Emerging Rapid Manufacturing Processes

2006 ◽  
pp. 55-80 ◽  
Author(s):  
Neil Hopkinson ◽  
Phill Dickens
Keyword(s):  
Rapid Manufacturing ◽  
Manufacturing Processes

A Methodological Approach to Radical Technological Changes and Improvements in Electron Beam Technology

2010 ◽  
Author(s):  
Marco Cavallaro ◽  
Giovanni Moroni ◽  
Michael Zaeh ◽  
Stefan Lutzmann ◽  
Markus Kahnert
Keyword(s):  
Decision Making ◽  
Electron Beam ◽  
Statistical Approach ◽  
Methodological Approach ◽  
Dimensional Accuracy ◽  
Rapid Manufacturing ◽  
Manufacturing Processes ◽  
Technological Changes ◽  
Integrated Methodology ◽  
Influencing Parameters

Predicting of the optimal machining conditions for experimental results and dimensional accuracy plays an important role in process planning. In addition, whenever there is a new unknown process, great importance has to be placed on the estimation of all operative conditions with rational and logical planning methodologies. The aim of this work is to obtain feasible conditions for Electron Beam (EB) technology, using a welding machine, which is then converted for additive manufacturing processes. At the beginning of the research there was a state of uncertainty about the influencing parameters and the use of EB for rapid manufacturing process; a multi-disciplinary and integrated methodology was then performed in order to carry out the work. The proposed methodology is composed of several techniques, including a method to support multi-decision making problems and a statistical approach.

Rapid Manufacturing with Direct Metal Laser Sintering

2002 ◽  
Vol 758 ◽  
Author(s):  
J-E. Lind ◽  
J. Hanninen ◽  
J. Kotila ◽  
O. Nyrhila ◽  
T. Syvanen
Keyword(s):  
Surface Roughness ◽  
Layer Thickness ◽  
Process Development ◽  
Die Casting ◽  
Laser Sintering ◽  
Thin Layers ◽  
Rapid Manufacturing ◽  
Manufacturing Processes ◽  
Direct Metal Laser Sintering ◽  
Process Work

ABSTRACTThe term Rapid Manufacturing is today very often used as a substitute for Rapid Prototyping, because the manufacturing processes and materials have developed so much that the parts produced with the machines can even be used as functional production parts. For Direct Metal Laser Sintering (DMLS) this was enabled by the introduction of the powders for 20 micron layer thickness; steel-based powder in 2001 and bronze-based powder in 2002. Successful rapid manufacturing with DMLS does not only mean the reduction of layer thickness, but it is a sum of many factors that had to be optimized in order to make the process work with the 20 micron layer thickness: the metal powder behavior in very thin layers is not the same as with thicker layers, the demands for the support structures are higher and the possibility of using multiples of the layer thickness gives additional freedom. By optimizing the process parameters the UTS values for the steel-based powder increased up to 600 MPa and for the bronze-based powder up to 400 MPa. At the same time the surface roughness (Ra) values after shot peening were 3 microns and 2 microns, respectively. Although using thinner layers also increases the building time the advantage is gained in drastically reduced finishing times due to increased surface quality and detail resolution. Typical geometries produced by DMLS are difficult-to-manufacture components and components typically produced by P/M or even by die-casting. The paper covers the development aspects in both material and process development and also presents some realized case studies.

Analysis of the Quality of Rapid Manufacturing Technology Based on the Silicone Rubber Mold

2013 ◽  
Vol 432 ◽  
pp. 253-257
Author(s):  
Xue Fang Chen ◽  
Jian Hong Du ◽  
Hong Wei Li
Keyword(s):  
Silicone Rubber ◽  
Manufacturing Technology ◽  
Curing Temperature ◽  
Rapid Manufacturing ◽  
Manufacturing Processes ◽  
Exhaust Port ◽  
Channel Distribution ◽  
Mold Making ◽  
Silicone Rubber Mold

The rapid manufacturing processes include making prototype mold, making silicone rubber mold and pouring parts. According to the study of rapid manufacturing based on silicone rubber mold, factors that impact the characteristics of products, the quality of surface and the accuracy of dimension are discovered. The curing temperature and time affect the properties of products. The smoothness of prototype surface, gate position, exhaust port position, channel distribution and pouring speed affect the quality of the products surface. The shrinkage of the material affects the accuracy of products dimension. Moreover, some measures and methods that improve the products quality also be illustrated.

scholarly journals Optimization of roughing operations in CNC machining for rapid manufacturing processes

2014 ◽  
Vol 2 (1) ◽  
pp. 519-529 ◽  
Author(s):  
Muhammed Nafis Osman Zahid ◽  
Keith Case ◽  
Darren Watts
Keyword(s):  
Cnc Machining ◽  
Rapid Manufacturing ◽  
Manufacturing Processes

scholarly journals Analysis of rapid manufacturing—using layer manufacturing processes for production

2003 ◽  
Vol 217 (1) ◽  
pp. 31-39 ◽  
Author(s):  
N Hopkinson ◽  
P Dicknes
Keyword(s):  
Computer Aided Design ◽  
Unit Cost ◽  
Three Dimensional ◽  
Rapid Manufacturing ◽  
Fused Deposition Modelling ◽  
Manufacturing Processes ◽  
Fused Deposition ◽  
Layer Manufacturing ◽  
End Use ◽  
Traditional Manufacturing

Rapid prototyping (RP) technologies that have emerged over the last 15 years are all based on the principle of creating three-dimensional geometries directly from computer aided design (CAD) by stacking two-dimensional profiles on top of each other. To date most RP parts are used for prototyping or tooling purposes; however, in future the majority may be produced as end-use products. The term ‘rapid manufacturing’ in this context uses RP technologies as processes for the production of end-use products. This paper reports findings from a cost analysis that was performed to compare a traditional manufacturing route (injection moulding) with layer manufacturing processes (stereolithography, fused deposition modelling and laser sintering) in terms of the unit cost for parts made in various quantities. The results show that, for some geometries, it is more economical to use layer manufacturing methods than it is to use traditional approaches for production in the thousands.

Numerical Simulation of Random Packing of Spherical Particles for Powder-Based Additive Manufacturing

2009 ◽  
Vol 131 (3) ◽  
Author(s):  
Jianhua Zhou ◽  
Yuwen Zhang ◽  
J. K. Chen
Keyword(s):  
Additive Manufacturing ◽  
Pair Distribution Function ◽  
Random Packing ◽  
Spherical Particles ◽  
Rapid Manufacturing ◽  
Manufacturing Processes ◽  
Packing Structure ◽  
Sequential Addition ◽  
Traditional Manufacturing ◽  
Complex Parts

Powder-based additive manufacturing is an efficient and rapid manufacturing technique because it allows fabrication of complex parts that are often unobtainable by traditional manufacturing processes. A better understanding of the packing structure of the powder is urgently needed for the powder-based additive manufacturing. In this study, the sequential addition packing algorithm is employed to investigate the random packing of spherical particles with and without shaking effect. The 3D random packing structures are demonstrated by illustrative pictures and quantified in terms of pair distribution function, coordination number, and packing density. The results are presented and discussed aiming to produce the desirable packing structures for powder-based additive manufacturing.

The potential of electrospinning in rapid manufacturing processes

2011 ◽  
Vol 6 (2) ◽  
pp. 63-77 ◽  
Author(s):  
Geoffrey R. Mitchell ◽  
Kyung-hwa Ahn ◽  
Fred J. Davis
Keyword(s):  
Rapid Manufacturing ◽  
Manufacturing Processes
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