An Investigation on Achieving Sustainability in Fused Deposition Modeling via Topology Optimization

Fused deposition modeling (FDM) is one of the important additive layer manufacturing techniques, used to fabricate products from heated polymer materials. Like other manufacturing processes, sustainability interventions are desirable in FDM to attain energy and resource efficiency simultaneously with good product quality. This paper reports the results of investigation conducted by the authors on effect of topology optimization strategy on quality of FDM parts and sustainability of the process. A total of eighteen experiments have been conducted by varying infill pattern and density at three levels each for optimized and unoptimized topology, based on Taguchi L18 technique. Statistical fitness of the data has been insured by ANOVA. Both infill density and pattern have been found the significant parameters. Better mechanical strength has been obtained for topology optimized FDM parts. A set of confirmation experiments have been conducted followed by quantification of sustainability and indicated that improved mechanical properties simultaneously with enhanced sustainability can be achieved via topology optimization in FDM process

Additive Manufacturing of Flexible Material for Pneumatic Actuators Application

In this paper, endurance of peristaltic linear pneumatic actuators was studied using different hose geometries. Towards this goal, different hose geometries were additively manufactured using Fused Layer Manufacturing techniques of Thermoplastic Polyurethane Elastomer. Material properties of the elastomer were studied using Differential Scanning Calorimetry and the tensile test. The relations between the sample’s print temperature and build direction on the actuator endurance were investigated. Lastly, the relation between the geometry design of the PLPA actuator and its endurance is also discussed. Based on this methodology, authors present results showing that the use of a customized shaped hose with geometrical reinforcement at sides leads to a considerable rise in the hose endurance, when compared with the conventional circular design.

Embedded Obfuscated Barcodes for Identification of Genuine Additive Manufactured Parts

Additive manufacturing (AM) has been adopted for manufacturing complex shaped highly customized components for aerospace, automotive, and medical fields, where intellectual property protection and counterfeit detection are major concerns. New technologies such as Blockchain have been promising in supply chain authentication. However, AM due to layer-by-layer manufacturing process provides opportunities of embedding information inside the part during manufacturing, which has been explored recently to embed identification codes inside the parts. The present work studies the possibility of printing a barcode inside the additively manufactured part and develops a scheme to obfuscate the code design to read differently from different directions to enhance the security and protect the intellectual property. The embedded three-dimensional codes are scanned using a micro-CT scan. This scheme of embedded obfuscated codes proves to be a highly customizable and efficient process while securing product design files.

Geometrical Degrees of Freedom for Cellular Structures Generation: A New Classification Paradigm

Cellular structures (CSs) have been used extensively in recent years, as they offer a unique range of design freedoms. They can be deployed to create parts that can be lightweight by introducing controlled porous features, while still retaining or improving their mechanical, thermal, or even vibrational properties. Recent advancements in additive manufacturing (AM) technologies have helped to increase the feasibility and adoption of cellular structures. The layer-by-layer manufacturing approach offered by AM is ideal for fabricating CSs, with the cost of such parts being largely independent of complexity. There is a growing body of literature concerning CSs made via AM; this presents an opportunity to review the state-of-the-art in this domain and to showcase opportunities in design and manufacturing. This review will propose a novel way of classifying cellular structures by isolating their Geometrical Degrees of Freedom (GDoFs) and will explore the recent innovations in additively manufactured CSs. Based on the present work, the design inputs that are common in CSs generation will be highlighted. Furthermore, the work explores examples of how design inputs have been used to drive the design domain through various case studies. Finally, the review will highlight the manufacturability limitations of CSs in AM.

Integrating layer by layer manufacturing for the realization of polymer complex geometries with scanning devices: re-building by digital data

The additive manufacturing technique represents a way to realize components or prototypes without the use of conventional tools.The research presented aims at proposing a methodology based on the use of three different techniques that are the poly-jet 3D using UV photo-polymerization, the FDM of polyamide materials and the FDM of PLA materials. The original data were used at the beginning with the first technique in order to detect the shape and the geometry by a 3D SCANNER. The objective was the re-building of a model shape made using a procedure in which the input file characteristics were updated starting from those got by the scanning device in order to respect the original requirements defined in the computer aided environment. It was found that the physical re-building of an object is depending the characteristics of the input file that needs to be digitally processed in order to get the desired shape and geometry. In that way also FDM using PLA and polyamide materials can be utilized to get components or prototypes from scanned digital data. The results are reported in details.

POTENTIAL ANALYSIS OF ADDITIVE LAYER MANUFACTURING TECHNOLOGIES USED FOR PROCESSING POLYMER COMPONENTS

In previous years, the usage of additive layer processing grew considerably. Different companies, including motor cars, aerospace, equipment, communications and medical devices utilize additional layer production. However, at present, processed additive layer products comprise less than one percent of all items manufactured. If the prices of additive layer processing systems decline, the manner in which customers communicate with suppliers will be modified. Additional development layer innovations provide the market and culture with different possibilities. It will make the personalized development of strong lightweight goods simpler, and prototypes that with past manufacturing techniques were not feasible. However, the application of this device may be hampered and delayed by numerous obstacles. Many situations require higher costs than conventional approaches for making a component utilizing additive layer production techniques. This study reviews the cost literature for the development of additive layer and attempts to recognize situations in which additive production may be cost-effective and also to identify new methods of minimizing costs in the usage of this technology