Robot Assisted Additive Manufacturing of Thin Multifunctional Structures

2018 ◽  
Author(s):  
Prahar M. Bhatt ◽  
Max Peralta ◽  
Hugh A. Bruck ◽  
Satyandra K. Gupta
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing System ◽  
Robotic Manipulator ◽  
Manufacturing Processes ◽  
Layer By Layer ◽  
Robot Assisted ◽  
Manufacturing Operations ◽  
Multiple Materials

Thin multifunctional structures need to be composed from many different materials. Currently, very few additive manufacturing processes are capable of working with multiple materials. Additive manufacturing processes that work with multiple different materials pose significant constraints on material options. This significantly limits the kind of multifunctional structures that can be produced using additive manufacturing. A robot assisted sheet lamination based additive manufacturing system is developed in this paper. The system utilizes a 6-DOF robotic manipulator to perform the manufacturing operations such as cutting, assembly, tape-layup, and bonding to build the part layer by layer. A flexible ornithopter wing have been built using the proposed system. We have characterized the system in terms of part performance as well as automation efficiency.

Enabler für die personalisierte Produktion*/Automated additive manufacturing processes as enabler for personalized production – A sample application for tailor-made products

2019 ◽  
Vol 109 (03) ◽  
pp. 179-183
Author(s):  
J. Fischer ◽  
P. Springer ◽  
S. Fulga-Beising ◽  
K. Abu El-Qomsan
Keyword(s):  
Data Analysis ◽  
Additive Manufacturing ◽  
Manufacturing System ◽  
Personal Data ◽  
Industrie 4.0 ◽  
Manufacturing Processes ◽  
Automated Production ◽  
Sample Application

Das Fraunhofer IPA forscht an Workflows und Methoden für die Herstellung personalisierter Produkte von der Erfassung persönlicher Daten über die Analyse und Modellierung bis hin zur flexiblen, automatisierten Fertigung der Produkte. Der Beitrag beschreibt einen beispielhaften Anwendungsfall: die Herstellung einer personalisierten Brille. Für die nötige Flexibilität in der Fertigung wurde ein vollständig automatisiertes additives Fertigungssystem entwickelt, das im Applikationszentrum Industrie 4.0 des Fraunhofer IPA und des Instituts für Industrielle Fertigung und Fabrikbetrieb IFF der Universität Stuttgart integriert ist.   Fraunhofer IPA examines workflows and methods for the production of personalized products from the acquisition of personal data, analysis and modelling to the flexible, automated production of the products. This paper exemplifies an application using the production of personalized glasses. For this purpose, a fully automated additive manufacturing system was developed to provide the necessary flexibility in manufacturing.

scholarly journals The flexibility of industrial additive manufacturing systems

2018 ◽  
Vol 38 (12) ◽  
pp. 2313-2343 ◽  
Author(s):  
Daniel R. Eyers ◽  
Andrew T. Potter ◽  
Jonathan Gosling ◽  
Mohamed M. Naim
Keyword(s):  
Additive Manufacturing ◽  
Operations Management ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Detailed Examination ◽  
Multiple Sources ◽  
Content Type ◽  
Commercial Practice ◽  
Systems Perspective ◽  
Manufacturing Operations

Purpose Flexibility is a fundamental performance objective for manufacturing operations, allowing them to respond to changing requirements in uncertain and competitive global markets. Additive manufacturing machines are often described as “flexible,” but there is no detailed understanding of such flexibility in an operations management context. The purpose of this paper is to examine flexibility from a manufacturing systems perspective, demonstrating the different competencies that can be achieved and the factors that can inhibit these in commercial practice. Design/methodology/approach This study extends existing flexibility theory in the context of an industrial additive manufacturing system through an investigation of 12 case studies, covering a range of sectors, product volumes, and technologies. Drawing upon multiple sources, this research takes a manufacturing systems perspective that recognizes the multitude of different resources that, together with individual industrial additive manufacturing machines, contribute to the satisfaction of demand. Findings The results show that the manufacturing system can achieve seven distinct internal flexibility competencies. This ability was shown to enable six out of seven external flexibility capabilities identified in the literature. Through a categorical assessment the extent to which each competency can be achieved is identified, supported by a detailed explanation of the enablers and inhibitors of flexibility for industrial additive manufacturing systems. Originality/value Additive manufacturing is widely expected to make an important contribution to future manufacturing, yet relevant management research is scant and the flexibility term is often ambiguously used. This research contributes the first detailed examination of flexibility for industrial additive manufacturing systems.

