scholarly journals Toolpath Strategies for 5DOF and 6DOF Extrusion-Based Additive Manufacturing

2019 ◽  
Vol 9 (19) ◽  
pp. 4168 ◽  
Author(s):  
Mathias Laustsen Jensen ◽  
Rasoul Mahshid ◽  
Greta D’Angelo ◽  
Jeppe U. Walther ◽  
Malte K. Kiewning ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Projection Method ◽  
Degrees Of Freedom ◽  
Tool Path ◽  
Final Part ◽  
Support Material ◽  
Need For Support ◽  
Am Processes ◽  
Case Effect ◽  
Parent Child

This paper introduces two new deposition-strategies for five degrees of freedom (5DOF) and 6DOF extrusion-based additive manufacturing (AM), called the tool path projection- and parent-child-approach, respectively. The tool path projection method can be automated, and allows for the generation of concentric shells layers, which remedy geometrical deviations (known as the stair-case effect) that are typically seen in 3DOF AM processes that potentially require secondary post treatment by machining or grinding of the final part. In the parent-child approach, the designer specifies the manufacturing direction for each distinct feature, thereby helping to remove the need for support material, as well as enabling new features to be dynamically added to the part.

scholarly journals DECOMPOSITION ALGORITHM FOR TOOL PATH PLANNING FOR WIRE-ARC ADDITIVE MANUFACTURING

2018 ◽  
Vol Vol.18 (No.1) ◽  
pp. 96-107 ◽  
Author(s):  
Lam NGUYEN ◽  
Johannes BUHL ◽  
Markus BAMBACH
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Computer Aided Design ◽  
Tool Path ◽  
Heuristic Method ◽  
Support Material ◽  
Build Time ◽  
Cad Models ◽  
Aided Design ◽  
Wire Arc Additive Manufacturing

Three-axis machines are limited in the production of geometrical features in powder-bed additive manufacturing processes. In case of overhangs, support material has to be added due to the nature of the process, which causes some disadvantages. Robot-based wire-arc additive manufacturing (WAAM) is able to fabricate overhangs without adding support material. Hence, build time, waste of material, and post-processing might be reduced considerably. In order to make full use of multi-axis advantages, slicing strategies are needed. To this end, the CAD (computer-aided design) model of the part to be built is first partitioned into sub-parts, and for each sub-part, an individual build direction is identified. Path planning for these sub-parts by slicing then enables to produce the parts. This study presents a heuristic method to deal with the decomposition of CAD models and build direction identification for sub-entities. The geometric data of two adjacent slices are analyzed to construct centroidal axes. These centroidal axes are used to navigate the slicing and building processes. A case study and experiments are presented to exemplify the algorithm.

But Will it Print?: Assessing Student Use of Design for Additive Manufacturing and Exploring its Effect on Design Performance and Manufacturability

2019 ◽  
Author(s):  
Rohan Prabhu ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Undergraduate Students ◽  
Educational Interventions ◽  
Support Material ◽  
Design Performance ◽  
Process Characteristics ◽  
Build Time ◽  
And Performance ◽  
Am Processes ◽  
Design For Am

Abstract Additive manufacturing (AM) enables engineers to improve the functionality and performance of their designs by adding complexity at little to no additional cost. However, AM processes also exhibit certain unique limitations, such as the presence of support material, which must be accounted for to ensure that designs can be manufactured feasibly and cost-effectively. Given these unique process characteristics, it is important for an AM-trained workforce to be able to incorporate both opportunistic and restrictive design for AM (DfAM) considerations into the design process. While AM/DfAM educational interventions have been discussed in the literature, limited research has investigated the effect of these interventions on students’ use of DfAM. Furthermore, limited research has explored how DfAM use affects the performance of students’ AM designs. This research explores this gap through an experimental study with 123 undergraduate students. Specifically, participants were exposed to either restrictive DfAM or dual DfAM (both opportunistic and restrictive) and then asked to participate in an AM design challenge. The students’ final designs were evaluated for (1) performance with respect the design objectives and constraints, and (2) the use of the various aspects of DfAM. The results showed that the use of certain DfAM considerations, such as minimum feature size and support material mass, successfully predicted the performance of the AM designs. Further, while the variations in DfAM education did not influence the performance of the AM designs, it did have an effect on the students’ use of certain DfAM concepts in their final designs. These results highlight the influence of DfAM education in bringing about an increase in students’ use of DfAM. Moreover, the results demonstrate the potential influence of DfAM in reducing build time and build material of the students’ AM designs, thus improving design performance and manufacturability.

scholarly journals A Novel Additive Manufacturing Method of Cellulose Gel

Materials ◽  
2021 ◽  
Vol 14 (22) ◽  
pp. 6988
Author(s):  
Hossein Najaf Zadeh ◽  
Daniel Bowles ◽  
Tim Huber ◽  
Don Clucas
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Material Design ◽  
Potential Method ◽  
Support Material ◽  
Gel Structure ◽  
Manufacturing Method ◽  
Wide Range ◽  
Need For Support ◽  
Cellulose Gel

Screen-additive manufacturing (SAM) is a potential method for producing small intricate parts without waste generation, offering minimal production cost. A wide range of materials, including gels, can be shaped using this method. A gel material is composed of a three-dimensional cross-linked polymer or colloidal network immersed in a fluid, known as hydrogel when its main constituent fluid is water. Hydrogels are capable of absorbing and retaining large amounts of water. Cellulose gel is among the materials that can form hydrogels and, as shown in this work, has the required properties to be directly SAM, including shear thinning and formation of post-shearing gel structure. In this study, we present the developed method of SAM for the fabrication of complex-shaped cellulose gel and examine whether successive printing layers can be completed without delamination. In addition, we evaluated cellulose SAM without the need for support material. Design of Experiments (DoE) was applied to optimize the SAM settings for printing the novel cellulose-based gel structure. The optimum print settings were then used to print a periodic structure with micro features and without the need for support material.

