Design and manufacturing of a Selective Laser Sintering test bench to test sintering materials

The goal of this project is to design and build a prototype of recoating system for a laser cutting machine to turn it into a selective laser sintering printing machine. This prototype will be used to study new sintering materials and to design, if decided, a SLS 3D printing Machine (Selective Laser Sintering). This project has been developed in the installations and funded by Fundació CIM. The project develops the mechanical design and the electronic system design. Both parts are explained on this paper, so new users can use the machine and can understand the system. With this paper, it is expected that it can be improved in a future to test other parameters and configurations. The paper is divided in three basic blocks that are summed up here: The first block is an introduction to the 3D printing technologies. The most used of them are explained and selective laser sintering is explained in deep. With this block the reader can understand why it is important to develop the SLS technology and what has to be done to improve the machines and the technology. The second block is a discussion on the mechanical design of the machine. The general idea of the machine is explained so the user can understand why the machine is designed in this way. After that, each part is detailed to see how the different mechanical challenges where overtaken. At the end of the block, there is a small calculations section needed on the electronic part. The third block is an extensive explanation of the electronic system that controls and moves the machine. In that block, the different components are explained so the user can understand its basics working principles. It is also explained how the selection of the electronic components was done. Then everything is put together to see the whole electronic system. Along with this paper, there are annexes that provide some extra information for the reader. One of this annexes refers to the mechanical part and the other one has some datasheets and coding for the electronic section. The whole design has been done in SOLIDWORKS cad software and its electric extension ELECWORKS. The programming job was done with Arduino compiler

Building real-time embedded applications on QduinoMC: a web-connected 3D printer case study

Single Board Computers (SBCs) are now emerging with multiple cores, ADCs, GPIOs, PWM channels, integrated graphics, and several serial bus interfaces. The low power consumption, small form factor and I/O interface capabilities of SBCs with sensors and actuators makes them ideal in embedded and real-time applications. However, most SBCs run non-realtime operating systems based on Linux and Windows, and do not provide a user-friendly API for application development. This paper presents QduinoMC, a multicore extension to the popular Arduino programming environment, which runs on the Quest real-time operating system. QduinoMC is an extension of our earlier single-core, real-time, multithreaded Qduino API. We show the utility of QduinoMC by applying it to a specific application: a web-connected 3D printer. This differs from existing 3D printers, which run relatively simple firmware and lack operating system support to spool multiple jobs, or interoperate with other devices (e.g., in a print farm). We show how QduinoMC empowers devices with the capabilities to run new services without impacting their timing guarantees. While it is possible to modify existing operating systems to provide suitable timing guarantees, the effort to do so is cumbersome and does not provide the ease of programming afforded by QduinoMC.http://www.cs.bu.edu/fac/richwest/papers/rtas_2017.pdfAccepted manuscrip

Three-dimensional microfabrication through a multimode optical fiber

Additive manufacturing, also known as 3D printing, is an advanced manufacturing technique that allows the fabrication of arbitrary macroscopic and microscopic objects. All 3D printing systems require large optical elements or nozzles in proximity to the built structure. This prevents their use in applications in which there is no direct access to the area where the objects have to be printed. Here, we demonstrate three-dimensional microfabrication based on two-photon polymerization (TPP) with sub diffraction-limited resolution through an ultra-thin, 50 mm long printing nozzle of 560 micrometers in diameter. Using wavefront shaping, femtosecond infrared pulses are focused and scanned through a multimode optical fiber (MMF) inside a photoresist that polymerizes via two-photon absorption. We show the construction of arbitrary 3D structures of 500 nm resolution on the other side of the fiber. To our knowledge, this is the first demonstration of microfabrication through a multimode optical fiber. Our work represents a new area which we refer to as endofabrication

Digital manufacturing: what are we able to print?

In a rational exercise, in the present paper it is extrapolated how the development of ICTs (information and communication technologies) and the incipient technological development of additive manufacturing has the potential to change our society. In the following, it is analyzing the evolution of man over physical matter and how this has shaped our society. The main milestones or key stages in history that have marked a transcendental change in the human-machine-environment relationship have been identified and consequently have led us to ask ourselves: What is next, how far are we, and what are we capable of printing? In an attempt to identify the current state of the art, highlighting the possibilities those additive technologies can offerPostprint (published version

Contextual impacts on industrial processes brought by the digital transformation of manufacturing: a systematic review

