in AM which reduces the surface integrity of the final products is the stair case error which happens due to layer by layer manufacturing process. A new method is presented to model the surface roughness of FDM parts based on considering a new geometry for the cusps. Variety of observations were conducted to model the exact geometry of the cusp. Considering that cusp geometry affects the surface roughness directly, the new geometry was used to predict the surface roughness distribution as a function of layer thickness and surface angle of the final FDM products. The model was validated by designing a set of experiments using 3D measurements of the surface roughness under high resolution surface topography device and the predicted model was in a good agreement with the experimental results.

scholarly journals Embedded Obfuscated Barcodes for Identification of Genuine Additive Manufactured Parts

2021 ◽  
Author(s):  
Fei Chen ◽  
DINESH PINISETTY ◽  
Nikhil Gupta
Keyword(s):  
Supply Chain ◽  
Additive Manufacturing ◽  
Intellectual Property ◽  
Manufacturing Process ◽  
New Technologies ◽  
Three Dimensional ◽  
Code Design ◽  
Layer By Layer ◽  
Micro Ct ◽  
Layer Manufacturing

Abstract Additive manufacturing (AM) has been adopted for manufacturing complex shaped highly customized components for aerospace, automotive, and medical fields, where intellectual property protection and counterfeit detection are major concerns. New technologies such as Blockchain have been promising in supply chain authentication. However, AM due to layer-by-layer manufacturing process provides opportunities of embedding information inside the part during manufacturing, which has been explored recently to embed identification codes inside the parts. The present work studies the possibility of printing a barcode inside the additively manufactured part and develops a scheme to obfuscate the code design to read differently from different directions to enhance the security and protect the intellectual property. The embedded three-dimensional codes are scanned using a micro-CT scan. This scheme of embedded obfuscated codes proves to be a highly customizable and efficient process while securing product design files.

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.

Multi-Extrusion Additive Manufacturing for Error Compensation: A Demonstrative Case Study

2020 ◽  
Author(s):  
Chen Kan ◽  
Zehao Ye ◽  
Yiran Yang ◽  
Lei Di ◽  
Deep Shah ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Error Compensation ◽  
Manufacturing Industry ◽  
Dimensional Accuracy ◽  
Production Method ◽  
Geometric Error ◽  
Layer By Layer ◽  
Subtractive Manufacturing

Abstract The global additive manufacturing industry has been rapidly increasing, owing to its unique layer-by-layer production method. While additive manufacturing has superior capabilities compared to traditional subtractive manufacturing, limitations still exist, which significantly hinder the larger-scale implementations of additive manufacturing. Some challenging issues include unsatisfactory dimensional accuracy, surface quality, etc. In the literature, extensive research efforts have dedicated to detecting, predicting, and compensating process errors using various methodologies. In this work, a new approach is proposed for error compensation using multi-extrusion additive manufacturing process. Three demonstrative case studies are conducted, i.e., multicolor and/or multimaterial printing, geometric error compensation, and rough surface compensation. Experimental results have shown that the proposed approach is effective in utilizing the multi-nozzle capability in additive manufacturing quality control. Notably, the proposed approach has remarkable potentials to be extended for in-situ error compensation. Our future forays will focus on integrating the proposed approach with in-situ process monitoring approaches for layer-wise defection and compensation of process anomalies.

scholarly journals A Layer-Arranged Meshless Method for the Simulation of Additive Manufacturing with Irregular Shapes

Micromachines ◽  
2021 ◽  
Vol 12 (6) ◽  
pp. 674
Author(s):  
Ming-Hsiao Lee ◽  
Wen-Hwa Chen ◽  
Ying Mao
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Meshless Method ◽  
Element Distribution ◽  
Layer By Layer ◽  
Analysis Model ◽  
Printing Process ◽  
Manufacturing Method ◽  
Geometry Model ◽  
Analysis Scheme

Additive manufacturing (3D Printing) has become a promising manufacturing method as it can produce parts in a flexible and efficient way, especially for very irregular parts. However, during the printing process, the material experiences a great temperature change from the melting temperature to room temperature; this causes high thermal strains and induces distinct deformations which degrade the quality of the printed parts, especially in metal 3D printing. In order to reduce possible problems and find possible solutions, a prior evaluation by simulation is often adopted. Nevertheless, since the 3D printing process generates parts in a layer-by-layer way, the analysis model should also be layer-by-layer arranged and used with a layer-by-layer based analysis process to simulate the layer-by-layer additive printing; otherwise, the simulation may not match the real behavior. In order to meet these requirements, a new meshless method is proposed to match the situations and handle these problems. As a meshless method, the modeling is not constrained by the element distribution. In addition, the analysis model generated with the proposed method can be arranged in a layer-by-layer way and combined with the proposed layer-by-layer analysis scheme, so it can then match and simulate the printing processes. Furthermore, the layer-by-layer arranged models can be automatically created, directly based on the STL (STereo-Lithography) geometry model, which is a de facto standard in the 3D printing industry. This makes the proposed approach more straightforward and efficient. To validate the proposed method, two parts with holes inside have been printed and simulated for comparison. The results show a good agreement. In addition, a highly irregular part has also been simulated to demonstrate the effectiveness and efficiency of this proposed method.

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