Journal articles: 'Additive manufacture'

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Lancea, Camil, Valentin-Marian Stamate, Lucia-Antoneta Chicoş, Sebastian-Marian Zaharia, Alin-Mihai Pop, Ionut-Stelian Pascariu, and George-Răzvan Buican. "Design and additive manufacturing of brushless electric motor components." MATEC Web of Conferences 343 (2021): 01007. http://dx.doi.org/10.1051/matecconf/202134301007.

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The electric motor components are manufactured through the additive process of fused filament fabrication in order to verify the functionality of the electric motor assembly. This process was chosen due to the advantages it confers: fast obtaining of components, low manufacturing costs, no tools required for processing or for moulds manufacturing. Through the fused filament fabrication process, parts with complex geometries, which cannot be obtained by classical machining, can be manufactured. Due to the above-mentioned advantages, this technology is extremely useful for the manufacture and testing of prototypes. The paper aims to manufacture components of a brushless electric motor in order to verify the assembling compatibility and manufacturing accuracy.

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Escher, C., and C. Mutke. "Additive Manufacturing of Tool Steels*." HTM Journal of Heat Treatment and Materials 77, no. 2 (April 1, 2022): 143–55. http://dx.doi.org/10.1515/htm-2022-1002.

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Abstract Additive manufacturing of tool steels represents a great challenge, yet it offers new possibilities for the tool manufacture of, for example, complex forming tools with conformal cooling. First, this contribution gives an overview of the most relevant additive manufacturing processes, the materials and processing concepts. By means of a hybrid manufactured press hardening tool for high-strength sheet metal parts, an example of practical implementation is presented subsequently.

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Loukaides, Evripides G., Rhodri W. C. Lewis, and Christopher R. Bowen. "Additive manufacture of multistable structures." Smart Materials and Structures 28, no. 2 (January 21, 2019): 02LT02. http://dx.doi.org/10.1088/1361-665x/aae4f6.

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García-Gascón, César, Pablo Castelló-Pedrero, and Juan Antonio García-Manrique. "Minimal Surfaces as an Innovative Solution for the Design of an Additive Manufactured Solar-Powered Unmanned Aerial Vehicle (UAV)." Drones 6, no. 10 (October 2, 2022): 285. http://dx.doi.org/10.3390/drones6100285.

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This paper aims to describe the methodology used in the design and manufacture of a fixed-wing aircraft manufactured using additive techniques together with the implementation of technology based on solar panels. The main objective is increasing the autonomy and range of the UAV’s autonomous missions. Moreover, one of the main targets is to improve the capabilities of the aeronautical industry towards sustainable aircrafts and to acquire better mechanical properties owing to the use of additive technologies and new printing materials. Further, a lower environmental impact could be achieved through the use of renewable energies. Material extrusion (MEX) technology may be able to be used for the manufacture of stronger and lighter parts by using gyroids as the filling of the printed material. The paper proposes the use of minimal surfaces for the reinforcement of the UAV aircraft wings. This type of surface was never used because it is not possible to manufacture it using conventional techniques. The rapid growth of additive technologies led to many expectations for new design methodologies in the aeronautical industry. In this study, mechanical tests were carried out on specimens manufactured with different geometries to address the design and manufacture of a UAV as a demonstrator. In addition, to carry out the manufacture of the prototype, a 3D printer with a movable bench similar to a belt, that allows for the manufacture of parts without limitations in the Z axis, was tested. The parts manufactured with this technique can be structurally improved, and it is possible to avoid manufacturing multiple prints of small parts of the aircraft that will have to be glued later, decreasing the mechanical properties of the UAV. The conceptual design and manufacturing of a solar aircraft, SolarÍO, using additive technologies, is presented. A study of the most innovative 3D printers was carried out that allowed for the manufacture of parts with an infinite Z-axis and, in addition, a filler based on minimal surfaces (gyroids) was applied, which considerably increased the mechanical properties of the printed parts. Finally, it can be stated that in this article, the potential of the additive manufacturing as a new manufacturing process for small aircrafts and for the aeronautical sector in the future when new materials and more efficient additive manufacturing processes are already developed is demonstrated.

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Pfeffer, Stefan, Patrick Springer, Tobias Granse, Martin Neff, Simon Leitl, Albert Dorneich, Markus Fritton, and Frank Geiger. "Additive Fertigung individualisierter Sensorgehäuse/Additive manufacturing of individualised sensor housings." wt Werkstattstechnik online 112, no. 11-12 (2022): 737–42. http://dx.doi.org/10.37544/1436-4980-2022-11-12-11.

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Induktive Sensoren werden in Einschraubgehäusen als Standardkomponenten eingesetzt. In einem Verbund aus Fraunhofer-Institut für Produktionstechnik und Automatisierung IPA sowie den Firmen Arburg GmbH und Balluff GmbH wurde ein Ansatz entwickelt, um derartige Sensoren in individualisierbaren Gehäusen zu fertigen. Dieser Beitrag beschreibt wie Gehäuse additiv gefertigt und vergossen werden können. Zusätzlich werden Ergebnisse industrieller Qualifikationstests zur Evaluation der Sensoren beschrieben. Inductive sensors are used in screw-in housings as standard components. In an alliance of Fraunhofer IPA and the companies Arburg GmbH und Co. KG and Balluff GmbH, an approach was developed to manufacture such sensors in customizable housings. The publication describes how housings can be additively manufactured and molded. In addition, results of industrial qualification tests for the evaluation of the sensors are described.

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Veiga, Fernando, Trunal Bhujangrao, Alfredo Suárez, Eider Aldalur, Igor Goenaga, and Daniel Gil-Hernandez. "Validation of the Mechanical Behavior of an Aeronautical Fixing Turret Produced by a Design for Additive Manufacturing (DfAM)." Polymers 14, no. 11 (May 27, 2022): 2177. http://dx.doi.org/10.3390/polym14112177.

