scholarly journals Heterogeneous Material Additive Manufacturing for Hot-Stamping Die

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1210 ◽  
Author(s):  
Myoung-Pyo Hong ◽  
Jin-Jae Kim ◽  
Woo-Sung Kim ◽  
Min-Kyu Lee ◽  
Ki-Man Bae ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Industry ◽  
Hot Stamping ◽  
Continuous Process ◽  
Flow Analysis ◽  
Three Dimensional ◽  
Value Added ◽  
Heterogeneous Material ◽  
Stamping Die ◽  
Manufacturing Technologies

Additive manufacturing (AM) has recently been receiving global attention. As an innovative alternative to existing manufacturing technologies, AM can produce three-dimensional objects from various materials. In the manufacturing industry, AM improves production cost, time, and quality in comparison to existing methods. In addition, AM is applied in the fabrication and production of objects in diverse fields. In particular, metal AM has been continuously commercialized in high value-added industries such as aerospace and health care by many research and development projects. However, the applicability of metal AM to the mold and die industry and other low value-added industries is limited because AM is not as economical as current manufacturing technologies. Therefore, this paper proposes an effective solution to the problem. This study examines a method for using direct energy deposition and heterogeneous materials, a heterogeneous material additive-manufacturing process for metals used to optimize the cooling channels and a key process in manufacturing hot-stamping dies. The improvements in the cooling performances and uniform cooling were evaluated by heat-flow analysis in a continuous process. Finally, trial products were fabricated using the proposed method, and a trial for hot stamping was conducted to examine the possibility of it being used in commercial applications.

Additive Manufacturing: The Next Generation of Scapholunate Ligament Reconstruction

2021 ◽  
Author(s):  
Matthew N. Rush ◽  
Christina Salas ◽  
Lorraine Mottishaw ◽  
Damian Fountain ◽  
Deana Mercer
Keyword(s):  
Additive Manufacturing ◽  
Ligament Reconstruction ◽  
Three Dimensional ◽  
Biological Properties ◽  
Bone Interface ◽  
Significant Strength ◽  
Efficient Integration ◽  
Manufacturing Methods ◽  
Manufacturing Techniques ◽  
Manufacturing Technologies

Abstract Background Ligament reconstruction, as a surgical method used to stabilize joints, requires significant strength and tissue anchoring to restore function. Historically, reconstructive materials have been fraught with problems from an inability to withstand normal physiological loads to difficulties in fabricating the complex organization structure of native tissue at the ligament-to-bone interface. In combination, these factors have prevented the successful realization of nonautograft reconstruction. Methods A review of recent improvements in additive manufacturing techniques and biomaterials highlight possible options for ligament replacement. Description of Technique In combination, three dimensional-printing and electrospinning have begun to provide for nonautograft options that can meet the physiological load and architectures of native tissues; however, a combination of manufacturing methods is needed to allow for bone-ligament enthesis. Hybrid biofabrication of bone-ligament tissue scaffolds, through the simultaneous deposition of disparate materials, offer significant advantages over fused manufacturing methods which lack efficient integration between bone and ligament materials. Results In this review, we discuss the important chemical and biological properties of ligament enthesis and describe recent advancements in additive manufacturing to meet mechanical and biological requirements for a successful bone–ligament–bone interface. Conclusions With continued advancement of additive manufacturing technologies and improved biomaterial properties, tissue engineered bone-ligament scaffolds may soon enter the clinical realm.

A Review of Bone Graft Substitutes Made From HA-Polymer Composite Scaffolds and Fabrication Potential With Laser-Based Additive Manufacturing Processes

2015 ◽  
Author(s):  
Hera Wu ◽  
Shuting Lei
Keyword(s):  
Additive Manufacturing ◽  
Bone Graft ◽  
Three Dimensional ◽  
Bone Graft Substitute ◽  
Biological Properties ◽  
Porous Scaffolds ◽  
Composite Scaffolds ◽  
Bone Graft Substitutes ◽  
Manufacturing Technologies ◽  
High Level

Hydroxyapatite, a bioactive ceramic, has been combined with biodegradable polymers to create composite three-dimensional interconnected porous scaffolds for bone graft substitutes. The materials and fabrication methods of these composite scaffolds are reviewed. The resulting mechanical and biological properties of scaffolds produced from the combination of certain materials and fabrication methods are analyzed. Requirements for a bone graft substitute and third generation scaffolds with the addition of osteoinductive and osteogenic features to composite scaffolds including biomolecule delivery and cell seeding are also introduced. Finally, the benefits of using additive manufacturing technologies to enable high level of control over the design of interconnected pore structure are discussed.

