scholarly journals Additive Manufacturing of Polymer Materials: Progress, Promise and Challenges

Polymers ◽  
2021 ◽  
Vol 13 (5) ◽  
pp. 753
Author(s):  
Saad Saleh Alghamdi ◽  
Sabu John ◽  
Namita Roy Choudhury ◽  
Naba K. Dutta
Keyword(s):  
Additive Manufacturing ◽  
Shape Memory Polymers ◽  
Polymeric Materials ◽  
Polymer Materials ◽  
Research Needs ◽  
Future Perspectives ◽  
Responsive Materials ◽  
Manufacturing Method ◽  
Traditional Manufacturing ◽  
Am Processes

The use of additive manufacturing (AM) has moved well beyond prototyping and has been established as a highly versatile manufacturing method with demonstrated potential to completely transform traditional manufacturing in the future. In this paper, a comprehensive review and critical analyses of the recent advances and achievements in the field of different AM processes for polymers, their composites and nanocomposites, elastomers and multi materials, shape memory polymers and thermo-responsive materials are presented. Moreover, their applications in different fields such as bio-medical, electronics, textiles, and aerospace industries are also discussed. We conclude the article with an account of further research needs and future perspectives of AM process with polymeric materials.

scholarly journals Additive Manufacturing of Information Carriers Based on Shape Memory Polyester Urethane

Polymers ◽  
2019 ◽  
Vol 11 (6) ◽  
pp. 1005 ◽  
Author(s):  
Dilip Chalissery ◽  
Thorsten Pretsch ◽  
Sarah Staub ◽  
Heiko Andrä
Keyword(s):  
Additive Manufacturing ◽  
Shape Memory ◽  
Shape Memory Polymers ◽  
Qr Code ◽  
Stimuli Responsive ◽  
Fused Filament Fabrication ◽  
Responsive Materials ◽  
Manufacturing Method ◽  
Polyester Urethane ◽  
Machine Readable

Shape memory polymers (SMPs) are stimuli-responsive materials, which are able to retain an imposed, temporary shape and recover the initial, permanent shape through an external stimulus like heat. In this work, a novel manufacturing method is introduced for thermoresponsive quick response (QR) code carriers, which originally were developed as anticounterfeiting technology. Motivated by the fact that earlier manufacturing processes were sometimes too time-consuming for production, filaments of a polyester urethane (PEU) with and without dye were extruded and processed into QR code carriers using fused filament fabrication (FFF). Once programmed, the distinct shape memory properties enabled a heating-initiated switching from non-decodable to machine-readable QR codes. The results demonstrate that FFF constitutes a promising additive manufacturing technology to create complex, filigree structures with adjustable horizontal and vertical print resolution and, thus, an excellent basis to realize further technically demanding application concepts for shape memory polymers.

scholarly journals Investigation of microstructure and hardness of a rib geometry produced by metal forming and wire-arc additive manufacturing

2018 ◽  
Vol 190 ◽  
pp. 02005 ◽  
Author(s):  
Markus Hirtler ◽  
Angelika Jedynak ◽  
Benjamin Sydow ◽  
Alexander Sviridov ◽  
Markus Bambach
Keyword(s):  
Additive Manufacturing ◽  
Metal Forming ◽  
Batch Size ◽  
Unit Costs ◽  
Batch Sizes ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
Forming Tools ◽  
Wire Arc Additive Manufacturing ◽  
Am Processes

Within the scope of consumer-oriented production, individuality and cost-effectiveness are two essential aspects, which can barely be met by traditional manufacturing technologies. Conventional metal forming techniques are suitable for large batch sizes. If variants or individualized components have to be formed, the unit costs rise due to the inevitable tooling costs. For such applications, additive manufacturing (AM) processes, which do not require tooling, are more suitable. Due to the low production rates and limited build space of AM machines, the manufacturing costs are highly dependent on part size and batch size. Hence, a combination of both manufacturing technologies i.e. conventional metal forming and additive manufacturing seems expedient for a number of applications. The current study develops a process chain combining forming and additive manufacturing. First, a semi-finished product is formed with forming tools of reduced complexity and then finished by additive manufacturing. This research investigates the addition of features using AlSi12 created by Wire Arc Additive Manufacturing (WAAM) on formed EN-AW 6082 preforms. By forming, the strength of the material was increased, while this effect was partly reduced by the heat input of the WAAM process.