Robotic Additive Manufacturing System of GMAW Constrained by Electromagnetism

2014 ◽  
Vol 889-890 ◽  
pp. 1132-1135
Author(s):  
Fan Jun Meng ◽  
De Ma Ba ◽  
Feng Liang Yin ◽  
Jun Du
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Manufacturing System ◽  
Laser System ◽  
Cad Model ◽  
Layer By Layer ◽  
Three Dimension ◽  
Measuring Device ◽  
Forming Temperature ◽  
Monitoring Precision

A robotic additive manufacturing system of GMAW constrained by electromagnetism has been developed recently. In this paper, the work principle, functions and composition of this system are introduced. A metal part to be manufactured should be constructured three-dimension CAD model firstly, then the delamination process of three-dimension model is carried out. Furthermore, the forming path planning of additive manufacturing is performed and finally the part is fabricated layer-by-layer in virtue of GMAW process. The additive manufacturing system consists of the robot system, GMAW power, a device producing magnetic field, a linear laser system monitoring precision of the forming part, a digital measuring device monitoring forming temperature,central control system and software modules that support various functions. The functions of the additive manufacturing system comprise CAD model construction of parts, discretization of three-dimension model, forming path planning and GMAW deposition forming layer-by-layer, and etc. It is indicated that the exploitation of the additive manufacturing system will provide an effective way for the manufacturing of metal parts.

scholarly journals Analysis and characterization of additive manufacturing processes

2021 ◽  
Vol 13 (4) ◽  
pp. 167-180
Author(s):  
Andra TOFAN-NEGRU ◽  
Cristian BARBU ◽  
Amado STEFAN ◽  
Ioana-Carmen BOGLIS
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Cutting Tools ◽  
Manufacturing Processes ◽  
Layer By Layer ◽  
Advantages And Disadvantages ◽  
Finishing Processes ◽  
Short Time ◽  
Physical Phenomena ◽  
Am Processes

Recently, additive manufacturing (AM) processes have expanded rapidly in various fields of the industry because they offer design freedom, involve layer-by-layer construction from a computerized 3D model (minimizing material consumption), and allow the manufacture of parts with complex geometry (thus offering the possibility of producing custom parts). Also, they provide the advantage of a short time to make the final parts, do not involve the need for auxiliary resources (cutting tools, lighting fixtures or coolants) and have a low impact on the environment. However, the aspects that make these technologies not yet widely used in industry are poor surface quality of parts, uncertainty about the mechanical properties of products and low productivity. Research on the physical phenomena associated with additive manufacturing processes is necessary for proper control of the phenomena of melting, solidification, vaporization and heat transfer. This paper addresses the relevant additive manufacturing processes and their applications and analyzes the advantages and disadvantages of AM processes compared to conventional production processes. For the aerospace industry, these technologies offer possibilities for manufacturing lighter structures to reduce weight, but improvements in precision must be sought to eliminate the need for finishing processes.

