scholarly journals DESIGN COMPLEXITY AS A DRIVER FOR ADDITIVE MANUFACTURING PROCESS IMPROVEMENT

2020 ◽  
Author(s):  
Nishkal George ◽  
Boppana Chowdary
Keyword(s):  
Additive Manufacturing ◽  
Design Space Exploration ◽  
Performance Indicator ◽  
Extrusion Process ◽  
Experimental Models ◽  
Production Costs ◽  
Design Features ◽  
Design Complexity ◽  
Filter Model ◽  
Material Extrusion

Design complexity in additive manufacturing (AM) is a current issue in the research community, fueled by the well-known phrase “complexity for free”. This statement has promoted the assumption that complex geometries may be achieved without any increase in the cost of production. However, recent research has indicated that increasing shape complexity produces an increase in production costs for the material extrusion process. This challenges the mainstream assumption that AM technologies provide ‘complexity for free’. The AM community requires further investigation of design complexity and its impact on sustainable production when used as a Design for Manufacturing (DfM) tool. This paper proposes a data-driven method which uses design complexity as an AM performance indicator for the material extrusion process. The manufacturing responses included build time (BT), dimensional accuracy (DA) and complexity index (CI). Design space exploration of an automotive air filter model was achieved by varying five critical design features which impact complexity. The study utilized a Face Centered Central Composite Design (FCCCD) of three levels for the design features, comprising 32 experimental models. The optimal model was manufactured based on multi-objective optimization using the MINITAB© response optimizer. This method exploits the design features to achieve target performance and manufacturability. The viability of design complexity as an AM performance indicator was discussed leading to three major improvements to the Product Design and Development (PDD) process for AM. The proposed improvements have the potential to reduce process times and minimize resources, providing a sustainable AM approach for developing regions.

scholarly journals Weld formation during material extrusion additive manufacturing

Soft Matter ◽  
2017 ◽  
Vol 13 (38) ◽  
pp. 6761-6769 ◽  
Author(s):  
Jonathan E. Seppala ◽  
Seung Hoon Han ◽  
Kaitlyn E. Hillgartner ◽  
Chelsea S. Davis ◽  
Kalman B. Migler
Keyword(s):  
Additive Manufacturing ◽  
Fracture Mechanics ◽  
Extrusion Process ◽  
Weld Formation ◽  
Material Extrusion

A combination of thermography, rheology, and fracture mechanics captures weld formation during the material extrusion process.

scholarly journals Research on Curved Layer Slicing and Spatial Path Generation Method in Five-axis Material Extrusion Process

2021 ◽  
Vol 1884 (1) ◽  
pp. 012013
Author(s):  
Anpei Li ◽  
Lianggang Li ◽  
Yaxiong Liu ◽  
Bin Cui ◽  
Yongkang Li ◽  
...  
Keyword(s):  
Extrusion Process ◽  
Path Generation ◽  
Material Extrusion ◽  
Five Axis

From Design Complexity to Build Quality in Additive Manufacturing—A Sensor-Based Perspective

2019 ◽  
Vol 3 (1) ◽  
pp. 1-4 ◽  
Author(s):  
Ruimin Chen ◽  
Farhad Imani ◽  
Edward Reutzel ◽  
Hui Yang
Keyword(s):  
Additive Manufacturing ◽  
Design Complexity

Electrical Properties of Additively Manufactured Acrylonitrile Butadiene Styrene/Carbon Nanotube Nanocomposite

2018 ◽  
Author(s):  
Dominic Thaler ◽  
Nahal Aliheidari ◽  
Amir Ameli
Keyword(s):  
Electrical Conductivity ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Functional Materials ◽  
Acrylonitrile Butadiene Styrene ◽  
Extrusion Process ◽  
Print Quality ◽  
Fused Deposition ◽  
Order Of Magnitude ◽  
Butadiene Styrene

