Design and Development of a Mold for Patternless Casting Using AM/3D Printing

2021 ◽  
Vol 1033 ◽  
pp. 98-102
Author(s):  
Taha Waqar ◽  
Muhammad Azhar Ali Khan ◽  
Muhammad Asad ◽  
Faramarz Djavanroodi ◽  
Jamal Nayfeh
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Large Scale ◽  
Casting Process ◽  
Mold Material ◽  
Mold Design ◽  
3D Design ◽  
Casting Mold ◽  
Direct Printing ◽  
Cad Modelling

Additive manufacturing is a technology that is influencing every facet of manufacturing such as casting. 3D printing in particular has the potential to revolutionize castings in terms of precision and time taken in production. Patternless molds increase the efficiency of the casting process for large scale manufactured components. Therefore, ceramic based molds can be utilized for low temperature alloy parts such as mounting brackets. Nowadays, 3D printing technologies allow the direct printing of these molds. This is possible with the aid of CAD modelling of the casting mold which allows instant printing of patternless molds. The aim of this work is to introduce an approach to prepare a 3D design for a casting mold that can be manufactured using 3D printing technology. Mold design was made using Solidworks software according to standardized calculations from which cope and drag components were extracted. Candidates for potential mold material are highlighted along with advantages & limitations of utilizing 3D printing methodology.

scholarly journals Design and Simulation on Investment Casting Mold for Metal Matrix Composite Material

2011 ◽  
Vol 66-68 ◽  
pp. 1676-1681 ◽  
Author(s):  
Taufik ◽  
Shamsuddin Sulaiman ◽  
B.T. Hang Tuah Baharudin ◽  
M.K.A.M. Arifin ◽  
Arep Ariff Hambali
Keyword(s):  
Composite Material ◽  
Investment Casting ◽  
Metal Matrix ◽  
Casting Process ◽  
Mold Design ◽  
Casting Mold ◽  
Compressor Impeller ◽  
Investment Casting Process ◽  
Temperature And Pressure ◽  
Metal Matrix Composite Material

This paper presents the design and simulation on investment casting mold for metal matrix composite material. The study was investigating the design parameters for the casting mold and simulated the temperature and pressure on the mold. Compressor impeller selected as the product of the study. Among the various types of casting techniques, investment casting process is the most suitable process to produce the compressor impeller. The alternative design of casting mold of investment casting was generated using CAD software. Concept scoring was prepared to select the suitable design for the investment casting process. Material selection of compressor is Aluminum Silicon Carbide. Stainless steel AISI H13 is selected as the material for the mold. The parameter for the mold design is included branch, gating, sprue and runner. The analysis was presented to the mold by using ANSYS simulation tool to determine the temperature and pressure of the mold. In addition, three case studies were presented and compared the static pressure in different velocity and temperature of the mold design. The result showed the runner and the branch size were important to produce the molten metal flow into the mold pattern. As a result, the design of investment casting mold was proposed.

Energy Efficient Multi-Robotic 3D Printing for Large-Scale Construction – Framework, Challenges, and a Systematic Approach

2021 ◽  
Author(s):  
Azadeh Haghighi ◽  
Abdullah Mohammed ◽  
Lihui Wang
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Energy Efficient ◽  
Large Scale ◽  
Systematic Approach ◽  
Smart Manufacturing ◽  
Energy Aware ◽  
Robot Positioning ◽  
Novel Concept ◽  
And Control

Abstract An emerging trend in smart manufacturing of the future is robotic additive manufacturing or 3D printing which introduces numerous advantages towards fast and efficient printing of high-quality customized products. In the case of the construction industry, and specifically in large-scale settings, multi-robotic additive manufacturing (i.e., adopting a team of 3D printer robots) has been found to be a promising solution in order to overcome the existing size limitations. Consequently, several research efforts regarding the development and control of such robotic additive manufacturing solutions have been reported in the literature. However, given the increasing environmental concerns, establishing novel methodologies for energy-efficient processing and planning of these systems towards higher sustainability is necessary. This paper presents a novel framework towards energy-efficient multi-robotic additive manufacturing and describes the overall challenges with respect to the energy efficiency. The energy module of the proposed framework is implemented in a simulation environment. In addition, a systematic approach for energy-aware robot positioning is introduced based on the novel concept of reciprocal energy map. The reciprocal energy map is established based on the original energy map calculated by the energy module and can be used for identifying the low energy zones for positioning and relocation of robots during the printing process.

