THE APPLICATION OF WELD-BASED ADDITIVE MANUFACTURING STEEL TO STRUCTURAL ENGINEERING

2019 ◽  
Vol 6 (1) ◽  
Author(s):  
Vittoria Laghi ◽  
Michele Palermo ◽  
Giada Gasparini ◽  
Stefano Silvestri ◽  
Tomaso Trombetti
Keyword(s):  
Additive Manufacturing ◽  
Structural Engineering ◽  
Mechanical Characteristics ◽  
Manufacturing Processes ◽  
Building Structures ◽  
Welded Steel ◽  
3D Printed ◽  
Printing Processes ◽  
Suitable Technique ◽  
Printing Parameters

The present work aims at providing the first considerations upon the application of innovative manufacturing technology for civil engineering purposes. In particular, among the 3D printing processes currently available, Weld-Based Additive Manufacturing (WAM) results to be the most suitable technique for the realization of innovative structural forms in metal material. The great potential of taking the printing head "out of the box" allows for the construction of innovative shapes by adding layer upon layer of welded steel. In particular, the study is focused on the realization of the first 3D-printed steel footbridge by a Dutch company held in Amsterdam, called MX3D, and its Additive manufacturing process, which results in specific constraints and limitations to be taken into account for design purposes. First, the design issues are described, by considering the printing parameters to be adopted for the realization of large-dimensions structures, and then the implications in terms of specific geometrical and mechanical characteristics are studied. These first engineering evaluations are intended to pave the way towards the development of a ground-breaking technology for the fully-automated design and construction of novel 3D-printed building structures through innovative robotic manufacturing processes whose parameters are still not fully known

Optimization studies on diagrid columns realized with Wire-and-Arc Additive Manufacturing process

2019 ◽  
Author(s):  
Vittoria Laghi ◽  
Michele Palermo ◽  
Giada Gasparini ◽  
Tomaso Trombetti
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Structural Engineering ◽  
Parametric Design ◽  
Digital Design ◽  
Building Structures ◽  
Structural Shape ◽  
Welded Steel ◽  
New Family ◽  
3D Printed

<p>The present work explores the possibilities of 3D printing applied to structural engineering field to create innovative design and optimized shapes. By means of Wire-and-Arc Additive Manufacturing, structural members are manufactured by placing layer upon layer of welded steel material in an automated process. Additive Manufacturing, thanks to the theoretical freedom in the geometrical shapes that can be obtained, open completely new possibilities for designers. On the other hand, specific aspects related to material properties and geometrical irregularities characteristics of such innovative manufacturing processes have to be properly considered in the design phase. Along with digital design tools recently developed and applied in architecture and construction for the realization of new shapes and forms through parametric design, the work presents a new structural shape for diagrid columns to obtain structurally optimized forms adapted to be efficiently realized by means of Wire-and-Arc Additive Manufacturing process taking into account the specific features of the printing process. The outcome of the study is the final realization of the column in a 1:2 scaled dimension. These first engineering evaluations are intended to pave the way towards the design of a new family of optimized structural elements to be efficiently 3D-printed, towards the fully-automated design and construction of novel 3D-printed building structures.</p>

scholarly journals Strength Comparison of FDM 3D Printed PLA Made by Different Manufacturers

TEM Journal ◽  
2020 ◽  
pp. 966-970
Author(s):  
Damir Hodžić ◽  
Adi Pandžić ◽  
Ismar Hajro ◽  
Petar Tasić
Keyword(s):  
Experimental Study ◽  
Additive Manufacturing ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Manufacturing Technique ◽  
Plastic Materials ◽  
Wide Range ◽  
3D Printed ◽  
The Difference ◽  
Printing Parameters

Widely used additive manufacturing technique for plastic materials is Fused Deposition Modelling (FDM). The FDM technology has gained interest in industry for a wide range of applications, especially today when large number of different materials on the market are available. There are many different manufacturers for the same FDM material where the difference in price goes up to 50%. This experimental study investigates possible difference in strength of the 3D printed PLA material of five different manufacturers. All specimens are 3D printed on Ultimaker S5 printer with the same printing parameters, and they are all the same colour.

scholarly journals Suitability of Recycled PLA Filament Application in Fused Filament Fabrication Process

2021 ◽  
Vol 15 (4) ◽  
pp. 491-497
Author(s):  
Tomislav Breški ◽  
Lukas Hentschel ◽  
Damir Godec ◽  
Ivica Đuretek
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Polylactic Acid ◽  
Design Of Experiment ◽  
Experimental Approach ◽  
Manufacturing Processes ◽  
Support Structures ◽  
Fused Filament Fabrication ◽  
Layer Height ◽  
Printing Parameters