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The design of parts in such critical sectors as the manufacturing of aeronautical parts is awaiting a paradigm shift due to the introduction of additive manufacturing technologies. The manufacture of parts designed by means of the design-oriented additive manufacturing methodology (DfAM) has acquired great relevance in recent years. One of the major gaps in the application of these technologies is the lack of studies on the mechanical behavior of parts manufactured using this methodology. This paper focuses on the manufacture of a turret for the clamping of parts for the aeronautical industry. The design of the lightened turret by means of geometry optimization, the manufacture of the turret in polylactic acid (PLA) and 5XXX series aluminum alloy by means of Wire Arc Additive Manufacturing (WAAM) technology and the analysis by means of finite element analysis (FEA) with its validation by means of a tensile test are presented. The behavior of the part manufactured with both materials is compared. The conclusion allows to establish which are the limitations of the part manufactured in PLA for its orientation to the final application, whose advantages are its lower weight and cost. This paper is novel as it presents a holistic view that covers the process in an integrated way from the design and manufacture to the behaviour of the component in use.

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Salgado-Lopez, Juan Manuel, Enrique Martinez-Franco, Celso Cruz-Gonzalez, Jorge Corona-Castuera, and Jhon Alexander Villada-Villalobos. "Microstructure and Microhardness Evolution of Additively Manufactured Cellular Inconel 718 after Heat Treatment with Different Aging Times." Metals 12, no. 12 (December 14, 2022): 2141. http://dx.doi.org/10.3390/met12122141.

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The manufacture of cellular structures using high-performance materials is possible thanks to the additive manufacturing of metals. However, it is well known that the mechanical and microstructural properties of metals manufactured by this technique do not correspond to those of the same metals manufactured by conventional methods. It is well known that the mechanical properties depend on the direction of manufacture, the size of the pieces, and the type of cell structure used. In addition, the effect of heat treatments on parts manufactured by additive manufacturing differs from parts manufactured by conventional methods. In this work, the microstructure and microhardness of cellular structures of Inconel 718, manufactured by additive manufacturing under heat treatments with different aging times, were evaluated. It was found that the time of the first aging impacts the microhardness and its homogeneity, affecting the microstructure. The highest hardness was obtained for an aging time of 8 h, while the lowest standard deviation was obtained at 10 h. Finally, it is shown that the aging time influences a more homogeneous distribution of the elements and phases.

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Childerhouse, Thomas, and Martin Jackson. "Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes." Metals 9, no. 6 (June 15, 2019): 689. http://dx.doi.org/10.3390/met9060689.

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Near net shape (NNS) manufacturing offers an alternative to conventional processes for the manufacture of titanium alloy components. Compared to the conventional routes, which typically require extensive material removal of forged billets, NNS methods offer more efficient material usage and can significantly reduce machining requirements. Furthermore, NNS manufacturing processes offer benefits such as greater flexibility and reduced costs compared to conventional methods. Processes such as metal additive manufacturing (AM) have started to be adopted in niche applications, most notably for the manufacture of medical implants, where many conventionally forged components have been replaced by those manufactured by AM processes. However, for more widespread adoption of these emerging processes, an improvement in the confidence in the techniques by manufacturers is necessary. This requires addressing challenges such as the limited mechanical properties of parts in their as-built condition compared to wrought products and the post-process machining requirements of components manufactured by these routes. In this review, processes which use a powder or wire feedstock are evaluated to assess their capabilities for the manufacture of titanium alloy components. These processes include powder bed fusion and direct energy deposition metal additive processes as well as hybrid routes, which combine powder metallurgy with thermomechanical post-processing.

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Kasatkin, M. M., T. D. Kozhina, and M. M. Federov. "Additive Technologies in Airplane-Engine Manufacture." Russian Engineering Research 39, no. 3 (March 2019): 262–67. http://dx.doi.org/10.3103/s1068798x19030110.

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Mcparland, Kyle, Zachary Larimore, Paul Parsons, Austin Good, John Suarez, and Mark Mirotznik. "Additive Manufacture of Custom Radiofrequency Connectors." IEEE Transactions on Components, Packaging and Manufacturing Technology 12, no. 1 (January 2022): 168–73. http://dx.doi.org/10.1109/tcpmt.2021.3134603.

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McMillan, Matthew, Marten Jurg, Martin Leary, and Milan Brandt. "Programmatic Lattice Generation for Additive Manufacture." Procedia Technology 20 (2015): 178–84. http://dx.doi.org/10.1016/j.protcy.2015.07.029.

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Golyadinets, V. P., V. N. Koposov, A. S. Shul'ga, and E. A. Kutkovaya. "Utilization of sludge from additive manufacture." Chemistry and Technology of Fuels and Oils 23, no. 4 (April 1987): 178–79. http://dx.doi.org/10.1007/bf00731818.

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Leary, Martin, Luigi Merli, Federico Torti, Maciej Mazur, and Milan Brandt. "Optimal topology for additive manufacture: A method for enabling additive manufacture of support-free optimal structures." Materials & Design 63 (November 2014): 678–90. http://dx.doi.org/10.1016/j.matdes.2014.06.015.

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Ullah, A. M. M. Sharif, D. M. D’Addona, Khalifa H. Harib, and Than Lin. "Fractals and Additive Manufacturing." International Journal of Automation Technology 10, no. 2 (March 4, 2016): 222–30. http://dx.doi.org/10.20965/ijat.2016.p0222.

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Fractal geometry can create virtual models of complex shapes as CAD data, and from these additive manufacturing can directly create physical models. The virtual-model-building capacity of fractal geometry and the physical-model-building capacity of additive manufacturing can be integrated to deal with the design and manufacturing of complex shapes. This study deals with the manufacture of fractal shapes using commercially available additive manufacturing facilities and 3D CAD packages. Particular interest is paid to building physical models of an IFS-created fractal after remodeling it for manufacturing. This article introduces three remodeling methodologies based on binary-grid, convex/concave-hull, and line-model techniques. The measurements of the manufactured fractal shapes are also reported, and the degree of accuracy that can be achieved by the currently available technology is shown.