Additive manufacturing of shape memory polymers: effects of print orientation and infill percentage on shape memory recovery properties

2020 ◽  
Vol 26 (9) ◽  
pp. 1593-1602
Author(s):  
Jorge Villacres ◽  
David Nobes ◽  
Cagri Ayranci
Keyword(s):  
Additive Manufacturing ◽  
Shape Memory ◽  
Shape Recovery ◽  
Fused Deposition Modeling ◽  
Large Strain ◽  
Shape Memory Polymers ◽  
Polymeric Materials ◽  
Content Type ◽  
Fused Deposition ◽  
Memory Recovery

Purpose The purpose of this paper is to study the shape memory properties of SMP samples produced through a MEAM process. Fused deposition modeling or, as it will be referred to in this paper, material extrusion additive manufacturing (MEAM) is a technique in which polymeric materials are extruded though a nozzle creating parts via accumulation and joining of different layers. These layers are fused together to build three-dimensional objects. Shape memory polymers (SMP) are stimulus responsive materials, which have the ability to recover their pre-programmed form after being exposed to a large strain. To induce its shape memory recovery movement, an external stimulus such as heat needs to be applied. Design/methodology/approach This project investigates and characterizes the influence of print orientation and infill percentage on shape recovery properties. The analyzed shape recovery properties are shape recovery force, shape recovery speed and time elapsed before activation. To determine whether the analyzed factors produce a significant variation on shape recovery properties, t-tests were performed with a 95% confidence factor between each analyzed level. Findings Results proved that print angle and infill percentage do have a significant impact on recovery properties of the manufactured specimens. Originality/value The manufacturing of SMP objects through a MEAM process has a vast potential for different applications; however, the shape recovery properties of these objects need to be analyzed before any practical use can be developed. These have not been studied as a function of print parameters, which is the focus of this study.

scholarly journals Potential and Scope of Additive Manufacturing in Aerospace Industry with Reference to India

2019 ◽  
Vol 8 (6S4) ◽  
pp. 1085-1089
Keyword(s):  
Additive Manufacturing ◽  
Labour Force ◽  
Aerospace Industry ◽  
Current Method ◽  
Spare Parts ◽  
Manufacturing Method ◽  
The World ◽  
Cost Of Production ◽  
Production Requirement ◽  
Traditional Manufacturing

Aerospace industry is one of the fastest growing industries in the world. Especially in India, it is estimated to grow in exponential rate owing to the rapid globalization and the fact that India is one of the world centres for tourism and trade. This exponential growth in the field of aerospace industry puts more demand on manufacturing and design of aircraft and its components. Unfortunately, the tradition method on spare parts production for aerospace industry cannot supply the growing demand to its fullest because it is time consuming and the cost of production is very high. Additive manufacturing, being one of the most revolutionary methods of is an appropriate substitute for the traditional manufacturing process in the aerospace industry as mass production becomes cheaper and save much of time. It also provides the flexibility to change the design and manufacturing method of any particular component with most ease at any stage from design to production. Additive manufacturing displays unarguable traits compared to traditional manufacturing in material saving, cost of production, requirement of skilled labour force and time consumption, especially in aerospace industry. However, there is not one single method of designing or producing the required component and this paper intends to classify and discuss each method in details and in comparison with each other. Few methods that are discussed in this paper include EBM, SLM, MD and LMD. In spite of the overwhelming advantage the technology has over the current method, it still faces few challenges to be fully implemented in floor level which is also focused in this paper in particular to India.