Fused filament fabrication (FFF) is currently one of the most popular additive manufacturing processes due to its simplicity and low running and material costs. Support structures, which are necessary for overhanging surfaces during production, in most cases need to be manually removed and as such, they become waste material. In this paper, experimental approach is utilised in order to assess suitability of recycling support structures into recycled filament for FFF process. Mechanical properties of standardized specimens made from recycled polylactic acid (PLA) filament as well as influence of layer height and infill density on those properties were investigated. Optimal printing parameters for recycled PLA filaments are determined with Design of Experiment methods (DOE).

scholarly journals Printability of 3D Printed Hydrogel Scaffolds: Influence of Hydrogel Composition and Printing Parameters

2019 ◽  
Vol 10 (1) ◽  
pp. 292 ◽  
Author(s):  
Saman Naghieh ◽  
MD Sarker ◽  
N. K. Sharma ◽  
Zohra Barhoumi ◽  
Xiongbiao Chen
Keyword(s):  
Flow Behavior ◽  
Three Dimensional ◽  
Methyl Cellulose ◽  
Alginate Hydrogel ◽  
Hydrogel Scaffolds ◽  
Number Of Factors ◽  
3D Printed ◽  
The Difference ◽  
Printing Processes ◽  
Printing Parameters

Extrusion-based bioprinting of hydrogel scaffolds is challenging due to printing-related issues, such as the lack of capability to precisely print or deposit hydrogels onto three-dimensional (3D) scaffolds as designed. Printability is an index to measure the difference between the designed and fabricated scaffold in the printing process, which, however, is still under-explored. While studies have been reported on printing hydrogel scaffolds from one or more hydrogels, there is limited knowledge on the printability of hydrogels and their printing processes. This paper presented our study on the printability of 3D printed hydrogel scaffolds, with a focus on identifying the influence of hydrogel composition and printing parameters/conditions on printability. Using the hydrogels synthesized from pure alginate or alginate with gelatin and methyl-cellulose, we examined their flow behavior and mechanical properties, as well as their influence on printability. To characterize the printability, we examined the pore size, strand diameter, and other dimensions of the printed scaffolds. We then evaluated the printability in terms of pore/strand/angular/printability and irregularity. Our results revealed that the printability could be affected by a number of factors and among them, the most important were those related to the hydrogel composition and printing parameters. This study also presented a framework to evaluate alginate hydrogel printability in a systematic manner, which can be adopted and used in the studies of other hydrogels for bioprinting.

Optimization of 3D printed porous materials accounting for manufacturing defects

2021 ◽  
Vol 263 (3) ◽  
pp. 3143-3148
Author(s):  
Jean Boulvert ◽  
Théo Cavalieri ◽  
Vicente Romero-García ◽  
Gwénaël Gabard ◽  
Jean-Philippe Groby
Keyword(s):  
Additive Manufacturing ◽  
Porous Materials ◽  
Numerical Models ◽  
Manufacturing Processes ◽  
Perfect Absorption ◽  
Manufacturing Defects ◽  
Low Weight ◽  
Minimization Algorithms ◽  
3D Printed ◽  
Experimental Validations

Open-cell materials are well-known for their low price, low weight, and broadband acoustic behavior. They form one of the most used class of acoustic treatments but suffer from a lack of versatility when made by conventional manufacturing processes. Recent advances in additive manufacturing allow to produce porous materials having a controlled microstructure. In this way, the design of treatments including porous materials is not limited to a catalog of existing media. The macroscopic behavior is governed by the micro-geometry of the porous medium, which can be estimated by numerical models. Then, acoustic treatments can be optimized numerically using predicting models and minimization algorithms. However, additive manufacturing induces defects often too complex to be accounted for numerically. In this presentation, a method allowing to obtain the parametric model of the intrinsic behavior of a 3D-printed porous material is presented. The corrected model is used in the optimization of several porous treatments; namely, graded porous materials, folded porous materials and metaporous surfaces. These treatments are versatile and display remarkable properties. They provide quasi-perfect absorption at several frequencies that can be out of reach of standard porous treatments in normal or oblique incidence. Experimental validations confirm the relevance of the proposed design processes.

Study and Application of Machine Learning Methods in Modern Additive Manufacturing Processes

2022 ◽  
pp. 75-95
Author(s):  
Ranjit Barua ◽  
Sudipto Datta ◽  
Pallab Datta ◽  
Amit Roychowdhury
Keyword(s):  
Machine Learning ◽  
Additive Manufacturing ◽  
Quality Evaluation ◽  
Mechanical Characteristics ◽  
Manufacturing Processes ◽  
Superior Part ◽  
Machine Learning Methods ◽  
Excellent Control ◽  
Part Feature ◽  
Counting Model

Additive manufacturing (AM) make simpler the manufacturing of difficult geometric structures. Its possibility has quickly prolonged from the manufacture of pre-fabrication conception replicas to the making of finish practice portions driving the essential for superior part feature guarantee in the additively fabricated products. Machine learning (ML) is one of the encouraging methods that can be practiced to succeed in this aim. A modern study in this arena contains the procedure of managed and unconfirmed ML algorithms for excellent control and forecast of mechanical characteristics of AM products. This chapter describes the development of applying machine learning (ML) to numerous aspects of the additive manufacturing whole chain, counting model design, and quality evaluation. Present challenges in applying machine learning (ML) to additive manufacturing and possible solutions for these problems are then defined. Upcoming trends are planned in order to deliver a general discussion of this additive manufacturing area.

