scholarly journals Benefits of Non-Planar Printing Strategies Towards Eco-Efficient 3D Printing

2021 ◽  
Vol 13 (4) ◽  
pp. 1599
Author(s):  
Adrián Martínez Cendrero ◽  
Gabriele Maria Fortunato ◽  
Juan Manuel Munoz-Guijosa ◽  
Carmelo De Maria ◽  
Andrés Díaz Lantada
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Environmental Impacts ◽  
Production Costs ◽  
Support Tools ◽  
Potential Benefits ◽  
Alternative Approaches ◽  
Printing Processes ◽  
Interesting Alternative

The present work focuses on studying and demonstrating the potential benefits of non-planar printing, as compared to conventional 3D printing, in terms of improved eco-impacts. To this end, a case study of a medical or ergonomic device, which may benefit from non-planar printing in different ways, is completely developed and manufactured employing alternative approaches, which are quantified, as regards production costs and environmental impacts. Three 3D printing processes are used: two of them relying on non-planar printing, one using conventional 2D printing trajectories. Relevant benefits are achieved thanks to the possibility, enabled by non-planar 3D printing, of manufacturing products upon reusable rapid tools. These support tools constitute an interesting alternative to the support meshes generally employed in additive manufacturing, which are normally a relevant source of waste and involve costly post-processes.

Applicability and integration of concrete additive manufacturing in construction industry: A case study

2021 ◽  
pp. 095440542098610
Author(s):  
Mohamed Ramadany ◽  
Mohamed Saad Bajjou
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Construction Industry ◽  
State Of The Art ◽  
Construction Sector ◽  
Key Factors ◽  
Concrete Material ◽  
New Challenges ◽  
Printing Processes

The spread of additive manufacturing in recent years has broadened the sector of applications, namely in the construction field. This technology enables new functionalities and opportunities to be considered for the construction industry. Indeed, 3D printing processes can directly or indirectly affect the concrete material. Besides the printing processes for concrete structures, there are other indirect uses of 3D concrete printing, such as the manufacture of molds and formwork. However, its integration raises new challenges. This paper is first devoted to the state-of-the-art regarding the use of additive manufacturing in construction through a bibliographical study and an overview of various experiences in different countries. Secondly, the opportunities of such technologies for the construction sector will be discussed. Then, the issues and challenges related to the applicability and integration of concrete additive manufacturing will be highlighted. Finally, a diagnosis of the applicability and integration of concrete additive manufacturing has been made by analyzing the results of a survey of Moroccan professionals. The objective is to raise and identify key factors for successful integration.

The Environmental Impacts of Metal Powder Bed Additive Manufacturing

2020 ◽  
Vol 143 (3) ◽  
Author(s):  
Jiankan Liao ◽  
Daniel R. Cooper
Keyword(s):  
Additive Manufacturing ◽  
Environmental Impacts ◽  
Metal Powder ◽  
Future Research ◽  
Research Directions ◽  
Powder Bed ◽  
Direct Energy ◽  
Potential Benefits ◽  
Future Research Directions ◽  
Am Processes

Abstract Additive manufacturing (AM) is widely recognized as a critical pillar of advanced manufacturing and is moving from the design shop to the factory floor. As AM processes become more popular, it is paramount that engineers and policymakers understand and then reduce their environmental impacts. This article structures the current work on the environmental impacts of metal powder bed processes: selective laser melting (SLM), direct metal laser sintering (DMLS), electron beam melting (EBM), and binder jetting (BJ). We review the potential benefits and pitfalls of AM in each phase of a part's lifecycle and in different application domains (e.g., remanufacturing and hybrid manufacturing). We highlight critical uncertainties and future research directions throughout. The environmental impacts of AM are sensitive to the specific production and use-phase context; however, several broad lessons can be extracted from the literature. Unlike in conventional manufacturing, powder bed production impacts are dominated by the generation of the direct energy (electricity) required to operate the AM machines. Combined with a more energy-intensive feedstock (metal powder), this means that powder bed production impacts are higher than in conventional manufacturing unless production volumes are very small (saving tool production impacts), and/or there are significant material savings through part light weighting or improved buy-to-fly ratios.

