scholarly journals Optimization Methodology for Additive Manufacturing of Customized Parts by Fused Deposition Modeling (FDM). Application to a Shoe Heel

Polymers ◽  
2020 ◽  
Vol 12 (9) ◽  
pp. 2119 ◽  
Author(s):  
Amabel García-Dominguez ◽  
Juan Claver ◽  
Miguel A. Sebastián
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Parametric Design ◽  
General Structure ◽  
Visual Programming ◽  
Application Development ◽  
Fused Deposition ◽  
Final Design ◽  
Optimization Methodology ◽  
Manufacturing Technologies

Additive manufacturing technologies offer important new manufacturing possibilities, but its potential is so big that only with the support of other technologies can it really be exploited. In that sense, parametric design and design optimization tools appear as two appropriate complements for additive manufacturing. Synergies existing between these three technologies allow for integrated approaches to the design of customized and optimized products. While additive manufacturing makes it possible to materialize overly complex geometries, parametric design allows designs to be adapted to custom characteristics and optimization helps to choose the best solution according to the objectives. This work represents an application development of a previous work published in Polymers which exposed the general structure, operation and opportunities of a methodology that integrates these three technologies by using visual programming with Grasshopper. In this work, the different stages of the methodology and the way in which each one modifies the final design are exposed in detail, applying it to a case study: the design of a shoe heel for FDM—an interesting example both from the perspectives of ergonomic and mass customization. Programming, operation and results are exposed in detail showing the complexity, usefulness and potential of the methodology, with the aim of helping other researchers to develop proposals in this line.

scholarly journals Integration of Additive Manufacturing, Parametric Design, and Optimization of Parts Obtained by Fused Deposition Modeling (FDM). A Methodological Approach

Polymers ◽  
2020 ◽  
Vol 12 (9) ◽  
pp. 1993 ◽  
Author(s):  
Amabel García-Dominguez ◽  
Juan Claver ◽  
Miguel A. Sebastián
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Parametric Design ◽  
Methodological Approach ◽  
Visual Programming ◽  
Design And Optimization ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Manufacturing Technologies ◽  
General Geometry

The use of current computer tools in both manufacturing and design stages breaks with the traditional conception of productive process, including successive stages of projection, representation, and manufacturing. Designs can be programmed as problems to be solved by using computational tools based on complex algorithms to optimize and produce more effective solutions. Additive manufacturing technologies enhance these possibilities by providing great geometric freedom to the materialization phase. This work presents a design methodology for the optimization of parts produced by additive manufacturing and explores the synergies between additive manufacturing, parametric design, and optimization processes to guide their integration into the proposed methodology. By using Grasshopper, a visual programming application, a continuous data flow for parts optimization is defined. Parametric design tools support the structural optimization of the general geometry, the infill, and the shell structure to obtain lightweight designs. Thus, the final shapes are obtained as a result of the optimization process which starts from basic geometries, not from an initial design. The infill does not correspond to pre-established patterns, and its elements are sized in a non-uniform manner throughout the piece to respond to different local loads. Mass customization and Fused Deposition Modeling (FDM) systems represent contexts of special potential for this methodology.

scholarly journals Precision and Energy Usage for Additive Manufacturing

2013 ◽  
Author(s):  
Lee Clemon ◽  
Anton Sudradjat ◽  
Maribel Jaquez ◽  
Aditya Krishna ◽  
Marwan Rammah ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Energy Demand ◽  
Fused Deposition Modeling ◽  
Distinct Pattern ◽  
Energy Usage ◽  
Warm Up ◽  
Part Quality ◽  
Fused Deposition ◽  
Manufacturing Technologies ◽  
Control Part

