Manufacturability Research Articles

The industrialization of additive manufacturing

AbstractOur world is constantly facing a wide variety of social challenges — currently, issues such as climate change, security, demographic change, and resource conservation are of significant importance and show an acute need for action. Among other things, disruptive technologies are needed to tackle such problems. Additive manufacturing (AM) is regarded as the ‘game changer/paradigm shift’ technology for the digital, automated production of the future — as the key enabler of ‘Production 2.0’. This sustainable and resilient technology enables new paths to innovative solutions across all industries through a high degree of individualization (mass customization) and great design freedom (‘manufacture for design’ instead of ‘design for manufacture‘). For example, internally cooled turbine blades for H2‐capable gas turbines, lightweight structures for more efficient aircraft or patient‐specific implants are only made possible by AM. In this way, AM makes an important contribution to solving the social challenges mentioned above now it is necessary to transfer this technology to board industrial use.

Goal modelling in aeronautics: Practical applications for aircraft and manufacturing designs

Goal modelling in aeronautics: Practical applications for aircraft and manufacturing designs

Cooperative augmented assembly (CAA): augmented reality for on-site cooperative robotic fabrication

Recent years have witnessed significant advances in computational design and robotic fabrication for large-scale manufacturing. Although these advances have enhanced the speed, precision, and reproducibility of digital fabrication processes, they often lack adaptability and fail to integrate manual actions in a digital model. Addressing this challenge, the present study introduces cooperative augmented assembly (CAA), a phone-based mobile Augmented Reality (AR) application that facilitates cooperative assembly of complex timber structures between humans and robots. CAA enables augmented manual assembly, intuitive robot control and supervision, and task sharing between humans and robots, creating an adaptive digital fabrication process. To allocate tasks to manual or robotic actions, the mobile AR application allows multiple users to access a shared digital workspace. This is achieved through a flexible communication system that allows numerous users and robots to cooperate seamlessly. By harnessing a cloud-based augmented reality system in combination with an adaptive digital model, CAA aims to better incorporate human actions in robotic fabrication setups, facilitating human–machine cooperation workflows and establishing a highly intuitive, adaptable digital fabrication process within the Architecture, Engineering, and Construction sector.

Design for Circular Manufacturing and Assembly (DfCMA): Synergising Circularity and Modularity in the Building Construction Industry

Modular construction is emerging into the limelight in the construction industry as one of the front-running modern methods of construction, facilitating multiple benefits, including improved productivity. Meanwhile, Circular Economy (CE) principles are also becoming prominent in the Building Construction Industry (BCI), which is infamous for its prodigious resource consumption and waste generation. In essence, the basic concepts of modular construction and CE share some commonalities in their fundamental design principles, such as standardisation, simplification, prefabrication, and mobility. Hence, exploring ways of synergising circularity and modularity in the design stage with a Whole Life Cycle (WLC) of value creation and retention is beneficial. By conducting a thorough literature review, supported by expert interviews and brainstorming sessions, followed by a case study, the concept of Design for Circular Manufacturing and Assembly (DfCMA) was proposed to deliver circularity and modularity synergistically in circularity-oriented modular construction. This novel conceptualisation of DfCMA is envisaged to be a value-adding original theoretical contribution of this paper. Furthermore, the findings are expected to add value to the BCI by proposing a way forward to synergise circularity and modularity to contribute substantially towards an efficient circular built environment.

Molecular Engineering Chemical Pre-lithiation Reagent with Low Redox Potential for Graphite Anode Enables High Coulombic Efficiency.

Graphite (Gr) is a low-cost and high-stability anode for lithium-ion batteries (LIBs). However, Gr anode exhibits an obstinate drawback of low initial Coulombic efficiency (ICE), owing to the active lithium loss for the solid electrolyte interphase (SEI) layer. Herein, a straightforward and effective chemical pre-lithiation strategy is proposed to compensate for the lithium loss. A molecular engineering phenanthrene-based lithium-arene complex (Ph-based LAC) reagent is designed by density functional theory (DFT) calculations. The engineering Ph-based reagent enhances the stability of the π-electron system and the electron-donating capacity, resulting in a reduced redox potential to facilitate lithium transfer. The electrochemical distinct of the Ph-based reagent is illustrated, the prelithiation process in a low Li-insertion platform, and the lithiation degree is controllable with the dipping time (ICE = 102%, 3min). Notably, a denser and homogeneous SEI layer has pre-formed to enhance the Li+ transport and interface stability. Moreover, the lithium-ion full batteries assemble with LiFePO4 and NCM811 cathode, which exhibits high ICE (96.5% and 90.3%) and energy density (310 and 333Whkg-1). These findings present a facile and controllable pre-lithiation strategy to compensate for the lithium of LIBs, providing new valuable insights into the design and optimization of battery manufacture.