scholarly journals Possibilities of Preoperative Medical Models Made by 3D Printing or Additive Manufacturing

2016 ◽  
Vol 2016 ◽  
pp. 1-6 ◽  
Author(s):  
Mika Salmi
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
3D Modeling ◽  
Mechanical Engineering ◽  
3D Model ◽  
Model Reconstruction ◽  
3D Model Reconstruction ◽  
Wide Range ◽  
Printing Processes ◽  
Binder Jetting

Most of the 3D printing applications of preoperative models have been focused on dental and craniomaxillofacial area. The purpose of this paper is to demonstrate the possibilities in other application areas and give examples of the current possibilities. The approach was to communicate with the surgeons with different fields about their needs related preoperative models and try to produce preoperative models that satisfy those needs. Ten different kinds of examples of possibilities were selected to be shown in this paper and aspects related imaging, 3D model reconstruction, 3D modeling, and 3D printing were presented. Examples were heart, ankle, backbone, knee, and pelvis with different processes and materials. Software types required were Osirix, 3Data Expert, and Rhinoceros. Different 3D printing processes were binder jetting and material extrusion. This paper presents a wide range of possibilities related to 3D printing of preoperative models. Surgeons should be aware of the new possibilities and in most cases help from mechanical engineering side is needed.

Additive manufacturing a powerful tool for the aerospace industry

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mahyar Khorasani ◽  
AmirHossein Ghasemi ◽  
Bernard Rolfe ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Production Costs ◽  
Process Chain ◽  
Post Processing ◽  
Jet Engine ◽  
Content Type ◽  
Support Optimization ◽  
The Cost

Purpose Additive manufacturing (AM) offers potential solutions when conventional manufacturing reaches its technological limits. These include a high degree of design freedom, lightweight design, functional integration and rapid prototyping. In this paper, the authors show how AM can be implemented not only for prototyping but also production using different optimization approaches in design including topology optimization, support optimization and selection of part orientation and part consolidation. This paper aims to present how AM can reduce the production cost of complex components such as jet engine air manifold by optimizing the design. This case study also identifies a detailed feasibility analysis of the cost model for an air manifold of an Airbus jet engine using various strategies, such as computer numerical control machining, printing with standard support structures and support optimization. Design/methodology/approach Parameters that affect the production price of the air manifold such as machining, printing (process), feedstock, labor and post-processing costs were calculated and compared to find the best manufacturing strategy. Findings Results showed that AM can solve a range of problems and improve production by customization, rapid prototyping and geometrical freedom. This case study showed that 49%–58% of the cost is related to pre- and post-processing when using laser-based powder bed fusion to produce the air manifold. However, the cost of pre- and post-processing when using machining is 32%–35% of the total production costs. The results of this research can assist successful enterprises, such as aerospace, automotive and medical, in successfully turning toward AM technology. Originality/value Important factors such as validity, feasibility and limitations, pre-processing and monitoring, are discussed to show how a process chain can be controlled and run efficiently. Reproducibility of the process chain is debated to ensure the quality of mass production lines. Post-processing and qualification of the AM parts are also discussed to show how to satisfy the demands on standards (for surface quality and dimensional accuracy), safety, quality and certification. The original contribution of this paper is identifying the main production costs of complex components using both conventional and AM.