scholarly journals Stereolithographic Additive Manufacturing of High Precision Glass Ceramic Parts

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1492 ◽  
Author(s):  
Julia Anna Schönherr ◽  
Sonja Baumgartner ◽  
Malte Hartmann ◽  
Jürgen Stampfl
Keyword(s):  
Additive Manufacturing ◽  
High Precision ◽  
Glass Ceramic ◽  
Glass Ceramics ◽  
Dimensional Accuracy ◽  
Ct Scanning ◽  
Micro Computed Tomography ◽  
3D Printed ◽  
Ceramic Manufacturing ◽  
Printing Processes

Lithography based additive manufacturing (AM) is one of the most established and widely used 3D-printing processes. It has enabled the processing of many different materials from thermoplast-like polymers to ceramics that have outstanding feature resolutions and surface quality, with comparable properties of traditional materials. This work focuses on the processing of glass ceramics, which have high optical demands, precision and mechanical properties specifically suitable for dental replacements, such as crowns. Lithography-based ceramic manufacturing (LCM) has been chosen as the optimal manufacturing process where a light source with a defined wavelength is used to cure and structure ceramic filled photosensitive resins. In the case of glass ceramic powders, plastic flow during thermal processing might reduce the precision, as well as the commonly observed sintering shrinkage associated with the utilized temperature program. To reduce this problem, particular sinter structures have been developed to optimize the precision of 3D-printed glass ceramic crowns. To evaluate the precision of the final part, testing using digitizing methods from optical to tactile systems were utilized with the best results were obtained from micro computed tomography (CT) scanning. These methods resulted in an optimized process allowing for possible production of high precision molar crowns with dimensional accuracy and high reproducibility.

scholarly journals Surface Quality of 3D-Printed Models as a Function of Various Printing Parameters

Materials ◽  
2019 ◽  
Vol 12 (12) ◽  
pp. 1970 ◽  
Author(s):  
Christin Arnold ◽  
Delf Monsees ◽  
Jeremias Hey ◽  
Ramona Schweyen
Keyword(s):  
Surface Roughness ◽  
Support Structures ◽  
Roughness Index ◽  
Data Record ◽  
3D Printed ◽  
The Mean ◽  
Printing Processes ◽  
Printing Parameters ◽  
Required Quality

Although 3D-printing is common in dentistry, the technique does not produce the required quality for all target applications. Resin type, printing resolution, positioning, alignment, target structure, and the type and number of support structures may influence the surface roughness of printed objects, and this study investigates the effects of these variables. A stereolithographic data record was generated from a master model. Twelve printing processes were executed with a stereolithography Desktop 3D Printer, including models aligned across and parallel to the printer front as well as solid and hollow models. Three layer thicknesses were used, and in half of all processes, the models were inclined at 15°. For comparison, eight gypsum models and milled polyurethane models were manufactured. The mean roughness index of each model was determined with a perthometer. Surface roughness values were approximately 0.65 µm (master), 0.87–4.44 µm (printed), 2.32–2.57 µm (milled), 1.72–1.86 µm (cast plaster/alginate casting), and 0.98–1.03 µm (cast plaster/polyether casting). The layer height and type and number of support structures influenced the surface roughness of printed models (p ≤ 0.05), but positioning, structure, and alignment did not.

scholarly journals An Architecture for Hybrid Manufacturing Combining 3D Printing and CNC Machining

2016 ◽  
Vol 2016 ◽  
pp. 1-12 ◽  
Author(s):  
Marcel Müller ◽  
Elmar Wings
Keyword(s):  
Additive Manufacturing ◽  
Cnc Machining ◽  
Numerical Control ◽  
Manufacturing Processes ◽  
Hybrid Manufacturing ◽  
Cnc Machine ◽  
Subtractive Manufacturing ◽  
3D Printed ◽  
One Machine ◽  
Complex Parts

Additive manufacturing is one of the key technologies of the 21st century. Additive manufacturing processes are often combined with subtractive manufacturing processes to create hybrid manufacturing because it is useful for manufacturing complex parts, for example, 3D printed sensor systems. Currently, several CNC machines are required for hybrid manufacturing: one machine is required for additive manufacturing and one is required for subtractive manufacturing. Disadvantages of conventional hybrid manufacturing methods are presented. Hybrid manufacturing with one CNC machine offers many advantages. It enables manufacturing of parts with higher accuracy, less production time, and lower costs. Using the example of fused layer modeling (FLM), we present a general approach for the integration of additive manufacturing processes into a numerical control for machine tools. The resulting CNC architecture is presented and its functionality is demonstrated. Its application is beyond the scope of this paper.

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