Pub Date : 2024-07-03DOI: 10.1108/rpj-03-2024-0129
Mert Gülçür, Dmitry Isakov, Jérôme Charmet, Gregory J. Gibbons
Purpose This study aims to investigate the demoulding characteristics of material-jetted rapid mould inserts having different surface textures for micro-injection moulding using in-line measurements and surface metrology. Design/methodology/approach Material-jetted inserts with the negative cavity of a circular test product were fabricated using different surface finishes and printing configurations, including glossy, matte and vertical settings. In-line measurements included the recording of demoulding forces at 10 kHz, which was necessary to capture the highly-dynamic characteristics. A robust data processing algorithm was used to extract reliable demoulding energies per moulding run. Thermal imaging captured surface temperatures on the inserts after demoulding. Off-line measurements, including focus variation microscopy and scanning electron microscopy, compared surface textures after a total of 60 moulding runs. Findings A framework for capturing demoulding energies from material-jetted rapid tools was demonstrated and compared to the literature. Glossy surfaces resulted in significantly reduced demoulding forces compared to the industry standard steel moulds in the literature and their material-jetted counterparts. Minimal changes in the surface textures of the material-jetted inserts were found, which could potentially permit their prolonged usage. Significant correlations between surface temperatures and demoulding energies were demonstrated. Originality/value The research presented here addresses the very topical issue of demoulding characteristics of soft, rapid tools, which affect the quality of prototyped products and tool durability. This was done using state-of-the-art, high-speed sensing technologies in conjunction with surface metrology and their durability for the first time in the literature.
{"title":"Investigating demoulding characteristics of material jetted rapid mould inserts for microinjection moulding using inline monitoring and surface metrology","authors":"Mert Gülçür, Dmitry Isakov, Jérôme Charmet, Gregory J. Gibbons","doi":"10.1108/rpj-03-2024-0129","DOIUrl":"https://doi.org/10.1108/rpj-03-2024-0129","url":null,"abstract":"\u0000Purpose\u0000This study aims to investigate the demoulding characteristics of material-jetted rapid mould inserts having different surface textures for micro-injection moulding using in-line measurements and surface metrology.\u0000\u0000\u0000Design/methodology/approach\u0000Material-jetted inserts with the negative cavity of a circular test product were fabricated using different surface finishes and printing configurations, including glossy, matte and vertical settings. In-line measurements included the recording of demoulding forces at 10 kHz, which was necessary to capture the highly-dynamic characteristics. A robust data processing algorithm was used to extract reliable demoulding energies per moulding run. Thermal imaging captured surface temperatures on the inserts after demoulding. Off-line measurements, including focus variation microscopy and scanning electron microscopy, compared surface textures after a total of 60 moulding runs.\u0000\u0000\u0000Findings\u0000A framework for capturing demoulding energies from material-jetted rapid tools was demonstrated and compared to the literature. Glossy surfaces resulted in significantly reduced demoulding forces compared to the industry standard steel moulds in the literature and their material-jetted counterparts. Minimal changes in the surface textures of the material-jetted inserts were found, which could potentially permit their prolonged usage. Significant correlations between surface temperatures and demoulding energies were demonstrated.\u0000\u0000\u0000Originality/value\u0000The research presented here addresses the very topical issue of demoulding characteristics of soft, rapid tools, which affect the quality of prototyped products and tool durability. This was done using state-of-the-art, high-speed sensing technologies in conjunction with surface metrology and their durability for the first time in the literature.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"116 s434","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141682590","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-02DOI: 10.1108/rpj-02-2024-0069
F. Mwania, M. Maringa, J. Nsengimana, Jacobus van der Walt
Purpose The current analysis was conducted to investigate the quality of surfaces and geometry of tracks printed using PolyMideTM CoPA, PolymaxTM PC and PolyMideTM PA6-CF materials through fused deposition modelling (FDM). This study also examined the degree of fusion of adjacent filaments (tracks) to approximate the optimal process parameters of the three materials. Design/methodology/approach Images of fused adjacent filaments were acquired using scanning electron microscopy (SEM), after which, they were analysed using Image J Software and Minitab Software to determine the optimal process parameters. Findings The optimal process parameters for PolyMideTM CoPA are 0.25 mm, 40 mm/s, −0.10 mm, 255°C and 0.50 mm for layer thickness, printing speed, hatch spacing, extrusion temperature and extrusion width, respectively. It was also concluded that the optimal process parameters for PolymaxTM PC are 0.30 mm, 40 mm/s, 0.00 mm, 260°C and 0.6 mm for layer thickness, printing speed, hatch spacing, extrusion temperature and extrusion width, respectively. Research limitations/implications It was difficult to separate tracks printed using PolyMideTM PA6-CF from the support structure, making it impossible to examine and determine their degree of fusion using SEM. Social implications The study provides more knowledge on FDM, which is one of the leading additive manufacturing technology for polymers. The information provided in this study helps in continued uptake of the technique, which can help create job opportunities, especially among the youth and young engineers. Originality/value This study proposes a new and a more accurate method for optimising process parameters of FDM at meso-scale level.
