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

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.

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Quickest Change Point Detection in Shape Inspection of Additively Manufactured Parts Under a Multi-Resolution Framework

Volume 1: Additive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering; Manufacturing Equipment and Automation ◽

10.1115/msec2020-8243 ◽

2020 ◽

Author(s):

Yu Jin ◽

Haitao Liao ◽

Harry Pierson

Keyword(s):

Point Cloud ◽

Geometric Error ◽

Change Point Detection ◽

Layer By Layer ◽

Shape Inspection ◽

The One ◽

Alignment Errors ◽

Point Detection

Abstract In-situ layer-by-layer inspection is essential to achieving the full capability and advantages of additive manufacturing in producing complex geometries. The shape of each inspected layer can be described by a 2D point cloud obtained by slicing a thin layer of 3D point cloud acquired from 3D scanning. In practice, a scanned shape must be aligned with the corresponding base-truth CAD model before evaluating its geometric accuracy. Indeed, the observed geometric error is attributed to systematic, random, and alignment errors, where the systematic error is the one that triggers an alarm of system anomalies. In this work, a quickest change detection (QCD) algorithm is applied under a multi-resolution alignment and inspection framework 1) to differentiate errors from different error sources, and 2) to identify the layer where the earliest systematic deviation distribution changes during the printing process. Numerical experiments and a case study on a human heart are conducted to illustrate the performance of the proposed method in detecting layer-wise geometric error.

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DATA ANALYSIS AS THE BASIS FOR IMPROVED DESIGN FOR ADDITIVE MANUFACTURING (DFAM)

Proceedings of the Design Society ◽

10.1017/pds.2021.81 ◽

2021 ◽

Vol 1 ◽

pp. 811-820

Author(s):

Dominika Hamulczuk ◽

Ola Isaksson

Keyword(s):

Additive Manufacturing ◽

Manufacturing Industry ◽

Printing Process ◽

Design Perspective ◽

Improved Design ◽

Print Process ◽

Printing Parameters

AbstractAdditive Manufacturing (AM) has a large potential to revolutionize the manufacturing industry, yet the printing parameters and part design have a profound impact on the robustness of the printing process as well as the resulting quality of the manufactured components. To control the printing process, a substantial number of parameters is measured while printing and used primarily to control and adjust the printing process in-situ. The question raised in this paper is how to benefit from these data being gathered to gain insight into the print process stability. The case study performed included the analysis of data gathered during printing 22 components. The analysis was performed with a widely used Random Forest Classifier. The study revealed that the data did contain some detectable patterns that can be used further in assessing the quality of the printed component, however, they were distinct enough so that in case the test and train sets were comprised of separate components the predictions’ result was very poor. The study gives a good understanding of what is necessary to do a meaningful analytics study of manufacturing data from a design perspective.

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Evaluation of geometrical benchmark artifacts containing multiple overhang lengths fabricated using material extrusion technique

JOURNAL OF MECHANICAL ENGINEERING AND SCIENCES ◽

10.15282/jmes.14.3.2020.28.0573 ◽

2020 ◽

Vol 14 (3) ◽

pp. 7296-7308

Author(s):

Siti Nur Humaira Mazlan ◽

Aini Zuhra Abdul Kadir ◽

N. H. A. Ngadiman ◽

M.R. Alkahari

Keyword(s):

3D Model ◽

Laser Scanner ◽

Dimensional Accuracy ◽

Fused Deposition Modelling ◽

Layer By Layer ◽

Fused Deposition ◽

Layer Technique ◽

Subtractive Manufacturing ◽

Manufacturing Features ◽

Layer Problem

Fused deposition modelling (FDM) is a process of joining materials based on material entrusion technique to produce objects from 3D model using layer-by-layer technique as opposed to subtractive manufacturing. However, many challenges arise in the FDM-printed part such as warping, first layer problem and elephant food that was led to an error in dimensional accuracy of the printed parts especially for the overhanging parts. Hence, in order to investigate the manufacturability of the FDM printed part, various geometrical and manufacturing features were developed using the benchmarking artifacts. Therefore, in this study, new benchmarking artifacts containing multiple overhang lengths were proposed. After the benchmarking artifacts were developed, each of the features were inspected using 3D laser scanner to measure the dimensional accuracy and tolerances. Based on 3D scanned parts, 80% of the fabricated parts were fabricated within ±0.5 mm of dimensional accuracy as compared with the CAD data. In addition, the multiple overhang lengths were also successfully fabricated with a very significant of filament sagging observed.