On the Capabilities of a Multi-Modality 3D Bioprinter for Customized Biomedical Devices

2015 ◽  
Author(s):  
Prashanth Ravi ◽  
Panos S. Shiakolas ◽  
Tre Welch ◽  
Tushar Saini ◽  
Kristine Guleserian ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Device Fabrication ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Stl File ◽  
Diverse Application ◽  
Multiple Materials ◽  
Manufacturing Platform ◽  
Single Construct ◽  
Manufacturing Technologies

Currently, there is a major shift in medical device fabrication research towards layer-by-layer additive manufacturing technologies; mainly owing to the relatively quick transition from a solid model (.STL file) to an actual prototype. The current manuscript introduces a Custom Multi-Modality 3D Bioprinter (CMMB) developed in-house, combining the Fused Filament Fabrication (FFF), Photo Polymerization (PP), Viscous Extrusion (VE), and Inkjet (IJ) printing technologies onto a single additive manufacturing platform. Methodologies to address limitation in the ability to customize construct properties layer-by-layer and to incorporate multiple materials in a single construct have been evaluated using open source 3D printing softwares Slic3r and Repetier-Host. Such customization empowers the user to fabricate constructs with tailorable anisotropic properties by combining different print technologies and materials. To this end, procedures which allow the integration of more than one distinct modality of the CMMB during a single print session were developed and evaluated, and are discussed. The current setup of the CMMB provides the capability to fabricate personalized medical devices using patient data from an MRI or a CT scan. Initial experiments and fabricated constructs demonstrate the potential of the CMMB for research in diverse application areas within biomedical engineering.

scholarly journals PART ORIENTATION AND SEPARATION TO REDUCE PROCESS COSTS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 2399-2408
Author(s):  
Jannik Reichwein ◽  
Eckhard Kirchner
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing System ◽  
Geometric Design ◽  
Component Separation ◽  
System Component ◽  
Layer By Layer ◽  
Manufacturing Costs ◽  
Complex Component ◽  
Supporting Structure ◽  
Part Orientation

AbstractAdditive manufacturing offers great potential in geometric design through the layer-by-layer production of components. This is often used in the development of additively manufactured components to make components lighter. An even greater reduction in mass is possible if several components are combined into a more complex component. However, as complexity increases, so do the manufacturing costs, due to a higher demand for supporting structure, reworking and longer production time. Especially for complex components, which make poor use of the space available in the additive manufacturing system, component separation can be a useful way of reducing manufacturing costs. Therefore, a procedure for automated component separation is presented, which determines an optimal cutting plane with respect to the manufacturing costs. The presented procedure is evaluated using two exemplary components where a reduction of manufacturing costs up to 54 % could be achieved.

scholarly journals AVANCES EN EL DESARROLLO DE UN SISTEMA DE MANUFACTURA ADITIVA BASADO EN STEP-NC

2018 ◽  
Vol 4 (1) ◽  
pp. 39-53 ◽  
Author(s):  
Efrain Rodriguez ◽  
Renan Bonnard ◽  
Alberto José Alvares
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Reference Model ◽  
Object Oriented Programming ◽  
Numerical Control ◽  
Layer By Layer ◽  
Machining Processes ◽  
Material Deposition ◽  
Nc Program

The new standard of numerical control, known as STEP-NC, is categorized as the future of the advanced manufacturing systems. Greater flexibility and interoperability are some potential benefits offered by STEP-NC to meet the challenges of the new industrial landscape that is envisaged with the advent of Industry 4.0. Meanwhile, STEP-NC object-oriented programming has been partially applied and developed for machining processes (milling, turning...). But with the processes of additive manufacturing has not happened the same and the development is still incipient. This work presents the advances in the development of a new STEP-NC compliant additive manufacturing system, focusing particularly on the development of the information model. The application model activities in the IDEF0 nomenclature and application reference model in EXPRESS are presented. The AM-layer-feature concept has been introduced to define the manufacturing feature of additive processes based on material deposition layer-by-layer. Finally, a STEP-NC program generated from the EXPRESS model is presented, which can be implemented on an additive manufacturing system to validate the proposed model.                                                                                           

A Model Predictive Repetitive Process Control Formulation for Additive Manufacturing Processes

2015 ◽  
Author(s):  
Patrick M. Sammons ◽  
Douglas A. Bristow ◽  
Robert G. Landers
Keyword(s):  
Additive Manufacturing ◽  
Process Control ◽  
Predictive Control ◽  
Reference Signal ◽  
Deposition Process ◽  
Open Loop ◽  
Two Dimensions ◽  
Manufacturing Processes ◽  
Layer By Layer ◽  
Repetitive Process