{"title":"Investigating surfaces, geometry and degree of fusion of tracks printed using fused deposition modelling to optimise process parameters for polymeric materials at meso-scale","authors":"F. Mwania, M. Maringa, J. Nsengimana, Jacobus van der Walt","doi":"10.1108/rpj-02-2024-0069","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0069","url":null,"abstract":"\u0000Purpose\u0000The current analysis was conducted to investigate the quality of surfaces and geometry of tracks printed using PolyMideTM CoPA, PolymaxTM PC and PolyMideTM PA6-CF materials through fused deposition modelling (FDM). This study also examined the degree of fusion of adjacent filaments (tracks) to approximate the optimal process parameters of the three materials.\u0000\u0000\u0000Design/methodology/approach\u0000Images of fused adjacent filaments were acquired using scanning electron microscopy (SEM), after which, they were analysed using Image J Software and Minitab Software to determine the optimal process parameters.\u0000\u0000\u0000Findings\u0000The optimal process parameters for PolyMideTM CoPA are 0.25 mm, 40 mm/s, −0.10 mm, 255°C and 0.50 mm for layer thickness, printing speed, hatch spacing, extrusion temperature and extrusion width, respectively. It was also concluded that the optimal process parameters for PolymaxTM PC are 0.30 mm, 40 mm/s, 0.00 mm, 260°C and 0.6 mm for layer thickness, printing speed, hatch spacing, extrusion temperature and extrusion width, respectively.\u0000\u0000\u0000Research limitations/implications\u0000It was difficult to separate tracks printed using PolyMideTM PA6-CF from the support structure, making it impossible to examine and determine their degree of fusion using SEM.\u0000\u0000\u0000Social implications\u0000The study provides more knowledge on FDM, which is one of the leading additive manufacturing technology for polymers. The information provided in this study helps in continued uptake of the technique, which can help create job opportunities, especially among the youth and young engineers.\u0000\u0000\u0000Originality/value\u0000This study proposes a new and a more accurate method for optimising process parameters of FDM at meso-scale level.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"25 6","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141687965","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-27DOI: 10.1108/rpj-12-2023-0423
Hasan Baş, Fatih Yapıcı, Erhan Ergün
Purpose The use of additive manufacturing in many branches of industry is increasing significantly because of its many advantages, such as being able to produce complex parts that cannot be produced by classical methods, using fewer materials, easing the supply chain with on-site production, being able to produce with all kinds of materials and producing lighter parts. The binder jetting technique, one of the additive manufacturing methods researched within the scope of this work, is predicted to be the additive manufacturing method that will grow the most in the next decade, according to many economic reports. Although additive manufacturing methods have many advantages, they can be slower than classical manufacturing methods regarding production speed. For this reason, this study aims to increase the manufacturing speed in the binder jetting method. Design/methodology/approach Adaptive slicing and variable binder amount algorithm (VBAA) were used to increase manufacturing speed in binder jetting. Taguchi method was used to optimize the layer thickness and saturation ratio in VBAA. According to the Taguchi experimental design, 27 samples were produced in nine different conditions, three replicates each. The width of the samples in their raw form was measured. Afterward, the samples were sintered at 1,500 °C for 2 h. After sintering, surface roughness and density tests were performed. Therefore, the methods used have been proven to be successful. In addition, measurement possibilities with image processing were investigated to make surface roughness measurements more accessible and more economical. Findings As a result of the tests, the optimum printing condition was decided to be 180–250 µm for layer thickness and 50% for saturation. A separate test sample was then designed to implement adaptive slicing. This test sample was produced in three pieces: adaptive (180–250 µm), thin layer (180 µm) and thick layer (250 µm) with the determined parameters. The roughness values of the adaptive sliced sample and the thin layer sample were similar and better than the thick layer sample. A similar result was obtained using 12.31% fewer layers in the adaptive sample than in the thin layer sample. Originality/value The use of adaptive slicing in binder jetting has become more efficient. In this way, it will increase the use of adaptive slicing in binder jetting. In addition, a cheap and straightforward image processing method has been developed to calculate the surface roughness of the parts.