Fabrication of Cu-Infiltrated Journal Bearing by Binder Jetting Additive Manufacturing

In this study, considering the economic feasibility of products that can be produced through the binder jetting additive manufacturing process, 316L stainless steel, a widely used material with a wide particle size ranging from 15 to 106 μm, was used. The lubrication effect was increased by internal patterning through design for additive manufacturing, and journal bearing parts with excellent load resistance and wear resistance were implemented by using wear-resistant Cu as an infiltration material. In addition, to investigate the amount of Cu infiltrated as a function of porosity, the parts were pre-sintered from 1423 K to 1573 K, and the best performance was obtained when Cu was infiltrated after pre-sintering at 1473 K. As a result of rig testing of Cu-infiltrated journal bearings, mechanical properties were obtained that were more than 50% improved compared to those of mass products.

Enhancing Printability Through Design Feature Analysis for 3D Food Printing Process Optimization

We present a novel, systematic method for evaluating design printability in 3D food printing using a scoring system based on the Design for Additive Manufacturing (DfAM) guidelines. This study addresses a gap in the current literature by proposing a structured approach to assess and enhance the printability of 3D food designs. Our framework consists of a set of nine critical questions derived from the multi-level DfAM guidelines, focusing on key printability factors including unsupported features, geometric accuracy, and surface finish. The evaluation process converts qualitative assessments into numerical values, resulting in a comprehensive printability score that categorizes designs into high, moderate, or low printability levels. To validate the effectiveness of this method, we conducted a case study involving five different designs. The scoring system successfully explores the design space and maximizes the printability of 3D food products. This method alleviates the challenges in design evaluation compared with traditional trial-and-error approaches. The results demonstrate the practicality and efficiency of our framework’s output. The proposed methodology provides a structured approach to design evaluation, offering practical insights and a valuable tool for improving the success rate of 3D printed food products. This research contributes to the field by offering a systematic framework for assessing and enhancing the printability of 3D food designs, potentially accelerating the adoption and effectiveness of 3D food printing technology in various applications.

Analysis of the degradation in transmission accuracy of RV reducers considering the wear clearance between cycloidal wheels and pinwheels

To accurately determine the transmission accuracy degradation pattern of Rotate Vector (RV) reducers due to wear, a predictive method is proposed that simultaneously considers the initial clearance and wear clearance between the cycloid wheel and the pinwheel. The initial clearance is derived from a comprehensive gear system analysis, considering assembly errors, manufacturing errors and modifications. Building on this, the wear depth of the cycloid wheel tooth profile is numerically simulated using Archard's wear theory, revealing the wear distribution pattern under various operating conditions. A Gaussian regression model is used to predict the maximum wear amount for different operational durations. Based on the predicted wear amount, a multi-body dynamic simulation model incorporating wear clearance was established to analyze the transmission error under varying clearance conditions. Results indicate that the wear depth along the tooth profile initially increases and then decreases. The depth and region of wear along the tooth profile gradually increase with load and output speed, with the impact of load on the wear region being greater than that of output speed. Under the initial clearance condition, the maximum transmission error is 22.91″. As the wear clearance increases, transmission accuracy declines sharply. When the cumulative wear clearance reaches 0.2 mm, the transmission error exceeds the allowable backlash limit. This study provides a theoretical reference for predicting accuracy degradation and guides the manufacturing design of RV reducers.

Planning of a Single Flow Channel in Valve Blocks Based on Additive Manufacturing and the Ant Colony Algorithm

As electro-hydrostatic actuator (EHA) technology advances towards lightweight and integration, the demand for enhanced internal flow pathways in hydraulic valve blocks intensifies. However, owing to the constraints imposed by traditional manufacturing processes, conventional hydraulic integrated valve blocks fail to satisfy the demands of a more compact channel layout and lower energy dissipation. Notably, the subjectivity in the arrangement of internal passages results in a time-consuming and labor-intensive process. This study employed additive manufacturing technology and the ant colony algorithm and B-spline curves for the meticulous design of internal passages within an aviation EHA valve block. The layout environment for the valve block passages was established, and path optimization was achieved using the ant colony algorithm, complemented by smoothing using B-spline curves. Three-dimensional modeling was performed using SolidWorks software, revealing a 10.03% reduction in volume for the optimized passages compared with the original passages. Computational fluid dynamics (CFD) simulations were performed using Fluent software, demonstrating that the algorithmically optimized passages effectively prevented the occurrence of vortices at right-angled locations, exhibited superior flow characteristics, and concurrently reduced pressure losses by 34.09%–36.36%. The small discrepancy between the experimental and simulation results validated the efficacy of the ant colony algorithm and B-spline curves in optimizing the passage design, offering a viable solution for channel design in additive manufacturing.