Laser Additive Manufacturing

3D Printing ◽  
2017 ◽  
pp. 154-171 ◽  
Author(s):  
Rasheedat M. Mahamood ◽  
Esther T. Akinlabi
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Computer Aided Design ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Cad Model ◽  
Laser Additive Manufacturing ◽  
Computer Aided ◽  
Manufacturing Technologies ◽  
Aided Design

Laser additive manufacturing is an advanced manufacturing process for making prototypes as well as functional parts directly from the three dimensional (3D) Computer-Aided Design (CAD) model of the part and the parts are built up adding materials layer after layer, until the part is competed. Of all the additive manufacturing process, laser additive manufacturing is more favoured because of the advantages that laser offers. Laser is characterized by collimated linear beam that can be accurately controlled. This chapter brings to light, the various laser additive manufacturing technologies such as: - selective laser sintering and melting, stereolithography and laser metal deposition. Each of these laser additive manufacturing technologies are described with their merits and demerits as well as their areas of applications. Properties of some of the parts produced through these processes are also reviewed in this chapter.

scholarly journals A 3D weaving infill pattern for fused filament fabrication

2021 ◽  
Author(s):  
Yuan Yao ◽  
Cheng Ding ◽  
Mohamed Aburaia ◽  
Maximilian Lackner ◽  
Lanlan He
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Repetitive Structure ◽  
Mechanical Linkage ◽  
Manufacturing Technologies ◽  
Dimensional Object ◽  
Anisotropy Of Mechanical Properties ◽  
3D Weaving

Abstract The Fused Filament Fabrication process is the most used additive manufacturing process due to its simplicity and low operating costs. In this process, a thermoplastic filament is led through an extruder, melted, and applied to a building platform by the axial movements of an automated Cartesian system in such a way that a three-dimensional object is created layer by layer. Compared to other additive manufacturing technologies, the components produced have mechanical limitations and are often not suitable for functional applications. To reduce the anisotropy of mechanical strength in fused filament fabrication (FFF), this paper proposes a 3D weaving deposit path planning method that utilizes a 5-layer repetitive structure to achieve interlocking and embedding between neighbor slicing planes to improve the mechanical linkage within the layers. The developed algorithm extends the weaving path as an infill pattern to fill different structures and makes this process feasible on a standard three-axis 3D printer. Compared with 3D weaving printed parts by layer-to-layer deposit, the anisotropy of mechanical properties inside layers is significantly reduced to 10.21% and 0.98%.

scholarly journals Pilot Demonstration of Hot Sheet Metal Forming Using 3D Printed Dies

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5695
Author(s):  
Jaume Pujante ◽  
Borja González ◽  
Eduard Garcia-Llamas
Keyword(s):  
Additive Manufacturing ◽  
Hot Spot ◽  
Hot Stamping ◽  
Design Strategies ◽  
Press Hardening ◽  
Cooling Channels ◽  
Plant Environment ◽  
Conformal Cooling Channels ◽  
3D Printed ◽  
Manufacturing Technologies

Since the popularization of press hardening in the early noughties, die and tooling systems have experienced considerable advances, with tool refrigeration as an important focus. However, it is still complicated to obtain homogeneous cooling and avoid hot spot issues in complex geometries. Additive Manufacturing allows designing cavities inside the material volume with little limitation in terms of channel intersection or bore entering and exit points. In this sense, this technology is a natural fit for obtaining surface-conforming cooling channels: an attractive prospect for refrigerated tools. This work describes a pilot experience in 3D-printed press hardening tools, comparing the performance of additive manufactured Maraging steel 1.2709 to conventional wrought hot work tool steel H13 on two different metrics: durability and thermal performance. For the first, wear studies were performed in a controlled pilot plant environment after 800 hot stamping strokes in an omega tool configuration. On the second, a demonstrator tool based on a commercial tool with hot spot issues, was produced by 3D printing including surface-conformal cooling channels. This tool was then used in a pilot press hardening line, in which tool temperature was analyzed and compared to an equivalent tool produced by conventional means. Results show that the Additive Manufacturing technologies can be successfully applied to the production of press hardening dies, particularly in intricate geometries where new cooling channel design strategies offer a solution for hot spots and inhomogeneous thermal loads.