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Antoniac, Iulian, Veronica Manescu (Paltanea), Gheorghe Paltanea, Aurora Antoniac, Iosif Vasile Nemoianu, Mircea Ionut Petrescu, Horatiu Dura, and Alin Danut Bodog. "Additive Manufactured Magnesium-Based Scaffolds for Tissue Engineering." Materials 15, no. 23 (December 6, 2022): 8693. http://dx.doi.org/10.3390/ma15238693.

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Additive manufacturing (AM) is an important technology that led to a high evolution in the manufacture of personalized implants adapted to the anatomical requirements of patients. Due to a worldwide graft shortage, synthetic scaffolds must be developed. Regarding this aspect, biodegradable materials such as magnesium and its alloys are a possible solution because the second surgery for implant removal is eliminated. Magnesium (Mg) exhibits mechanical properties, which are similar to human bone, biodegradability in human fluids, high biocompatibility, and increased ability to stimulate new bone formation. A current research trend consists of Mg-based scaffold design and manufacture using AM technologies. This review presents the importance of biodegradable implants in treating bone defects, the most used AM methods to produce Mg scaffolds based on powder metallurgy, AM-manufactured implants properties, and in vitro and in vivo analysis. Scaffold properties such as biodegradation, densification, mechanical properties, microstructure, and biocompatibility are presented with examples extracted from the recent literature. The challenges for AM-produced Mg implants by taking into account the available literature are also discussed.

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Mazur, Maciej, Martin Leary, Matthew McMillan, Joe Elambasseril, and Milan Brandt. "SLM additive manufacture of H13 tool steel with conformal cooling and structural lattices." Rapid Prototyping Journal 22, no. 3 (April 18, 2016): 504–18. http://dx.doi.org/10.1108/rpj-06-2014-0075.

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Purpose Additive manufacture (AM) such as selective laser melting (SLM) provides significant geometric design freedom in comparison with traditional manufacturing methods. Such freedom enables the construction of injection moulding tools with conformal cooling channels that optimize heat transfer while incorporating efficient internal lattice structures that can ground loads and provide thermal insulation. Despite the opportunities enabled by AM, there remain a number of design and processing uncertainties associated with the application of SLM to injection mould tool manufacture, in particular from H13/DIN 1.2344 steel as commonly used in injection moulds. This paper aims to address several associated uncertainties. Design/methodology/approach A number of physical and numerical experimental studies are conducted to quantify SLM-manufactured H13 material properties, part manufacturability and part characteristics. Findings Findings are presented which quantify the effect of SLM processing parameters on the density of H13 steel components; the manufacturability of standard and self-supporting conformal cooling channels, as well as structural lattices in H13; the surface roughness of SLM-manufactured cooling channels; the effect of cooling channel layout on the associated stress concentration factor and cooling uniformity; and the structural and thermal insulating properties of a number of structural lattices. Originality/value The contributions of this work with regards to SLM manufacture of H13 of injection mould tooling can be applied in the design of conformal cooling channels and lattice structures for increased thermal performance.

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Roberts , Andrew, Recep Kahraman, Desi Bacheva, and Gavin Tabor. "Modelling of Powder Removal for Additive Manufacture Postprocessing." Journal of Manufacturing and Materials Processing 5, no. 3 (August 6, 2021): 86. http://dx.doi.org/10.3390/jmmp5030086.

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A critical challenge underpinning the adoption of Additive Manufacture (AM) as a technology is the postprocessing of manufactured components. For Powder Bed Fusion (PBF), this can involve the removal of powder from the interior of the component, often by vibrating the component to fluidise the powder to encourage drainage. In this paper, we develop and validate a computational model of the flow of metal powder suitable for predicting powder removal from such AM components. The model is a continuum Eulerian multiphase model of the powder including models for the granular temperature; the effect of vibration can be included through appropriate wall boundaries for this granular temperature. We validate the individual sub-models appropriate for AM metal powders by comparison with in-house and literature experimental results, and then apply the full model to a more complex geometry typical of an AM Heat Exchanger. The model is shown to provide valuable and accurate results at a fraction of the computational cost of a particle-based model.

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Fedorová, Lucia, Irenej Poláček, Radovan Hudák, Mária Mihaliková, and Jozef Živčák. "A Comparison of Mechanical Properties of Lumbar Bilateral Implants Manufactured by Additive and Conventional Technologies." Key Engineering Materials 635 (December 2014): 139–42. http://dx.doi.org/10.4028/www.scientific.net/kem.635.139.

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Spinal implants are mechanical equipments that facilitate fusion, correct deformities, and stabilize and strengthen the spine. To make an implant efficient, it has to endure without any failure, especially mechanical damage, stand all the static and dynamic loads incurred in spine during everyday activities, and maintain the necessary position of motive segments during the bone adhesion. [1] Human spine is exposed to the highest load in the lumbar section [2]; therefore, lumbar bilateral implants require higher attention in terms of mechanical parameters verification. The main objective of this paper was to compare mechanical properties of lumbar bilateral systems using the spinal implants manufactured by the conventional method and the Direct Metal Laser Sintering method (DMLS). Detection of mechanical properties enables the assessment of possible replacement of commercial manufacture with the DMLS manufacture. On the basis of the ASTM F1717 standards providing the essentials for the comparison of mechanical properties of spinal systems, twenty mechanical compression tests were carried out. Mechanical tests were carried out using 20 spinal bars with the diameter of 11 mm and the fastening length of 260 mm, manufactured by the DMLS technology while using the EOSINT M280 equipment (EOS, Germany), and 20 identical spinal bars manufactured by the conventional technology. Results obtained in mechanical compression tests indicate that both manufacture methods are comparable and there are no significant differences between them, as for the strength characteristics. Other trials will be focused on static tensile tests and cyclical tests of lumbar bilateral systems.

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Liu, Dan, Boyoung Lee, Aleksandr Babkin, and Yunlong Chang. "Research Progress of Arc Additive Manufacture Technology." Materials 14, no. 6 (March 15, 2021): 1415. http://dx.doi.org/10.3390/ma14061415.

