Produktivitätssteigerung durch Hybridisierung im 3D-Druck/Process development for the automated production of plastic parts with integrated functional components. Increased productivity through hybridization in 3D printing

2020 ◽  
Vol 110 (07-08) ◽  
pp. 521-525
Author(s):  
Michael Baranowski ◽  
Markus Netzer ◽  
Sven Coutandin ◽  
Jürgen Fleischer
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Process ◽  
Process Development ◽  
Flexible Production ◽  
Additive Fertigung ◽  
Automated Production ◽  
Individualized Production ◽  
Plastic Parts ◽  
Functional Components

Die additive Fertigung erlaubt eine standortunabhängige sowie de facto individualisierte Produktion von Bauteilen mit nahezu beliebiger Komplexität. Für die flexible Herstellung von hochfunktionalen Hybridbauteilen fehlt es allerdings an entsprechenden Maschinenkonzepten sowie Automatisierungslösungen. Durch ein hier vorgestelltes Anlagenkonzept sollen Funktionskomponenten in den additiven Herstellungsprozess integriert und neue Möglichkeiten der Bauteilhybridisierung erforscht werden.   Additive manufacturing allows a location-independent and de facto individualized production of components of almost any complexity. However, there is a need for appropriate machine concepts and automation solutions for the flexible production of highly functional hybrid components. A plant concept presented here is intended to integrate functional components into the additive manufacturing process and to explore new possibilities for component hybridization.

Thermal, structural, and mechanical effects of nanofibrillated cellulose in polylactic acid filaments for additive manufacturing

BioResources ◽  
2020 ◽  
Vol 15 (4) ◽  
pp. 7954-7964
Author(s):  
Diego Gomez-Maldonado ◽  
Maria Soledad Peresin ◽  
Christina Verdi ◽  
Guillermo Velarde ◽  
Daniel Saloni
Keyword(s):  
Tensile Strength ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Polylactic Acid ◽  
Modulus Of Elasticity ◽  
Manufacturing Process ◽  
Thermal Characterization ◽  
Nanofibrillated Cellulose ◽  
Small Decrease ◽  
The Matrix

As the additive manufacturing process gains worldwide importance, the need for bio-based materials, especially for in-home polymeric use, also increases. This work aims to develop a composite of polylactic acid (PLA) and nanofibrillated cellulose (NFC) as a sustainable approach to reinforce the currently commercially available PLA. The studied materials were composites with 5 and 10% NFC that were blended and extruded. Mechanical, structural, and thermal characterization was made before its use for 3D printing. It was found that the inclusion of 10% NFC increased the modulus of elasticity in the filaments from 2.92 to 3.36 GPa. However, a small decrease in tensile strength was observed from 55.7 to 50.8 MPa, which was possibly due to the formation of NFC aggregates in the matrix. This work shows the potential of using PLA mixed with NFC for additive manufacturing.

Finite Element Analysis of Additive Manufacturing Based on Fused Deposition Modeling: Distortions Prediction and Comparison With Experimental Data

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
Alberto Cattenone ◽  
Simone Morganti ◽  
Gianluca Alaimo ◽  
Ferdinando Auricchio
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Step Size ◽  
Time Step ◽  
Time Step Size ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
The Impact ◽  
Functional Components

Additive manufacturing (or three-dimensional (3D) printing) is constantly growing as an innovative process for the production of complex-shape components. Among the seven recognized 3D printing technologies, fused deposition modeling (FDM) covers a very important role, not only for producing representative 3D models, but, mainly due to the development of innovative material like Peek and Ultem, also for realizing structurally functional components. However, being FDM a production process involving high thermal gradients, non-negligible deformations and residual stresses may affect the 3D printed component. In this work we focus on meso/macroscopic simulations of the FDM process using abaqus software. After describing in detail the methodological process, we investigate the impact of several parameters and modeling choices (e.g., mesh size, material model, time-step size) on simulation outcomes and we validate the obtained results with experimental measurements.

Laser Consolidation: A Novel Additive Manufacturing Process for Making Net-Shape Functional Metallic Components for Gas Turbine Applications

2015 ◽  
Author(s):  
Lijue Xue ◽  
Yangsheng Li ◽  
Jianyin Chen ◽  
Shaodong Wang
Keyword(s):  
Additive Manufacturing ◽  
Gas Turbine ◽  
Manufacturing Process ◽  
High Performance ◽  
National Research Council ◽  
Dimensional Accuracy ◽  
Materials Used ◽  
Manufacturing Technologies ◽  
Metallic Parts ◽  
Functional Components

Laser consolidation (LC) is a novel additive manufacturing process being developed by the National Research Council Canada (NRC) at its London facility. LC offers unique capabilities in the production of net-shape functional metallic parts requiring no further post-machining. NRC’s LC technology has achieved dimensional accuracy of up to +/−0.05 mm with a surface finish up to 1 μm Ra (depending on the materials used in the manufacturing process). The LC process differs from other additive manufacturing technologies by its high precision deposition system that can build functional parts or features on top of existing parts using various high performance materials and alloys. In this paper, laser consolidation of various high performance materials (such as Ni-base super alloys and Ti-6Al-4V alloy) will be discussed and the examples will be given on building complex functional components and repairing parts otherwise unrepairable for gas turbine and other applications.