scholarly journals Metal Additive Manufacturing for Satellites and Rockets

2021 ◽  
Vol 11 (24) ◽  
pp. 12036
Author(s):  
Tomasz Blachowicz ◽  
Guido Ehrmann ◽  
Andrea Ehrmann
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Heat Pipes ◽  
Space Applications ◽  
Metal Additive Manufacturing ◽  
Magnetic Shields ◽  
Custom Made ◽  
Manufacturing Technologies ◽  
Harsh Conditions ◽  
Metal Additive

The emerging technology of 3D printing can not only be used for rapid prototyping, but will also play an important role in space exploration. Additive manufactured parts can be used in diverse space applications, such as magnetic shields, heat pipes, thrusters, etc. Three-dimensional printed parts offer reduced mass, high possible complexity, and fast printability of custom-made objects. On the other hand, materials which are not excessively damaged by the harsh conditions in space and are also printable by available technologies are not abundantly available. This review gives an overview of recent metal additive manufacturing technologies and their possible applications in space, with a focus on satellites and rockets, highlighting already applied technologies and materials and gives an outlook on possible future applications and challenges.

Deposition Conditions for Laser Formation Processes with Filler Wire

2016 ◽  
Vol 10 (6) ◽  
pp. 899-908 ◽  
Author(s):  
Naoki Seto ◽  
◽  
Hiroshi Sato ◽  
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Formation Processes ◽  
Processing Conditions ◽  
Feeding Type ◽  
Feeding Speed ◽  
Wire Feeding ◽  
Manufacturing Technologies ◽  
Deposition Conditions ◽  
Traveling Speed

Recently, studies on three-dimensional (3D) formation technology, which is capable of forming components directly, have become increasingly popular as a part of additive manufacturing technologies. However, a very limited amount of information has been published about its processing conditions or settings. In this study, we have prototyped a wire-feeding type 3D laser deposition equipment to publish information about adjusting the deposition conditions and examining the deposition characteristics, which can be used as a reference by engineers who carry out 3D formations. We hope that this study can contribute significantly to the progress in additive manufacturing technologies.Using the proposed equipment, we determined the deposition conditions under which the melting of a specimen can be limited to a shallow depth, while making depositions of sufficient height on the specimen. These deposition conditions are a laser power of 2.0 kW, a laser traveling speed of 1.5 m/min, and a wire-feeding speed of 7.7 m/min. Further, we confirmed that slight tuning of these deposition conditions even allows for 10-layer depositions and depositions containing curved lines.

Micro‐Additive Manufacturing Technologies of Three‐Dimensional MEMS

2021 ◽  
Author(s):  
Hany Hassanin ◽  
Ghazal Sheikholeslami ◽  
Pooya Sareh ◽  
Rihana B. Ishaq
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Manufacturing Technologies

A Functional Classification Framework for the Conceptual Design of Additive Manufacturing Technologies

2011 ◽  
Vol 133 (12) ◽  
Author(s):  
Christopher B. Williams ◽  
Farrokh Mistree ◽  
David W. Rosen
Keyword(s):  
Additive Manufacturing ◽  
Conceptual Design ◽  
Design Methodology ◽  
Three Dimensional ◽  
New Classification ◽  
Metal Artifacts ◽  
Three Dimensional Printing ◽  
Classification Framework ◽  
Manufacturing Technologies ◽  
Dimensional Printing

Many different additive manufacturing (AM) technologies enable the realization of prototypes and fully-functional artifacts. Although very different in solution principle and embodiment, significant functional commonality exists among the technologies. This commonality affords the authors an opportunity to propose a new classification framework for additive manufacturing technologies. Specifically, by following the systematic abstraction approach proposed by the design methodology of Pahl and Beitz, the authors first identify the working principles of each AM process. A morphological matrix is then employed to functionally present these principles such that commonalities between processes can be identified. In addition to using it as a means of classifying existing processes, the authors present the framework as a tool to aid a designer in the conceptual design of new additive manufacturing technologies. The authors close the paper with an example of such an implementation; specifically, the conceptual design of a novel means of obtaining metal artifacts from three-dimensional printing.

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