Design and Fabrication of Structural Connections Using Bi-Directional Evolutionary Structural Optimization and Additive Manufacturing

2016 ◽  
Vol 846 ◽  
pp. 571-576 ◽  
Author(s):  
Hamed Seifi ◽  
Mike Xie ◽  
James O’Donnell ◽  
Nicholas Williams
Keyword(s):  
Additive Manufacturing ◽  
Structural Optimization ◽  
Large Scale ◽  
Limited Area ◽  
Complex Structures ◽  
Evolutionary Structural Optimization ◽  
3D Printed ◽  
Structural Connections ◽  
Definition Of ◽  
Processing Steps

The need to simplify the construction issues of complex structures leads to definition of SmartNodes project as a research which aims to confine the complexity of structure to a limited area (nodes) in order to decrease processing steps and labor intensity by application of additive manufacturing (AM) techniques. Bi-Directional Evolutionary Structural Optimization (BESO) is used to design efficient and elegant nodal connections of large scale spatial structures and minimise the volume of nodes to be printed and to ultimately replace welded, forged and cast connections by 3D printed connections. The prototypes discussed in this paper demonstrate BESO design process through two generic cases.

History of Additive Manufacturing

2017 ◽  
pp. 1-24 ◽  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Large Scale ◽  
Selective Laser Sintering ◽  
3D Printer ◽  
3D Objects ◽  
History Of ◽  
Pros And Cons ◽  
3D Printed ◽  
The Common

History of additive manufacturing started in the 1980s in Japan. Stereolithography was invented first in 1983. After that tens of other techniques were invented under the common name 3D printing. When stereolithography was invented rapid prototyping did not exists. Tree years later new technique was invented: selective laser sintering (SLS). First commercial SLS was in 1990. At the end of 20t century, first bio-printer was developed. Using bio materials, first kidney was 3D printed. Ten years later, first 3D Printer in the kit was launched to the market. Today we have large scale printers that printed large 3D objects such are cars. 3D printing will be used for printing everything everywhere. List of pros and cons questions rising every day.

scholarly journals Surface Preparation and Treatment for Large-Scale 3D-Printed Composite Tooling Coating Adhesion

Coatings ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 457 ◽  
Author(s):  
Philipp Sauerbier ◽  
James Anderson ◽  
Douglas Gardner
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Lower Cost ◽  
Numerical Control ◽  
Fused Deposition Modelling ◽  
Filler Materials ◽  
Coating Adhesion ◽  
Fused Deposition ◽  
Composite Tooling ◽  
3D Printed

Recent advances in large-scale thermoplastic additive manufacturing (AM), using fused deposition modelling (FDM), have shown that the technology can effectively produce large aerospace tools with common feed stocks, costing 2.3 $/kg, such as a 20% carbon-filled acrylonitrile butadiene styrene (ABS). Large-scale additive manufacturing machines have build-volumes in the range of cubic meters and use commercially available pellet feedstock thermoplastics, which are significantly cheaper (5–10 $/kg) than the filament feedstocks for desktop 3D printers (20–50 $/kg). Additionally, large-scale AM machines have a higher material throughput on the order of 50 kg/h. This enables the cost-efficient tool production for several industries. Large-scale 3D-printed tooling will be computerized numerical control (CNC)-machined and -coated, to provide a surface suitable for demolding the composite parts. This paper outlines research undertaken to review and improve the adhesion of the coating systems to large, low-cost AM composite tooling, for marine or infrastructure composite applications. Lower cost tooling systems typically have a lower dimensional accuracy and thermal operating requirements than might be required for aerospace tooling. As such, they can use lower cost commodity grade thermoplastics. The polymer systems explored in the study included polypropylene (PP), styrene-maleic anhydride (SMA), and polylactic acid (PLA). Bio-based filler materials were used to reduce cost and increase the strength and stiffness of the material. Fillers used in the study included wood flour, at 30% by weight and spray-dried cellulose nano-fibrils, at 20% by weight. Applicable adhesion of the coating was achieved with PP, after surface treatment, and untreated SMA and PLA showed desirable coating adhesion results. PLA wood-filled composites offered the best properties for the desired application and, furthermore, they have environment-friendly advantages.

scholarly journals Property Analysis of Photo-Polymerization-Type 3D-Printed Structures Based on Multi-Composite Materials

2021 ◽  
Vol 11 (18) ◽  
pp. 8545
Author(s):  
So-Ree Hwang ◽  
Min-Soo Park
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Composite Materials ◽  
3D Printing ◽  
Bending Test ◽  
3D Printer ◽  
Complex Structures ◽  
Photo Polymerization ◽  
Anisotropic Structures ◽  
3D Printed

