Traditional Manufacturing Methods Research Articles

3D Printing and Blue Sustainability: Taking Advantage of Process-Induced Defects for the Metallic Ion Removal from Water.

Additive manufacturing (AM), commonly known as 3D printing, allows for the manufacturing of complex systems that are not possible using traditional manufacturing methods. Nevertheless, some disadvantages are attributed to AM technologies. One of the most often referred to is the defects of the produced components, particularly the porosity. One approach to solving this problem is to consider it as a non-problem, i.e., taking advantage of the defects. Commercially, LAY-FOMM®60 polymer was successfully used in AM through a material extrusion process. This filament is a blend of two polymers, one of them soluble in water, allowing, after its removal from the printed components, the increase in porosity. The defects produced were exploited to evaluate the metallic ion removal capacity of manufactured components using non-potable tap water. Two experimental setups, continuous and ultrasound-assisted methods, were compared, concerning their water cleaning capacity. Results revealed that continuous setup presented the highest metallic ion removal capacity (>80%) for the following three studied metallic ions: iron, copper, and zinc. High water swelling capacity (~80%) and the increase in porosity of 3D-printed parts played a significant role in the ion sorption capacity. The developed strategy could be considered a custom and affordable alternative to designing complex filtration/separation systems for environmental and wastewater treatment applications.

Development of Micro Electrical Discharge Machine and Micro-hole Machining Using Multiple Micro Electrodes

Recent advances in microtechnology have highlighted the need for fabricating microscopic parts with complex three-dimensional structures. This, in turn, has increased the demand for innovative tools. Micro electrical discharge machining (MEDM) is one such technique that has proven to be effective in producing parts that are difficult to fabricate using traditional manufacturing methods, such as micro shafts and micro holes. Therefore, this study focuses on the development of a specialized MEDM system that incorporates an optimized wire electrical discharge grinding (WEDG) module. Additionally, the study successfully fabricates microelectrodes for use as cutting tools using the MEDM/WEDG system. These micro-electrodes are then utilized in the precise fabrication of various types of multiple micro electrodes through the use of reverse electrical discharge machining (REDM). These multiple micro electrodes are subsequently employed in precise hole machining operations using MEDM. The application of REDM signifies a significant technological advancement in the precision fabrication of microstructures. Furthermore, it is expected to greatly enhance the versatility and efficiency of microtechnology manufacturing processes. Overall, REDM represents a new approach to manufacturing that is capable of producing more complex and high-precision microstructures.

Development of Micro Electrical Discharge Machine and Micro-hole Machining Using Multiple Micro Electrodes

Recent advances in microtechnology have highlighted the need for fabricating microscopic parts with complex three-dimensional structures. This, in turn, has increased the demand for innovative tools. Micro electrical discharge machining (MEDM) is one such technique that has proven to be effective in producing parts that are difficult to fabricate using traditional manufacturing methods, such as micro shafts and micro holes. Therefore, this study focuses on the development of a specialized MEDM system that incorporates an optimized wire electrical discharge grinding (WEDG) module. Additionally, the study successfully fabricates microelectrodes for use as cutting tools using the MEDM/WEDG system. These micro-electrodes are then utilized in the precise fabrication of various types of multiple micro electrodes through the use of reverse electrical discharge machining (REDM). These multiple micro electrodes are subsequently employed in precise hole machining operations using MEDM. The application of REDM signifies a significant technological advancement in the precision fabrication of microstructures. Furthermore, it is expected to greatly enhance the versatility and efficiency of microtechnology manufacturing processes. Overall, REDM represents a new approach to manufacturing that is capable of producing more complex and high-precision microstructures.

Multiscale periodic homogenization for additive manufacturing of honeycomb lattices

Additive manufacturing (AM) is revolutionizing how we create things, offering innovative solutions that rival traditional manufacturing methods. In Fused Filament Fabrication (FFF), incorporating continuous fiber-reinforced filaments has significantly enhanced mechanical properties, making them valuable across diverse sectors like aerospace, automotive, and robotics. However, before printing a part, numerical simulation for design verification is essential. Yet, there’s a lack of suitable tools for modeling the complex material properties, particularly for composite lattice structures. To address this, we propose a three-level periodic homogenization method. The first level focuses on modeling individual filaments, followed by characterizing inter-bead voids at the second level, and finally, modeling collective lattice behavior at the third level. Hexagonal cellular lattice composite structures were modeled and tested to confirm the method’s accuracy and its value in supporting simulation and modular design for the composite FFF process.

