A Review of Automotive Spare-Part Reconstruction Based on Additive Manufacturing

In the Industry 4.0 scenario, additive manufacturing (AM) technologies play a fundamental role in the automotive field, even in more traditional sectors such as the restoration of vintage cars. Car manufacturers and restorers benefit from a digital production workflow to reproduce spare parts that are no longer available on the market, starting with original components, even if they are damaged. This review focuses on this market niche that, due to its growing importance in terms of applications and related industries, can be a significant demonstrator of future trends in the automotive supply chain. Through selected case studies and industrial applications, this study analyses the implications of AM from multiple perspectives. Firstly, various types of AM processes are used, although some are predominant due to their cost-effectiveness and, therefore, their better accessibility and wide diffusion. In some applications, AM is used as an intermediate process to develop production equipment (so-called rapid tooling), with further implications in the digitalisation of conventional primary technologies and the entire production process. Secondly, the additive process allows for on-demand, one-off, or small-batch production. Finally, the ever-growing variety of spare parts introduces new problems and challenges, generating constant opportunities to improve the finish and performance of parts, as well as the types of processes and materials, sometimes directly involving AM solution providers

A comparison of processing techniques for producing prototype injection moulding inserts.

This project involves the investigation of processing techniques for producing low-cost moulding inserts used in the particulate injection moulding (PIM) process. Prototype moulds were made from both additive and subtractive processes as well as a combination of the two. The general motivation for this was to reduce the entry cost of users when considering PIM. PIM cavity inserts were first made by conventional machining from a polymer block using the pocket NC desktop mill. PIM cavity inserts were also made by fused filament deposition modelling using the Tiertime UP plus 3D printer. The injection moulding trials manifested in surface finish and part removal defects. The feedstock was a titanium metal blend which is brittle in comparison to commodity polymers. That in combination with the mesoscale features, small cross-sections and complex geometries were considered the main problems. For both processing methods, fixes were identified and made to test the theory. These consisted of a blended approach that saw a combination of both the additive and subtractive processes being used. The parts produced from the three processing methods are investigated and their respective merits and issues are discussed

Reducing risk in pre-production investigations through undergraduate engineering projects.

This poster is the culmination of final year Bachelor of Engineering Technology (B.Eng.Tech) student projects in 2017 and 2018. The B.Eng.Tech is a level seven qualification that aligns with the Sydney accord for a three-year engineering degree and hence is internationally benchmarked. The enabling mechanism of these projects is the industry connectivity that creates real-world projects and highlights the benefits of the investigation of process at the technologist level. The methodologies we use are basic and transparent, with enough depth of technical knowledge to ensure the industry partners gain from the collaboration process. The process we use minimizes the disconnect between the student and the industry supervisor while maintaining the academic freedom of the student and the commercial sensitivities of the supervisor. The general motivation for this approach is the reduction of the entry cost of the industry to enable consideration of new technologies and thereby reducing risk to core business and shareholder profits. The poster presents several images and interpretive dialogue to explain the positive and negative aspects of the student process

Surface engineering by titanium particulate injection mounding

In a recent study a structural hold down component was designed and produced using the particulate injection moulding (PIM) process. The material of choice was titanium due not only to the material properties but also due to the desire to create custom made components for a state-of-the-art marine vessel. On removal from the mould the green parts were seen to have an irregular surface on the top face. The irregular surface presented no through part defects and although the surface irregularities were caused by separation of the two-phases the effect was restricted to the outer surface of the parts. In a more historic study by the author the surface properties of titanium dental implants were modified by the use of adaptive mould inserts during the moulding phase of PIM. These two contrasting studies are considered and have become the basis of a current investigation looking to engineer surface irregularities in an ordered fashion. The application of meso-machining, and additive manufacture are considered and the functionality which may arise are presented