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Additive manufacturing technology is a special processing technology that has developed rapidly in the past 30 years. The materials used are divided into powder and wire. Additive manufacturing technology using wire as the material has the advantages of high deposition rate, uniform composition, and high density. It has received increasingly more attention, especially for the high efficiency and rapid prototyping of large-size and complex-shaped components. Wire arc additive manufacturing has its unique advantages. The concept, connotation, and development history of arc additive manufacturing technology in foreign countries are reviewed, and the current research status of arc-based metal additive manufacturing technology is reviewed from the principles, development history, process, and practical application of arc additive manufacturing technology. It focuses on the forming system, forming material, residual stress and pores, and other defect controls of the technology, as well as the current methods of mechanical properties and process quality improvement, and the development prospects of arc additive manufacturing technology are prospected. The results show that the related research work of wire arc additive manufacturing technology is still mainly focused on the experimental research stage and has yet not gone deep into the exploration of the forming mechanism. The research work in this field should be more in-depth and systematic from the physical process of forming the molten pool system from the perspectives of stability, the organization evolution law, and performance optimization. We strive to carry out wire arc additive forming technology and theoretical research to promote the application of this technology in modern manufacturing.

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Matviichuk, V. A., V. M. Nesterenkov, and O. M. Berdnikova. "Additive electron beam technology for manufacture of metal products from powder materials." Paton Welding Journal 2022, no. 2 (February 28, 2022): 16–25. http://dx.doi.org/10.37434/tpwj2022.02.03.

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Staub, Alexandre, Lucas Brunner, Adriaan B. Spierings, and Konrad Wegener. "A Machine-Learning-Based Approach to Critical Geometrical Feature Identification and Segmentation in Additive Manufacturing." Technologies 10, no. 5 (September 16, 2022): 102. http://dx.doi.org/10.3390/technologies10050102.

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Additive manufacturing (AM) processes offer a good opportunity to manufacture three- dimensional objects using various materials. However, many of the processes, notably laser Powder bed fusion, face limitations in manufacturing specific geometrical features due to their physical constraints, such as the thermal conductivity of the surrounding medium, the internal stresses, and the warpage or weight of the part being manufactured. This work investigates the opportunity to use machine learning algorithms in order to identify hard-to-manufacture geometrical features. The segmentation of these features from the main body of the part permits the application of different manufacturing strategies to improve the overall manufacturability. After selecting features that are particularly problematic during laser powder bed fusion using stainless steel, an algorithm is trained using simple geometries, which permits the identification of hard-to-manufacture features on new parts with a success rate of 88%, showing the potential of this approach.

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Downing, David, Matthew McMillan, Milan Brandt, and Martin Leary. "Programmatic lattice generation tools for additive manufacture." Software Impacts 12 (May 2022): 100262. http://dx.doi.org/10.1016/j.simpa.2022.100262.

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WEI, ChongBin, YuFeng ZHENG, Yan CHENG, CaiMei WANG, Ming LI, Hong CAI, XiaoChen ZHOU, et al. "Biomedical titanium implants based on additive manufacture." SCIENTIA SINICA Technologica 46, no. 11 (October 31, 2016): 1097–115. http://dx.doi.org/10.1360/n092016-00046.

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Byrne, Oisín, Fergal Coulter, Mark Glynn, James F. X. Jones, Aisling Ní Annaidh, Eoin D. O'Cearbhaill, and Dónal P. Holland. "Additive Manufacture of Composite Soft Pneumatic Actuators." Soft Robotics 5, no. 6 (December 2018): 726–36. http://dx.doi.org/10.1089/soro.2018.0030.

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Capel, Andrew J., Steve Edmondson, Steven D. R. Christie, Ruth D. Goodridge, Richard J. Bibb, and Matthew Thurstans. "Design and additive manufacture for flow chemistry." Lab on a Chip 13, no. 23 (2013): 4583. http://dx.doi.org/10.1039/c3lc50844g.

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Chen, Nan, Guoqiang Ma, Wanquan Zhu, Andrew Godfrey, Zhijian Shen, Guilin Wu, and Xiaoxu Huang. "Enhancement of an additive-manufactured austenitic stainless steel by post-manufacture heat-treatment." Materials Science and Engineering: A 759 (June 2019): 65–69. http://dx.doi.org/10.1016/j.msea.2019.04.111.

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Motibane, Londiwe, Lerato Tshabalala, Mashudu Tshifularo, Rocky Ramokolo, Waldo van der Westhuizen, Chemist Mabena, Jaco Hart, and Philip Loveday. "A comparison of sound transmission of middle ear prostheses manufactured via SLM." MATEC Web of Conferences 370 (2022): 10002. http://dx.doi.org/10.1051/matecconf/202237010002.

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Middle ear surgeries involve Total Ossicular Replacement Prosthesis (TORP) or Partial Ossicular Replacement Prosthesis, where all or some of the three ossicle bones are replaced. Current prostheses are dissimilar to the natural ossicles in geometry, size and only recover up to 75% sound transmission. Additive manufacturing offers complex, near-net shape geometries that allow for patient specific implants. A novel design is used to manufacture a TORP in Ti6Al4V(ELI) via Additive Manufacturing. The sound transmission level of the of the additively manufactured titanium prosthesis was measured by laser doppler vibrometry and compared to that of a Silver additively manufactured prosthesis. The sound transmission level of the additively manufactured prostheses are also compared to that of the international standards and literature using this method.

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McEwen, Iain, David Cooper, Jay Warnett, Nadia Kourra, Mark Williams, and Gregory Gibbons. "Design & Manufacture of a High-Performance Bicycle Crank by Additive Manufacturing." Applied Sciences 8, no. 8 (August 13, 2018): 1360. http://dx.doi.org/10.3390/app8081360.