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Rheed Studies of a-Axis Oriented DyBa2Cu3O7 Films Grown by All-MBE

MRS Proceedings ◽

10.1557/proc-502-221 ◽

1997 ◽

Vol 502 ◽

Author(s):

Ivan Bozovic ◽

J. N. Eckstein ◽

Natasha Bozovic ◽

J. O'Donnell

Keyword(s):

Phase Transitions ◽

Secondary Phase ◽

Atomic Layer ◽

High Energy ◽

Layer By Layer ◽

Growth Modes ◽

Flow Surface ◽

Surface Phase Transitions

ABSTRACTReal-time, in-situ surface monitoring by reflection high-energy electron diffraction (RHEED) has been the key enabling component of atomic-layer-by-layer molecular beam epitaxy (ALL-MBE) of complex oxides. RHEED patterns contain information on crystallographic arrangements and long range order on the surface; this can be made quantitative with help of numerical simulations. The dynamics of RHEED patterns and intensities reveal a variety of phenomena such as nucleation and dissolution of secondary-phase precipitates, switching between growth modes (layer-by-layer, step-flow), surface phase transitions (surface reconstruction, roughening, and even phase transitions induced by the electron beam itself), etc. Some of these phenomena are illustrated here, using as a case study our recent growth of atomically smooth a-axis oriented DyBa2Cu3O7 films.

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ADDITIVE MANUFACTURING - APPLICATION OPPORTUNITIES FOR THE AVIATION INDUSTRY

Journal of Air Transport Studies ◽

10.38008/jats.v6i2.59 ◽

2015 ◽

Vol 6 (2) ◽

pp. 63-86

Author(s):

Dipesh Dhital ◽

Yvonne Ziegler

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Computer Aided Design ◽

Free Form ◽

Aviation Industry ◽

Layer By Layer ◽

Printing Technology ◽

3D Printing Technology ◽

Subtractive Manufacturing ◽

Aided Design

Additive Manufacturing also known as 3D Printing is a process whereby a real object of virtually any shape can be created layer by layer from a Computer Aided Design (CAD) model. As opposed to the conventional Subtractive Manufacturing that uses cutting, drilling, milling, welding etc., 3D printing is a free-form fabrication process and does not require any of these processes. The 3D printed parts are lighter, require short lead times, less material and reduce environmental footprint of the manufacturing process; and is thus beneficial to the aerospace industry that pursues improvement in aircraft efficiency, fuel saving and reduction in air pollution. Additionally, 3D printing technology allows for creating geometries that would be impossible to make using moulds and the Subtractive Manufacturing of drilling/milling. 3D printing technology also has the potential to re-localize manufacturing as it allows for the production of products at the particular location, as and when required; and eliminates the need for shipping and warehousing of final products.

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Evaluation of Assembly Part Build Orientation in Additive Manufacturing Environment using Data Envelopment Analysis

MATEC Web of Conferences ◽

10.1051/matecconf/201929302002 ◽

2019 ◽

Vol 293 ◽

pp. 02002 ◽

Cited By ~ 1

Author(s):

Kasin Ransikarbum ◽

Rapeepan Pitakaso ◽

Namhun Kim

Keyword(s):

Data Envelopment Analysis ◽

Additive Manufacturing ◽

Process Planning ◽

Data Envelopment ◽

3D Objects ◽

Lathe Machine ◽

Subtractive Manufacturing ◽

Personal Use ◽

Using Data

Whereas Subtractive Manufacturing (SM) is a process by which 3D objects are constructed by cutting material away from a solid block of material, such as milling and lathe machine; Additive Manufacturing (AM) is a synonym for 3D printing and other processes by which 3D objects are constructed by successively depositing material in layers. Recently, AM has become widespread for both industrial and personal use thanks to the freedom and benefits it provides in designing parts, reducing lead time, improving inventory, and supply chain. However, few studies examine process planning issues in AM. In addition, existing studies focus on production of an individual part alone. In this study, we examine the assembly orientation alternatives’ efficiency using Data Envelopment Analysis (DEA) technique for different AM technologies and their associated materials under conflicting criteria. A case study of hardware fasteners using bolt and nut fabrication is illustrated in the study. Our results show that different AM technologies and materials clearly impact efficiency of part production and thus suggest optimal orientation in AM process planning platform.

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Redesigning a Reaction Control Thruster for Metal-Based Additive Manufacturing: A Case Study in Design for Additive Manufacturing

Volume 2A: 42nd Design Automation Conference ◽

10.1115/detc2016-59722 ◽

2016 ◽

Author(s):

Matthew R. Woods ◽

Nicholas A. Meisel ◽

Timothy W. Simpson ◽

Corey J. Dickman

Keyword(s):

Additive Manufacturing ◽

Attitude Control ◽

Development Effort ◽

Design For Additive Manufacturing ◽

Powder Bed ◽

Subtractive Manufacturing ◽

End Use ◽

Manufacturing Time ◽

Novel Design

Prior research has shown that powder bed fusion additive manufacturing (AM) can be used to make functional, end-use components from powdered metallic alloys, such as Inconel® 718 super alloy. However, these end-use products are often based on designs developed for more traditional subtractive manufacturing processes without taking advantage of the unique design freedoms afforded by AM. In this paper, we present a case study involving the redesign of NASA’s existing “Pencil” thruster used for spacecraft attitude control. The initial “Pencil” thruster was designed for, and manufactured using, traditional subtractive methods. The main focus in this paper is to (a) review the Design for Additive Manufacturing (DfAM) concepts and considerations used in redesigning the thruster and (b) compare it with a parallel development effort redesigning the original thruster to be manufactured more effectively using subtractive processes. The results from this study show how developing end-use AM components using DfAM guidelines can significantly reduce manufacturing time and costs while introducing new and novel design geometries.

