Mask-Less Electrochemical Additive Manufacturing: A Feasibility Study

2015 ◽  
Vol 137 (2) ◽  
Author(s):  
Murali M. Sundaram ◽  
Abishek B. Kamaraj ◽  
Varun S. Kumar
Keyword(s):  
Additive Manufacturing ◽  
Electrochemical Deposition ◽  
Pulse Wave ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Simulation Studies ◽  
Feature Size ◽  
Metallic Structures ◽  
Wave Characteristics ◽  
Cad Models

Additive manufacturing (AM) of metallic structures by laser based layered manufacturing processes involve thermal damages. In this work, the feasibility of mask-less electrochemical deposition as a nonthermal metallic AM process has been studied. Layer by layer localized electrochemical deposition using a microtool tip has been performed to manufacture nickel microstructures. Three-dimensional free hanging structures with about 600 μm height and 600 μm overhang are manufactured to establish the process capability. An inhouse built CNC system was integrated in this study with an electrochemical cell to achieve 30 layers thick microparts in about 5 h by AM directly from STL files generated from corresponding CAD models. The layer thickness achieved in this process was about 10 μm and the minimum feature size depends on the tool width. Simulation studies of electrochemical deposition performed to understand the pulse wave characteristics and their effects on the localization of the deposits.

scholarly journals STUDIES ON MASK-LESS ELECTROCHEMICAL ADDITIVE MANUFACTURING

2021 ◽  
Author(s):  
Abhishek Bhardwaj
Keyword(s):  
Additive Manufacturing ◽  
High Power ◽  
Room Temperature ◽  
Three Dimensional ◽  
High Impact ◽  
Layer By Layer ◽  
Metal Parts ◽  
3D Cad ◽  
Cad Models

<div>Added substance Manufacturing (AM) of metallic designs is a warm cycle of layer by layer metal added substance fabricating measure produces parts straightforwardly from 3D CAD models. In this assembling interaction confined electrochemical affidavit joins with the added substance producing technique to make metal parts at room temperature. In this paper, the attainability of Mask-less Electrochemical Additive Manufacturing (ECAM), as a non-warm interaction is considered. Layer by layer testimony has been finished utilizing the electrochemical tips to make nickel microstructures. All the while beat wave qualities and their impacts on affidavit have been considered. </div><div>Confined electrodeposition (LED) was investigated as an AM the interaction with high power over measure boundaries and yield boundaries. The confinement of electrodeposition is completed by utilizing Ultra microelectrodes (UME) and low tossing power electrolytes. Variety in some cycle boundaries, for example, voltage and terminal hole are found to have a high impact on yield boundaries like thickness. The reproductions can anticipate the yield width of affidavit of analyses with a blunder of 8- 30%, so it can possibly apply as an added substance-producing strategy of complex three-dimensional (3D) parts on the microscale.</div>

scholarly journals STUDIES ON MASK-LESS ELECTROCHEMICAL ADDITIVE MANUFACTURING

2021 ◽  
Author(s):  
Abhishek Bhardwaj
Keyword(s):  
Additive Manufacturing ◽  
High Power ◽  
Room Temperature ◽  
Three Dimensional ◽  
High Impact ◽  
Layer By Layer ◽  
Metal Parts ◽  
3D Cad ◽  
Cad Models

<div>Added substance Manufacturing (AM) of metallic designs is a warm cycle of layer by layer metal added substance fabricating measure produces parts straightforwardly from 3D CAD models. In this assembling interaction confined electrochemical affidavit joins with the added substance producing technique to make metal parts at room temperature. In this paper, the attainability of Mask-less Electrochemical Additive Manufacturing (ECAM), as a non-warm interaction is considered. Layer by layer testimony has been finished utilizing the electrochemical tips to make nickel microstructures. All the while beat wave qualities and their impacts on affidavit have been considered. </div><div>Confined electrodeposition (LED) was investigated as an AM the interaction with high power over measure boundaries and yield boundaries. The confinement of electrodeposition is completed by utilizing Ultra microelectrodes (UME) and low tossing power electrolytes. Variety in some cycle boundaries, for example, voltage and terminal hole are found to have a high impact on yield boundaries like thickness. The reproductions can anticipate the yield width of affidavit of analyses with a blunder of 8- 30%, so it can possibly apply as an added substance-producing strategy of complex three-dimensional (3D) parts on the microscale.</div>

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

Increasing Part Accuracy in Additive Manufacturing Processes Using a k-d Tree Based Clustered Adaptive Layering

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Neeraj Panhalkar ◽  
Ratnadeep Paul ◽  
Sam Anand
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Adaptive Slicing ◽  
Stl File ◽  
Build Time ◽  
Standard File Format ◽  
Aided Design ◽  
Profile Errors