The digital transformation of manufacturing (a phenomenon also known as "Industry 4.0" or "Smart Manufacturing") is finding a growing interest both at practitioner and academic levels, but is still in its infancy and needs deeper investigation. Even though current and potential advantages of digital manufacturing are remarkable, in terms of improved efficiency, sustainability, customization, and flexibility, only a limited number of companies has already developed ad hoc strategies necessary to achieve a superior performance. Through a systematic review, this study aims at assessing the current state of the art of the academic literature regarding the paradigm shift occurring in the manufacturing settings, in order to provide definitions as well as point out recurring patterns and gaps to be addressed by future research. For the literature search, the most representative keywords, strict criteria, and classification schemes based on authoritative reference studies were used. The final sample of 156 primary publications was analyzed through a systematic coding process to identify theoretical and methodological approaches, together with other significant elements. This analysis allowed a mapping of the literature based on clusters of critical themes to synthesize the developments of different research streams and provide the most representative picture of its current state. Research areas, insights, and gaps resulting from this analysis contributed to create a schematic research agenda, which clearly indicates the space for future evolutions of the state of knowledge in this field

A simple, low-cost conductive composite material for 3D printing of electronic sensors

3D printing technology can produce complex objects directly from computer aided digital designs. The technology has traditionally been used by large companies to produce fit and form concept prototypes (‘rapid prototyping’) before production. In recent years however there has been a move to adopt the technology as full-scale manufacturing solution. The advent of low-cost, desktop 3D printers such as the RepRap and Fab@Home has meant a wider user base are now able to have access to desktop manufacturing platforms enabling them to produce highly customised products for personal use and sale. This uptake in usage has been coupled with a demand for printing technology and materials able to print functional elements such as electronic sensors. Here we present formulation of a simple conductive thermoplastic composite we term ‘carbomorph’ and demonstrate how it can be used in an unmodified low-cost 3D printer to print electronic sensors able to sense mechanical flexing and capacitance changes. We show how this capability can be used to produce custom sensing devices and user interface devices along with printed objects with embedded sensing capability. This advance in low-cost 3D printing with offer a new paradigm in the 3D printing field with printed sensors and electronics embedded inside 3D printed objects in a single build process without requiring complex or expensive materials incorporating additives such as carbon nanotubes

Rotational 3D Printing of Sensor Devices using Reactive Ink Chemistries

This paper charts progress in three key areas of a project supported by both UK government and UK industry to manufacture novel sensor devices using rotary 3D printing technology and innovative ink chemistries; (1) the development of an STL file slicing algorithm that returns constant Z height 2D contour data at a resolution that matches the given print head setup, allowing digital images to be generated of the correct size without the need for scaling; (2) the development of image transformation algorithms which allow images to be printed at higher resolutions using tilted print heads and; (3) the formulation of multi part reaction inks which combine and react on the substrate to form solid material layers with a finite thickness. A Direct Light Projection (DLP) technique demonstrated the robustness of the slice data by constructing fine detailed three dimensional test pieces which were comparable to identical parts built in an identical way from slice data obtained using commercial software. Material systems currently under investigation include plaster, stiff polyamides and epoxy polymers and conductive metallic’s. Early experimental results show conductivities of silver approaching 1.42x105 Siemens/m.Mechanical Engineerin

Design of highly stabilized nanocomposite inks based on biodegradable polymer-matrix and gold nanoparticles for Inkjet Printing

Nowadays there is a worldwide growing interest in the Inkjet Printing technology owing to its potentially high levels of geometrical complexity, personalization and resolution. There is also social concern about usage, disposal and accumulation of plastic materials. In this work, it is shown that sugar-based biodegradable polyurethane polymers exhibit outstanding properties as polymer-matrix for gold nanoparticles composites. These materials could reach exceptional stabilization levels, and demonstrated potential as novel robust inks for Inkjet based Printing. Furthermore, a physical comparison among different polymers is discussed based on stability and printability experiments to search for the best ink candidate. The University of Seville logo was printed by employing those inks, and the presence of gold was confirmed by ToF-SIMS. This approach has the potential to open new routes and applications for fabrication of enhanced biomedical nanometallic-sensors using stabilized AuNP.Spanish Ministerio de Economía y Competitividad MINECO, (Grants Nos. CTQ2016- 78703-P and MAT2016-78703-P)Junta de Andalucía (Consolidation Grant for Research Group FQM135 and 2017/FQM-386, P-2018/809)University of Seville (V y VI Plan Propio PP2016-5937

Survey on Additive Manufacturing, Cloud 3D Printing and Services

Cloud Manufacturing (CM) is the concept of using manufacturing resources in a service oriented way over the Internet. Recent developments in Additive Manufacturing (AM) are making it possible to utilise resources ad-hoc as replacement for traditional manufacturing resources in case of spontaneous problems in the established manufacturing processes. In order to be of use in these scenarios the AM resources must adhere to a strict principle of transparency and service composition in adherence to the Cloud Computing (CC) paradigm. With this review we provide an overview over CM, AM and relevant domains as well as present the historical development of scientific research in these fields, starting from 2002. Part of this work is also a meta-review on the domain to further detail its development and structure