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A new practical workflow for the laser Powder Bed Fusion (PBF) process, incorporating topological design, mechanical simulation, manufacture, and validation by computed tomography is presented, uniquely applied to a consumer product (crank for a high-performance racing bicycle), an approach that is tangible and adoptable by industry. The lightweight crank design was realised using topology optimisation software, developing an optimal design iteratively from a simple primitive within a design space and with the addition of load boundary conditions (obtained from prior biomechanical crank force–angle models) and constraints. Parametric design modification was necessary to meet the Design for Additive Manufacturing (DfAM) considerations for PBF to reduce build time, material usage, and post-processing labour. Static testing proved performance close to current market leaders with the PBF manufactured crank found to be stiffer than the benchmark design (static load deflection of 7.0 ± 0.5 mm c.f. 7.67 mm for a Shimano crank at a competitive mass (155 g vs. 175 g). Dynamic mechanical performance proved inadequate, with failure at 2495 ± 125 cycles; the failure mechanism was consistent in both its form and location. This research is valuable and novel as it demonstrates a complete workflow from design, manufacture, post-treatment, and validation of a highly loaded PBF manufactured consumer component, offering practitioners a validated approach to the application of PBF for components with application outside of the accepted sectors (aerospace, biomedical, autosports, space, and power generation).

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Sanchez Ramirez, Alberto, Manuel Enrique Islán Marcos, Fernando Blaya Haro, Roberto D’Amato, Rodolfo Sant, and José Porras. "Application of FDM technology to reduce aerodynamic drag." Rapid Prototyping Journal 25, no. 4 (May 13, 2019): 781–91. http://dx.doi.org/10.1108/rpj-09-2018-0251.

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Purpose The purpose of this paper is to analyze the aerodynamic improvements obtained in a wing section with a NACA 0018 airfoil manufactured using the fused deposition modeling (FDM) technique with regard to a smooth surface made by milling. The creation of micro-riblets on the surface of the airfoil, due to the deposition of the material layer by layer, improves the general aerodynamic performance of the parts, provided that the riblets are parallel to the flow line. The incidence of the thickness of the thread deposited in each layer – to be the variable on which the geometry of the riblets is based – was studied. Design/methodology/approach The wing section was designed using 3D software. Three different models were designed by rapid prototyping, using additive and subtractive manufacturing. Two of the profiles were manufactured using FDM varying the thickness of the layer to be able to compare the aerodynamic improvements. The third model was manufactured using a subtractive rapid prototyping machine generating a smooth surface profile. These three models were tested inside the wind tunnel to be able to quantify the aerodynamic efficiency according to the geometry and the riblets size. Findings The manufacture of an aerodynamic profile using FDM provides, in addition to the lightness and the ability to design parts with complex geometries, an improvement in the aerodynamic efficiency of 10 per cent compared with profiles with a smooth surface. Practical implications With the aerodynamic advantage gained through the use of FDM positions, the additive manufacturing serves as an excellent alternative for the manufacture of lightweight aerodynamic parts, with low structural loading and with low Reynolds number (∼5·105). This technological advantage would be applied to the UAV (unmanned aerial vehicle) industry. Originality/value The study carried out in this article demonstrates that the use of FDM as a manufacture process of end-used parts that are subject to movement generates an additional advantage that had not been considered. The additive manufacturing allows us to directly manufacture riblets by creating the necessary surface so as to reduce the aerodynamic drag.

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Batalha, A. E. F., and R. M. Araújo. "Development of removable partial dentures by using additive manufacture and casting processes." Archives of Materials Science and Engineering 1, no. 87 (September 1, 2017): 33–40. http://dx.doi.org/10.5604/01.3001.0010.5969.

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Purpose: This work aims to present a methodology developed for dimensional analysis of removable partial dentures, following a route with a model manufactured by additive manufacture and a further casting process of a Co-Cr alloy part. Design/methodology/approach: The method for designing and manufacturing removable partial dentures (RPD) is focused on their completely virtual design. They are manufactured with resin additive manufacturing chrome-cobalt cast alloys. A 3D image correlation scanner was used for dimensional and geometrical tolerance analysis. Findings: The prostheses manufactured by CAD-CAM route are more accurate than conventional ones, but they suffer distortion during the casting process. This distortion did not interfere with the patient's well-being or with the adaptation to the prosthesis. Research limitations/implications: The technique presented herein paper allows preparing better fitting prosthesis. Providing the best comfort and masticatory power. Practical implications: Improving the precision in the manufacturing process of a removable partial denture is very important for professional dentists and their patients. Originality/value: The proposed technique and the work approach provide the prosthesis preparation with shorter ambulatory time in addition to greater comfort to the patient.

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Sanchez-Alonso, Elsa, Gonzalo Valdes-Vidal, and Alejandra Calabi-Floody. "Experimental Study to Design Warm Mix Asphalts and Recycled Warm Mix Asphalts Using Natural Zeolite as Additive for Sustainable Pavements." Sustainability 12, no. 3 (January 29, 2020): 980. http://dx.doi.org/10.3390/su12030980.

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There are currently various technologies for the manufacture of warm mix asphalts (WMA). This paper presents the possibility of using a natural zeolite to manufacture WMA as an alternative to existing synthetic products for the manufacture of this type of mixture. Moreover, the possibility of manufacturing WMA with the addition of recycled asphalt pavement (RAP) using natural zeolite as the basis of a warm mix technology was evaluated. Firstly, asphalt mixtures were manufactured at three different temperatures (145 °C, 135 °C, and 125 °C) with different percentages of natural zeolite to determine the temperature and the optimum content for the manufacture of WMA. Then, the zeolite moisture content and its release over time were determined at different temperatures, and its distribution in the binder was checked at different concentrations by scanning electron microscopy and fluorescence. Next, with the optimum zeolite content, the addition of RAP between 10–30% in the WMA at the same three manufacturing temperatures was evaluated. Two types of compaction were used: the impact and gyratory compactions. The Marshall parameters were evaluated for all the designed mixtures. The results indicated that the manufacture of WMA with the addition of natural zeolite is feasible, and depending on the required mixing temperature, recycled WMA with different percentages of RAP can be obtained.

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Leary, Martin, Richard Piola, Jeff Shimeta, Steven Toppi, Scott Mayson, Matthew McMillan, and Milan Brandt. "Additive manufacture of anti-biofouling inserts for marine applications." Rapid Prototyping Journal 22, no. 2 (March 21, 2016): 416–34. http://dx.doi.org/10.1108/rpj-02-2014-0022.