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Tension testing of additively manufactured specimens of 17-4 PH processed by Bound Metal Deposition

IOP Conference Series Materials Science and Engineering ◽

10.1088/1757-899x/1201/1/012037 ◽

2021 ◽

Vol 1201 (1) ◽

pp. 012037

Author(s):

F Bjørheim ◽

I M La Torraca Lopez

Keyword(s):

Additive Manufacturing ◽

Computer Aided Design ◽

Industrial Sector ◽

Metal Deposition ◽

Layer By Layer ◽

High Momentum ◽

Subtractive Manufacturing ◽

Tension Testing ◽

Thermal Histories ◽

Aided Design

Abstract In contrast to the traditional ways of subtractive manufacturing, additive manufacturing (AM), also known as 3D printing, adapts computer-aided design to iteratively build the component or part layer by layer. The technology has recently gained a high momentum, both within academia, but also within the industrial sector. However, it is common that parts produced by AM will have more defects than parts produced by traditional methods. The objective of this paper is to investigate a new method of additive manufacturing, namely the bound metal deposition method (BMD). This method seemed promising from the perspective that the metal is not iteratively being melted, similar to such as welding. In fact, the part is first printed, then washed, for then to be sintered. Consequently, avoiding the complex thermal histories/cycles. It was found that the material will exhibit anisotropic behaviour, and have a mesh of crack like defects, related to the printing orientation.

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EDITORIAL NOTE VOL 4, NO 3 (2014)

Journal of Intelligence Studies in Business ◽

10.37380/jisib.v4i3.102 ◽

2015 ◽

Vol 4 (3) ◽

Author(s):

Klaus Solberg Søilen

Keyword(s):

Additive Manufacturing ◽

Manufacturing Industry ◽

Disruptive Innovation ◽

Patent Analysis ◽

Strategic Decision ◽

Editorial Note ◽

Evaluation Instrument ◽

Parallel Hybrid ◽

Theoretical Paper

JISIB continues to publish Case Studies. In addition we also publish in this issue Patents Analyses. Patent analyses can be read both as examples of how to perform such analyses, but may also find interest within specific industries. Professor Henri Dou, who is a founding father of this journal, was one of the pioneers in this area, also with the development of patent analyses software. We have also included a conceptual and theoretical paper. All of the contributions in this issue show that scientific work does not have to be limited to more narrowly defined empirical studies.The second paper by Salavdor et al. is dedicated to Associate Professor Jonas Rundquist, a colleague at Halmstad University and at the same time a great admirer of the Spanish speaking Americas, who passed away in December 2014. He will be greatly missed.The first article by Salvador and Léon is a patent analysis of the industry for hybrid vehicules. The paper shows that the company with the highest patent activity also has a strong focus on collaborative technology development. The analysis further shows that research on parallel hybrid vehicle predominate, followed by series-hybrid and series-parallel hybrid type. The findings support the strategic decision process for organizations, companies, institutes and other stakeholders involved in this sector. The analysis and procedure presented can be used for analyses in other industries.The second paper by Salador et al. is also a patent analysis, but this time for the Additive Manufacturing industry. Unlike the first paper this one identifies a number of trends through a keyword patent analysis. “The main areas of research are focused on shaping of plastics and after-treatment of shaped products and working metallic powder and manufacture articles from this material”. The leading countries on additive manufacturing research are United States, Great Britain and Switzerland.The third article by Vriens and Solberg Søilen is an attempt to show the implication of disruptive innovation on Intelligence Studies. It is a theoretical paper. Through a broad discussion of disruptive innovation theory the authors arrive at what they coin”Disruptive Intelligence”. In addition they describe ‘biases’ which may impair the production of ‘disruptive intelligence’.The Fourth article is a case study written by Calof. It is about how the National Research Council’s Technical Intelligence Unit work with intelligence. The study shows that intelligence users understood and could appreciate a combination of hard and soft intelligence type measures. A survey in the form of an intelligence evaluation instrument was developed to gather data for the paper.The last article by Avner is a case study about CI in the Israeli defense industry. It confirms previous assumption that the industry in general and especially in Israel is using CI intensively to support the decision making process.As always we would first of all like to thank the authors for their contributions to this issue of JISIB.On behalf of the Editorial Board,Sincerely Yours,Prof. Dr. Klaus Solberg SøilenEditor-in-chief

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