{"title":"Effective use of adaptive slicing in binder jetting using Taguchi method and surface roughness measurement with image processing","authors":"Hasan Baş, Fatih Yapıcı, Erhan Ergün","doi":"10.1108/rpj-12-2023-0423","DOIUrl":"https://doi.org/10.1108/rpj-12-2023-0423","url":null,"abstract":"Purpose\u0000The use of additive manufacturing in many branches of industry is increasing significantly because of its many advantages, such as being able to produce complex parts that cannot be produced by classical methods, using fewer materials, easing the supply chain with on-site production, being able to produce with all kinds of materials and producing lighter parts. The binder jetting technique, one of the additive manufacturing methods researched within the scope of this work, is predicted to be the additive manufacturing method that will grow the most in the next decade, according to many economic reports. Although additive manufacturing methods have many advantages, they can be slower than classical manufacturing methods regarding production speed. For this reason, this study aims to increase the manufacturing speed in the binder jetting method.\u0000\u0000Design/methodology/approach\u0000Adaptive slicing and variable binder amount algorithm (VBAA) were used to increase manufacturing speed in binder jetting. Taguchi method was used to optimize the layer thickness and saturation ratio in VBAA. According to the Taguchi experimental design, 27 samples were produced in nine different conditions, three replicates each. The width of the samples in their raw form was measured. Afterward, the samples were sintered at 1,500 °C for 2 h. After sintering, surface roughness and density tests were performed. Therefore, the methods used have been proven to be successful. In addition, measurement possibilities with image processing were investigated to make surface roughness measurements more accessible and more economical.\u0000\u0000Findings\u0000As a result of the tests, the optimum printing condition was decided to be 180–250 µm for layer thickness and 50% for saturation. A separate test sample was then designed to implement adaptive slicing. This test sample was produced in three pieces: adaptive (180–250 µm), thin layer (180 µm) and thick layer (250 µm) with the determined parameters. The roughness values of the adaptive sliced sample and the thin layer sample were similar and better than the thick layer sample. A similar result was obtained using 12.31% fewer layers in the adaptive sample than in the thin layer sample.\u0000\u0000Originality/value\u0000The use of adaptive slicing in binder jetting has become more efficient. In this way, it will increase the use of adaptive slicing in binder jetting. In addition, a cheap and straightforward image processing method has been developed to calculate the surface roughness of the parts.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"48 12","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141098117","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-27DOI: 10.1108/rpj-09-2023-0313
Muhammed Kofoğlu, D. Yunus, Necati Ercan
Purpose Lattice structures are widely used for achieving optimal topology in additive manufacturing. However, the use of different lattices in a single design can result in stress concentrations at the transition points. This study aims to investigate the influence of Bezier curves on mechanical properties during the transformation from one lattice structure to another. It specifically focuses on the transition from a hexagonal to diamond lattice, using Bezier curves of various orders. Design/methodology/approach The curves were designed by passing them through the same control points for different orders, such as third, fifth and seventh. The samples were sliced for 3D printing, and a tensile test was conducted. Young’s modulus and energy absorption abilities were measured to compare the mechanical properties of the models created with Bezier curves for the transformation between hexagonal and diamond models. Findings The analysis revealed a gradual change in mechanical properties from the hexagonal to the diamond lattice. Moreover, different orders of Bezier curves exhibited varying mechanical properties during the transformation between the two lattices. As the order of the Bezier curve increased, the mechanical properties smoothly changed from the hexagonal to diamond lattice. This prevented stress concentrations or mechanical behavior mismatch caused by sudden deformations at the transitions between the curves used in the design. Originality/value The study’s innovative use of Bezier curves of different orders to smoothly transformation between hexagonal and diamond lattices in additive manufacturing offers a practical solution to prevent stress concentrations and mechanical inconsistencies during such design transitions.