Introduction to Mechanism Design for Manufacturing

Introduction to Mechanism Design for Manufacturing

Three–dimensional matrices for enhanced coral settlement through design for additive manufacturing

Purpose The effects of climate change have been contributing to coral reef degradation. Artificial reefs are one method being used to counteract this destruction. However, the most common artificial approaches, such as sunken vehicles and prefabricated cement reefs, do not allow adequate coral development. This paper aims to demonstrate how designers, using additive manufacturing and computational design techniques, can create artificial reefs that better mimic natural reef structures. Design/methodology/approach This research focuses on developing three-dimensional matrices through computational design using additive manufacturing to achieve better coral settlement. A “Nature Centered Design” approach was followed, with the corals at the center of the design project. Samples with different geometries and roughness, produced using paste-based extrusion with porcelain and porcelain with oyster shell, were tested in a controlled environment to investigate the settlement preference of soft corals. Findings The rapid prototyping of samples confirmed the preference of corals to settle to complex surfaces compared to smooth surfaces. Porcelain showed comparable results to Portland cement, suggesting further testing potential. A closer resemblance to the natural and intricate forms found in coral reefs was achieved through computational design. Originality/value This paper proposes a new approach combining rapid prototyping with coral’s biological responses to enhance the understanding of their surface settlement preference. The Nature Centered Design approach, with additive manufacturing and computational design, made it possible to create an innovative working model that could be customized depending on the implementation area or intended coral species, validating the design approach as a method to support environmental conservation.

Investigating the human capabilities for intuitive evaluation of component manufacturability

This article explores the intersection of Design for Manufacturing (DFM) principles and human cognition in component manufacturability. In the context of contemporary manufacturing challenges, where design and manufacturing departments often operate separately, this study aims to bridge the gap by investigating human capabilities in intuitively assessing manufacturability during the design phase. Research employs experimental trials with visual stimuli representing various part designs, categorizing them based on adherence to DFM rules. Participants, without prior formal education in DFM, are tasked with choosing the more manufacturable component within a pair. Results indicate that a majority of participants demonstrate an innate ability to make correct manufacturability assessments. Additionally, the study evaluates the impact of stimulus exposure time on participant performance. These findings provide valuable insights into the intuitive aspects of human manufacturability assessment and lay the groundwork for further research, including larger participant groups and deeper exploration of decision-making processes and knowledge types involved in DFM practices. The main contribution of presented study involves showcasing human capabilities for component manufacturability assessment with the use of intuitive thinking and quick decision-making in place of following strict rulesets and design principles.

Construction of the technological process and design development of a multifunctional unit for processing vital soybeans with ultrasound. Feasibility of water-crude suspension

Cereals and legumes have a porous structure, being an inert carrier during mass exchange processes; they contain voids in the form of pores and stomata, on the surface of which there are foreign extractable substances in a solid state, in particular, trypsin and urease inhibitor proteins. These substances, due to their harmful effect on the final product, are subject to removal by extraction. One of the methods for inactivating anti-nutritional substances is ultrasonic treatment of soybeans.The article discusses the technology of inactivating inhibitors that worsen food and protein value of vital soybeans. The developed technology was aimed at dissolving a solid substance - soybean inhibitor protein in a liquid, carried out due to molecular diffusion, intensifying the processes of mass transfer and mass return. When creating a suspension by mixing the solid (crushed soybean grain) and liquid (water) phases, water molecules, which are a solvent, penetrate under the action of capillary forces into the pores and stomata of the treated body, begin to penetrate. On this basis, technological directions of research have been established, a sequence has been built and the physical essence of operations has been substantiated, consisting of four main ones - grinding soybean grain, creating a “water-soybean” suspension, ultrasonic (US) treatment of soybeans, drying. As a result of the conducted research, optimal technological parameters have been established for intensifying the process of inactivation of anti-nutritional substances contained in native soybeans: the degree of grinding of soybean grains is 0.5-1.0 mm; the ratio of water-soy suspension (1:1). The efficiency of the developed technological process will be factors affecting the quality of the resulting products, the duration and energy intensity of the process, resource conservation, simplicity of design and low cost of manufacture, the possibility of automation.

