scholarly journals Design Optimisation for 3D printed SLM objects

2021 ◽  
Author(s):  
◽  
Stephen Tane Hill
Keyword(s):  
3D Printing ◽  
Selective Laser Melting ◽  
Manufacturing Process ◽  
Computer Aided Design ◽  
Design Research ◽  
Process Models ◽  
Physical Models ◽  
Laser Melting ◽  
3D Printed

<p>A common misconception about additive manufacturing (3D printing) is that any shape can be made in any material at the press of a button. The reality is that each process and material requires distinct Computer Aided Design (CAD) files that need to be optimised to the physical limitations of the manufacturing process. This optimisation process can have significant effects on the designer’s aesthetic intentions. Selective Laser Melting (SLM) is the new benchmark for functional 3D printed titanium designs where the optimisation process plays an important role in the outcome of the end product. The limitations imposed by the manufacturing process include build support material, heat transfer and post processing and designs are required to be optimised before the manufacturing process can commence. To date, case studies written on the SLM process have focused largely on engineering and functional applications in particular within the medical industry. However; this process has not been extensively studied from a visual and aesthetic industrial design perspective. This research will gather specific knowledge about the technical limitations involved in the Selective Laser Melting process and explore through a case study approach how a designer s intentions can be maintained or even enhanced when using this technology. With greater understanding of the SLM technology, the optimisation process may further provide positive outcomes to the designer by saving time, money and waste.  This case study is built on an existing product design file as a base model. Refinements to the model were made based on findings from existing design research as well as digital and physical models. The existing design research was focused on challenges designers encounter using 3D printing technologies including SLM as well as the optimisation process. Models and design iterations were developed using Nigel Cross’s four step model of exploration, generation, evaluation and communication. By iteratively redesigning aspects of the model to conform to the SLM limitations, this study reviews opportunities for areas to reduce material without compromising the design intent.</p>

scholarly journals Design Optimisation for 3D printed SLM objects

2021 ◽  
Author(s):  
◽  
Stephen Tane Hill
Keyword(s):  
3D Printing ◽  
Selective Laser Melting ◽  
Manufacturing Process ◽  
Computer Aided Design ◽  
Design Research ◽  
Process Models ◽  
Physical Models ◽  
Laser Melting ◽  
3D Printed

<p>A common misconception about additive manufacturing (3D printing) is that any shape can be made in any material at the press of a button. The reality is that each process and material requires distinct Computer Aided Design (CAD) files that need to be optimised to the physical limitations of the manufacturing process. This optimisation process can have significant effects on the designer’s aesthetic intentions. Selective Laser Melting (SLM) is the new benchmark for functional 3D printed titanium designs where the optimisation process plays an important role in the outcome of the end product. The limitations imposed by the manufacturing process include build support material, heat transfer and post processing and designs are required to be optimised before the manufacturing process can commence. To date, case studies written on the SLM process have focused largely on engineering and functional applications in particular within the medical industry. However; this process has not been extensively studied from a visual and aesthetic industrial design perspective. This research will gather specific knowledge about the technical limitations involved in the Selective Laser Melting process and explore through a case study approach how a designer s intentions can be maintained or even enhanced when using this technology. With greater understanding of the SLM technology, the optimisation process may further provide positive outcomes to the designer by saving time, money and waste.  This case study is built on an existing product design file as a base model. Refinements to the model were made based on findings from existing design research as well as digital and physical models. The existing design research was focused on challenges designers encounter using 3D printing technologies including SLM as well as the optimisation process. Models and design iterations were developed using Nigel Cross’s four step model of exploration, generation, evaluation and communication. By iteratively redesigning aspects of the model to conform to the SLM limitations, this study reviews opportunities for areas to reduce material without compromising the design intent.</p>

scholarly journals Integration of 3D printing in computer-aided design and engineering course

2020 ◽  
Vol 9 (4) ◽  
pp. 934
Author(s):  
Mohd Hairi Mohd Zaman ◽  
Mohd Hadri Hafiz Mokhtar ◽  
Mohd Faisal Ibrahim ◽  
Aqilah Baseri Huddin ◽  
Gan Kok Beng
Keyword(s):  
3D Printing ◽  
Computer Aided Design ◽  
Engineering Students ◽  
Physical Models ◽  
Global Issues ◽  
Electronic Engineering ◽  
Computer Aided ◽  
Development Goals ◽  
3D Printed ◽  
Aided Design

Engineering students at an undergraduate level typically learn the design aspect and concept through lectures and practical sessions using computeraided software. However, the current computer-aided design and engineering (CAD/CAE) course did not expose the students to apply and relate the latest advanced technologies to solve global issues, for instance as listed in the United Nations Sustainable Development Goals (UN SDG). Therefore, an improved CAD/CAE course taken by the students of the Electrical and Electronic Engineering Programme in Universiti Kebangsaan Malaysia integrates 3D printing and conduct their project based on UN SDG themes. A total of 22 projects was produced, which involves both mechanical and electrical design with some of the physical models were 3D printed. Thus, students able to strengthen their understanding of the design concept through the integration of 3D printing and simultaneously aware of the current global issues.