{"title":"Lattice optimization of fiber-reinforced polymer parts fabricated by additive manufacturing: the impact of Bezier curve order on mechanical properties","authors":"Muhammed Kofoğlu, D. Yunus, Necati Ercan","doi":"10.1108/rpj-09-2023-0313","DOIUrl":"https://doi.org/10.1108/rpj-09-2023-0313","url":null,"abstract":"\u0000Purpose\u0000Lattice structures are widely used for achieving optimal topology in additive manufacturing. However, the use of different lattices in a single design can result in stress concentrations at the transition points. This study aims to investigate the influence of Bezier curves on mechanical properties during the transformation from one lattice structure to another. It specifically focuses on the transition from a hexagonal to diamond lattice, using Bezier curves of various orders.\u0000\u0000\u0000Design/methodology/approach\u0000The curves were designed by passing them through the same control points for different orders, such as third, fifth and seventh. The samples were sliced for 3D printing, and a tensile test was conducted. Young’s modulus and energy absorption abilities were measured to compare the mechanical properties of the models created with Bezier curves for the transformation between hexagonal and diamond models.\u0000\u0000\u0000Findings\u0000The analysis revealed a gradual change in mechanical properties from the hexagonal to the diamond lattice. Moreover, different orders of Bezier curves exhibited varying mechanical properties during the transformation between the two lattices. As the order of the Bezier curve increased, the mechanical properties smoothly changed from the hexagonal to diamond lattice. This prevented stress concentrations or mechanical behavior mismatch caused by sudden deformations at the transitions between the curves used in the design.\u0000\u0000\u0000Originality/value\u0000The study’s innovative use of Bezier curves of different orders to smoothly transformation between hexagonal and diamond lattices in additive manufacturing offers a practical solution to prevent stress concentrations and mechanical inconsistencies during such design transitions.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"51 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141098241","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-21DOI: 10.1108/rpj-10-2023-0379
Ch. Kapil Ror, Vishal Mishra, S. Negi, V. M
Purpose This study aims to evaluate the potential of using the in-nozzle impregnation approach to reuse recycled PET (RPET) to develop continuous banana fiber (CBF) reinforced bio-composites. The mechanical properties and fracture morphology behavior are evaluated to establish the relationships between layer spacing–microstructural characteristics–mechanical properties of CBF/RPET composite. Design/methodology/approach This study uses RPET filament developed from post-consumer PET bottles and CBF extracted from agricultural waste banana sap. RPET serves as the matrix material, while CBF acts as the reinforcement. The test specimens were fabricated using a customized fused deposition modeling 3D printer. In this process, customized 3D printer heads were used, which have a unique capability to extrude and deposit print fibers consisting of a CBF core coated with an RPET matrix. The tensile and flexural samples were 3D printed at varying layer spacing. Findings The Young’s modulus (E), yield strength (sy) and ultimate tensile strength of the CBF/RPET sample fabricated with 0.7 mm layer spacing are 1.9 times, 1.25 times and 1.8 times greater than neat RPET, respectively. Similarly, the flexural test results showed that the flexural strength of the CBF/RPET sample fabricated at 0.6 mm layer spacing was 47.52 ± 2.00 MPa, which was far greater than the flexural strength of the neat RPET sample (25.12 ± 1.94 MPa). Social implications This study holds significant social implications highlighting the growing environmental sustainability and plastic waste recycling concerns. The use of recycled PET material to develop 3D-printed sustainable structures may reduce resource consumption and encourages responsible production practices. Originality/value The key innovation lies in the concept of in-nozzle impregnation approach, where RPET is reinforced with CBF to develop a sustainable composite structure. CBF reinforcement has made RPET a superior, sustainable, environmentally friendly material that can reduce the reliance on virgin plastic material for 3D printing.
