Analysis for understanding and standardization of additive manufacturing processes

2021 ◽  
Author(s):  
Alexander Matschinski ◽  
Tim Osswald ◽  
Klaus Drechsler
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Manufacturing Systems ◽  
Polymer Melt ◽  
Thermal Shrinkage ◽  
Target Component ◽  
Associated Functions ◽  
Cooling Mechanism ◽  
Characteristic Values ◽  
As Stress

The market segment of additive manufacturing is showing an annual growth of more than ten percent, with extrusion-based processes being the larger segment of the market. The scope of use is limited to secondary structures. Equipment manufacturers try to guarantee constant material characteristics by closed systems. The characteristic values are up to 50% below the ones from injection molding. The processing of high-performance polymers with reinforcing fibers is an additional challenge. Further development requires an opening of the material and manufacturing systems. The guidelines and standardization for this are still missing. For this reason, a functional analysis (FA) according to TRIZ ("theory of the resolution of invention-related tasks") is performed within this study. This identifies the undesired functions and quantifies their coupling with process components and parameters. In the FA, the manufactured part is the target component in order to address its quality. This way the FA identifies five undesirable functions in the process. These are: deform, cool, weaken, swell and shape. For hightemperature thermoplastics, thermal shrinkage is the primary cause of geometric tolerance. Therefore, the deformation is largely dependent on the cooling mechanism. For a detailed analysis, the polymer melt is further disassembled. The results are six sub-components. The weakening is mainly due to the physical phase of the voids, which exists during the entire processing. The breakdown comprises physical fields such as stress, temperature and flow. These determine the output properties as well as the bonding between the layers. The associated functions are the swelling and shaping. In order to generate broadly applicable standardizations, research questions for further investigation are derived from this study.

scholarly journals Direct laser additive manufacturing of high performance oxide ceramics: a state-of-the-art review

2021 ◽  
Author(s):  
Stefan Pfeiffer ◽  
Kevin Florio ◽  
Dario Puccio ◽  
Marco Grasso ◽  
Bianca Maria Colosimo ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
State Of The Art ◽  
Oxide Ceramics ◽  
Laser Additive Manufacturing ◽  
Direct Laser

scholarly journals MODEL-BASED DESIGN OF AM COMPONENTS TO ENABLE DECENTRALIZED DIGITAL MANUFACTURING SYSTEMS

2021 ◽  
Vol 1 ◽  
pp. 2127-2136
Author(s):  
Olivia Borgue ◽  
John Stavridis ◽  
Tomas Vannucci ◽  
Panagiotis Stavropoulos ◽  
Harry Bikas ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Data Generation ◽  
Production Networks ◽  
Model Based ◽  
Manufacturing Technologies ◽  
Am Processes ◽  
Final Consumer

AbstractAdditive manufacturing (AM) is a versatile technology that could add flexibility in manufacturing processes, whether implemented alone or along other technologies. This technology enables on-demand production and decentralized production networks, as production facilities can be located around the world to manufacture products closer to the final consumer (decentralized manufacturing). However, the wide adoption of additive manufacturing technologies is hindered by the lack of experience on its implementation, the lack of repeatability among different manufacturers and a lack of integrated production systems. The later, hinders the traceability and quality assurance of printed components and limits the understanding and data generation of the AM processes and parameters. In this article, a design strategy is proposed to integrate the different phases of the development process into a model-based design platform for decentralized manufacturing. This platform is aimed at facilitating data traceability and product repeatability among different AM machines. The strategy is illustrated with a case study where a car steering knuckle is manufactured in three different facilities in Sweden and Italy.

scholarly journals Additive Manufacturing of Sensors for Military Monitoring Applications

Polymers ◽  
2021 ◽  
Vol 13 (9) ◽  
pp. 1455
Author(s):  
David T. Bird ◽  
Nuggehalli M. Ravindra
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Sensor Technology ◽  
Distinct Advantage ◽  
Industrial Sectors ◽  
Sensor Fabrication ◽  
The Us ◽  
3D Printed ◽  
Maximum Protection ◽  
The Many

The US Department of Defense (DoD) realizes the many uses of additive manufacturing (AM) as it has become a common fabrication technique for an extensive range of engineering components in several industrial sectors. 3D Printed (3DP) sensor technology offers high-performance features as a way to track individual warfighters on the battlefield, offering protection from threats such as weaponized toxins, bacteria or virus, with real-time monitoring of physiological events, advanced diagnostics, and connected feedback. Maximum protection of the warfighter gives a distinct advantage over adversaries by providing an enhanced awareness of situational threats on the battle field. There is a need to further explore aspects of AM such as higher printing resolution and efficiency, with faster print times and higher performance, sensitivity and optimized fabrication to ensure that soldiers are more safe and lethal to win our nation’s wars and come home safely. A review and comparison of various 3DP techniques for sensor fabrication is presented.