Research on a Support-Free Five-Degree-of-Freedom Additive Manufacturing Method.

When using traditional 3D printing equipment to manufacture overhang models, it is often necessary to generate support structures to assist in the printing of parts. The post-processing operation of removing the support structures after printing is time-consuming and wastes material. In order to solve the above problems, a support-free five-degree-of-freedom additive manufacturing (SFAM) method is proposed. Through the homogeneous coordinate transformation matrix, the forward and inverse kinematics equations of the five-degree-of-freedom additive manufacturing device (FAMD) are established, and the joint variables of each axis are solved to realize the five-axis linkage of the additive manufacturing (AM) device. In this research work, initially, the layered curve is obtained through the structural lines of the overhang model, and a continuous path planning of the infill area is performed on it, and further, the part printing experiments are conducted on the FAMD. Compared with the traditional three-axis additive manufacturing (TTAM) method, the SFAM method shortens the printing time by 23.58% and saves printing materials by 33.06%. The experimental results show that the SFAM method realizes the support-free printing of overhang models, which not only improves the accuracy of the parts but also the manufacturing efficiency of the parts.

Cytocompatibility of Polymers for Skin-Contact Applications Produced via Pellet Extrusion.

Orthoses and prostheses (O&P) play crucial roles in assisting individuals with limb deformities or amputations. Proper material selection for these devices is imperative to ensure mechanical robustness and biocompatibility. While traditional manufacturing methods have limitations in terms of customization and reproducibility, additive manufacturing, particularly pellet extrusion (PEX), offers promising advancements. In applications involving direct contact with the skin, it is essential for materials to meet safety standards to prevent skin irritation. Hence, this study investigates the biocompatibility of different thermoplastic polymers intended for skin-contact applications manufactured through PEX. Surface morphology analysis revealed distinct characteristics among materials, with TPE-70ShA exhibiting notable irregularities. Cytotoxicity assessments using L929 fibroblasts indicated non-toxic responses for most materials, except for TPE-70ShA, highlighting the importance of material composition in biocompatibility. Our findings underscore the significance of adhering to safety standards in material selection and manufacturing processes for medical devices. While this study provides valuable insights, further research is warranted to investigate the specific effects of individual ingredients and explore additional parameters influencing material biocompatibility. Overall, healthcare practitioners must prioritize patient safety by meticulously selecting materials and adhering to regulatory standards in O&P manufacturing.

Effect of Thermal Shock Conditions on the Low-Cycle Fatigue Performance of 3D-Printed Materials: Acrylonitrile Butadiene Styrene, Acrylonitrile-Styrene-Acrylate, High-Impact Polystyrene, and Poly(lactic acid).

3D printing technology is becoming a widely adopted alternative to traditional polymer manufacturing methods. The most important advantage of 3D printing over traditional manufacturing methods, such as injection molding or extrusion, is the short time from the creation of a new design to the finished product. Nevertheless, 3D-printed parts generally have lower strength and lower durability compared to the same parts manufactured using traditional methods. Resistance to the environmental conditions in which a 3D-printed part operates is important to its durability. One of the most important factors that reduces durability and degrades the mechanical properties of 3D-printed parts is temperature, especially rapid temperature changes. In the case of inhomogeneous internal geometry and heterogeneous material properties, rapid temperature changes can have a significant impact on the degradation of 3D-printed parts. This degradation is more severe in high-humidity environments. Under these complex service conditions, information on the strength and fatigue behavior of 3D-printed polymers is limited. In this study, we evaluated the effects of high humidity and temperature changes on the durability and strength properties of 3D-printed parts. Samples made of commonly available materials such as ABS (Acrylonitrile Butadiene Styrene), ASA (Acrylonitrile-Styrene-Acrylate), HIPS (High-Impact Polystyrene), and PLA (Poly(lactic acid)) were subjected to temperature cycling, from an ambient temperature to -20 °C, and then were heated to 70 °C. After thermal treatment, the samples were subjected to cyclic loading to determine changes in their fatigue life relative to non-thermally treated reference samples. The results of cyclic testing showed a decrease in durability for samples made of ASA and HIPS. The ABS material proved to be resistant to the environmental effects of shocks, while the PLA material exhibited an increase in durability. Changes in the internal structure and porosity of the specimens under temperature changes were also evaluated using microcomputed tomography (microCT). Temperature changes also affected the porosity of the samples, which varied depending on the material used.