{"title":"Utilizing in-nozzle impregnation for enhancing the strength of recycled PET-derived 3D printed continuous banana fiber reinforced bio-composites","authors":"Ch. Kapil Ror, Vishal Mishra, S. Negi, V. M","doi":"10.1108/rpj-10-2023-0379","DOIUrl":"https://doi.org/10.1108/rpj-10-2023-0379","url":null,"abstract":"Purpose\u0000This study aims to evaluate the potential of using the in-nozzle impregnation approach to reuse recycled PET (RPET) to develop continuous banana fiber (CBF) reinforced bio-composites. The mechanical properties and fracture morphology behavior are evaluated to establish the relationships between layer spacing–microstructural characteristics–mechanical properties of CBF/RPET composite.\u0000\u0000Design/methodology/approach\u0000This study uses RPET filament developed from post-consumer PET bottles and CBF extracted from agricultural waste banana sap. RPET serves as the matrix material, while CBF acts as the reinforcement. The test specimens were fabricated using a customized fused deposition modeling 3D printer. In this process, customized 3D printer heads were used, which have a unique capability to extrude and deposit print fibers consisting of a CBF core coated with an RPET matrix. The tensile and flexural samples were 3D printed at varying layer spacing.\u0000\u0000Findings\u0000The Young’s modulus (E), yield strength (sy) and ultimate tensile strength of the CBF/RPET sample fabricated with 0.7 mm layer spacing are 1.9 times, 1.25 times and 1.8 times greater than neat RPET, respectively. Similarly, the flexural test results showed that the flexural strength of the CBF/RPET sample fabricated at 0.6 mm layer spacing was 47.52 ± 2.00 MPa, which was far greater than the flexural strength of the neat RPET sample (25.12 ± 1.94 MPa).\u0000\u0000Social implications\u0000This study holds significant social implications highlighting the growing environmental sustainability and plastic waste recycling concerns. The use of recycled PET material to develop 3D-printed sustainable structures may reduce resource consumption and encourages responsible production practices.\u0000\u0000Originality/value\u0000The key innovation lies in the concept of in-nozzle impregnation approach, where RPET is reinforced with CBF to develop a sustainable composite structure. CBF reinforcement has made RPET a superior, sustainable, environmentally friendly material that can reduce the reliance on virgin plastic material for 3D printing.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"97 17","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141116197","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Purpose While performance demands in the natural world are varied, graded lattice structures reveal distinctive mechanical properties with tremendous engineering application potential. For biomechanical functions where mechanical qualities are required from supporting under external loading and permeability is crucial which affects bone tissue engineering, the geometric design in lattice structure for bone scaffolds in loading-bearing applications is necessary. However, when tweaking structural traits, these two factors frequently clash. For graded lattice structures, this study aims to develop a design-optimization strategy to attain improved attributes across different domains. Design/methodology/approach To handle diverse stress states, parametric modeling is used to produce strut-based lattice structures with spatially varied densities. The tailored initial gradients in lattice structure are subject to automatic property evaluation procedure that hinges on finite element method and computational fluid dynamics simulations. The geometric parameters of lattice structures with numerous objectives are then optimized using an iterative optimization process based on a non-dominated genetic algorithm. Findings The initial stress-based design of graded lattice structure with spatially variable densities is generated based on the stress conditions. The results from subsequent dual-objective optimization show a series of topologies with gradually improved trade-offs between mechanical properties and permeability. Originality/value In this study, a novel structural design-optimization methodology is proposed for mathematically optimizing strut-based graded lattice structures to achieve enhanced performance in multiple domains.
{"title":"A novel design method based onmulti–objective optimization for graded lattice structure by additive manufacturing","authors":"Xiangyun Li, Liuxian Zhu, Shuaitao Fan, Yingying Wei, Daijian Wu, Shan Gong","doi":"10.1108/rpj-09-2023-0330","DOIUrl":"https://doi.org/10.1108/rpj-09-2023-0330","url":null,"abstract":"\u0000Purpose\u0000While performance demands in the natural world are varied, graded lattice structures reveal distinctive mechanical properties with tremendous engineering application potential. For biomechanical functions where mechanical qualities are required from supporting under external loading and permeability is crucial which affects bone tissue engineering, the geometric design in lattice structure for bone scaffolds in loading-bearing applications is necessary. However, when tweaking structural traits, these two factors frequently clash. For graded lattice structures, this study aims to develop a design-optimization strategy to attain improved attributes across different domains.\u0000\u0000\u0000Design/methodology/approach\u0000To handle diverse stress states, parametric modeling is used to produce strut-based lattice structures with spatially varied densities. The tailored initial gradients in lattice structure are subject to automatic property evaluation procedure that hinges on finite element method and computational fluid dynamics simulations. The geometric parameters of lattice structures with numerous objectives are then optimized using an iterative optimization process based on a non-dominated genetic algorithm.\u0000\u0000\u0000Findings\u0000The initial stress-based design of graded lattice structure with spatially variable densities is generated based on the stress conditions. The results from subsequent dual-objective optimization show a series of topologies with gradually improved trade-offs between mechanical properties and permeability.\u0000\u0000\u0000Originality/value\u0000In this study, a novel structural design-optimization methodology is proposed for mathematically optimizing strut-based graded lattice structures to achieve enhanced performance in multiple domains.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"138 48","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141114663","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-21DOI: 10.1108/rpj-01-2024-0016