Novel Development of Implant Elements Manufactured through Selective Laser Melting 3D Printing

2021 ◽  
pp. 2001488
Author(s):  
Piotr Kuryło ◽  
Małgorzata Cykowska-Błasik ◽  
Edward Tertel ◽  
Łukasz Pałka ◽  
Piotr Pruszyński ◽  
...  
Keyword(s):  
3D Printing ◽  
Selective Laser Melting ◽  
Laser Melting

ANISOTROPIC CUTTING FORCE CHARACTERISTICS IN MILLING OF MARAGING STEEL PROCESSED THROUGH SELECTIVE LASER MELTING

2021 ◽  
pp. 1-16
Author(s):  
Shoichi Tamura ◽  
Takashi Matsumura ◽  
Atsushi Ezura ◽  
Kazuo Mori
Keyword(s):  
Additive Manufacturing ◽  
Cutting Force ◽  
Maraging Steel ◽  
Selective Laser Melting ◽  
Cutting Forces ◽  
Manufacturing Process ◽  
Laser Scanning ◽  
Force Model ◽  
Laser Melting ◽  
Scanning Direction

Abstract Additive manufacturing process of maraging steel has been studied for high value parts in aerospace and automotive industries. The hybrid additive / subtractive manufacturing is effective to achieve tight tolerances and surface finishes. The additive process induces anisotropic mechanical properties of maraging steel, which depends on the laser scanning direction. Because anisotropy in the workpiece material has an influence on the cutting process, the surface finish and the dimension accuracy change according to the direction of the cutter feed with respect to the laser scanning direction. Therefore, the cutting parameters should be determined to control the cutting force considering material anisotropy. The paper discusses the cutting force in milling of maraging steel stacked with selective laser melting, as an additive manufacturing process. Anisotropic effect on the cutting forces is proved with the changing rate of the cutting force in milling of the workpieces stacked by repeating laser scanning at 0/90 degrees and 45/-45 degrees. The cutting forces, then, are analyzed in the chip flow models with piling up of orthogonal cuttings. The force model associates anisotropy with the shear stress on the shear plane. The changes in the cutting forces with the feed direction are discussed in the cutting tests and analysis.

Constraints and limitations of concrete 3D printing in architecture

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Chien-Ho Ko
Keyword(s):  
3D Printing ◽  
Manufacturing Process ◽  
Computer Aided Design ◽  
Research Approach ◽  
Layer By Layer ◽  
Content Type ◽  
Improve Design ◽  
Study Results ◽  
Computer Aided ◽  
Property Control

Purpose Additive manufacturing of concrete (AMoC) is an emerging technology for constructing buildings. However, due to the nature of the concrete property and constructing buildings in layers, constraints and limitations are encountered while applying AMoC in architecture. This paper aims to analyze the constraints and limitations that may be encountered while using AMoC in architecture. Design/methodology/approach A descriptive research approach is used to conduct this study. First, basic notions of AMoC are introduced. Then, challenges of AMoC, including hardware, material property, control and design, are addressed. Finally, strategies that may be used to overcome the challenges are discussed. Findings Factors influencing the success of AMoC include hardware, material, control methods, manufacturing process and design. Considering these issues in the early design phase is crucial to achieving a successful computer-aided design (CAD)/computer-aided manufacturing (CAM) integration to bring CAD and CAM benefits into the architecture industry. Originality/value In three-dimensional (3D) printing, objects are constructed layer by layer. Printing results are thus affected by the additive method (such as toolpath) and material properties (such as tensile strength and slump). Although previous studies attempt to improve AMoC, most of them focus on the manufacturing process. However, a successful application of AMoC in architecture needs to consider the possible constraints and limitations of concrete 3D printing. So far, research on the potential challenges of applying AMoC in architecture from a building lifecycle perspective is still limited. The study results of this study could be used to improve design and construction while applying AMoC in architecture.

scholarly journals Fracture Toughness of Hybrid Components with Selective Laser Melting 18Ni300 Steel Parts

2018 ◽  
Vol 8 (10) ◽  
pp. 1879 ◽  
Author(s):  
Luis Santos ◽  
Joel de Jesus ◽  
José Ferreira ◽  
José Costa ◽  
Carlos Capela
Keyword(s):  
Fracture Toughness ◽  
Selective Laser Melting ◽  
Compact Tension ◽  
Powder Materials ◽  
Layer By Layer ◽  
Laser Melting ◽  
Conventional Steel ◽  
Scan Rate ◽  
Aisi H13 ◽  
3D Printed

Selective Laser Melting (SLM) is currently one of the more advanced manufacturing and prototyping processes, allowing the 3D-printing of complex parts through the layer-by-layer deposition of powder materials melted by laser. This work concerns the study of the fracture toughness of maraging AISI 18Ni300 steel implants by SLM built over two different conventional steels, AISI H13 and AISI 420, ranging the scan rate between 200 mm/s and 400 mm/s. The SLM process creates an interface zone between the conventional steel and the laser melted implant in the final form of compact tension (CT) samples, where the hardness is higher than the 3D-printed material but lower than the conventional steel. Both fully 3D-printed series and 3D-printed implants series produced at 200 mm/s of scan rate showed higher fracture toughness than the other series built at 400 mm/s of scan rate due to a lower level of internal defects. An inexpressive variation of fracture toughness was observed between the implanted series with the same parameters. The crack growth path for all samples occurred in the limit of interface/3D-printed material zone and occurred between laser melted layers.