Additive manufacturing (AM) is widely used in aerospace, automobile, and medical industries for building highly accurate parts using a layer by layer approach. The stereolithography (STL) file is the standard file format used in AM machines and approximates the three-dimensional (3D) model of parts using planar triangles. However, as the STL file is an approximation of the actual computer aided design (CAD) surface, the geometric errors in the final manufactured parts are pronounced, particularly in those parts with highly curved surfaces. If the part is built with the minimum uniform layer thickness allowed by the AM machine, the manufactured part will typically have the best quality, but this will also result in a considerable increase in build time. Therefore, as a compromise, the part can be built with variable layer thicknesses, i.e., using an adaptive layering technique, which will reduce the part build time while still reducing the part errors and satisfying the geometric tolerance callouts on the part. This paper describes a new approach of determining the variable slices using a 3D k-d tree method. The paper validates the proposed k-d tree based adaptive layering approach for three test parts and documents the results by comparing the volumetric, cylindricity, sphericity, and profile errors obtained from this approach with those obtained using a uniform slicing method. Since current AM machines are incapable of handling adaptive slicing approach directly, a “pseudo” grouped adaptive layering approach is also proposed here. This “clustered slicing” technique will enable the fabrication of a part in bands of varying slice thicknesses with each band having clusters of uniform slice thicknesses. The proposed k-d tree based adaptive slicing approach along with clustered slicing has been validated with simulations of the test parts of different shapes.

Advancements in Manufacturing Technology With Additive Manufacturing and Its Context With Industry 4.0

2021 ◽  
pp. 1-24
Author(s):  
Ganzi Suresh
Keyword(s):  
Additive Manufacturing ◽  
Industry 4.0 ◽  
Industrial Revolution ◽  
Three Dimensional ◽  
Metal Alloys ◽  
Layer By Layer ◽  
Post Processing ◽  
Clear Insight ◽  
Am Processes ◽  
Insight Into

Additive manufacturing (AM) is also known as 3D printing and classifies various advanced manufacturing processes that are used to manufacture three dimensional parts or components with a digital file in a sequential layer-by-layer. This chapter gives a clear insight into the various AM processes that are popular and under development. AM processes are broadly classified into seven categories based on the type of the technology used such as source of heat (ultraviolet light, laser) and type materials (resigns, polymers, metal and metal alloys) used to fabricate the parts. These AM processes have their own merits and demerits depending upon the end part application. Some of these AM processes require extensive post-processing in order to get the finished part. For this process, a separate machine is required to overcome this hurdle in AM; hybrid manufacturing comes into the picture with building and post-processing the part in the same machine. This chapter also discusses the fourth industrial revolution (I 4.0) from the perspective of additive manufacturing.

Scalable submicrometer additive manufacturing

Science ◽  
2019 ◽  
Vol 366 (6461) ◽  
pp. 105-109 ◽  
Author(s):  
Sourabh K. Saha ◽  
Dien Wang ◽  
Vu H. Nguyen ◽  
Yina Chang ◽  
James S. Oakdale ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Design Space ◽  
Three Dimensional ◽  
Complex Structures ◽  
Layer By Layer ◽  
Promising Candidate ◽  
Single Digit ◽  
Cross Sectional ◽  
Two Photon ◽  
Nanoscale Features

High-throughput fabrication techniques for generating arbitrarily complex three-dimensional structures with nanoscale features are desirable across a broad range of applications. Two-photon lithography (TPL)–based submicrometer additive manufacturing is a promising candidate to fill this gap. However, the serial point-by-point writing scheme of TPL is too slow for many applications. Attempts at parallelization either do not have submicrometer resolution or cannot pattern complex structures. We overcome these difficulties by spatially and temporally focusing an ultrafast laser to implement a projection-based layer-by-layer parallelization. This increases the throughput up to three orders of magnitude and expands the geometric design space. We demonstrate this by printing, within single-digit millisecond time scales, nanowires with widths smaller than 175 nanometers over an area one million times larger than the cross-sectional area.

scholarly journals A 3D weaving infill pattern for fused filament fabrication

2021 ◽  
Author(s):  
Yuan Yao ◽  
Cheng Ding ◽  
Mohamed Aburaia ◽  
Maximilian Lackner ◽  
Lanlan He
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Repetitive Structure ◽  
Mechanical Linkage ◽  
Manufacturing Technologies ◽  
Dimensional Object ◽  
Anisotropy Of Mechanical Properties ◽  
3D Weaving

Abstract The Fused Filament Fabrication process is the most used additive manufacturing process due to its simplicity and low operating costs. In this process, a thermoplastic filament is led through an extruder, melted, and applied to a building platform by the axial movements of an automated Cartesian system in such a way that a three-dimensional object is created layer by layer. Compared to other additive manufacturing technologies, the components produced have mechanical limitations and are often not suitable for functional applications. To reduce the anisotropy of mechanical strength in fused filament fabrication (FFF), this paper proposes a 3D weaving deposit path planning method that utilizes a 5-layer repetitive structure to achieve interlocking and embedding between neighbor slicing planes to improve the mechanical linkage within the layers. The developed algorithm extends the weaving path as an infill pattern to fill different structures and makes this process feasible on a standard three-axis 3D printer. Compared with 3D weaving printed parts by layer-to-layer deposit, the anisotropy of mechanical properties inside layers is significantly reduced to 10.21% and 0.98%.