Evaluation of Thermal Gelation of F-127 in a Non-Aqueous Solvent and its Suitability as a Support Material for Additive Manufacturing

2014 ◽  
Vol 911 ◽  
pp. 226-231 ◽  
Author(s):  
Muhammad Fahad ◽  
Maqsood Ahmed Khan ◽  
Marianne Gilbert
Keyword(s):  
Additive Manufacturing ◽  
Elevated Temperatures ◽  
Industrial Applications ◽  
Manufacturing Processes ◽  
Support Material ◽  
Support Materials ◽  
Thermal Gelation ◽  
Aqueous Solvent ◽  
Reverse Thermal Gel ◽  
Am Processes

Pluronics are well known for their reverse thermal gel (RTG) formation in aqueous solutions and have been used in a variety of industrial applications. Additive Manufacturing processes that utilize jetting technology require support materials for building parts that comprise holes, cavities and/or overhangs. Currently available support materials include waxes which due to their brittleness, are weak and can lead to accuracy issues during part building via jetting technology. Pluronic F-127 in a non-aqueous solvent (Formamide) have been investigated in this paper for thermal gelation at elevated temperatures and the suitability of this composition as support material for jetting based AM processes have been evaluated.

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

scholarly journals MODEL-BASED DESIGN OF AM COMPONENTS TO ENABLE DECENTRALIZED DIGITAL MANUFACTURING SYSTEMS

2021 ◽  
Vol 1 ◽  
pp. 2127-2136
Author(s):  
Olivia Borgue ◽  
John Stavridis ◽  
Tomas Vannucci ◽  
Panagiotis Stavropoulos ◽  
Harry Bikas ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Data Generation ◽  
Production Networks ◽  
Model Based ◽  
Manufacturing Technologies ◽  
Am Processes ◽  
Final Consumer

AbstractAdditive manufacturing (AM) is a versatile technology that could add flexibility in manufacturing processes, whether implemented alone or along other technologies. This technology enables on-demand production and decentralized production networks, as production facilities can be located around the world to manufacture products closer to the final consumer (decentralized manufacturing). However, the wide adoption of additive manufacturing technologies is hindered by the lack of experience on its implementation, the lack of repeatability among different manufacturers and a lack of integrated production systems. The later, hinders the traceability and quality assurance of printed components and limits the understanding and data generation of the AM processes and parameters. In this article, a design strategy is proposed to integrate the different phases of the development process into a model-based design platform for decentralized manufacturing. This platform is aimed at facilitating data traceability and product repeatability among different AM machines. The strategy is illustrated with a case study where a car steering knuckle is manufactured in three different facilities in Sweden and Italy.

scholarly journals Additive Manufacturing for Effective Smart Structures: The Idea of 6D Printing

2021 ◽  
Vol 5 (5) ◽  
pp. 119
Author(s):  
Stelios K. Georgantzinos ◽  
Georgios I. Giannopoulos ◽  
Panteleimon A. Bakalis
Keyword(s):  
Additive Manufacturing ◽  
Degrees Of Freedom ◽  
Smart Structures ◽  
Interaction Mechanism ◽  
Modeling And Simulations ◽  
Environmental Stimulus ◽  
Material Component ◽  
Design And Manufacturing ◽  
First Time ◽  
Printing Techniques

This paper aims to establish six-dimensional (6D) printing as a new branch of additive manufacturing investigating its benefits, advantages as well as possible limitations concerning the design and manufacturing of effective smart structures. The concept of 6D printing, to the authors’ best knowledge, is introduced for the first time. The new method combines the four-dimensional (4D) and five-dimensional (5D) printing techniques. This means that the printing process is going to use five degrees of freedom for creating the final object while the final produced material component will be a smart/intelligent one (i.e., will be capable of changing its shape or properties due to its interaction with an environmental stimulus). A 6D printed structure can be stronger and more effective than a corresponding 4D printed structure, can be manufactured using less material, can perform movements by being exposed to an external stimulus through an interaction mechanism, and it may learn how to reconfigure itself suitably, based on predictions via mathematical modeling and simulations.

Toward Metamodels for Composable and Reusable Additive Manufacturing Process Models

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Paul Witherell ◽  
Shaw Feng ◽  
Timothy W. Simpson ◽  
David B. Saint John ◽  
Pan Michaleris ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Metal Powder ◽  
Manufacturing Process ◽  
Process Model ◽  
Model Development ◽  
Process Models ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Future Work ◽  
Am Processes

In this paper, we advocate for a more harmonized approach to model development for additive manufacturing (AM) processes, through classification and metamodeling that will support AM process model composability, reusability, and integration. We review several types of AM process models and use the direct metal powder bed fusion AM process to provide illustrative examples of the proposed classification and metamodel approach. We describe how a coordinated approach can be used to extend modeling capabilities by promoting model composability. As part of future work, a framework is envisioned to realize a more coherent strategy for model development and deployment.

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