scholarly journals Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding

Polymers ◽  
2021 ◽  
Vol 13 (2) ◽  
pp. 309
Author(s):  
Praveen Kannan Rajamani ◽  
Tatyana Ageyeva ◽  
József Gábor Kovács
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Mass Production ◽  
Bonding Strength ◽  
High Surface ◽  
High Volume ◽  
Fused Filament Fabrication ◽  
Injection Molded ◽  
The Creation ◽  
Manufacturing Techniques

The new trend in the composites industry, as dictated by Industry 4.0, is the personalization of mass production to match every customer’s individual needs. Such synergy can be achieved when several traditional manufacturing techniques are combined within the production of a single part. One of the most promising combinations is additive manufacturing (AM) with injection molding. AM offers higher production freedom in comparison with traditional techniques. As a result, even very sophisticated geometries can be manufactured by AM at a reasonable price. The bottleneck of AM is the production rate, which is several orders of magnitude slower than that of traditional plastic mass production technologies. On the other hand, injection molding is a manufacturing technique for high-volume production with little possibility of customization. The customization of injection-molded parts is usually very expensive and time-consuming. In this research, we offered a solution for the individualization of mass production, which includes 3D printing a baseplate with the subsequent overmolding of a rib element on it. We examined the bonding between the additive-manufactured component and the injection-molded component. As bonding strength between the coupled elements is significantly lower than the strength of the material, we proposed five strategies to improve bonding strength. The strategies are optimizing the printing parameters to obtain high surface roughness, creating an infill density in fused filament fabrication (FFF) parts, creating local infill density, creating microstructures, and incorporating fibers into the bonding area. We observed that the two most effective methods to increase bonding strength are the creation of local infill density and the creation of a microstructure at the contact area of FFF-printed and injection-molded elements. This increase was attributed to the porous structures that both methods created. The melt during injection molding flowed into these pores and formed micro-mechanical interlocking.

scholarly journals Using Large-Scale Additive Manufacturing (LSAM) as a Bridge Manufacturing Process in Response to Shortages in PPE During the COVID-19 Outbreak

2020 ◽  
Vol 6 (4) ◽  
Author(s):  
Elizabeth Grace Bishop ◽  
Simon James Leigh
Keyword(s):  
Additive Manufacturing ◽  
Mass Production ◽  
Large Scale ◽  
Protective Equipment ◽  
Production Volume ◽  
Fused Filament Fabrication ◽  
The Face ◽  
Production Techniques ◽  
Manufacturing Techniques ◽  
Significant Production

The global COVID-19 pandemic has led to an international shortage of Personal Protective Equipment (PPE), with traditional supply chains unable to cope with the significant demand leading to critical shortfalls. A number of open and crowd sourced initiatives have sought to address this shortfall by producing equipment such as protective face shields using additive manufacturing techniques such as Fused Filament Fabrication (FFF). This paper reports the process of designing and manufacturing protective face shields using Large-scale Additive Manufacturing (LSAM) to produce the major thermoplastic components of the face shield. LSAM offers significant advantages over other Additive Manufacturing (AM) technologies in bridge manufacturing scenarios as a true transition between prototypes and mass production techniques such as injection moulding. In the context of production of COVID-19 face shields, the ability to produce the optimised components in under five minutes compared to what would typically take one to two hours using another AM technologies meant that significant production volume could be achieved rapidly with minimal staffing.

scholarly journals Design of Shape Memory Thermoplastic Material Systems for FDM-Type Additive Manufacturing

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4254
Author(s):  
Paulina A. Quiñonez ◽  
Leticia Ugarte-Sanchez ◽  
Diego Bermudez ◽  
Paulina Chinolla ◽  
Rhyan Dueck ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Shape Memory ◽  
Thermomechanical Processing ◽  
Material Selection ◽  
Shape Memory Polymer ◽  
Fused Filament Fabrication ◽  
Materials Development ◽  
Thermoplastic Material ◽  
Polymer Systems ◽  
Injection Molded

The work presented here describes a paradigm for the design of materials for additive manufacturing platforms based on taking advantage of unique physical properties imparted upon the material by the fabrication process. We sought to further investigate past work with binary shape memory polymer blends, which indicated that phase texturization caused by the fused filament fabrication (FFF) process enhanced shape memory properties. In this work, two multi-constituent shape memory polymer systems were developed where the miscibility parameter was the guide in material selection. A comparison with injection molded specimens was also carried out to further investigate the ability of the FFF process to enable enhanced shape memory characteristics as compared to other manufacturing methods. It was found that blend combinations with more closely matching miscibility parameters were more apt at yielding reliable shape memory polymer systems. However, when miscibility parameters differed, a pathway towards the creation of shape memory polymer systems capable of maintaining more than one temporary shape at a time was potentially realized. Additional aspects related to impact modifying of rigid thermoplastics as well as thermomechanical processing on induced crystallinity are also explored. Overall, this work serves as another example in the advancement of additive manufacturing via materials development.