Additive manufacturing, commonly called 3D printing, has been studied extensively because it can be used to fabricate complex structures; however, polymer-based 3D printing has limitations in terms of implementing certain functionalities, so it is limited in the production of conceptual prototypes. As such, polymer-based composites and multi-material 3D printing are being studied as alternatives. In this study, a DLP 3D printer capable of printing multiple composite materials was fabricated using a movable separator and structures with various properties were fabricated by selectively printing two composite materials. After the specimen was fabricated based on the ASTM, the basic mechanical properties of the structure were compared through a 3-point bending test and a ball rebound test. Through this, it was shown that structures with various mechanical properties can be fabricated using the proposed movable-separator-based DLP process. In addition, it was shown that this process can be used to fabricate anisotropic structures, whose properties vary depending on the direction of the force applied to the structure. By fabricating multi-joint grippers with varying levels of flexibility, it was shown that the proposed process can be applied in the fabrication of soft robots as well.

scholarly journals Design for Additive Manufacturing and Advanced Development Methods Applied to an Innovative Multifunctional Fan

2020 ◽  
pp. 52-85
Author(s):  
Leonardo Frizziero ◽  
Giampiero Donnici ◽  
Alfredo Liverani ◽  
Karim Dhaimini
Keyword(s):  
Additive Manufacturing ◽  
Quality Function Deployment ◽  
Large Scale ◽  
Three Dimensional ◽  
Product Development Process ◽  
Business Success ◽  
Scale Production ◽  
Key Factor ◽  
Definition Of

In an increasingly competitive business world, the “time to market” of products has become a key factor for business success. There are different techniques that anticipate design mistakes and launch products on the market in less time. Among the most used methodologies in the design and definition of the requirements, quality function deployment (QFD) and design for Six Sigma (DFSS) can be used. In the prototyping phase, it is possible to address the emerging technology of additive manufacturing. Today, three-dimensional printing is already used as a rapid prototyping technique. However, the real challenge that industry is facing is the use of these machineries for large-scale production of parts, now possible with new HP multi-fusion. The aim of this article is to study the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (lamp, aroma diffuser and fan) through the Multi Jet Fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP's Multi Jet Fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

Lessons Learnt from a National Competition on Structural Optimization and Additive Manufacturing

2020 ◽  
Vol 1 (1) ◽  
pp. 151-159
Author(s):  
Yulin Xiong ◽  
Dingwen Bao ◽  
Xin Yan ◽  
Tao Xu ◽  
Yi Min Xie
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Structural Optimization ◽  
Optimization Approach ◽  
Loading Test ◽  
Highly Efficient ◽  
Evolutionary Structural Optimization ◽  
National Competition ◽  
Optimal Material ◽  
Manufacturing Technologies

Background:: As an advanced design technique, topology optimization has received much attention over the past three decades. Topology optimization aims at finding an optimal material distribution in order to maximize the structural performance while satisfying certain constraints. It is a useful tool for the conceptional design. At the same time, additive manufacturing technologies have provided unprecedented opportunities to fabricate intricate shapes generated by topology optimization. Objective:: To design a highly efficient structure using topology optimization and to fabricate it using additive manufacturing. Method:: The bi-directional evolutionary structural optimization (BESO) technique provides the conceptional design, and the topology-optimized result is post-processed to obtain smooth structural boundaries. Results:: We have achieved a highly efficient and elegant structural design which won the first prize in a national competition in China on design optimization and additive manufacturing. Conclusion:: In this paper, we present an effective topology optimization approach to maximize the structural load-bearing capacity and establish a procedure to achieve efficient and elegant structural designs. : In the loading test of the final competition, our design carried the highest loading and won the first prize in the competition, which demonstrates the capability of BESO in engineering applications.

scholarly journals Process and Evaluation of Automated Robotic Fabrication System for In-Situ Structure Confinement

2021 ◽  
pp. 368-379
Author(s):  
B. Bala Murali Kumar ◽  
Yun Chung Hsueh ◽  
Zhuoyang Xin ◽  
Dan Luo
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Rapid Progression ◽  
Additive Process ◽  
Manufacturing Method ◽  
Robotic Fabrication ◽  
Fibre Reinforced Polymer ◽  
3D Printed ◽  
Fabrication Parameters

AbstractThe additive manufacturing process is gaining momentum in the construction industry with the rapid progression of large-scale 3D printed technologies. An established method of increasing the structural performance of concrete is by wrapping it with Fibre Reinforced Polymer (FRP). This paper proposes a novel additive process to fabricate a FRP formwork by dynamic layer winding of the FRP fabric with epoxy resin paired with an industrial scale robotic arm. A range of prototypes were fabricated to explore and study the fabrication parameters. Based on the systemic exploration, the limitations, the scope, and the feasibility of the proposed additive manufacturing method is studied for large scale customisable structural formworks.

Definition of Parameters by Process of Additive Manufacturing for Tactile Perception

2017 ◽  
Author(s):  
Sandra Regina Marchi ◽  
Maria Lucia Okimoto ◽  
ALESSANDRO MARQUES ◽  
Ramón Sigifredo Cortés Paredes ◽  
Rafael Lima Vieira
Keyword(s):  
Additive Manufacturing ◽  
Tactile Perception ◽  
Definition Of
Sign in / Sign up

Export Citation Format

Share Document