Additive Manufacturing (AM) processes are a class of manufacturing processes in which parts are fabricated in a layer-by-layer fashion. The layer-by-layer fabrication method creates layer-to-layer dynamics. Implementing process control that neglects the layer-to-layer dynamics can lead to process instability. While repetitive process controllers which utilize only layer-to-layer feedback are a viable method, their usefulness is limited in that they are not well-suited for tracking non-periodic layer-domain references. However, since the entire reference signal is typically known a priori in AM process fabrications, a predictive control methodology can be useful for controlling fabrications in which the reference signal is non-periodic. In this paper a model predictive control formulation is extended to two-dimensions and utilized for repetitive process control Simulation results comparing open-loop and controlled fabrications for a Laser Metal Deposition process are given.

scholarly journals Advanced computational modelling of metallic wire-arc additive manufacturing

2021 ◽  
Author(s):  
Dejan Kovšca ◽  
Bojan Starman ◽  
Aljaž Ščetinec ◽  
Damjan Klobčar ◽  
Nikolaj Mole
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Computational Modelling ◽  
Single Layer ◽  
Robotic Manipulator ◽  
Data File ◽  
Layer By Layer ◽  
Printing Technology ◽  
Material Layer ◽  
Wire Arc Additive Manufacturing

Wire-arc welding-based additive manufacturing (WAAM) is a 3D printing technology for production of near-net-shape parts with complex geometry. This printing technology enables to build up a required shape layer by layer with a deposition of a consumable welding wire, where the welding arc is a source of heat. Welding is usually performed by CNC-controlled robotic manipulator, which provides a controlled location of material layer adding. Because the process itself involves thermo-mechanically complex phenomena, Finite Element-based virtual models are commonly employed to optimize the process parameters. This paper presents advanced computational modelling of the WAAM of a tube. A thermo-mechanical numerical model of the process is calibrated against experimental data, measured as temperature variation at the acquisition point. The virtual modelling starts with a preparation of the tube geometry in CAD software, where the geometry of the single-layer cross-section is assumed. The geometry is then exported to a G-code format data file and used to control robotic manipulator motion. On the other side, the code serves as an input to in-house developed code for automatic FEs activation in the simulation of the material layer-adding process. The time of activation of the finite elements (FEs) is directly related to the material deposition rate. The activation of the FEs is followed by a heat source, modeled with a double ellipsoidal power density distribution. The thermo-mechanical problem was solved as uncoupled to speed-up computation.

scholarly journals ADDITIVE MANUFACTURING – ENABLING DIGITAL ARTISANS

2021 ◽  
Vol 1 ◽  
pp. 323-332
Author(s):  
Priyabrata Rautray ◽  
Boris Eisenbart
Keyword(s):  
Artificial Intelligence ◽  
Additive Manufacturing ◽  
Case Studies ◽  
Manufacturing Process ◽  
New Technologies ◽  
Cultural Practices ◽  
Manufacturing Processes ◽  
Art And Science ◽  
The Future ◽  
Multiple Materials

AbstractNew technologies have always been disruptive for established systems and processes. Additive Manufacturing (AM) is proving to be one such process which has the potential to disrupt handicraft and its manufacturing processes. AM is customisable, adopt multiple materials and is not restricted by the manufacturing process. Our research discusses this global phenomenon with case studies to highlights the growth of a new kind of professionals known as ‘Digital Artisans’. These artisans will assimilate the latest technologies with the cultural practices of the societies to create a new genre of products. The evolution of such artisans will be majorly led by people who have an equal inclination towards art and science and can act as the bridge between the handicrafts and technology. The development of such artisans will be supported by academics that will serve as a cradle and expose them to AM, design and handicraft. Its will also help in paving the growth of contemporary artisans who will utilise the strength of algorithms, artificial intelligence, CAD software and traditional aesthetics to create handicrafts of the future.

Sign in / Sign up

Export Citation Format

Share Document