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Purpose Biofouling of marine vessels results in significant operational costs, as well as the bio-security risk associated with the transport of marine pests. Biofouling is particularly rapid in sea-chest water intakes due to elevated temperatures and circulating flow. Inspection challenges are exacerbated, as sea chests are difficult to inspect and clean. This paper aims to present a method that utilises the flexibility and low-batch capabilities of additive manufacture to manufacture custom sea-chest inserts that eliminate circulating flow and increase the uniformity of shear stress distributions to enable more constant ablation of anti-biofouling coatings. Design/methodology/approach An automated design procedure has been developed to optimise sea-chest insert geometry to achieve desirable flow characteristics, while eliminating the necessity for support material in FDM manufacture – thereby significantly reducing build cost and time. Findings Numerical flow simulation confirms that the fluid-flow approximation is robust for optimising sea-chest insert geometry. Insert geometry can be manipulated to enable support-free additive manufacture; however, as the threshold angle for support-free manufacture increases, the set of feasible sea-chest aspect ratios decreases. Research limitations/implications The surface of revolution that defines the optimal insert geometry may result in features that are not compatible with additive manufacture constraints. An alternate geometry is proposed that may be more useful in practice without compromising anti-biofouling properties. Practical implications Marine sea-chest biofouling results in significant negative environmental and economic consequence. The method developed in this paper can reduce the negative impact of sea-chest biofouling. Social implications Marine sea-chest biofouling results in significant resource consumption and emissions. The method developed in this paper can reduce the negative impact of sea-chest biofouling. Originality/value The method presented in this paper provides an entirely original opportunity to utilise additive manufacture to mitigate the effects of marine biofouling.

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Kozak, Jerzy, Tomasz Zakrzewski, Marta Witt, and Martyna Dębowska-Wąsak. "Selected Problems of Additive Manufacturing Using SLS/SLM Processes." Transactions on Aerospace Research 2021, no. 1 (March 1, 2021): 24–44. http://dx.doi.org/10.2478/tar-2021-0003.

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Abstract Additive Manufacturing (AM) based on Selective Laser Sintering (SLS) and Selective Laser Melting (SLM) is relatively widely used to manufacture complex shape parts made from metallic alloys, ceramic and polymers. Although the SLM process has many advantages over the conventional machining, main disadvantages are the relatively poor surface quality and the occurrence of the material structure defect porosity. The paper presents key problems directly related to the implementation of AM, and in particular the selection and optimization of process conditions. The first section examines the issues of dimensional accuracy, the second surface quality and porosity problem determining the mechanical properties of manufactured products.

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Langebeck, Anika, Annika Bohlen, Hannes Freisse, and Frank Vollertsen. "Additive manufacturing with the lightweight material aluminium alloy EN AW-7075." Welding in the World 64, no. 3 (December 4, 2019): 429–36. http://dx.doi.org/10.1007/s40194-019-00831-z.

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AbstractAs a widely used additive manufacturing technique, the laser metal deposition process (LMD) also known as direct energy deposition (DED) is often used to manufacture large-scale parts. Advantages of the LMD process are the high build-up rate as well as its nearly limitless build-up volume. To manufacture large-scale parts in lightweight design with high strength aluminium alloy EN AW-7075, the LMD process has a disadvantage that must be considered. During the process, the aluminium alloy is melted and has therefore a high solubility for hydrogen. As soon as the melt pool solidifies again, the hydrogen cannot escape the melt and hydrogen pores are formed which weakens the mechanical properties of the manufactured part. To counter this disadvantage, the hydrogen must be successfully kept away from the process zone. Therefore, the covering of the process zone with shielding gas can be improved by an additional shielding gas shroud. Furthermore, the process parameters energy input per unit length as well as the horizontal overlapping between two single tracks can be varied to minimize the pore volume. Best results can be achieved in single tracks with an elevated energy input per unit length from 3000 to 6000 J/cm. To manufacture layers, a minimal horizontal overlapping will lead to lowest pore volume, although this results in a very wavy surface, as a compromise of low pore volume and a nearly even surface a horizontal overlapping of 30 to 37% leads to a pore volume of 0.95% ± 0.50%.

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Dzogbewu, Thywill Cephas. "Additive manufacturing of TiAl-based alloys." Manufacturing Review 7 (2020): 35. http://dx.doi.org/10.1051/mfreview/2020032.

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The ever-increasing demand for developing lightweight, high-temperature materials that can operate at elevated temperatures is still a subject of worldwide research and TiAl-based alloys have come to the fore. The conventional methods of manufacturing have been used successfully to manufacture the TiAl-based alloy. However, due to the inherent limitations of the conventional methods to produce large TiAl components with intricate near-net shapes has limit the widespread application and efficiency of the TiAl components produced using conventional methods. Metal additive manufacturing such as Electron Beam Melting technology could manufacture the TiAl alloys with intricate shapes but lack geometrical accuracy. Laser powder bed fusion (LPBF) technology could manufacture the TiAl-based alloys with intricate shapes with geometrical accuracy. However, the inherent high rate of heating and cooling mechanisms of the LPBF process failed to produce crack-free TiAl components. Various preheating techniques have been experimented, to reduce the high thermal gradient and residual stress during the LPBF process that causes the cracking of the TiAl components. Although these techniques have not reached industrial readiness up to now, encouraging results have been achieved.

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Zou, Lei, Lei Li, Jian Hua Cai, Hai Ying Yang, and Jun Chen. "Forming Process of Wire and Arc Additive Manufacture." Materials Science Forum 1035 (June 22, 2021): 198–205. http://dx.doi.org/10.4028/www.scientific.net/msf.1035.198.

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The forming process of wire and arc additively manufacture (WAAM) was studied using the self-developed and designed WAAM system. The single-pass and single-layer weld bead samples were prepared with different process parameters, and the cross-sectional dimensions of the weld bead were measured. The influence rules of weld current, welding speed, wire feed speed and welding height on the weld bead size were obtained. In addition, the overlap experiment of the WAAM forming process was also carried out. The multiple and multilayer lap samples with different overlap rates were prepared, and the cross-sections of the lap samples were observed and analyzed. Finally, the overlap rate range of 35-45% with good forming effect was obtained.