Review of Most Recent Progress on Development of Polymer Heat Exchangers for Thermal Management Applications

2015 ◽  
Author(s):  
David C. Deisenroth ◽  
Martinus Adrian Arie ◽  
Serguei Dessiatoun ◽  
Amir Shooshtari ◽  
Michael Ohadi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Thermal Performance ◽  
Heat Exchangers ◽  
High Performance ◽  
Elevated Temperatures ◽  
Polymeric Materials ◽  
Cost Effective ◽  
Polymer Materials ◽  
Manufacturing Cost ◽  
Polymer Heat Exchangers

Polymeric materials have several favorable properties for heat transfer systems, including low weight, low manufacturing cost, antifouling, and anticorrosion. Additionally, polymers are typically electrical insulators, making them favorable for applications in which electrical conductivity is a concern. Examples of utilizing these favorable properties are discussed. The drawbacks to raw polymer materials include low thermal conductivity, low structural strength, and poor stability at elevated temperatures. Methods of mitigating these unfavorable properties, including loading the polymer with other materials and developing new polymers, are discussed. Enhanced geometric designs enabled by additive manufacturing can also improve thermal performance of polymer heat exchangers. Results of a research study utilizing additive manufacturing toward developing high-performance and cost-effective polymer heat exchangers for an air-to-liquid application are reviewed and discussed. Finally, needs for further research on enhancing polymer thermal performance are discussed.

A Review on Process Monitoring and Control in Metal-Based Additive Manufacturing

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Gustavo Tapia ◽  
Alaa Elwany
Keyword(s):  
Additive Manufacturing ◽  
Process Monitoring ◽  
Monitoring And Control ◽  
Part Quality ◽  
Industrial Sectors ◽  
Process Monitoring And Control ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
And Control ◽  
Am Processes

There is consensus among both the research and industrial communities, and even the general public, that additive manufacturing (AM) processes capable of processing metallic materials are a set of game changing technologies that offer unique capabilities with tremendous application potential that cannot be matched by traditional manufacturing technologies. Unfortunately, with all what AM has to offer, the quality and repeatability of metal parts still hamper significantly their widespread as viable manufacturing processes. This is particularly true in industrial sectors with stringent requirements on part quality such as the aerospace and healthcare sectors. One approach to overcome this challenge that has recently been receiving increasing attention is process monitoring and real-time process control to enhance part quality and repeatability. This has been addressed by numerous research efforts in the past decade and continues to be identified as a high priority research goal. In this review paper, we fill an important gap in the literature represented by the absence of one single source that comprehensively describes what has been achieved and provides insight on what still needs to be achieved in the field of process monitoring and control for metal-based AM processes.

scholarly journals Current advances and future perspectives of additive manufacturing for functional polymeric materials and devices

SusMat ◽  
2021 ◽  
Vol 1 (1) ◽  
pp. 127-147
Author(s):  
Chuhong Zhang ◽  
Yijun Li ◽  
Wenbin Kang ◽  
Xingang Liu ◽  
Qi Wang
Keyword(s):  
Additive Manufacturing ◽  
Polymeric Materials ◽  
Future Perspectives

scholarly journals Investigating the Gap between Research and Practice in Additive Manufacturing

2021 ◽  
Author(s):  
Jennifer Bracken ◽  
Zachary Bentley ◽  
James Meye ◽  
Erik Miller ◽  
Jablokow Kathryn W. ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Idea Generation ◽  
Concept Generation ◽  
Technical Problems ◽  
Before And After ◽  
Implementation Time ◽  
Design Objects ◽  
Traditional Manufacturing ◽  
Commercial Organization ◽  
Am Processes