Dongfei Li, Hongtao Wang, Ning Dai
Purpose This paper aims to propose a method for automatic design of additive manufacturing (AM) flow channel paths driven by path length and pressure loss. The research focuses on the automatic design of channel paths, intending to achieve the shortest flow channel length or minimum pressure loss and improve the design efficiency of AM parts. Design/methodology/approach The initial layout of the flow channels is redesigned to consider the channels print supports. Boundary conditions and constraints are defined according to the redesigned channels layout, and the equation consisting of channel length and pressure loss is used as the objective function. Then the path planning simulation is performed based on particle swarm algorithm. The proposed method describes the path of flow channels using spline cures. The spline curve is controlled by particle (one particle represents a path), and the particle is randomly generated within the design space. After the path planning simulation is completed, the generated paths are used to create 3D parts. Findings Case study 1 demonstrates the automatic design of hydraulic spool valve. Compared to conventional spool valve, the pressure loss was reduced by 86% and the mass was reduced by 83%. The design results of case study 2 indicate that this approach is able to find the shortest channel path with lower computational cost. Originality/value The automatic design method of flow channel paths driven by path length and pressure loss presented in this paper provides a novel solution for the creation of AM flow components.
目的 本文旨在提出一种根据路径长度和压力损失自动设计增材制造（AM）流道路径的方法。研究重点是自动设计流道路径，以实现最短的流道长度或最小的压力损失，提高 AM 零件的设计效率。根据重新设计的流道布局定义边界条件和约束条件，并将流道长度和压力损失组成的方程作为目标函数。然后基于粒子群算法进行路径规划模拟。所提出的方法使用样条曲线来描述水流通道的路径。花键曲线由粒子控制（一个粒子代表一条路径），粒子在设计空间内随机生成。案例研究 1 演示了液压阀芯的自动设计。与传统阀芯相比，压力损失减少了 86%，质量减少了 83%。案例研究 2 的设计结果表明，这种方法能够以较低的计算成本找到最短的通道路径。原创性/价值本文介绍的由路径长度和压力损失驱动的流道路径自动设计方法为创建 AM 流动部件提供了一种新颖的解决方案。
{"title":"A novel design model of flow channel paths for additive manufacturing","authors":"Dongfei Li, Hongtao Wang, Ning Dai","doi":"10.1108/rpj-01-2024-0016","DOIUrl":"https://doi.org/10.1108/rpj-01-2024-0016","url":null,"abstract":"\u0000Purpose\u0000This paper aims to propose a method for automatic design of additive manufacturing (AM) flow channel paths driven by path length and pressure loss. The research focuses on the automatic design of channel paths, intending to achieve the shortest flow channel length or minimum pressure loss and improve the design efficiency of AM parts.\u0000\u0000\u0000Design/methodology/approach\u0000The initial layout of the flow channels is redesigned to consider the channels print supports. Boundary conditions and constraints are defined according to the redesigned channels layout, and the equation consisting of channel length and pressure loss is used as the objective function. Then the path planning simulation is performed based on particle swarm algorithm. The proposed method describes the path of flow channels using spline cures. The spline curve is controlled by particle (one particle represents a path), and the particle is randomly generated within the design space. After the path planning simulation is completed, the generated paths are used to create 3D parts.\u0000\u0000\u0000Findings\u0000Case study 1 demonstrates the automatic design of hydraulic spool valve. Compared to conventional spool valve, the pressure loss was reduced by 86% and the mass was reduced by 83%. The design results of case study 2 indicate that this approach is able to find the shortest channel path with lower computational cost.\u0000\u0000\u0000Originality/value\u0000The automatic design method of flow channel paths driven by path length and pressure loss presented in this paper provides a novel solution for the creation of AM flow components.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"89 11","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141116148","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-21DOI: 10.1108/rpj-11-2023-0392
N. Kladovasilakis, P. Charalampous, Ioannis Kostavelis, Dimitrios Tzovaras
Purpose This paper aims to present an integrated system designed for quality control and inspection in additive manufacturing (AM) technologies. Design/methodology/approach The study undertakes a comprehensive examination of the process in three distinct stages. First, the quality of the feedstock material is inspected during the preprocessing step. Subsequently, the main research topic of the study is directed toward the 3D printing process itself with real-time monitoring procedures using computer vision methods. Finally, an evaluation of the 3D printed parts is conducted, using measuring methods and mechanical experiments. Findings The main results of this technical paper are the development and presentation of an integrated solution for quality control and inspection in AM processes. Originality/value The proposed solution entails the development of a promising tool for the optimization of the quality in 3D prints based on machine learning algorithms.