Additive manufacturing is an emerging method to produce customized parts with functional materials without big investments. As one of the common additive manufacturing methods, fused deposition modeling (FDM) uses thermoplastic-based feedstock. It has been recently adapted to fabricate composite materials too. Acrylonitrile butadiene styrene (ABS) is the most widely used material as FDM feedstock. However, it is an electrically insulating polymer. Carbon Nanotubes (CNTs) on the other hand are highly conductive. They are attractive fillers because of their high aspect ratio, and excellent mechanical and physical properties. Therefore, a nanocomposite of these two materials can give an electrically conductive material that is potentially compatible with FDM printing. This work focuses on the investigation of the relationships between the FDM process parameters and the electrical conductivity of the printed ABS/CNT nanocomposites. Nanocomposite filaments with CNT contents up to 10wt% were produced using a twin-screw extruder followed by 3D printing using FDM method. The starting material was pellets from a masterbatch containing 15 wt% CNT. Compression-molded samples of ABS/CNT were also prepared as the bulk baselines. The effects of CNT content and nozzle size on the through-layer and in-layer electrical conductivity of the printed nanocomposites were analyzed. Overall, a higher percolation threshold was observed in the printed samples, compared to that of the compression-molded counterparts. This resulted in the conductivity of the printed samples that is at least one order of magnitude lower. Moreover, at CNT contents up to 5 wt%, the in-layer conductivity of the printed samples was almost two orders of magnitudes higher than that in the through-layer direction. In ABS/3 wt% CNT samples, the through-layer conductivity continuously decreased as the nozzle diameter was decreased from 0.8 mm to 0.35 mm. These variations in the electrical conductivity were explained in terms of the CNT alignment, caused by the extrusion process during the print, quality of interlayer bonding during deposition, and the voids created due to the discrete nature of the printing process.

scholarly journals Performance Evaluation of DSC Windows for Buildings

2013 ◽  
Vol 2013 ◽  
pp. 1-6 ◽  
Author(s):  
Jun-Gu Kang ◽  
Jin-Hee Kim ◽  
Jun-Tae Kim
Keyword(s):  
Solar Cells ◽  
Light Transmission ◽  
Dye Sensitized Solar Cells ◽  
Experimental Models ◽  
Production Costs ◽  
Zero Energy ◽  
Lower Efficiency ◽  
Dye Sensitized ◽  
Sensitized Solar Cells ◽  
Chemical Material

Interest in BIPV systems with dye-sensitized solar cells (DSCs) that can replace building windows has increased for zero energy buildings. Although DSCs have lower efficiency in terms of electricity generation than silicon solar cells, they allow light transmission and application of various colors; they also have low production costs, which make them especially suitable for BIPV systems. DSC research is interdisciplinary, involving electrical, chemical, material, and metal engineering. A considerable amount of research has been conducted on increasing the electrical efficiency of DSC and their modules. However, there has not been sufficient research on building applications of DSC systems. The aim of this study is to evaluate the optical performance and thermal performance of DSC windows in buildings. For this study, DSC experimental models with different thicknesses and dye colors were manufactured, and their optical properties, such as transmittance and reflectivity, were measured by a spectrometer. The thermal and optical characteristics of double-glazed windows with DSC were analyzed with a window performance analysis program, WINDOW 6.0.

scholarly journals EFFECT OF EXTRUSION PROCESS PARAMETERS ON MECHANICAL PROPERTIES OF 3D PRINTED PLA PRODUCT

2021 ◽  
Vol 6 (2) ◽  
pp. 119
Author(s):  
Nanang Ali Sutisna ◽  
Rakha Amrillah Fattah
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Extrusion Process ◽  
Experimental Procedure ◽  
Fused Deposition ◽  
Novel Approach ◽  
Deposition Modeling ◽  
3D Printed ◽  
3D Digital Models

The method of producing items through synchronously depositing material level by level, based on 3D digital models, is named Additive Manufacturing (AM) or 3D-printing. Amongs many AM methods, the Fused Deposition Modeling (FDM) technique along with PLA (Polylactic acid) material is commonly used in additive manufacturing. Until now, the mechanical properties of the AM components could not be calculated or estimated until they've been assembled and checked. In this work, a novel approach is suggested as to how the extrusion process affects the mechanical properties of the printed component to obtain how the parts can be manufactured or printed to achieve improved mechanical properties. This methodology is based on an experimental procedure in which the combination of parameters to achieve an optimal from a manufacturing experiment and its value can be determined, the results obtained show the effect of the extrusion process affects the mechanical properties.

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