Market pressures on manufacturing enterprises incentivize minimum resource consumption while maintaining part quality. Facilities with advanced manufacturing tools often utilize rapid prototyping for production of complicated or specialty parts. Additive manufacturing offers an alternative to traditional production methods which are often time and resource expensive. This study aims to explore part quality and energy usage for additive manufacturing through a focused study of Fused Deposition Modeling and Photopolymer Jetting technologies. A control part is developed for maintaining test consistency across different machines. The control part design consists of various positive and negative features including width varied slots and walls, ramps, and curved features so that the manufacturing of different surfaces may be investigated. Several different machine models are tested to evaluate precision for a variety of applications. Part quality is quantified by measuring the surface roughness in two directions for the control test part printed on each machine. Qualitatively, part quality is assessed by positive and negative feature resolution. High quality machines resolve features closely to design specifications. Lower quality machines do not resolve some features. In addition to exploring the effects of advertised print precision, layup density is varied on two machines. Advertised print resolution does not well represent the achievable feature sizes found in this study. Energy usage is quantified by measuring electricity demands while printing the control part on each of the five different machines. Power consumption in additive manufacturing is found to follow a distinct pattern comprised of standby, warm up, printing and idle phases. Measurement and analysis suggest a relationship between the precision of these machines and their respective energy demand. Part quality is found to generally improve with increased initial and process resource investment. The energy and quality assessment methods developed in this study are applicable to a greater variety of additive manufacturing technologies and will assist designers as additive manufacturing becomes more production friendly. The presented data also provides designers and production planners insight for improvements in the process decision making.

scholarly journals Environmental and Economic Analysis of FDM, SLS and MJF Additive Manufacturing Technologies

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4161 ◽  
Author(s):  
Vincenzo Tagliaferri ◽  
Federica Trovalusci ◽  
Stefano Guarino ◽  
Simone Venettacci
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Large Scale ◽  
Fused Deposition Modeling ◽  
Production Capacity ◽  
Optimal Choice ◽  
Scale Production ◽  
Fused Deposition ◽  
Manufacturing Technologies ◽  
The Impact

In this study, the authors present a comparative analysis of different additive manufacturing (AM) technologies for high-performance components. Four 3D printers, currently available on the Italian national manufacturing market and belonging to three different AM technologies, were considered. The analysis focused on technical aspects to highlight the characteristics and performance limits of each technology, economic aspects to allow for an assessment of the costs associated with the different processes, and environmental aspects to focus on the impact of the production cycles associated with these technologies on the ecosystem, resources and human health. This study highlighted the current limits of additive manufacturing technologies in terms of production capacity in the case of large-scale production of plastic components, especially large ones. At the same time, this study highlights how the geometry of the object to be developed greatly influences the optimal choice between the various AM technologies, in both technological and economic terms. Fused deposition modeling (FDM) is the technology that exhibits the greatest limitations hindering mass production due to production times and costs, but also due to the associated environmental impact.

scholarly journals Hydrostatic High-Pressure Post-Processing of Specimens Fabricated by DLP, SLA, and FDM: An Alternative for the Sterilization of Polymer-Based Biomedical Devices

Materials ◽  
2018 ◽  
Vol 11 (12) ◽  
pp. 2540 ◽  
Author(s):  
José Linares-Alvelais ◽  
J. Figueroa-Cavazos ◽  
C. Chuck-Hernandez ◽  
Hector Siller ◽  
Ciro Rodríguez ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Tensile Modulus ◽  
High Pressure Processing ◽  
Biomedical Devices ◽  
Digital Light Processing ◽  
Fused Deposition ◽  
Manufacturing Technologies

In this work, we assess the effects of sterilization in materials manufactured using additive manufacturing by employing a sterilization technique used in the food industry. To estimate the feasibility of the hydrostatic high-pressure (HHP) sterilization of biomedical devices, we have evaluated the mechanical properties of specimens produced by commercial 3D printers. Evaluations of the potential advantages and drawbacks of Fused Deposition Modeling (FDM), Digital Light Processing (DLP) technology, and Stereolithography (SLA) were considered for this study due to their widespread availability. Changes in mechanical properties due to the proposed sterilization technique were compared to values derived from the standardized autoclaving methodology. Enhancement of the mechanical properties of samples treated with Hydrostatic high-pressure processing enhanced mechanical properties, with a 30.30% increase in the tensile modulus and a 26.36% increase in the ultimate tensile strength. While traditional autoclaving was shown to systematically reduce the mechanical properties of the materials employed and damages and deformation on the surfaces were observed, HHP offered an alternative for sterilization without employing heat. These results suggest that while forgoing high-temperature for sanitization, HHP processing can be employed to take advantage of the flexibility of additive manufacturing technologies for manufacturing implants, instruments, and other devices.