3D Printing of Medical Models: A Literature Review

2017 ◽  
Author(s):  
Xingjian Wei ◽  
Li Zeng ◽  
Zhijian Pei
Keyword(s):  
3D Printing ◽  
Literature Review ◽  
Medical Curriculum ◽  
Industrial Applications ◽  
Physical Models ◽  
Research Directions ◽  
Anatomical Structures ◽  
Medical Models ◽  
3D Printed ◽  
Anatomy Teaching

Medical models are physical models of human or animal anatomical structures such as skull and heart. Such models are used in simulation and planning of complex surgeries. They can also be utilized for anatomy teaching in medical curriculum. Traditionally, medical models are fabricated by paraffin wax or silicone casting. However, this method is time-consuming, of low quality, and not suitable for personalization. Recently, 3D printing technologies are used to fabricate medical models. Various applications of 3D printed medical models in surgeries and anatomy teaching have been reported, and their advantages over traditional medical models have been well-documented. However, 3D printing of medical models bears some special challenges compared to industrial applications of 3D printing. This paper reviews more than 50 publications on 3D printing of medical models between 2006 and 2016, and discusses knowledge gaps and potential research directions in this field.

Anisotropic Cutting Force Characteristics in Milling of Maraging Steel Processed Through Selective Laser Melting

2021 ◽  
Author(s):  
Shoichi Tamura ◽  
Takashi Matsumura ◽  
Atsushi Ezura ◽  
Kazuo Mori
Keyword(s):  
Additive Manufacturing ◽  
Cutting Force ◽  
Maraging Steel ◽  
Selective Laser Melting ◽  
Cutting Forces ◽  
Manufacturing Process ◽  
Laser Scanning ◽  
Force Model ◽  
Laser Melting ◽  
Scanning Direction

Abstract Additive manufacturing process of maraging steel has been studied for high value parts in aerospace and automotive industries. The hybrid additive / subtractive manufacturing is effective to achieve tight tolerances and surface finishes. The additive process induces anisotropic mechanical properties of maraging steel, which depends on the laser scanning direction. Because anisotropy in the workpiece material has an influence on the cutting process, the surface finish and the dimension accuracy change according to the direction of the cutter feed with respect to the laser scanning direction. Therefore, the cutting parameters should be determined to control the cutting force considering material anisotropy. The paper discusses the cutting force in milling of maraging steel stacked with selective laser melting, as an additive manufacturing process. Anisotropic effect on the cutting forces is proved with the changing rate of the cutting force in milling of the workpieces stacked by repeating laser scanning at 0/90 degrees and 45/−45 degrees. The cutting forces, then, are analyzed in the chip flow models with piling up of orthogonal cuttings. The force model associates anisotropy with the shear stress on the shear plane. The changes in the cutting forces with the feed direction are discussed in the cutting tests and analysis.

scholarly journals 3D-Printable PP/SEBS Thermoplastic Elastomeric Blends: Preparation and Properties

Polymers ◽  
2019 ◽  
Vol 11 (2) ◽  
pp. 347 ◽  
Author(s):  
Shib Banerjee ◽  
Stephen Burbine ◽  
Nischay Kodihalli Shivaprakash ◽  
Joey Mead
Keyword(s):  
3D Printing ◽  
Carbon Black ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Polymeric Materials ◽  
Fused Deposition ◽  
3D Printed ◽  
Injection Molded ◽  
Preferential Location

Currently, material extrusion 3D printing (ME3DP) based on fused deposition modeling (FDM) is considered a highly adaptable and efficient additive manufacturing technique to develop components with complex geometries using computer-aided design. While the 3D printing process for a number of thermoplastic materials using FDM technology has been well demonstrated, there still exists a significant challenge to develop new polymeric materials compatible with ME3DP. The present work reports the development of ME3DP compatible thermoplastic elastomeric (TPE) materials from polypropylene (PP) and styrene-(ethylene-butylene)-styrene (SEBS) block copolymers using a straightforward blending approach, which enables the creation of tailorable materials. Properties of the 3D printed TPEs were compared with traditional injection molded samples. The tensile strength and Young’s modulus of the 3D printed sample were lower than the injection molded samples. However, no significant differences could be found in the melt rheological properties at higher frequency ranges or in the dynamic mechanical behavior. The phase morphologies of the 3D printed and injection molded TPEs were correlated with their respective properties. Reinforcing carbon black was used to increase the mechanical performance of the 3D printed TPE, and the balancing of thermoplastic elastomeric and mechanical properties were achieved at a lower carbon black loading. The preferential location of carbon black in the blend phases was theoretically predicted from wetting parameters. This study was made in order to get an insight to the relationship between morphology and properties of the ME3DP compatible PP/SEBS blends.

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