The Environmental Impacts of Metal Powder Bed Additive Manufacturing

2020 ◽  
Author(s):  
Jiankan Liao ◽  
Daniel R. Cooper
Keyword(s):  
Additive Manufacturing ◽  
Environmental Impacts ◽  
Metal Powder ◽  
Future Research ◽  
Research Directions ◽  
Powder Bed ◽  
Direct Energy ◽  
Potential Benefits ◽  
Future Research Directions ◽  
Am Processes

Abstract Additive manufacturing (AM) is widely recognized as a critical pillar of advanced manufacturing and is moving from the design shop to the factory floor. As AM processes become more popular, it is paramount that engineers and policymakers understand and then reduce their environmental impacts. This article structures the current work on the environmental impacts of metal powder bed processes: selective laser melting (SLM), direct metal laser sintering (DMLS), electron beam melting (EBM), and binder jetting (BJ). We review the potential benefits and pitfalls of AM in each phase of a part’s lifecycle and in different application domains (e.g., remanufacturing, hybrid manufacturing etc.). We highlight critical uncertainties and future research directions throughout. The environmental impacts of AM are sensitive to the specific production and use-phase context; however, several broad lessons can be extracted from the literature. Unlike in conventional manufacturing, powder bed production impacts are dominated by the generation of the direct energy (electricity) required to operate the AM machines. Combined with a more energy-intensive feedstock (metal powder) this means that powder bed production impacts are higher than in conventional manufacturing unless production volumes are very small (saving tool production impacts) and/or there are significant material savings through part light weighting or improved buy-to-fly ratios.

scholarly journals Green Construction in Building Renovation

2016 ◽  
Vol 21 (2) ◽  
pp. 63-70
Author(s):  
Barbara Ksit ◽  
Michał Majcherek
Keyword(s):  
Urban Environment ◽  
Green Roofs ◽  
Natural Form ◽  
Green Wall ◽  
Biological Surfaces ◽  
Potential Benefits ◽  
Green Walls ◽  
Urbanized Areas ◽  
Interesting Alternative

Abstract Modern materials and construction solutions draw more and more attention to ecology and building certification. Among the criteria appearing in revitalization, an important element is bringing plants back into heavily urbanized areas. In its natural form, this is not possible to carry out everywhere, often requiring large amounts of space. Nowadays, however, there are a number of green roofs and green wall systems, allowing “greener” construction without making significant changes in the urban environment. The article includes a presentation and analysis of selected solutions of biological surfaces known as green roofs and green walls, specifying various solutions and their most important features. The case study focuses primarily on material and design solutions, as well as the potential benefits, risks and limitations in their use. Plants structures on the surfaces of vertical and horizontal partitions continue to be a very interesting alternative to take into account when applying for grants, such as LEED or BREEAM certificates.

A Parallel Multiple Layer Cryolithography Device for the Manufacture of Biological Material for Tissue Engineering

2019 ◽  
Vol 13 (3) ◽  
Author(s):  
Gideon Ukpai ◽  
Joseph Sahyoun ◽  
Robert Stuart ◽  
Sky Wang ◽  
Zichen Xiao ◽  
...  
Keyword(s):  
Tissue Engineering ◽  
Additive Manufacturing ◽  
3D Printing ◽  
3D Structure ◽  
Three Dimensional ◽  
3D Object ◽  
New Device ◽  
Biological Matter ◽  
Simple Product ◽  
Printing Processes

While three-dimensional (3D) printing of biological matter is of increasing interest, current linear 3D printing processes lack the efficiency at scale required to mass manufacture products made of biological matter. This paper introduces a device for a newly developed parallel additive manufacturing technology for production of 3D objects, which addresses the need for faster, industrial scale additive manufacturing methods. The technology uses multilayer cryolithography (MLCL) to make biological products faster and in larger quantities by simultaneously printing two-dimensional (2D) layers in parallel and assembling the layers into a 3D structure at an assembly site, instead of sequentially and linearly assembling a 3D object from individual elements as in conventional 3D printing. The technique uses freezing to bind the 2D layers together into a 3D object. This paper describes the basic principles of MLCL and demonstrates the technology with a new device used to manufacture a very simple product that could be used for tissue engineering, as an example. An evaluation of the interlayer bonding shows that a continuous and coherent structure can be made from the assembly of distinct layers using MLCL.