Beam shaping to tackle laser powder bed fusion challenges

AbstractAdditive manufacturing (AM), a term synonymous with the future of fabrication, has revolutionized industries by offering unparalleled flexibility in design and production. At the heart of this transformative technology is laser‐based powder bed fusion of metals (PBF‐LB/M), the process with the highest geometrical resolution having the largest market share (86 %, Wohlers) amongst all AM processes. By selectively melting and fusing powder material layer by layer with a laser, PBF‐LB/M enables the creation of complex and high‐strength components, previously unthinkable with traditional subtractive manufacturing methods.

Empirical calibration method for the thermal simulation of Cu47Ti34Zr11Ni8 single tracks in laser powder bed fusion

Bulk metallic glasses (BMGs) are materials that, due to their amorphous microstructure, offer a unique combination of high strength, hardness, and elasticity, making them attractive for various applications. Using laser powder bed fusion (PBF-LB/M) enables overcoming the current limitations of BMGs in size and shape imposed by traditional manufacturing methods such as casting. Despite its potential, challenges such as porosity, (nano-) crystallization, and impurities affect the mechanical performance of additively manufactured BMGs. This study focuses on the Cu–Ti-based alloy Vit101, known for its higher strength and improved cost-effectiveness compared to Zr-based BMGs. In-situ high-speed pyrometry and thermal simulations of single tracks are employed to enhance the understanding of processing and controlling the thermal cycling of Vit101. The proposed experimental calibration is performed through an off-axis integration of the pyrometer, allowing for in-situ temperature measurements. The acquired data show sufficient congruence with the simulated cooling profiles. Minimal cooling rates in the range of 104 K/s were measured and simulated above the glass transition temperature, indicating a large leeway for further development of glass-forming alloys. Scan track widths are evaluated for validation, resulting in minor deviations between 0.47% and 3.17%. However, challenges emerge at high scanning speeds, leading to higher deviations attributed to balling phenomena, which are not considered in the numerical model.

Effects of heat treatment on the mechanical properties of 3D-printed polylactic acid: Study of competition between crystallization and interlayer bonding

Fused deposition modeling (FDM) is a popular additive manufacturing technique because of its flexibility, customization, cost-effectiveness, and eco-friendliness. However, due to the layer-by-layer fabrication process and the formation of voids, the mechanical properties of printed parts are lower than other manufacturing techniques. As a solution, heat treatments can effectively mitigate additive manufacturing limitations and improve the mechanical properties of printed parts. The interlayer bonding and subsequently mechanical properties of 3D-printed PLA were affected by the competition between crystallization and chain diffusion of 3D-printed polylactic acid during the heat treatment process. This competition highlights the importance of optimization of heat treatment. Additionally, crystallite growth could cause a reduction in some mechanical properties, like elongation. The size, distribution, and content of voids are also influenced by heat treatment, playing a crucial role in the mechanical properties of 3D-printed parts. In this research, printed samples were heat-treated at temperatures of 75 ºC, 110 ºC, and 130 ºC for two hours. Furthermore, compression-molded samples were fabricated to inspect a comparison of mechanical properties between the traditional and additive manufacturing methods and investigate the effect of layer-by-layer fabrication on these properties. Sample AM-75 showed a 15.5% improvement in bonding strength compared to the non-annealed printed sample, resulting in an increase of 20.2% in tensile strength and 275% in impact strength. Moreover, annealing the sample at 130 ºC resulted in a 7.6% reduction in porosity and a significant improvement of 220% in crystallinity, heat deflection temperature, flexural modulus, and flexural strength, with improvements of 121%, 29.5%, and 15.2% respectively.

A progressive overview of the mainstream additive manufacturing of ceramic components for industrial advancement

Additive manufacturing (AM), well-known as 3D printing, has revolutionized traditional manufacturing methods, particularly in the production of ceramic components. These techniques offer unique advantages and challenges in ceramic component production. Developing specific ceramic materials with AM improves the finished products' mechanical, thermal, and electrical characteristics. Integrating artificial intelligence and machine learning shows promise in improving process control and design optimization, spurring innovation and opening previously unimaginable possibilities, although problems such as material shrinkage, microstructural control, and surface polish remain crucial research areas. This review article presents a comprehensive overview of the advancements and applications of AM for ceramic pieces in the industrial sector. This study highlights the fundamental principles of AM, focusing on their difficulties and potential in ceramic fabrication. A comprehensive review of AM will deliver an understanding of its ability to alter industrial manufacturing and open the door to a new era of ceramic fabrication and applications.

Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective

In just a few short years, the additive manufacturing (AM) technology known as 3D printing has experienced intense growth from a niche technology to a disruptive innovation that has captured the imagination of mainstream manufacturers and hobbyists alike. The purpose of this article is to introduce the use of 3D printing for specific applications, materials, and manufacturing processes that help to optimize heat transfer in heat exchangers, with an emphasis on sustainability. The ability to create complex geometries, customize designs, and use advanced materials provides opportunities for more efficient and stable heat transfer solutions. One of the key benefits of incremental technology is the potential reduction in material waste compared to traditional manufacturing methods. By optimizing the design and structure of heat transfer components, 3D printing enables lighter yet more efficient solutions and systems. The localized manufacturing of components, which reduces the need for intensive transportation and associated carbon emissions, can lead to reduced energy consumption and improved overall efficiency. The customization and flexibility of 3D printing enables the integration of heat transfer components into renewable energy systems. This article presents the key challenges to be addressed and the fundamental research needed to realize the full potential of incremental manufacturing technologies to optimize heat transfer in heat exchangers. It also presents a critical discussion and outlook for solving global energy challenges through innovative incremental manufacturing technologies in the heat exchanger sector.

Crashworthiness capability comparison of a 3D Greek cross fractal structure additively manufactured with polyamide and thermoplastic polyurethane

Crashworthiness capability comparison of a 3D Greek cross fractal structure additively manufactured with polyamide and thermoplastic polyurethane

A Time-Frequency Domain Feature Extraction Approach Enhanced by Computer Vision for Wire Arc Additive Manufacturing Monitoring Using Fourier and Wavelet Transform

Wire arc additive manufacturing (WAAM) is a rapidly growing technology that offers several advantages over traditional manufacturing methods, such as high deposition rates and the ability to build large components in a cost-effective manner. However, WAAM is also prone to the generation of defects, so the timely identification of anomalies is important to reduce the waste and get components of high quality. To develop anomaly detection application, the feature extraction process represents a key ingredient which allows machine learning systems to analyze big data. Waveform GMAW welding processes are typically used in WAAM to reduce the heat input supplied to the material and avoid defects such as excessive bending of parts and residual stress. These processes are based on the controlled dip transfer principle, so the waveforms should repeat themselves during deposition. This suggests that the frequency content of the voltage and current welding signals acquired during the process can provide important information about the process state. In this research, an experimental campaign was conducted to collect data for pulsed welding and surface tension transfer (STT) processes during the deposition of mild steel ER70S6, stainless steel 316L, Aluminum 4043, and Inconel 718 alloys. Welding voltage and current signals were acquired during the building processes, and a frequency domain analysis was conducted using the Fast Fourier transform (FFT) and discrete wavelet transform (DWT) with the aim to extract features from signals aiming to better separate the feature space, which means improve anomaly detection performance in detecting defects like arc instability, porosity, geometrical defect due to arc blow and humping. Furthermore, a methodology based on time-frequency analysis enhanced by Gabor filter for texture anomaly detection of scalograms obtained by Morlet Continuous Wavelet Transform is proposed, which showed an improvement of performance in separation between normal and anomalous deposition of several materials under different welding technologies.

Novel 3D printed PZT-based piezoceramics for piezoelectric energy harvesting via digital light processing

Structure optimization is a highly effective way for enhancing the power output of piezoceramics. However, due to the high hardness and brittleness of these materials, traditional manufacturing methods are limited in their ability to optimize structures. Moreover, achieving new designs using the emerging digital light processing (DLP) technology is hindered by poor curing performance of piezoceramic slurry. To overcome these issues, this study proposes an innovative strategy of using the original powders as printing materials for DLP technology. Notably, the use of lead carbonate powders, rather than lead oxide, significantly improves the curing characteristics and printability of ceramic slurry. Additionally, lanthanum oxide powders are introduced as dopants to enhance the electrical properties of PZT ceramics. The printed piezoceramics exhibit excellent piezoelectric and dielectric performance under optimal La3+ content, coupled with superior transduction coefficient, electromechanical coupling factor and output voltages and currents. Our findings suggest a groundbreaking approach for fabricating piezoceramics with high energy-harvesting performance and complicated designed structure via digital light processing.