Additive manufacturing (AM) provides opportunities to design objects differently than traditional manufacturing methods allow, but only if designers understand the possibilities AM presents. In this study, we examined whether an AM workshop combined with an idea generation session could inspire engineering professionals to use AM solutions to solve current technical problems they face. All subjects were employees at an organization that will be referred to as Company X, a multinational commercial organization based in North America. During the study, we collected ideas for 24 projects generated before and after a training workshop focused on design for AM. In the workshop, we provided three hours of instruction about design for two metal-based AM processes. The participants’ ideas were assessed using four specific metrics: (1) cost, (2) time,(3) completeness of solution, and (4) quality, which was a function of feasibility, usefulness, and novelty. Using these data, we explored whether the workshop was effective in inspiring the participants to use AM methods and techniques from AM research in their concept generation and whether participants’ AM solutions showed improvement in cost, implementation time, and quality over non-AM designs generated before the workshop.

THE USE OF ADDITIVE MANUFACTURING TECHNOLOGY TO MANUFACTURE SLIDE BEARING SLEEVES – A PRELIMINARY STUDY

Tribologia ◽  
2020 ◽  
Vol 291 (3) ◽  
pp. 7-14
Author(s):  
Artur Andrearczyk ◽  
Paweł Bagiński
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Rapid Development ◽  
Polymeric Materials ◽  
Experimental Tests ◽  
Printing Technology ◽  
Manufacturing Method ◽  
3D Printing Technology ◽  
Preliminary Research ◽  
The Moment

The paper presents the application of an unconventional method of manufacturing bearing sleeves as well as the carrying out of preliminary research in which the manufactured components were used on a real object. Additive manufacturing methods are increasingly being used, which leads to the rapid development of technologies and their applications. The MultiJet Printing technology was used in the research, which allows precise 3D printing of sleeves made of polymeric materials. The first part of the article deals with the selected manufacturing method and the preparation of a model. The study aimed at evaluating the usefulness of bearings manufactured using the 3D printing technology to support slow-speed rotors. The preliminary research described focuses on the study of operating parameters such as the moment of friction and the bearing node temperature as a function of rotational speed during operation. Experimental tests were carried out at low rotational speeds. This paper presents and determines the scope of the application of bearings manufactured using 3D printing technology.

Prediction of Dielectric Electroactive Polymer Material Functionality

2018 ◽  
Author(s):  
Brittany Newell ◽  
Jose Garcia ◽  
Angello Vindrola
Keyword(s):  
Additive Manufacturing ◽  
Dielectric Material ◽  
Dielectric Materials ◽  
Polymer Materials ◽  
Elastic Model ◽  
Simple Method ◽  
Linear Elastic ◽  
Traditional Manufacturing ◽  
Printed Materials ◽  
The Relationship

Dielectric electroactive actuators (DEAs) are polymer materials capable of reallocating their shapes mechanically due to an electric stimulus [1]. They can also be used as sensors by producing an electrical change from an induced mechanical deformation [2]. However, production of these materials using traditional manufacturing methods is a challenging process. The use of additive manufacturing promises to be an improved method to overcome those challenges. In addition, selection of dielectric materials that can function as DEAs and are capable of being produced through additive manufacturing is challenging. The actuation capabilities of the DEA depend heavily on the electrical and mechanical material properties of the dielectric material used to build it, and not all dielectric materials have the capacity to function as DEAs. The likelihood of a material functioning as a DEA is difficult to predict due to the large number of variables. Therefore, this paper introduces a simple method for comparing materials, particularly 3-D printed materials for their viability to be used as DEAs. The study proposes a method to compare 3-D printable materials by using coefficients calculated from the materials’ electromechanical properties. This value is then compared to an ideal DEA material. The higher the value, the better the 3-D printable material will be in comparison to a selected optimal DEA material. The coefficient is based on a linear elastic model that describes the strain of the material in relation to the electromechanical pressure applied as a result of supplied voltage. This study tested three materials using a quantitative method along with experimental verification. The study demonstrates the relationship between the predictive coefficients and the physical actuation responses with disc-type actuators providing a simple method for predicting actuation potential of 3-D printable DEA material candidates.

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