Design of thermomechanical processes for tailored microstructures: Methodology and application to nanocrystalline titanium alloy Ti-13Nb-13Zr (NanoTNZ)

Thermomechanical processes enable tailoring of material properties and microstructures for advanced products. In medical technology, next-generation titanium implants require tailored material properties to improve health and quality of life. However, the interaction correlation between process parameters and material properties poses a major challenge for the design of thermomechanical manufacturing processes.In this paper, we present a methodology for the design of thermomechanical processes to achieve tailored microstructural properties through forming technology and heat treatments. The methodology consists of five systematic steps to address the complexity of multiphysical coupling relationships between temperature, stress, microstructure and alloy composition, and to provide a guideline for effective implementation. It is applied to the production of nanostructured Ti-13Nb-13Zr (NanoTNZ) alloy for dental implants. The designed process of severe plastic deformation, recrystallization treatment and aging lead to nanostructured microstructures smaller than 200 nm. The resulting mechanical properties (UTS > 980 MPa, Young’s modulus of 73 GPa) meet the desired goals for improved biomedical implant-bone interactions. The tailored material properties and microstructures of NanoTNZ are therefore highly promising for use as an implant material.The case study demonstrates the importance of a systematic method to manage the complexity of multiphysical coupling relationships in the design of thermomechanical processes to enable tailored microstructures for advanced materials and products.

Design and Architecture Definition for Advanced 3D Fan-Out Wafer-Level Packaging

Advanced 2.5D/3D wafer-level fan-out packaging technologies have been studied widely in literature and industry in recent years. Miniaturization, reduction in manufacturing costs, improvement in performance, and lower power consumption using packaging technologies drive increase in interconnect density and pitch scaling. Heterogeneous systems in package used in advanced packaging often include a combination of silicon, epoxy underfill or mold compounds, and organic or inorganic passivation or redistribution layers. This heterogeneity poses challenges with manufacturability, process selection, package architecture, and test vehicle design. The coefficient of thermal expansion mismatch, wafer warpage, and wafer yield are some of the critical process challenges. Delamination of silicon side wall or passivation to epoxy underfill or mold compound, joint fatigue are critical reliability challenges. This article explores various processes and reliability challenges with 3D wafer-level fan-out packaging and provides package design and architecture guidelines to overcome these failure modes. Stacked die-to-wafer test vehicles have been used for data collection. Different assembly materials, processes, and tooling have been evaluated to define comprehensive design rules.

Fabrication Information Modeling for Closed-Loop Design and Quality Improvement in Additive Manufacturing for construction

Additive Manufacturing (AM) has emerged as a disruptive technology with the potential to revolutionize the construction industry by integrating digital design with automated manufacturing. This paper presents and extends Fabrication Information Modeling (FIM), a comprehensive framework tailored for automated manufacturing in construction. FIM facilitates the seamless integration of digital design concepts with automated manufacturing processes, enabling precise control over fabrication information and enhancing construction efficiency and quality. This paper demonstrates its potential to optimize construction processes through a detailed exploration of FIM’s capabilities, including data preparation, path planning, simulation integration, robot control, and data feedback. By enabling a circular data flow between digital modeling and manufacturing, FIM is able to bridge the gap between digital design and physical construction, revolutionizing how construction projects are conceived, planned, and executed. The paper concludes by highlighting the challenges and future research directions in advancing FIM-based construction systems, emphasizing its transformative potential in driving innovation and sustainability in the construction industry.

Measurement and machining error assessment method for cycloid pump rotor profile based on STEP

Abstract The contour shape and machining precision of the rotor of an cycloid pump directly determine the sealing performance of the pump cavity. Precise measurement of contour machining errors is a crucial step in the manufacturing process. However, rotor contour curves are often designed by enterprises based on actual engineering needs, leading to inconsistency between the measured baseline contour and the designed contour, thus failing to accurately reflect the actual machining condition of the rotor. Therefore, this paper proposes a method for measuring the contour of the cycloid pump rotor and evaluating machining errors based on the standard for the exchange of product (STEP) files necessary for product design in manufacturing. Firstly, utilizing NX/OPEN API functions, contour coordinate points and unit normal vectors are obtained from the rotor’s STEP design data. Subsequently, by planning the process of measuring the closed continuous contour of the rotor, the transformation between the workpiece coordinate system and the measurement coordinate system is achieved to position the tested rotor, followed by analyzing the influence of different starting points on error measurement and evaluation determines the optimal starting point. Finally, a measurement sampling point strategy is established to collect data points of the actual machining contour of the rotor. By achieving the best matching between the actual machining contour and the measured baseline contour, a contour deviation calculation model is established. Utilizing gauge blocks enables accurate assessment of pitch deviation, radial runout, and tooth-to-tooth distance deviation, resulting in assessment results that better fit the actual meshing situation of the rotor. Experimental results verifies consistency between the measurements of the one-dimensional probe and Gleason measurements. This theory and method not only expand the measurement range of the one-dimensional probe but also provide more accurate and efficient guidance for the flexible machining of the rotor.