设计/方法/途径本研究分三个不同阶段对工艺流程进行全面检查。首先，在预处理步骤中检测原料材料的质量。随后，本研究的主要研究课题是利用计算机视觉方法对三维打印过程本身进行实时监控。最后，使用测量方法和机械实验对 3D 打印部件进行评估。研究结果本技术论文的主要成果是开发并展示了用于 AM 过程中质量控制和检测的集成解决方案。
{"title":"Q3D: a complete solution for quality control and inspection in additive manufacturing processes","authors":"N. Kladovasilakis, P. Charalampous, Ioannis Kostavelis, Dimitrios Tzovaras","doi":"10.1108/rpj-11-2023-0392","DOIUrl":"https://doi.org/10.1108/rpj-11-2023-0392","url":null,"abstract":"\u0000Purpose\u0000This paper aims to present an integrated system designed for quality control and inspection in additive manufacturing (AM) technologies.\u0000\u0000\u0000Design/methodology/approach\u0000The study undertakes a comprehensive examination of the process in three distinct stages. First, the quality of the feedstock material is inspected during the preprocessing step. Subsequently, the main research topic of the study is directed toward the 3D printing process itself with real-time monitoring procedures using computer vision methods. Finally, an evaluation of the 3D printed parts is conducted, using measuring methods and mechanical experiments.\u0000\u0000\u0000Findings\u0000The main results of this technical paper are the development and presentation of an integrated solution for quality control and inspection in AM processes.\u0000\u0000\u0000Originality/value\u0000The proposed solution entails the development of a promising tool for the optimization of the quality in 3D prints based on machine learning algorithms.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"23 9","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141118066","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-21DOI: 10.1108/rpj-10-2023-0352
Anand Mohan Pandey, S. Kapil, Manas Das
Purpose Selective jet electrodeposition (SJED) is an emerging additive manufacturing (AM) technology for realizing metallic components of nano and micro sizes. The deposited parts on the substrate form metallurgical bonding, so separating them from the substrate is an unsolved issue. Therefore, this paper aims to propose a method for separating the deposited micro parts from a sacrificial substrate. Furthermore, single and multi-bead optimization is performed to fabricate microparts with varying density. Design/methodology/approach A typical SJED process consists of a nozzle (to establish a column of electrolytes) retrofitted on a machine tool (to provide relative motion between substrate and nozzle) that deposits material atom-by-atom on a conductive substrate. Findings A comprehensive study of process parameters affecting the layer height, layer width and morphology of the deposited micro-parts has been provided. The uniformity in the deposited parts can be achieved with the help of low applied voltage and high scanning speed. Multi-bead analysis for the flat surface condition is experimentally performed, and the flat surface condition is achieved when the centre distance between two adjacent beads is kept at half of the width of a single bead. Originality/value Although several literatures have demonstrated that the SJED process can be used for the fabrication of parts; however, part fabrication through multi-bead optimization is limited. Moreover, the removal of the fabricated part from the substrate is the novelty of the current work.