ADDITIVE MANUFACTURING OF HIGH-LOADING POLYMER NANOCOMPOSITES WITH MULTISCALE ALIGNMENT

2021 ◽  
Author(s):  
SOYEON PARK ◽  
KUN (KELVIN) FU
Keyword(s):  
Additive Manufacturing ◽  
Polymer Nanocomposites ◽  
High Performance ◽  
Energy Storage Devices ◽  
Storage Devices ◽  
High Productivity ◽  
Macro Scale ◽  
The Matrix ◽  
Multiscale Structures ◽  
Printing Direction

Polymer nanocomposites have advantages in mechanical, electrical, and optical properties compared to individual components. These unique properties of the nanocomposites have attracted attention in many applications, including electronics, robotics, biomedical fields, automotive industries. To achieve their high performance, it is crucial to control the orientation of nanomaterials within the polymer matrix. For example, the electric conductivity will be maximized in the ordered direction of conductive nanomaterials such as graphene and carbon nanotubes (CNTs). Conventional fabrication methods are commonly used to obtain polymer nanocomposites with the controlled alignment of nanomaterials using electric or magnetic fields, fluid flow, and shear forces. Such approaches may be complex in preparing a manufacturing system, have low fabrication rate, and even limited structure scalability and complexity required for customized functional products. Recently, additive manufacturing (AM), also called 3D printing, has been developed as a major fabrication technology for nanocomposites with aligned reinforcements. AM has the ability to control the orientation of nanoparticles and offers a great way to produce the composites with cost-efficiency, high productivity, scalability, and design flexibility. Herein, we propose a manufacturing process using AM for the architected structure of polymer nanocomposites with oriented nanomaterials using a polylactic acid polymer as the matrix and graphite and CNTs as fillers. AM can achieve the aligned orientation of the nanofillers along the printing direction. Thus, it enables the fabrication of multifunctional nanocomposites with complex shapes and higher precision, from micron to macro scale. This method will offer great opportunities in the advanced applications that require complex multiscale structures such as energy storage devices (e.g., batteries and supercapacitors) and structural electronic devices (e.g., circuits and sensors).

Fractal Pattern Recognition of Image Profiles for Manufacturing Process Monitoring and Control

2018 ◽  
Author(s):  
Farhad Imani ◽  
Bing Yao ◽  
Ruimin Chen ◽  
Prahalada Rao ◽  
Hui Yang
Keyword(s):  
Additive Manufacturing ◽  
Process Monitoring ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Experimental Studies ◽  
Precision Machining ◽  
Monitoring And Control ◽  
Process Monitoring And Control ◽  
Ultra Precision ◽  
And Control

Nowadays manufacturing industry faces increasing demands to customize products according to personal needs. This trend leads to a proliferation of complex product designs. To cope with this complexity, manufacturing systems are equipped with advanced sensing capabilities. However, traditional statistical process control methods are not concerned with the stream of in-process imaging data. Also, very little has been done to investigate nonlinearity, irregularity, and inhomogeneity in image stream collected from manufacturing processes. This paper presents the multifractal spectrum and lacunarity measures to characterize irregular and inhomogeneous patterns of image profiles, as well as detect the hidden dynamics of the underlying manufacturing process. Experimental studies show that the proposed method not only effectively characterizes the surface finishes for quality control of ultra-precision machining but also provides an effective model to link process parameters with fractal characteristics of in-process images acquired from additive manufacturing. This, in turn, will allow a swift response to processes changes and consequently reduce the number of defective products. The proposed fractal method has strong potentials to be applied for process monitoring and control in a variety of domains such as ultra-precision machining, additive manufacturing, and biomanufacturing.

Solid-Based Additive Manufacturing Systems

2021 ◽  
pp. 75-88
Author(s):  
G.K. Awari ◽  
C.S. Thorat ◽  
Vishwjeet Ambade ◽  
D.P. Kothari
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Systems
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