MODELLING AND 3D PRINTING OF GAS ENGINE TURBINE BLADE

A turbine blade is the individual component which makes the turbine section of a gas turbine. The blades are used for extracting energy from the high temperature, high pressure gas produced by the combustor. This research focuses on the modeling, Analysis and 3D printing of gas engine turbine blades, aiming to enhance efficiency and performance in power generation. Utilizing advanced modelling softwares such as CATIA software, a detailed digital representation of the turbine blade was created, considering the aerodynamic feature. Further, the model is analysed in ANSYS for Subsequently, additive manufacturing techniques were employed to produce physical prototypes using high-strength, heat-resistant materials. The study evaluates the structural integrity, thermal resistance, and overall performance of the 3D-printed turbine blades, comparing them with traditional manufacturing methods. The findings contribute to the advancement of turbine technology, demonstrating the feasibility and benefits of 3D printing in optimizing gas engine turbine blade design for increased efficiency and reliability.

Stress concentrations and design for additive manufacturing: a design artefact approach to investigation

AbstractThe accelerated rate of product development and design complexities offered by Additive Manufacturing (AM) has allowed for innovation in the space industry. However, the surface roughness of parts poses a challenge, as it impacts performance and is tied to design choices. Design tools for traditional manufacturing methods fall short in AM contexts, prompting the need for alternative design processes. This work proposes an experimental approach to design for AM investigation using design artefacts to explore a process-structure-property-performance relationship.

The application and significance of 3D printing technology in biomedicine

3D printing technology, also known as rapid prototyping technology, is an emerging production and manufacturing method. Medical researchers can create various medical devices for patients' bodies with greater accuracy by converting 3D digital graphics from computer-aided design into physical entities and printing 3D objects layer by layer. Thriving as medicine is, 3D printing, being a widely used and promising technology, will make significant contributions to the progress of biomedical science in multiple directions. The fundamental principle of this technology is akin to building blocks, where small parts are assembled into a comprehensive structure, utilizing materials such as plastic, metal, ceramics, etc. In the production of medical equipment under traditional manufacturing methods, a significant amount of manual debugging is sometimes necessary, which often results in the waste of considerable time and resources. Nonetheless, the manufacturing technique of 3D printing can rapidly and precisely create intricate instruments, as well as produce implants or tissue models. The main focus of this article is to analyze recent progress, applications and restriction prospects of 3D printing in medical applications. The advancement that 3D technology gains across different domains and levels is poised to significantly influence future medical treatment. The significance is to clarify the application and significance of 3D printing technology in the biomedical field. Through the review and analysis of relevant literature, a comprehensive understanding of the research progress and existing problems on 3D printing in the biomedical domain be gained, providing references and inspiration for future research.

ADVANCING INDUSTRY 4.0 WITH ROS: A CASE STUDY ON AUTONOMOUS MOBILE ROBOT TECHNOLOGICAL ADVANCEMENTS

In the world of Industry 4.0, Autonomous Mobile Robots (AMRs) are now vital parts of modern industrial automation. This study examines how the Robot Operating System (ROS) plays a crucial role in advancing technology for AMRs. By looking at real-life examples, it shows how ROS helps in creating and using AMRs, changing how industrial processes work. The study demonstrates how ROS is being integrated into AMR design and operation, leading to improved autonomy, flexibility, and productivity in industrial settings. This study discusses how ROS-powered AMRs have transformed various tasks like material handling, warehouse logistics, and autonomous navigation, leading to increased productivity and cost-efficiency. It also explores the challenges and opportunities brought about by ROS in the Industry 4.0 era, including sensor fusion, machine learning, and human-robot teamwork. Furthermore, ROS not only influences the design and operation of AMR, but also enables smooth integration with advanced technologies such as sensor fusion and machine learning. This opens up opportunities for improved flexibility and teamwork between humans and robots in the ever-evolving environment of Industry 4.0. The importance of ROS in connecting traditional manufacturing practices with the changing demands of the fourth industrial revolution is emphasized.

EXPLORING THE FUTURE TRAJECTORY OF THE 3D PRINTING INDUSTRY: INNOVATIONS, GROWTH, AND OPPORTUNITIES

The 3D printing industry stands at the forefront of technological innovation, poised for substantial growth and transformation in the coming years. This research paper delves into the promising future of the 3D printing industry, examining the factors driving its expansion, projected market trends, and the implications for various sectors. While traditional manufacturing methods may not be entirely replaced, 3D printing is set to emerge as a significant player, offering increased capabilities, efficiency, and cost-effectiveness. This paper explores the evolving landscape of 3D printing technology and its potential to revolutionize industries, from healthcare to automotive, creating new avenues for entrepreneurs and reshaping production paradigms.