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 Material Extrusion Additive Manufacturing of Wood and Lignocellulosic Filled Composites

Polymers ◽  
2020 ◽  
Vol 12 (9) ◽  
pp. 2115
Author(s):  
Meghan E. Lamm ◽  
Lu Wang ◽  
Vidya Kishore ◽  
Halil Tekinalp ◽  
Vlastimil Kunc ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Present State ◽  
Material Properties ◽  
Large Scale ◽  
State Of The Art ◽  
Material Extrusion ◽  
Functional Additives ◽  
Natural Filler ◽  
Natural Fillers

Wood and lignocellulosic-based material components are explored in this review as functional additives and reinforcements in composites for extrusion-based additive manufacturing (AM) or 3D printing. The motivation for using these sustainable alternatives in 3D printing includes enhancing material properties of the resulting printed parts, while providing a green alternative to carbon or glass filled polymer matrices, all at reduced material costs. Previous review articles on this topic have focused only on introducing the use of natural fillers with material extrusion AM and discussion of their subsequent material properties. This review not only discusses the present state of materials extrusion AM using natural filler-based composites but will also fill in the knowledge gap regarding state-of-the-art applications of these materials. Emphasis will also be placed on addressing the challenges associated with 3D printing using these materials, including use with large-scale manufacturing, while providing insight to overcome these issues in the future.

scholarly journals Study of Additive Manufacturing for the Aircraft Industry

2020 ◽  
Vol 10 (2) ◽  
pp. 181-187
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Large Scale ◽  
Sufficient Information ◽  
Aircraft Industry ◽  
Scale Production ◽  
Printing Technology ◽  
3D Printing Technology ◽  
Traditional Manufacturing ◽  
Step Over

This is a review paper on 3D printing, its significance, and future scope in the aircraft industry.In this article, additive manufacturing is compared with traditional manufacturing in the context of the aircraft industry that gives more accurate knowledge about how additive manufacturing is more effective in terms of cost-cutting, waste prevention, customization, and large-scale production. We will go into the need for 3D printing technology, how it has taken in step over other manufacturing process and are being used for a host of different applications. The paper gives sufficient information about various types of material used in additive manufacturing with the applications, examples, requirements, and process moreover some overview of limitations as well. How Rapid tooling is used with a different process to reduce time and get more productive and efficient parts for the aircraft industries. The use of 3D printing technology in the aircraft industry plays a major role and gained immense applications. It has greatly affected the production line due to its flexibility and ease of production. It is capable of producing intricate parts, a more resilient and lightweight structure that achievesa weight reduction of 40-60%, subsequently result in a leaner cost structure, material saving, and lower fuel consumption.The last section deals with the future scope of additive manufacturing in the aircraft industry with various parameters design aircraft wings, complex design parts, additive manufacturing in space. More companies and the aerospace industry continue to see the value of 3D printing and begin developing on-site 3D printing operations and investing in the technology

Digital grotesque: Towards a micro-tectonic architecture

2013 ◽  
Vol 5 (2) ◽  
pp. 194-201
Author(s):  
Michael Hansmeyer ◽  
Benjamin Dillenburger
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Large Scale ◽  
New Technologies ◽  
Computational Design ◽  
Small Scale ◽  
Printing Technology ◽  
Recent Developments ◽  
Complex Forms ◽  
Specific Experiment

Computational design allows for architecture with an extraordinary degree of topographical and topological complexity. Limitations of traditional CNC technologies have until recently precluded this architecture from being fabricated. While additive manufacturing has made it possible to materialize these complex forms, this has occurred only at a very small scale. In trying to apply additive manufacturing to the construction of full-scale architecture, one encounters a dilemma: existing large-scale 3D printing methods can only print highly simplified shapes with rough details, while existing high-resolution technologies have limited print spaces, high costs, or material attributes that preclude a structural use. This paper provides a brief background on additive manufacturing technology and presents recent developments in sand-printing technology that overcome current 3D printing restrictions. It then presents a specific experiment, Digital Grotesque project, which is the first application of 3D sand-printing technology at an architecture scale. It describes how this project attempts to exploit the potentials of these new technologies.

