The potential of additive manufacturing in the smart factory industrial 4.0: A review

Additive manufacturing (AM) or three-dimensional (3D) printing has introduced a novel production method in design, manufacturing, and distribution to end-users. This technology has provided great freedom in design for creating complex components, highly customizable products, and efficient waste minimization. The last industrial revolution, namely industry 4.0, employs the integration of smart manufacturing systems and developed information technologies. Accordingly, AM plays a principal role in industry 4.0 thanks to numerous benefits, such as time and material saving, rapid prototyping, high efficiency, and decentralized production methods. This review paper is to organize a comprehensive study on AM technology and present the latest achievements and industrial applications. Besides that, this paper investigates the sustainability dimensions of the AM process and the added values in economic, social, and environment sections. Finally, the paper concludes by pointing out the future trend of AM in technology, applications, and materials aspects that have the potential to come up with new ideas for the future of AM explorations

Design for additive manufacturing: Trends, opportunities, considerations, and constraints

The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future challenges, and identifies promising directions for research and the exploitation of AM's full potential in industry

Design for additive manufacturing: trends, opportunities, considerations, and constraints

© 2016 CIRP. The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future challenges, and identifies promising directions for research and the exploitation of AM's full potential in industry

Five-Axis Machine Tool Condition Monitoring Using dSPACE Real-Time System

This paper presents the design, development and SIMULINK implementation of the lumped parameter model of C-axis drive from GEISS five-axis CNC machine tool. The simulated results compare well with the experimental data measured from the actual machine. Also the paper describes the steps for data acquisition using ControlDesk and hardware-in-the-loop implementation of the drive models in dSPACE real-time system. The main components of the HIL system are: the drive model simulation and input – output (I/O) modules for receiving the real controller outputs. The paper explains how the experimental data obtained from the data acquisition process using dSPACE real-time system can be used for the development of machine tool diagnosis and prognosis systems that facilitate the improvement of maintenance activities

A Modular Converter- and Signal-Processing-Platform for Academic Research in the Field of Power Electronics

For academic research it is mandatory that the theoretical evaluation and modelling of new control methods, modulation schemes, electrical machines, power electronic topologies, etc. is validated with accurate measurements. To guarantee a high quality and high performance research it is necessary to have a modular, scalable, user-friendly, adaptable and affordable system. This allows to put the focus on the research topics themselves rather than spending a high effort on the pure implementation of the theoretical research results. The system described in this paper consists of a software environment/toolchain and a hardware platform. The hardware platform can be subdivided into a power electronics platform and a System on Chip based signal processing system. Besides the hardware platform also a user-friendly software environment/toolchain for modelbased research is developed and illustrated in this paper. This new system enables rapid-prototyping of new algorithms, hardware and topologies

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

Engineering Method and Tool for the Complete Virtual Commissioning of Robotic Cells

Intelligent robotic manufacturing cells must adapt to ever-varying operating conditions, developing autonomously optimal manufacturing strategies to achieve the best quality and overall productivity. Intelligent and cognitive behaviors are realized by using distributed controllers, in which complex control logics must interact and process a wide variety of input/output signals. In particular, programmable logic controllers (PLCs) and robot controllers must be coordinated and integrated. Then, there is the need to simulate the robotic cells’ behavior for performance verification and optimization by evaluating the effects of both PLC and robot control codes. In this context, this work proposes a method, and its implementation into an integrated tool, to exploit the potential of ABB RobotStudio software as a virtual prototyping platform for robotic cells, in which real robots control codes are executed on a virtual controller and integrated with Beckhoff PLC environment. For this purpose, a PLC Smart Component was conceived as an extension of RobotStudio functionalities to exchange signals with a TwinCAT instance. The new module allows the virtual commissioning of a complete robotic cell to be performed, assessing the control logics effects on the overall productivity. The solution is demonstrated on a robotic assembly cell, showing its feasibility and effectiveness in optimizing the final performance

Applications of additive manufacturing in the construction industry

Additive Manufacturing (AM) or 3D printing, the process of fabricating components in a layer-wise fashion, has been increasingly applied in industries such as automotives and aerospace. In the 1990s, interest from the construction industry evolved through several experimental applications looking to reduce labor cost, waste material, or create complex shapes that are difficult to build using conventional construction methods. However, the full range of potential applications for construction have not been explored, and the industry’s involvement with AM is still considered at its early stages. As a first step, this thesis provides an extensive literature review of AM as it relates to the construction industry. This research identifies the most significant AM processes, compared to subtractive or formative processes, as well as some technologies and materials being used. A recommendation is given for potential advancements in applications for construction. The thesis also explores the use of typical small-scale material extrusion desktop 3D printers to print and test customized fastener-free connections. The intent of these connection tests is to explore novel ways in which AM technology can be used for structural and non-structural applications using commercial polymers. The connections were inspired by traditional wood joinery and modern proprietary connections. A four-point bending test was used to evaluate their potential structural performance in bending and to identify connection types that could be used for future investigations. Before AM can realize its full potential, interdisciplinary research is still needed to provide new materials, reliable printed parts, and new and repeatable processes. This thesis provides initial steps toward this goal by finding research gaps, identifying research trends in the area, and by exploring initial benefits and limitations for non-structural and structural applications in construction using available small-scale AM technology.Civil, Architectural, and Environmental Engineerin

Micro-manufacturing : research, technology outcomes and development issues

Besides continuing effort in developing MEMS-based manufacturing techniques, latest effort in Micro-manufacturing is also in Non-MEMS-based manufacturing. Research and technological development (RTD) in this field is encouraged by the increased demand on micro-components as well as promised development in the scaling down of the traditional macro-manufacturing processes for micro-length-scale manufacturing. This paper highlights some EU funded research activities in micro/nano-manufacturing, and gives examples of the latest development in micro-manufacturing methods/techniques, process chains, hybrid-processes, manufacturing equipment and supporting technologies/device, etc., which is followed by a summary of the achievements of the EU MASMICRO project. Finally, concluding remarks are given, which raise several issues concerning further development in micro-manufacturing