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Mehnen, Jörn, Jialuo Ding, Helen Lockett, and Panos Kazanas. "Design study for wire and arc additive manufacture." International Journal of Product Development 19, no. 1/2/3 (2014): 2. http://dx.doi.org/10.1504/ijpd.2014.060028.

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Stöckli, Fritz, Fabio Modica, and Kristina Shea. "Designing passive dynamic walking robots for additive manufacture." Rapid Prototyping Journal 22, no. 5 (August 15, 2016): 842–47. http://dx.doi.org/10.1108/rpj-11-2015-0170.

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Purpose Ongoing research in computational design synthesis of passive dynamic systems aims to automatically generate robotic configurations based on a given task. However, an automated design-to-fabrication process also requires a flexible fabrication method. This paper aims to explore designing and fabricating passive dynamic walking robots and all necessary components using single-material fused deposition modeling (FDM). Being able to fabricate all components of a robot using FDM is a step toward the goal of automated design and fabrication of passive dynamic robots. Design/methodology/approach Two different configurations of passive dynamic walking robots are re-designed to be fabricated using FDM. Different robotic joint assemblies are designed and tested. To arrive at feasible solutions, a modular design approach is chosen and adjustability of components after printing is integrated in the design. Findings The suitability of FDM for printing passive dynamic robots is shown to depend heavily on the sensitivity of the configuration. For one robot configuration, all components are printed in one job and only little assembly is needed after printing. For the second robot configuration, which has a more sensitive gait, a metal bearing is found to increase the performance substantially. Originality/value Printable, monolithic mechatronic systems require multi-material printing, including electronics. In contrast, passive dynamic systems not only have the potential to save energy and component cost compared to actuated systems but can also be fabricated using single-material FDM as demonstrated in this paper.

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Eriksson, Magnus, Malin Lervåg, Camilla Sørensen, Andreas Robertstad, Bård M. Brønstad, Bård Nyhus, Ragnhild Aune, Xiaobo Ren, and Odd M. Akselsen. "Additive manufacture of superduplex stainless steel using WAAM." MATEC Web of Conferences 188 (2018): 03014. http://dx.doi.org/10.1051/matecconf/201818803014.

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Superduplex stainless steels have been used in the oil and gas industry for a couple of decades due to the combination of excellent mechanical properties and corrosion resistance. The present investigation addresses the applicability of wire and arc additive manufacturing for this steel grade. Due to the inherent rapid heating and cooling, the initial base metal microstructure will be substantially altered, and complex thermal cycles may cause the formation of brittle secondary phases, among which the frequently observed intermetallic sigma phase is most harmful. However, no intermetallic phases have been observed, which is consistent with the low heat input employed, and the high Ni content in the wire. The microstructure observations in terms of ferrite volume fraction, Cr nitrides precipitation and the formation of secondary austenite are discussed together with the hardness measurements, tensile testing and notch toughness testing. It is concluded that additive manufacturing of superduplex stainless steels by wire and arc process is feasible.

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Derby, Brian. "Additive Manufacture of Ceramics Components by Inkjet Printing." Engineering 1, no. 1 (March 2015): 113–23. http://dx.doi.org/10.15302/j-eng-2015014.

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Kobryn, P. A., and S. L. Semiatin. "The laser additive manufacture of Ti-6Al-4V." JOM 53, no. 9 (September 2001): 40–42. http://dx.doi.org/10.1007/s11837-001-0068-x.

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Hirsch, M., P. Dryburgh, S. Catchpole-Smith, R. Patel, L. Parry, S. D. Sharples, I. A. Ashcroft, and A. T. Clare. "Targeted rework strategies for powder bed additive manufacture." Additive Manufacturing 19 (January 2018): 127–33. http://dx.doi.org/10.1016/j.addma.2017.11.011.

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Merkt, Simon, Arnd Kleyer, and Axel J. Hueber. "The Additive Manufacture of Patient-tailored Finger Implants." Laser Technik Journal 11, no. 2 (April 2014): 54–56. http://dx.doi.org/10.1002/latj.201400029.

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Reale Batista, Mariana Desiree, Swetha Chandrasekaran, Bryan Moran, Miguel A. Salazar de Troya, Adam Carleton, Thomas Roy, Manhao Zeng, et al. "Additive Manufacture of Graphene Electrodes for Supercapacitor Applications." ECS Meeting Abstracts MA2022-02, no. 1 (October 9, 2022): 60. http://dx.doi.org/10.1149/ma2022-02160mtgabs.

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Electrochemical energy storage devices, such as supercapacitors, are essential contributors to the implementation of sustainable energy. Supercapacitors exhibit fast charging/discharging ability and have attracted considerable attention within the automotive, aerospace, and telecommunication industries. Although these devices show great potential to meet power density metrics, they lack in terms of their energy density. To overcome this challenge, we are investigating better materials, architectures, and additive manufacturing techniques to print electrodes that increase the energy density while maintaining their high-power densities. Topology optimization was used to design an electrode with optimum performance. These electrodes were printed by projection micro stereolithography (PµSL) using PR48, a commercially available polymer resin. The printed electrodes were converted to carbon electrodes through pyrolysis at 1050 ֯C and characterized by cyclic voltammetry (CV), galvanostatic charge/discharge (GCD), and electrical impedance spectroscopy. The performance of the PR48 optimized electrodes were compared against PR48 electrodes printed as a simple cubic lattice structure previously shown to improve capacitance and rate capability. The results show that our optimized electrodes have higher areal capacitances for all the current densities tested and they perform better in GCD and CV tests. Lastly, to increase the surface area of the electrodes and increase the capacitance further, we developed a resin formulation by combining graphene oxide (GO) into TMPTA polymer. Electrodes printed with 3%GO/TMPTA have improved electrochemical performance compared to PR48 as evidenced by their higher capacitances and their better GCD and CV curves. This work demonstrates the benefits of using topology optimization to design electrodes and materials development to improve the functional properties of 3D printable resins. This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under contract DE-AC52-07NA27344. Lawrence Livermore National Security, LLC Figure 1

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Simonov, E. N., and K. M. Vinogradov. "Smart System for Additive Manufacture of Metal Parts." Russian Engineering Research 42, no. 10 (October 2022): 1065–69. http://dx.doi.org/10.3103/s1068798x22100306.