Additive manufacturing as an emerging technology for fabrication of microelectromechanical systems (MEMS)

2019 ◽  
Vol 2 (2) ◽  
pp. 175-197 ◽  
Author(s):  
Sanjay Kumar ◽  
Pulak Bhushan ◽  
Mohit Pandey ◽  
Shantanu Bhattacharya
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Microelectromechanical Systems ◽  
Manufacturing Sector ◽  
Process Improvements ◽  
Recent Success ◽  
Mems Fabrication ◽  
Recent Developments ◽  
Potential Applications ◽  
Printing Processes

The recent success of additive manufacturing processes (also called, 3D printing) in the manufacturing sector has led to a shift in the focus from simple prototyping to real production-grade technology. The enhanced capabilities of 3D printing processes to build intricate geometric shapes with high precision and resolution have led to their increased use in fabrication of microelectromechanical systems (MEMS). The 3D printing technology has offered tremendous flexibility to users for fabricating custom-built components. Over the past few decades, different types of 3D printing technologies have been developed. This article provides a comprehensive review of the recent developments and significant achievements in most widely used 3D printing technologies for MEMS fabrication, their working methodology, advantages, limitations, and potential applications. Furthermore, some of the emerging hybrid 3D printing technologies are discussed, and the current challenges associated with the 3D printing processes are addressed. Finally, future directions for process improvements in 3D printing techniques are presented.

Manufacturability Feedback and Model Correction for Additive Manufacturing

2014 ◽  
Author(s):  
Saigopal Nelaturi ◽  
Walter Kim ◽  
Arvind Rangarajan ◽  
Tolga Kurtoglu
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Medial Axis ◽  
Three Dimensional ◽  
Medial Axis Transform ◽  
Specific Design ◽  
Model Correction ◽  
Geometric Deviations ◽  
Physical Limitations ◽  
Printing Processes

Additive manufacturing, or 3d printing, is the process of building three dimensional solid shapes by accumulating material laid out in sectional layers. Additive manufacturing has been recognized for enabling production of complex custom parts that are difficult to manufacture otherwise. However, the dependence on build orientation and physical limitations of printing processes invariably lead to geometric deviations between manufactured and designed shapes that are usually evaluated after manufacture. In this paper, we formalize the measurement of such deviations in terms of a printability map that simulates the printing process and partitions each printed layer into disjoint regions with distinct local measures of size. We show that manufacturing capabilities such as printing resolution, and material specific design recommendations such as minimal feature sizes may be coupled in the printability map to evaluate expected deviations before manufacture. Furthermore, we demonstrate how partitions with size measures below required resolutions may be modified using properties of the medial axis transform, and use the corrected printability map to construct a representation of the manufactured model. We conclude by discussing several applications of the printability map for additive manufacturing.

Digital Solutions for Integrated and Collaborative Additive Manufacturing

2016 ◽  
Author(s):  
Yan Lu ◽  
Paul Witherell ◽  
Felipe Lopez ◽  
Ibrahim Assouroko
Keyword(s):  
Additive Manufacturing ◽  
Analytical Framework ◽  
Knowledge Bases ◽  
Software Tools ◽  
Data Models ◽  
Development Environment ◽  
Manufacturing Operations ◽  
Support Tools ◽  
Product Design Process

Software tools, knowledge of materials and processes, and data provide three pillars on which Additive Manufacturing (AM) lifecycles and value chains can be supported. These pillars leverage efforts dedicated to the development of AM databases, high-fidelity models, and design and planning support tools. However, as of today, it remains a challenge to integrate distributed AM data and heterogeneous predictive models in software tools to drive a more collaborative AM development environment. In this paper, we describe the development of an analytical framework for integrated and collaborative AM development. Information correlating material, product design, process planning and manufacturing operations are captured and managed in the analytical framework. A layered structure is adopted to support the composability of data, models and knowledge bases. The key technologies to enable composability are discussed along with a suite of tools that assist designers in the management of data, models and knowledge components. A proof-of-concept case study demonstrates the potential of the AM analytical framework.

Sign in / Sign up

Export Citation Format

Share Document