{"title":"A novel method of effectively fabricating the micro-objects by selective jet electrodeposition (SJED)","authors":"Anand Mohan Pandey, S. Kapil, Manas Das","doi":"10.1108/rpj-10-2023-0352","DOIUrl":"https://doi.org/10.1108/rpj-10-2023-0352","url":null,"abstract":"Purpose\u0000Selective jet electrodeposition (SJED) is an emerging additive manufacturing (AM) technology for realizing metallic components of nano and micro sizes. The deposited parts on the substrate form metallurgical bonding, so separating them from the substrate is an unsolved issue. Therefore, this paper aims to propose a method for separating the deposited micro parts from a sacrificial substrate. Furthermore, single and multi-bead optimization is performed to fabricate microparts with varying density.\u0000\u0000Design/methodology/approach\u0000A typical SJED process consists of a nozzle (to establish a column of electrolytes) retrofitted on a machine tool (to provide relative motion between substrate and nozzle) that deposits material atom-by-atom on a conductive substrate.\u0000\u0000Findings\u0000A comprehensive study of process parameters affecting the layer height, layer width and morphology of the deposited micro-parts has been provided. The uniformity in the deposited parts can be achieved with the help of low applied voltage and high scanning speed. Multi-bead analysis for the flat surface condition is experimentally performed, and the flat surface condition is achieved when the centre distance between two adjacent beads is kept at half of the width of a single bead.\u0000\u0000Originality/value\u0000Although several literatures have demonstrated that the SJED process can be used for the fabrication of parts; however, part fabrication through multi-bead optimization is limited. Moreover, the removal of the fabricated part from the substrate is the novelty of the current work.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"6 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141118489","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-04-26DOI: 10.1108/rpj-02-2024-0077
Valentin Marchal, Yicha Zhang, Rémy Lachat, N. Labed, François Peyraut
Purpose The use of continuous fiber-reinforced filaments improves the mechanical properties obtained with the fused filament fabrication (FFF) process. Yet, there is a lack of simulation tailored tools to assist in the design for additive manufacturing of continuous fiber composites. To build such models, a precise elastic model is required. As the porosity caused by interbead voids remains an important flaw of the process, this paper aims to build an elastic model integrating this aspect. Design/methodology/approach To study the amount of porosity, which could be a failure initiator, this study proposes a two step periodic homogenization method. The first step concerns the microscopic scale with a unit cell made of fiber and matrix. The second step is at the mesoscopic scale and combines the elastic material of the first step with the interbead voids. The void content has been set as a parameter of the model. The material models predicted with the periodic homogenization were compared with experimental results. Findings The comparison between periodic homogenization results and tensile test results shows a fair agreement between the experimental results and that of the numerical simulation, whatever the fibers’ orientations are. Moreover, a void content reduction has been observed by increasing the crossing angle from one layer to another. An empiric law giving the porosity according to this crossing angle was created. The model and the law can be further used for design evaluation and optimization of continuous fiber-reinforced FFF. Originality/value A new elastic model considering interbead voids and its variation with the crossing angle of the fibers has been built. It can be used in simulation tools to design high performance fused filament fabricated composite parts.
{"title":"Inter-bead void reduction by crossing printing routes of fused filament fabricated composites","authors":"Valentin Marchal, Yicha Zhang, Rémy Lachat, N. Labed, François Peyraut","doi":"10.1108/rpj-02-2024-0077","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0077","url":null,"abstract":"Purpose\u0000The use of continuous fiber-reinforced filaments improves the mechanical properties obtained with the fused filament fabrication (FFF) process. Yet, there is a lack of simulation tailored tools to assist in the design for additive manufacturing of continuous fiber composites. To build such models, a precise elastic model is required. As the porosity caused by interbead voids remains an important flaw of the process, this paper aims to build an elastic model integrating this aspect.\u0000\u0000Design/methodology/approach\u0000To study the amount of porosity, which could be a failure initiator, this study proposes a two step periodic homogenization method. The first step concerns the microscopic scale with a unit cell made of fiber and matrix. The second step is at the mesoscopic scale and combines the elastic material of the first step with the interbead voids. The void content has been set as a parameter of the model. The material models predicted with the periodic homogenization were compared with experimental results.\u0000\u0000Findings\u0000The comparison between periodic homogenization results and tensile test results shows a fair agreement between the experimental results and that of the numerical simulation, whatever the fibers’ orientations are. Moreover, a void content reduction has been observed by increasing the crossing angle from one layer to another. An empiric law giving the porosity according to this crossing angle was created. The model and the law can be further used for design evaluation and optimization of continuous fiber-reinforced FFF.\u0000\u0000Originality/value\u0000A new elastic model considering interbead voids and its variation with the crossing angle of the fibers has been built. It can be used in simulation tools to design high performance fused filament fabricated composite parts.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"26 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140652097","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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