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Kennedy, John, Lara Flanagan, Luke Dowling, G. J. Bennett, Henry Rice, and Daniel Trimble. "The Influence of Additive Manufacturing Processes on the Performance of a Periodic Acoustic Metamaterial." International Journal of Polymer Science 2019 (July 24, 2019): 1–11. http://dx.doi.org/10.1155/2019/7029143.

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Advancements in 3D print technology now allow the printing of structured acoustic absorbent materials at the appropriate microscopic scale and sample sizes. The repeatability of the fundamental cell unit of these metamaterials provides a pathway for the development of viable macro models to simulate built-up structures based on detailed models of the individual cell units; however, verification of such models on actual manufactured structures presents a challenge. In this paper, a design concept for an acoustic benchmark metamaterial consisting of an interlinked network of resonant chambers is considered. The form chosen is periodic with cubes incorporating spherical internal cavities connected through cylindrical openings on each face of the cube. This design is amenable to both numerical modelling and manufacture through additive techniques whilst yielding interesting acoustic behaviour. The paper reports on the design, manufacture, modelling, and experimental validation of these benchmark structures. The behaviour of the acoustic metamaterial manufactured through three different polymer-based printing technologies is investigated with reference to the numerical models and a metal powder-based print technology. At the scale of this microstructure, it can be seen that deviations in surface roughness and dimensional fidelity have a comparable impact on the experimentally measured values of the absorption coefficient.

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Austermann, Johannes, Alec J. Redmann, Vera Dahmen, Adam L. Quintanilla, Sue J. Mecham, and Tim A. Osswald. "Fiber-Reinforced Composite Sandwich Structures by Co-Curing with Additive Manufactured Epoxy Lattices." Journal of Composites Science 3, no. 2 (May 16, 2019): 53. http://dx.doi.org/10.3390/jcs3020053.

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In this paper, a new process of joining additive manufactured (AM) lattice structures and carbon fiber-reinforced plastics (CFRPs) to manufacture hybrid lattice sandwich structures without secondary bonding is investigated. Multiple variations of lattice structures are designed and 3D printed using Digital Light Synthesis (DLS) and a two-stage (B-stage) epoxy resin system. The resulting lattice structures are only partially cured and subsequently thermally co-cured with pre-impregnated carbon fiber reinforcement. The mechanical properties of the additive manufactured lattice structures are characterized by compressive tests. Furthermore, the mechanical properties of hybrid lattice sandwich structures are assessed by flexural beam testing. From compressive testing of the additive manufactured lattice structures, high specific strength can be ascertained. The mechanical behavior shows these lattice structures to be suitable for use as sandwich core materials. Flexural beam testing of hybrid lattice sandwich structures shows high strength and stiffness. Furthermore, the strength of the co-cured bond interface is high enough to surpass the strength of the lattice core.

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Sinev, Andrey Y., Roman A. Panasenko, Vlada S. Shamkova, Gennady K. Baryshev, and Aleksandr Vasilievich Berestov. "Sample Printing Device for Additive Manufacturing of Electronic Housings." Materials Science Forum 1037 (July 6, 2021): 105–10. http://dx.doi.org/10.4028/www.scientific.net/msf.1037.105.

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This work presents the results of work on a 3D printing device with a non-standard arrangement of the table and nozzle, which is necessary for the additive production of plastic cases for electronic devices. The non-standard arrangement of the table is caused by the need to use special accessories to hold third-party embedded elements of the case. A metal part - a contactor - is used as an embedded element. Due to the specific mortgage they made, as well as the experimental equipment, the authors came to the conclusion that it is economically more expedient to design and manufacture a prototype 3D printer than to modify the existing device. A sample of the FDM printing device was designed, manufactured and tested.

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Eyzaguirre, Diego, Rodrigo Salazar-Gamarra, Salvatore Binasco Lengua, and Luciano Lauria Dib. "Evaluation of additive manufacturing processes in the production of oculo-palpebral prosthesis." F1000Research 11 (May 9, 2022): 505. http://dx.doi.org/10.12688/f1000research.111231.1.

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Background: Prosthetic restorations are made to adapt or attach missing human parts in order to restore function and appearance. Maxillofacial defects connote a greater impact on patients, since the face cannot be concealed, and all the senses of the human body are expressed in it. Therefore, in order to restore the patient’s quality of life, they are the ones that require the best possible adaptation to the characteristics of the patients. Methods: For the maxillofacial prostheses to fit patients, they must be personalized for each patient. The NGO “Mais Identidade” is a multidisciplinary team that specializes in the rehabilitation of patients with maxillofacial trauma. They use digital manufacturing as a tool to manufacture personalized maxillofacial prostheses for patients. With the help of the NGO, the following research is conducted with the purpose of evaluating different methods of additive manufacturing, 3D printing, in order to select the equipment that suits the needs of the method used in the manufacture of maxillofacial prostheses. To this end, eyelid models will be manufactured in different additive manufacturing equipment, and these will be evaluated according to their economic, physical, and aesthetic characteristics.

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Gawel, Tomasz Grzegorz. "Review of Additive Manufacturing Methods." Solid State Phenomena 308 (July 2020): 1–20. http://dx.doi.org/10.4028/www.scientific.net/ssp.308.1.

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The manuscript reviews the additive manufacturing technology. The principle of operation of the most popular and new AM methods was discussed. the manuscript presents the possibility of skewing different materials for individual technologies. Additive manufacturing technologies have been described that can manufacture parts from polymers, metals, ceramics and composites.

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Journal articles on the topic 'Additive manufacture'

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