Foam additive manufacturing technology: main characteristics and experiments for hull mold manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Elodie Paquet ◽  
Alain Bernard ◽  
Benoit Furet ◽  
Sébastien Garnier ◽  
Sébastien Le Loch
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Process ◽  
Manufacturing Industry ◽  
Pressure Head ◽  
Manufacturing Technology ◽  
Cnc Machining ◽  
Numerical Control ◽  
Content Type ◽  
Additive Manufacturing Technology

Purpose The purpose of this paper is to present a novel methodology to produce a large boat hull with a foam additive manufacturing (FAM) process. To respond to shipping market needs, this new process is being developed. FAM technology is a conventional three-dimensional (3D) printing process whereby layers are deposited onto a high-pressure head mounted on a six-axis robotic arm. Traditionally, molds and masters are made with computer numerical control (CNC) machining or finished by hand. Handcrafting the molds is obviously time-consuming and labor-intensive, but even CNC machining can be challenging for parts with complex geometries and tight deadlines. Design/methodology/approach The proposed FAM technology focuses on the masters and molds, that are directly produced by 3D printing. This paper describes an additive manufacturing technology through which the operator can create a large part and its tools using the capacities of this new FAM technology. Findings The study shows a comparison carried out between the traditional manufacturing process and the additive manufacturing process, which is illustrated through an industrial case of application in the manufacturing industry. This work details the application of FAM technology to fabricate a 2.5 m boat hull mold and the results show the time and cost savings of FAM in the fabrication of large molds. Originality/value Finally, the advantages and drawbacks of the FAM technology are then discussed and novel features such as monitoring system and control to improve the accuracy of partly printed are highlighted.

scholarly journals Ceramic-Based 4D-Components: Additive Manufacturing (AM) of Ceramic-Based Functionally Graded Materials (FGM) by Thermoplastic 3D-Printing (T3DP)

2017 ◽  
Author(s):  
Uwe Scheithauer ◽  
Steven Weingarten ◽  
Robert Johne ◽  
Eric Schwarzer ◽  
Johannes Abel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Functionally Graded Materials ◽  
Functionally Graded ◽  
Brick Wall ◽  
Graded Materials ◽  
Material Test ◽  
Functional Components

In our study we investigated the additive manufacturing (AM) of ceramic-based Functionally Graded Materials (FGM) by the direct AM technology Thermoplastic 3D-Printing (T3DP). Zirconia components with a varying microstructure were additively manufactured by using thermoplastic suspensions with different contents of pore forming agents (PFA) and were co-sintered defect-free. Different materials were investigated concerning their suitability as PFA for the T3DP process. Different zirconia-based suspensions were prepared and used for AM of single- and multi-material test components. All samples were sintered defect-free and in the end we could realize a brick wall-like component consisting of dense (<1% porosity) and porous (approx. 5% porosity) zirconia areas to combine different properties in one component. The T3DP opens the door to AM of further ceramic-based 4D-components like multi-color or multi-material, especially multi-functional components.

Opportunities and challenges in additive manufacturing used in space sector:a comprehensive review

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Kashif Ishfaq ◽  
Muhammad Asad ◽  
Muhammad Arif Mahmood ◽  
Mirza Abdullah ◽  
Catalin Iulian Pruncu
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Process Development ◽  
Space Station ◽  
Mitigation Strategies ◽  
Successful Implementation ◽  
Space Applications ◽  
Content Type ◽  
Complex Parts ◽  
Space Conditions