Variance Quantification of Different Additive Manufacturing Processes for Acoustic Meta Materials

2021 ◽  
Vol 263 (4) ◽  
pp. 2708-2723
Author(s):  
Manuel Bopp ◽  
Arn Joerger ◽  
Matthias Behrendt ◽  
Albert Albers
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Production Process ◽  
Laser Scanning ◽  
Mode Shapes ◽  
Manufacturing Processes ◽  
3D Laser Scanning ◽  
Fused Filament Fabrication ◽  
Manufacturing Techniques ◽  
Different Levels

Many concepts for acoustic meta materials rely on additive manufacturing techniques. Depending on the production process and material of choice, different levels of precision and repeatability can be achieved. In addition, different materials have different mechanical properties, many of which are frequency dependent and cannot easily be measured directly. In this contribution the authors have designed different resonator elements, which have been manufactured utilizing Fused Filament Fabrication with ABSplus and PLA, as well as PolyJet Fabrication with VeroWhitePlus. All structures are computed in FEA to obtain the calculated Eigenfrequencies and mode shapes, with the respective literature values for each material. Furthermore, the dynamic behavior of multiple instances of each structure is measured utilizing a 3D-Laser-Scanning Vibrometer under shaker excitation, to obtain the actual Eigenfrequencies and mode shapes. The results are then analyzed in regards to variance between different print instances, and in regards to accordance between measured and calculated results. Based on previous work and this analysis the parameters of the FEA models are updated to improve the result quality.

scholarly journals Assessing the Suitability of Freeform Injection Molding for Low Volume Injection Molded Parts: A Design Science Approach

2021 ◽  
Vol 13 (3) ◽  
pp. 1313
Author(s):  
Elham Sharifi ◽  
Atanu Chaudhuri ◽  
Brian Vejrum Waehrens ◽  
Lasse Guldborg Staal ◽  
Saeed Davoudabadi Farahani
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Design Science ◽  
Series Production ◽  
Short Series ◽  
Science Approach ◽  
Molded Parts ◽  
Injection Molded ◽  
Low Volume ◽  
Cross Case Analysis

Low-volume manufacturing remains a challenge, especially for parts that need to be injection-molded. Freeform injection molding (FIM) is a novel method that combines elements from direct additive manufacturing (DAM) and injection molding (IM) to resolve some of the challenges seen in low-volume injection molding. In this study, we use a design science approach to explore the suitability of FIM for the manufacturing of low volume injection-molded parts. We provide an overview of the benefits and limitations of traditional IM and discuss how DAM and indirect additive manufacturing (IAM) methods, such as soft tooling and FIM, can address some of the existing drawbacks of IM for short series production. A set of different parts was identified and assessed using a design science-based approach to demonstrate how to incubate FIM as a solution to address the challenges faced in short series production with IM. This initial process innovation was followed by solution refinement, involving the optimization of the FIM processes. Finally, a “cross-case” analysis was conducted using the framework of context, intervention, mechanism and outcomes to generate insights about the generalizability of the results. It is concluded that FIM combines the short lead-times, low start-up costs and design freedom of DAM with the versatility and scalability of IM to allow manufacturers to bring low volume products to the market faster, more cheaply and with lower risk, and to maintain the relevance of these products through easy customization and adaptations once they have been launched.

scholarly journals An Analysis of Polymer Gear Wear in a Spur Gear Train Made Using FDM and FFF Methods Based on Tooth Surface Topography Assessment

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1649
Author(s):  
Jadwiga Pisula ◽  
Grzegorz Budzik ◽  
Paweł Turek ◽  
Mariusz Cieplak
Keyword(s):  
Additive Manufacturing ◽  
Operating Temperature ◽  
Coordinate Measuring Machine ◽  
Acrylonitrile Butadiene Styrene ◽  
Spur Gear ◽  
Gear Train ◽  
Tooth Surface ◽  
Fused Filament Fabrication ◽  
Measuring Machine ◽  
Manufacturing Techniques

This article focuses on wear tests of spur gears made with the use of additive manufacturing techniques from thermoplastic materials. The following additive manufacturing techniques were employed in this study: Melted and Extruded Modelling (FDM) and Fused Filament Fabrication (FFF). The study analysed gears made from ABS M-30 (Acrylonitrile Butadiene Styrene), ULTEM 9085 (PEI Polyetherimide) and PEEK (Polyetheretherketone), and the selection of these materials reflects their hierarchy in terms of economical application and strength parameters. A test rig designed by the authors was used to determine the fatigue life of polymer gears. Gear trains were tested under load in order to measure wear in polymer gears manufactured using FDM and FFF techniques. In order to understand the mechanism behind gear wear, further tests were performed on a P40 coordinate measuring machine (CMM) and a TalyScan 150 scanning instrument. The results of the gear tests made under load allow us to conclude that PEEK is resistant to wear and gear train operating temperature. Its initial topography undergoes slight changes in comparison to ABS M-30 and Ultem 9085. The biggest wear was reported for gears made from Ultem 9085. The hardness of the material decreased due to the loaded gear train’s operating temperature.