scholarly journals Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

2011 ◽  
Vol 199-200 ◽  
pp. 1984-1987 ◽  
Author(s):  
Olaf Diegel ◽  
Sarat Singamneni ◽  
Ben Huang ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Conductive Polymer ◽  
Fused Deposition ◽  
National University ◽  
Deposition Modeling ◽  
Plastic Components ◽  
Manufacturing Technologies ◽  
Plastic Parts

This paper describes a curved-layer additive manufacturing technology that has the potential to print plastic components with integral conductive polymer electronic circuits. Researchers at AUT University in New Zealand and the National University of Singapore have developed a novel Fused Deposition Modeling (FDM) process in which the layers of material that make up the part are deposited as curved layers instead of the conventional flat layers. This technology opens up possibilities of building curved plastic parts that have conductive electronic tracks and components printed as an integral part of the plastic component, thereby eliminating printed circuit boards and wiring. It is not possible to do this with existing flat-layer additive manufacturing technologies as the continuity of a circuit could be interrupted between the layers. With curved-layer fused deposition modeling (CLFDM) this problem is removed as continuous filaments in 3 dimensions can be produced, allowing for continuous conductive circuits.

scholarly journals 3D PRINTER DESIGN, MANUFACTURING AND EFFECT OF INFILL PATTERNS ON MECHANICAL PROPERTlES

2020 ◽  
Vol 4 (1) ◽  
pp. 13-24
Author(s):  
Hande Güler Özgül ◽  
Onur Tatlı
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Tensile Force ◽  
Three Dimensional ◽  
Charpy Impact ◽  
3D Printer ◽  
Direct Production ◽  
Fused Deposition ◽  
Technological Developments ◽  
Manufacturing Technologies

Along with the technological developments, it is an expected situation to discover new developed production methods. Additive manufacturing technologies, such as three-dimensional (3D) printers are one of these methods, allowing direct production of parts with complex geometries that cannot be produced by conventional methods. The most popular and inexpensive method among additive manufacturing technologies is FDM (Fused Deposition Modeling) method. This method is particularly interesting for the manufacture of parts with low production volumes. In this study, a 3D-FDM printer with a print volume of 200x200x210 mm has been designed and manufactured.PLA (polylactic acid) test samples having 2 different infill geometries were produced with the 3D printer. Tensile, three-point bending and charpyimpact tests were applied to these samples to investigate the effect of inner filling geometry on mechanical properties. The inner filling geometries are in the form of grid and gyroid. According to the results, while the geometry with the tensile force is "grid", while the geometry with the maximum bending force is "gyroid".It was concluded that different inner filling geometries do not have a significant impact on Charpy impact strength.

scholarly journals Getting Rid of the Wires: Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

2011 ◽  
Vol 467-469 ◽  
pp. 662-667 ◽  
Author(s):  
Olaf Diegel ◽  
Sarat Singamneni ◽  
Ben Huang ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Conductive Polymer ◽  
Plastic Shell ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Plastic Components ◽  
Manufacturing Technologies ◽  
Plastic Parts

This paper describes an additive manufacturing technology that has the potential to print plastic components with integral conductive polymer electronic circuits. This could have a major impact in the fields of robotics and mechatronics as it has the potential to allow large wiring looms, often an issue with complex robotic systems, to be printed as an integral part of the products plastic shell. This paper describes the development of a novel Fused Deposition Modeling (FDM) process in which the layers of material that make up the part are deposited as curved layers instead of the conventional flat layers. This opens up possibilities of building curved plastic parts that have conductive electronic tracks and components printed as an integral part of the plastic component, thereby eliminating printed circuit boards and wiring. It is not possible to do this with existing flatlayer additive manufacturing technologies as the continuity of a circuit could be interrupted between the layers. With curved-layer fused deposition modeling (CLFDM) this problem is removed as continuous filaments in 3 dimensions can be produced, allowing for continuous conductive circuits.