A Novel Additive Manufacturing File Format for Printed Electronics

2013 ◽  
Author(s):  
Neeraj Panhalkar ◽  
Ratnadeep Paul ◽  
Sam Anand
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Printed Electronics ◽  
Form Factors ◽  
Circuit Board ◽  
File Format ◽  
Electronic Components ◽  
Direct Printing ◽  
Manufacturing Information ◽  
The Cost

Additive Manufacturing (AM) based Printed Electronics (PE) is an emerging technique where electronic components and interconnects are printed directly on substrates using a layered technique. The direct printing of the electronic components allows large scale and ultra-thin components to be printed on a wide variety of substrates including glass, silicon and plastic. These attributes make AM based Printed Electronics an invaluable manufacturing technique in the area of electronic sensors and sensor networks where thin, flexible and rugged form factors are very important. However, currently this technology is a labor intensive and manual process with the machine operator using his experience and judgment to slice the CAD file of the part to create 2D layers at different levels. This manual process increases the overall production time as well as the cost of the product and also results in inconsistent quality of parts. A major challenge faced by existing AM based Printed Electronics users for automating this process is the lack of a standard input file format that can be used by different PE machines for producing the components in layers. To leverage the capabilities of both AM and PE processes, a new file format based on the Constructive Solid Geometry (CSG) technique is proposed in this research paper. This file format data will not only include CAD data in the form of CSG primitives and Boolean representation but will also include manufacturing information related to the AM based PE process. The manufacturing information embedded within this new format will include data about the location of the different electronic components such as interconnects, resistors, capacitors, inductors, transistors, memory and substrate, and the materials required for the different components part. Different circuit board components will be represented as primitives or a combination of primitives obtained using CSG technique. In addition to the new file format, a slicing algorithm will also be developed which can be used to create the layers automatically using user inputs. The proposed file format and the slicing algorithm will be explained with the help of a case study.

The Methods of Extending the Serve Life of Die Casting Dies in Industry Domain

2012 ◽  
Vol 487 ◽  
pp. 375-378
Author(s):  
Hua Qing Lai
Keyword(s):  
Material Selection ◽  
Die Casting ◽  
Casting Process ◽  
Mold Design ◽  
Treatment Technology ◽  
Casting Mold ◽  
Die Casting Die ◽  
Heat Treatment Technology ◽  
Die Life ◽  
Processing Material

Analysis of the casting mold in the casting process of the failure of several major forms of the structure from the die casting and die-casting mold design, manufacturing and processing, material selection, heat treatment technology and the use of die-casting mold, and other aspects of maintenance and maintenance to improve die-casting die life way.

Parallelized Additive Manufacturing of Variably Partitioned Volumes for Large Scale 3D Printing With Localized Quality

2020 ◽  
Author(s):  
Mahmoud Dinar
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Large Scale ◽  
Division Problem ◽  
Material Anisotropy ◽  
Need For Support ◽  
One Machine ◽  
Small Working ◽  
Load Conditions ◽  
Missed Opportunity

Abstract Despite the growing application of additive manufacturing (AM) in fabricating complex designs, most machines suffer from small working envelopes and slow processing speeds. One workaround to the problem of small throughput in AM is to partition the volume of a desired object and fabricate sub-volumes in parallel. Prior related work has focused on two problems. One is the geometric division problem, disregarding AM benefits and challenges in determining partitions. Others attempt to install multiple AM processing heads on the same machine, ensuring seamless bonding between deposited material from different heads while avoiding interference among them. A missed opportunity lies in deploying many independent machines simultaneously while considering benefits and limitations of AM. To that end, objects too large to be fabricated on one machine, are divided primarily into cubes that exploit benefits of AM. Specifically, the cubes are hollowed out in the direction of printing to reduce weight while avoiding the need for support structure, and depending on load conditions, packed in different orientations to mitigate material anisotropy.

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