scholarly journals Additive manufacturing using Fused Filament Fabrication: evolution and trends

2021 ◽  
Author(s):  
Julian Israel Aguilar-Duque ◽  
Jorge Luis Garcia ◽  
Juan Luis Hernández-Arellano
Keyword(s):  
Additive Manufacturing ◽  
Literature Review ◽  
Industrial Sector ◽  
Fused Filament Fabrication ◽  
The Creation ◽  
Academic Resources

Abstract This paper discusses Fused Filament Fabrication (FFF) technology to know their evolution and trends, analyzing the materials, workforce, machinery, methods, and management been used. A literature review is done regarding FFF usage between 2010–2020. Data is analyzed for identify the countries that are applying this technology, the industrial sector, academic resources available and a curve is fitted to data for forecasting a trend until 2025. Projections indicate a growth of 300% for workforce in FFF usage for 2025, 280% for machinery, 312% for materials, 275% for the creation and modification of methods and, 320% growth for management activities.

scholarly journals Adding Brand: Design, Branding and Additive Manufacture in the production of tangible prosthetic products.

2021 ◽  
Author(s):  
Matt Mcgowan
Keyword(s):  
Additive Manufacturing ◽  
Mass Production ◽  
Industry 4.0 ◽  
Design Research ◽  
Artificial Limbs ◽  
Additive Manufacture ◽  
Prosthetic Design ◽  
Below The Knee ◽  
3D Printed ◽  
The Creation

<p><b>Design, Branding and Additive Manufacture in the production of tangible prosthetic products. </b></p><p>For the New Zealand Artificial Limbs Service, (NZALS) prosthetic design has skipped the mechanisation and mass production paradigm seen in the automation of consumer production. This industry predominantly uses traditional hand fabrication methods to produce prosthetics as a one-off appendage. This research asks; how can design communicate the possibilities of Additive Manufacture? </p><p>This research addresses the creation of branded designed products for the NZALS, and as a result, exposes the predominantly service based industry of the NZALS to a product focused methodology through traditional </p><p>industrial design practices. This has been achievable by investigating emerging platforms of manufacturing in both Digital and Additive Manufacturing (3D printing), with the development of the designs in this research focused on brand, client and company identity. This focus addresses the integration of an Industry 4.0 model in favour of the amputee client, and realises future outlooks of prosthetic production envisioned by the NZLAS. </p><p>Design research in this thesis has seen the creation of two prosthetic products. Firstly, a below-the- knee Prosthetic Fairing (Easycover), and secondly, a fully 3D printed below-the- knee prosthetic (Easylimb). The research undertaken shows the importance of creating tangible and readymade products to allow the NZALS, it’s staff and amputee clientele, to understand the benefits of design, branding, and emerging platforms of manufacture in the production of prosthetic diversity. </p>

scholarly journals Mass-production and Distribution of Medical Face Shields Using Additive Manufacturing and Injection Molding Process for Healthcare System Support During COVID-19 Pandemic in Brazil

2020 ◽  
Author(s):  
Maria Elizete Kunkel ◽  
Mayra Torres Vasques ◽  
João Aléssio Juliano Perfeito ◽  
Nataly Rabelo Mina Zambrana ◽  
Tainara dos Santos Bina ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Mass Production ◽  
Large Scale ◽  
Fused Deposition Modeling ◽  
Public Hospitals ◽  
Injection Molding Process ◽  
Scale Production ◽  
Molding Process ◽  
Fused Deposition

Abstract Face shields have been adopted worldwide as personal protective equipment for healthcare professionals during the COVID-19 pandemic. This device provides a transparent facial physical barrier reducing the exposure to aerosol particles. The fused deposition modeling (FDM) is the most applied process of additive manufacturing due to its usability and low-cost. The injection molding (IM) is the fastest process for mass production. This study is the first to perform a qualitative comparison between the use of FDM and IM processes for mass production and rapid distribution of face shields in a pandemic. The design of the face shield and tests were conducted in prototyping cycles based on requirements of medical, Brazilian standards, manufacturing, and production. The FDM face shields manufacturing was carried out by a volunteer network, and the IM manufacturing was carried out by companies. The volunteers produced 35,000 medical face shields through the FDM process with daily delivery to several hospitals. A total of 80,000 face shields was produced by the IM process and delivered to remote Brazilian regions. The mass production of 115,000 face shields protected health professionals from public hospitals in all states of Brazil. In a pandemic, both FDM and IM processes are suitable for mass production of face shields. Once a committed network of volunteers is formed in strategic regions, the FDM process promotes a fast daily production. The IM process is the best option for large scale production of face shields and delivery to remote areas where access to 3D printing is reduced.

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