On design for additive manufacturing: evaluating geometrical limitations

2015 ◽  
Vol 21 (6) ◽  
pp. 662-670 ◽  
Author(s):  
Guido A. O. Adam ◽  
Detmar Zimmer
Keyword(s):  
Additive Manufacturing ◽  
Boundary Conditions ◽  
Fused Deposition Modeling ◽  
Independent Method ◽  
Design For Additive Manufacturing ◽  
Design Rules ◽  
Content Type ◽  
Fused Deposition ◽  
Geometrical Quality ◽  
Manufacturing Technologies

Purpose – The purpose of this paper is to present Design Rules for additive manufacturing and a method for their development. Design/methodology/approach – First, a process-independent method for the development of Design Rules was worked out. Therefore, geometrical standard elements and attributes that characterize the elements’ shapes have been defined. Next, the standard elements have been manufactured with different attribute values with Laser Sintering, Laser Melting and Fused Deposition Modeling, and their geometrical quality was examined. From the results, Design Rules for additive manufacturing were derived and summarized in a catalogue. Findings – Due to the process independent method, Design Rules were developed that apply for the different considered additive manufacturing technologies equally. These Design Rules are completely function-independent and easily transferable to individual part designs. Research limitations/implications – The developed Design Rules can only apply for the considered boundary conditions. To extend the Design Rules’ validity, their applicability should be proven for other boundary conditions. Practical implications – The developed Design Rules practically support the design of technical parts. Additionally they can be used for training and teaching in the field of “design for additive manufacturing”. Originality/value – The developed Design Rules constitute a first step toward general Design Rules for Additive Manufacturing. Thus, they might form a suitable basis for further scientific approaches, and the Design Rules can be used to set up teaching documentations for lessons and seminars.

scholarly journals Additive Manufacturing of a Bistable Mechanism Using Fused Deposition Modeling: Experimental and Theoretical Characterization

2019 ◽  
Author(s):  
Mouna Ben Salem ◽  
Guillaume Aiche ◽  
Yassine Haddab ◽  
Lennart Rubbert ◽  
Pierre Renaud
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
High Accuracy ◽  
Negative Stiffness ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Theoretical Characterization ◽  
Bistable Mechanism ◽  
Manufacturing Technologies

Abstract Bistable mechanisms can be used for performing specific functions such as locking or negative stiffness generation. These compliant structures are then of interest at different scales, with different corresponding manufacturing technologies. One of them is additive manufacturing, which is interesting for the integration of such structures. Although this technology has undergone a revolution with the development of high-accuracy machines, the manufacturing of small-sized compliant structures is still quite a challenge especially for bistable mechanisms, which was not yet finely characterized. This is the focus of this paper, with presentation of an experimental and analytical confrontation in the case of Fused Deposition Modeling (FDM).

A Computational Study of Strain Sensing via 3D-Printed CNF-Modified PLA Strain Gauges

2020 ◽  
Author(s):  
Cole M. Maynard ◽  
Julio A. Hernandez ◽  
Andrew Doak ◽  
Benjamin Mardikis ◽  
Monica Viz ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Electrical Properties ◽  
Fused Deposition Modeling ◽  
Carbon Nanofiber ◽  
Computational Study ◽  
Gauge Factor ◽  
Strain Sensing ◽  
Resistance Change ◽  
Fused Deposition ◽  
Manufacturing Technologies

Abstract Additive manufacturing technologies and products have seen significant growth in the last decade but have the potential to see greater advancement with the addition of functional material properties in filaments, vastly expanding the product range. Polylactic acid (PLA) is a common fused deposition modeling (FDM) material used for additive manufacturing. Currently, filament materials are limited in terms of electrical properties with the majority of filaments being dielectric. Imparting electrical properties via nanofiller modification of traditionally insulating PLA is an exciting direction for multi-functional additive manufacturing. The work presented in this manuscript computationally explores the piezoresistive strain sensing performance of multi-functional PLA. Specifically, we use experimental conductivity data collected from carbon nanofiber (CNF)-modified PLA to calibrate a computational piezoresistivity model. This computational model is then used to simulate the resistance change-strain relationship of a representative additively manufactured sensor shape. This study shows that the CNF/PLA sensor exhibits a non-linear response with a strain-dependent gauge factor ranging from 15.0 in compression to up to approximately 33.2 in tension. Computational tools such as the ones presented herein are important for further development of additively manufactured sensors since it allows researchers to explore a wide design space (e.g. shape, material type, etc.) without resorting to trial and error experimentation. This allows the incredible versatility of additive manufacturing to be more thoroughly leveraged.

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