Purpose The purpose of this study is to compile the successful implementation of three-dimensional (3D) printing in the space for the manufacturing of complex parts. 3D printing is an additive manufacturing (AM) technique that uses metallic powder, ceramic, or polymers to build simple/complex parts. The parts produced possess good strength, low weight, excellent mechanical properties and are cost-effective. This saves a considerable amount of both time and carrying cost. Thereof the challenges and opportunities that the space sector holds for AM is worth reviewing to provide a better insight into further developments and prospects for this technology. Design/methodology/approach The potentiality of 3D printing for the manufacturing of various components under space conditions has been explained. Here, the authors have reviewed the details of manufactured parts used for zero gravity missions, subjected to onboard International Space Station conditions and with those manufactured on earth. Followed by the major opportunities in 3D printing in space which include component repair, material characterization, process improvement and process development along with the new designs. The challenges such as space conditions, availability of power in space, the infrastructure requirements and the quality control or testing of the items that are being built in space are explained along with their possible mitigation strategies. Findings These components are well comparable with those prepared on earth which enables a massive cost saving. Other than the onboard manufacturing process, numerous other components and a complete robot/satellite for outer space applications were manufactured by AM. Moreover, these components can be recycled on board to produce feedstock for the next materials. The parts produced in space are bought back and compared with those built on earth. There is a difference in their nature i.e. the flight specimen showed a brittle nature and the ground specimen showed a denser nature. Originality/value The review discusses the advancements of 3D printing in space and provides numerous examples of the applications of 3D printing in space and space applications. The paper is solely dedicated to 3D printing in space. It provides a breakthrough in the literature as a limited amount of literature is available on this topic. The paper aims at highlighting all the challenges that AM faces in the space sector and also the future opportunities that await development.

Preliminary Study on Effects of the Process Parameters on Mechanical Properties in Liquid Holographic Volumetric Additive Manufacturing Process

2019 ◽  
Author(s):  
Sagil James ◽  
Thilakraj Shivakumar
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Process ◽  
Material Selection ◽  
Primary Source ◽  
Limited Range ◽  
Printing Technology ◽  
3D Printing Technology ◽  
Light Beams

Abstract The momentum of the additive manufacturing research is on a spurt. Additive manufacturing, also known as 3D printing process has been attracting the attention of the manufacturing community worldwide over the past decade. The 3D printing technology promises significant advances and applications in the area of automobiles, electronics, and medical devices and so on. However, this technology currently suffers from several limitations including large time consumption, need for support structures and limited range of material selection. This prevents its application in mass production. Holographic 3D printing, also referred to as (volumetric additive manufacturing) process is a very recent technique which uses multiple light beams intensified to form a build volume. A photosensitive liquid resin is solidified using the principle of constructive interference. The single light beam is not enough to produce the required intensity to cure the resin. While the combined interference could generate the required energy. The resulting part is printed in a fraction of seconds at once in contrast with the traditional 3D printing technology. This research studies the feasibility of a novel holographic volumetric additive manufacturing with an ultraviolet source of 365 nm as the primary source of energy. This propels the polymeric photochemical reaction between the monomer molecules. Also, experiments are conducted, incorporating various viscosity levels of the photopolymer material to suppress the oxygen dissolution. At the same time to observe the rate of curing of the photopolymer material. Finally, the mechanical properties of the build volume are analyzed.

Additive Fertigung multi-funktionaler Bauteile/Additive manufacturing of multi-functional components – Methodical product development for complex geometries, case study: Heatpipe

2020 ◽  
Vol 110 (07-08) ◽  
pp. 526-531
Author(s):  
Thomas Braun ◽  
Christoph Kiener
Keyword(s):  
Additive Manufacturing ◽  
Systems Engineering ◽  
Additive Fertigung ◽  
Powder Bed ◽  
Model Based ◽  
Functional Components ◽  
Model Based Systems Engineering ◽  
Dem Model ◽  
Monolithic Component

Bauteile mit hoher Geometriekomplexität sind wirtschaftlich attraktiv für die Herstellung mit additiven Fertigungsverfahren. Der Einsatz des V-Modells nach dem Model Based Systems Engineering (MBSE) erlaubt die Beherrschung dieser Komplexität im Entwicklungsprozess. Eine Fallstudie einer mit Laser-Strahlschmelzen (L-PBF) gefertigten Heatpipe demonstriert diese Komplexität: Wärmetransport, Nutzung des Kapillareffekts sowie eine Vakuumisolierung sind in einem monolithischen Bauteil kombiniert.   Components with high geometric complexity are economically attractive to be realized in additive manufacturing processes. Using the V-model in accordance with Model Based Systems Engineering (MBSE) addresses this complexity in the development process. A case study of a heatpipe manufactured using laser powder bed fusion (L-PBF) demonstrates this complexity: Heat transport, use of capillary effect and vacuum insulation are combined into one monolithic component.

scholarly journals Ready for Anything?

2021 ◽  
Vol 143 (3) ◽  
pp. 30-35
Author(s):  
Carlos M. Gonzalez
Keyword(s):  
Supply Chain ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Flexible Production ◽  
The Future

Abstract Stories of using 3D printing to respond to the pandemic throw a spotlight on additive manufacturing and its potential for fast, flexible production of critically needed parts. Whether it was face shields, nasopharyngeal swabs, or respiratory masks, additive manufacturing rose to the challenge to fill in the gap caused by a disrupted supply chain. Now, some industry observers are starting to ask whether 3D printing could be the future of manufacturing.

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