Development of innovative cross-disciplinary engineering showcase

The development of engineering education relies substantially on interactive showcases and practical knowledge. The cross-disciplinary engineering showcase is designed to be fully interactive by having user input, producing a tangible output, and to understand distinct elements from each of the engineering disciplines such as, civil, mechanical and electrical (CME). The showcase operates from the input of mechanical rotational energy by the user pedalling the exercycle. Mechanical energy is then transferred to the pump via a gear train, which converts the user input of 30 rpm to the optimal pump operating speed of 2900 rpm. Further, it is used to pump water from the lower eservoir to the upper reservoir via one of the three flow paths, which the user can select by opening or closing flow valves. Once the water reaches a given height, it then flows back to the lower reservoir via a micro-hydro generator. As a result, it generates electrical energy stored in a power bank that can be used by the user to charge a digital device. Also, the showcase has a QR code to digital media, which will provide an additional explanation/exposition of the presented engineering principles to the user/students. The aim of this project is to develop a cross- disciplinary engineering showcase to enhance student learnings by interpreting the CME engineering principles in schools, institutes, and universities

Development of innovative cross-disciplinary engineering showcase

The development of engineering education relies substantially on interactive showcases and practical knowledge. The cross-disciplinary engineering showcase is designed to be fully interactive by having user input, producing a tangible output, and to understand distinct elements from each of the engineering disciplines such as, civil, mechanical and electrical (CME). The showcase operates from the input of mechanical rotational energy by the user pedalling the exercycle. Mechanical energy is then transferred to the pump via a gear train, which converts the user input of 30 rpm to the optimal pump operating speed of 2900 rpm. Further, it is used to pump water from the lower eservoir to the upper reservoir via one of the three flow paths, which the user can select by opening or closing flow valves. Once the water reaches a given height, it then flows back to the lower reservoir via a micro-hydro generator. As a result, it generates electrical energy stored in a power bank that can be used by the user to charge a digital device. Also, the showcase has a QR code to digital media, which will provide an additional explanation/exposition of the presented engineering principles to the user/students. The aim of this project is to develop a cross- disciplinary engineering showcase to enhance student learnings by interpreting the CME engineering principles in schools, institutes, and universities

Step and Step-Nc as a Tool for Big Data in Cloud Manufacturing

The terms big data, cloud manufacturing, predictive and additive manufacturing, and Internet of Things (IoT) are being most commonly used in the manufacturing industry nowadays. These terms are related to the fourth industrial revolution that emphasizes automation and data exchange between manufacturing tools/elements. Communication occurs between machines, products and even technicians or operators through various technologies while creating records of each interaction resulting in rapid growth of amount of data to be stored. Data acquisition is not a major issue since a structure or framework can properly connect these data in improving manufacturing efficiency. However, lack of effort in collecting and storing manufacturing data in the whole product life cycle process has made integration to be almost difficult to achieve. In this study, the adoption of STEP-NC method/technique was demonstrated in suiting the current explosion of big data in the industrial and manufacturing sector. The proposed methodology was developed through a study of an entity file structure and hierarchical concept in STEP and STEP-NC in gathering manufacturing data in a unified database. The challenge would be in making sense of the data, revealing the patterns in it and using them for operational improvements. The outcome of this study will be useful to support strategic decision making in product manufacturing

Applications of AM

In this chapter, three strategic domains of Additive Manufacturing application are presented: tool making, medicine and transportation, with main benefits and results obtained by application of AM. Chapter presents some of on-going or already finished project from mentioned AM application fields

A comparison of processing techniques for producing prototype injection moulding inserts.

This project involves the investigation of processing techniques for producing low cost moulding inserts used in the particulate injection moulding (PIM) process. Prototype moulds were made from both additive and subtractive processes as well as a combination of the two. The general motivation for this was to reduce the entry cost of users when considering PIM. PIM cavity inserts were first made by conventional machining from a polymer block using the pocket NC desktop mill. PIM cavity inserts were also made by fused filament deposition modelling using the Tiertime UP plus 3D printer. The injection moulding trials manifested in surface finish and part removal defects. The feedstock was a titanium metal blend which is brittle in comparison to commodity polymers. That in combination with the meso-scale features, small cross sections and complex geometries were considered the main problems. For both processing methods fixes were identified and made to test the theory. These consisted of a blended approach that saw a combination of both the additive and subtractive processes being used. The parts produced from the three processing methods are investigated and their respective merits and issues are discussed