scholarly journals Experimental Investigation on Mechanical Properties of Part Fabricated by Wire Arc Additive Manufacturing Process

2021 ◽  
Author(s):  
Vivek Kumar P ◽  
◽  
Soundrapandian E ◽  
Jenin Joseph A ◽  
Kanagarajan E ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Three Dimensional ◽  
Casting Process ◽  
Significant Rise ◽  
Layer By Layer ◽  
Cnc Machine ◽  
Hardness Tester ◽  
Wire Arc Additive Manufacturing

Additive manufacturing process is a method of layer by layer joining of materials to create components from three-dimensional (3D) model data. After their introduction in the automotive sector a decade ago, it has seen a significant rise in research and growth. The Additive manufacturing is classified into different types based upon the energy source use in the fabrication process. In our project, we used self-build CNC machine that runs MACH3 software, as well as the MACH3 controller is used to control the welding torch motion for material addition through three axis movement (X, Y and Z). In the project we used ER70 S-6 weld wire for the fabrication and examined its microstructure and mechanical properties. Different layers of the specimen had different microstructures, according to microstructural studies of the product. Rockwell hardness tester used for testing hardness of the product. According to the observation of the part fabricated components using the Wire Arc Additive Manufacturing process outperformed the mechanical properties of mild steel casting process. The product fabricated by Wire Arc Additive Manufacturing process properties is superior to conventional casting process.

Spatial Iterative Learning Control for Multi-material Three-Dimensional Structures

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Zahra Afkhami ◽  
Christopher Pannier ◽  
Leontine Aarnoudse ◽  
David Hoelzle ◽  
Kira Barton
Keyword(s):  
Additive Manufacturing ◽  
Iterative Learning Control ◽  
Initial Conditions ◽  
Three Dimensional ◽  
Single Layer ◽  
Learning Control ◽  
Iterative Learning ◽  
Layer By Layer ◽  
Additive Process ◽  
Jet Printing

Abstract Iterative learning control (ILC) is a powerful technique to regulate repetitive systems. Additive manufacturing falls into this category by nature of its repetitive action in building three-dimensional structures in a layer-by-layer manner. In literature, spatial ILC (SILC) has been used in conjunction with additive processes to regulate single-layer structures with only one class of material. However, SILC has the unexplored potential to regulate additive manufacturing structures with multiple build materials in a three-dimensional fashion. Estimating the appropriate feedforward signal in these structures can be challenging due to iteration varying initial conditions, system parameters, and surface interaction dynamics in different layers of multi-material structures. In this paper, SILC is used as a recursive control strategy to iteratively construct the feedforward signal to improve part quality of 3D structures that consist of at least two materials in a layer-by-layer manner. The system dynamics are approximated by discrete 2D spatial convolution using kernels that incorporate in-layer and layer-to-layer variations. We leverage the existing SILC models in literature and extend them to account for the iteration varying uncertainties in the plant model to capture a more reliable representation of the multi-material additive process. The feasibility of the proposed diagonal framework was demonstrated using simulation results of an electrohydrodynamic jet printing (e-jet) printing process.

Thermofluid Properties of Ti-6Al-4V Melt Pool in Powder-Bed Electron Beam Additive Manufacturing

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
M Shafiqur Rahman ◽  
Paul J. Schilling ◽  
Paul D. Herrington ◽  
Uttam K. Chakravarty
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Heat Source ◽  
Thermal Behavior ◽  
Source Parameters ◽  
Three Dimensional ◽  
Full Density ◽  
Layer By Layer ◽  
Powder Bed ◽  
Melt Pool

Electron beam additive manufacturing (EBAM) is a powder-bed fusion additive manufacturing (AM) technology that can make full density metallic components using a layer-by-layer fabrication method. To build each layer, the EBAM process includes powder spreading, preheating, melting, and solidification. The quality of the build part, process reliability, and energy efficiency depends typically on the thermal behavior, material properties, and heat source parameters involved in the EBAM process. Therefore, characterizing those properties and understanding the correlations among the process parameters are essential to evaluate the performance of the EBAM process. In this study, a three-dimensional computational fluid dynamics (CFD) model with Ti-6Al-4V powder was developed incorporating the temperature-dependent thermal properties and a moving conical volumetric heat source with Gaussian distribution to conduct the simulations of the EBAM process. The melt pool dynamics and its thermal behavior were investigated numerically, and results for temperature profile, melt pool geometry, cooling rate and variation in density, thermal conductivity, specific heat capacity, and enthalpy were obtained for several sets of electron beam specifications. Validation of the model was performed by comparing the simulation results with the experimental results for the size of the melt pool.

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