Welding electrical connections between battery sheet metal materials and additively manufactured (AM) aluminum components: The effect of surface roughness

The integration of additive manufacturing's design versatility with a push for electrification can lead to unique innovations. In this context, when discussing welded joints, their quality and reliability play a significant role. The restricting factor for the use of laser powder bed fusion of metal (PBF-LB/M) additive manufactured (AM) parts is often their surface quality in the as-built state. In addition, the surface quality changes when part plane orientation changes. In this study, AlSi10Mg aluminum test samples were additive manufactured in seven different build angles. The AM samples were glass bead blasted after manufacturing, and the surface roughness of the joint surface area was optically measured. After the measurement, the AM samples were welded to nickel-plated copper and aluminum sheet metals. A continuous wave single-mode fiber laser with scanner optics was used to carry out the welding experiments in lap joint configuration. The structural and mechanical properties of the welds were evaluated by the macroscopic images of weld cross sections and tensile testing of the samples. The electric resistivity of the samples was also tested. Based on the measurement results of the samples, the impact of surface quality was discussed. The results indicated that there was no clear effect of building angle on the final weld quality. The worst surface quality in the joint area was on the test pieces in which the joint surface was facing down toward the build plate.

Modeling Approach of Cloud 4D Printing Service Composition Optimization Based on Non-Dominated Sorting Genetic Algorithm III

The manufacturing industry is currently experiencing a paradigm shift from traditional centralized systems to distributed, personalized, and cloud-based intelligent manufacturing ecosystems. The advent of 4-dimensional (4D) printing technology introduces dynamic characteristics to manufacturing design and functionality, necessitating the effective management of these emergent 4D printing services. This study aims to bridge the gap between the static nature of existing cloud manufacturing services and the dynamic requirements imposed by 4D printing technology. We propose a comprehensive multiobjective optimization model for cloud-based 4D printing service portfolios, incorporating the intricate complexities of 4D printing services and assessing the efficacy of the Non-Dominated Sorting Genetic Algorithm III (NSGA III) in optimizing these service portfolios to meet dynamic demands. In this research, the NSGA III algorithm is employed to develop a multiobjective optimization framework for 4D printing service portfolios, addressing critical issues such as service cost, time, quality, adaptability, and overall service optimization amidst fluctuating demand and service availability. The findings indicate that the NSGA III algorithm demonstrates superior performance in terms of generational distance (GD) and inverted generational distance (IGD), particularly excelling in convergence and diversity for high-dimensional optimization problems when compared to the comparison algorithms. The study concludes that the NSGA III algorithm exhibits significant potential in optimizing the orchestration of cloud-based 4D printing service portfolios, underscoring its effectiveness in managing the complexities associated with these services. This research provides valuable insights for the advancement of intelligent cloud-based 4D printing systems, paving the way for future developments in this field.

Microneedle Arrays: Advancements, Applications and Future Prospects in Pharmaceutical Delivery

Microneedle arrays have emerged as a cutting-edge technology revolutionizing the field of pharmaceutical delivery. These micron-sized needles offer a minimally invasive and painless approach to administer drugs, vaccines, and various therapeutic agents through the skin, bypassing traditional routes of administration. This review article comprehensively explores the advancements, applications, and future prospects of microneedle arrays in pharmaceutical delivery. This review delves into the different types of microneedle arrays, including solid, hollow, dissolving, and coated microneedles, highlighting their unique properties and fabrication techniques. The discussion encompasses recent breakthroughs in microneedle design, such as biodegradable materials, smart responsive systems, and personalized arrays tailored to specific patient needs. Furthermore, this review addresses the challenges and safety considerations associated with microneedle usage, such as skin irritation and regulatory aspects. It analyzes ongoing research efforts aimed at optimizing design, functionality, and scalability for large-scale manufacturing. The future prospects of microneedle arrays in pharmaceutical delivery qwew also discussed. Anticipated advancements in the field, including personalized medicine, combination therapy, and disease monitoring through biosensing, offer promising avenues for transformative healthcare solutions. In conclusion, microneedle arrays represent a paradigm shift in pharmaceutical delivery, offering numerous advantages over traditional methods. As research and development continue, these micro-sized devices hold the potential to revolutionize the landscape of drug administration, leading to safer, more effective, and patient-centric healthcare practices.