On Characterization and Optimization of Engineering Surfaces

Swedish manufacturing industry in collaboration with academia is exploring innovative ways to manufacture eco-efficient and resource efficient products. Consequently, improving manufacturing efficiency and quality has become the priority for the manufacturing sector to remain competitive in a sustainable way. To achieve this, control and optimization of manufacturing process and product’s performance are necessary. This has led to increase in demand for functional surfaces, which are engineering surfaces tailored to different applications. With new advancements in manufacturing and surface metrology, investigations are steadily progressing towards re-defining quality and meeting dynamic customer demands. In this thesis, surfaces produced by different manufacturing systems are investigated, and methods are proposed to improve specification and optimization.The definition and interpretation of surface roughness vary across the manufacturing industry and academia. It is well known that surface characterization helps to understand the manufacturing process and its influence on surface functional properties such as wear, friction, adhesivity, wettability, fluid retention and aesthetic properties such as gloss. Manufactured surfaces consist of features that are relevant and features that are not of interest. To be able to produce the intended function, it is important to identify and quantify the features of relevance. Use of surface texture parameters helps in quantifying these surface features with respect to type, region, spacing and distribution. Currently, surface parameters Ra or Sa that represent average roughness are widely used in the industry, but they may not provide adequate information on the surface. In this thesis, a general methodology, based on the standard surface parameters and statistical approach, is proposed to improve the specification for surface roughness and identify the combination of significant surface texture parameters that best describe the surface and extract valuable surface information.Surface topography generated by additive, subtractive and formative processes is investigated with the developed research approach. The roughness profile parameters and areal surface parameters defined in ISO, along with power spectral density and scale sensitive fractal analysis, are used for surface characterization and analysis. In this thesis, the application of regression statistics to identify the set of significant surface parameters that improve the specification for surface roughness is shown. These surface parameters are used to discriminate between the surfaces produced by multiple process variables at multiple levels. By analyzing the influence of process variables on the surface topography, the research methodology helps to understand the underlying physical phenomenon and enhance the domain-specific knowledge with respect to surface topography. Subsequently, it helps to interpret processing conditions for process and surface function optimization.The research methods employed in this study are valid and applicable for different manufacturing processes. This thesis can support the guidelines for manufacturing industry focusing on process and functional optimization through surface analysis. With increase in use of machine learning and artificial intelligence in automation, methodologies such as the one proposed in this thesis are vital in exploring and extracting new possibilities in functional surfaces

Additive Manufacturing-3D Printing in Product Design Education: Learning experiences using Fused Deposition Modeling (FDM)

This research on the participation of industrial design students’ experiences in 3D printing and 3D modelling demonstrates that they are successful in fully utilising additive manufacturing in the design process and as a final fabrication method in the product design area. The project begins with the literature review, prototyping tests, and students' participation in 3D modelling in the specific subject of industrial design. The outcome shared a guideline for how to use Rapid Prototyping (RP) 3D Printers in the model-making and prototyping processes. The result was an example of a design project practice that was made by modelling and then printed with 3D printing.  Keywords: 3D Printing, Product Design, Fused Deposition Modeling eISSN: 2398-4287© 2022. The Authors. Published for AMER ABRA cE-Bs by e-International Publishing House, Ltd., UK. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer–review under responsibility of AMER (Association of Malaysian Environment-Behaviour Researchers), ABRA (Association of Behavioural Researchers on Asians/Africans/Arabians) and cE-Bs (Centre for Environment-Behaviour Studies), Faculty of Architecture, Planning & Surveying, Universiti Teknologi MARA, Malaysia. DO

Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review

Advances in additive manufacturing technologies facilitate the fabrication of cellular materials that have tailored functional characteristics. The application of solid freeform fabrication techniques is especially exploited in designing scaffolds for tissue engineering. In this review, firstly, a classification of cellular materials from a geometric point of view is proposed; then, the main approaches on geometric modeling of cellular materials are discussed. Finally, an investigation on porous scaffolds fabricated by additive manufacturing technologies is pointed out. Perspectives in geometric modeling of scaffolds for tissue engineering are also proposed

Tekes projekti SuperMachines loppuraportti

Tutkimuksessa kerättiin best practice aineistoa ja kehitettiin internet alusta kerätyn aineiston tutkimiseen ja hakujen suorittamiseen. Aineisto löytyy internet osoitteesta: http://www.amcase.info/. Rekisteröitymällä kuka vain voi syöttää alustalle lisää aineistoa. Kappaleiden suunnitteluohjeet on julkaistu Suomen pikavalmistusyhdistyksen sivuilla: http://firpa.fi/html/am-tietoa.html. Ohjeesta löytyy mm. suositeltu minimi seinämänvahvuus, suositellun pienimmän yksityiskohdan koko, tyypillinen markkinoilta löytyvä rakennuskammin koko, sekä tyypilliset materiaalit. Valmiiden kokoonpanojen ja mekanismien suunnitteluun muodostettiin Objet 30 ja UPrint SE+ laitteelle ohjeistus josta löytyy pienin radiaalinen välys, aksiaalinen välys, sekä pienin rako riippuen rakennussuunnasta. Tutkimusprojektin aikana seurattiin alan teknologian kehitystä. Kahden vuoden aikana markkinoille ilmaantui noin. 50 uutta laitevalmistajaa, sekä noin 300 erilaista laitetta, sekä lukuisia materiaaleja. Merkittävimmät uudistukset listattiin ja pohdittiin mahdollisia kehityssuuntia. Kaikki uudet toimijat ja laitteet päivitettiin Firpan ylläpitämään tietokantaan: http://firpa.fi/html/am-tietoa.html. Markkinoilla on selvä suuntaus tuotantokomponenttien valmistamiseen, kotitulostimien hintojen laskemiseen, sekä isompien kappaleiden valmistamiseen. Muovilevy komponenttien muovaamista tutkittiin laserin ja alipaineen avulla DDShape laitteella. Laitteella onnistuttiin tekemään testikappaleita ja laitetta saatiin kehitettyä eteenpäin. Laitteiston kehittämiseksi ja kaupallistamisen tueksi Tekes on myöntänyt "Tutkimusideoista uutta tietoa ja liiketoimintaa" (TUTLI) rahoituksen. ISF mini projektissa onnistuttiin kehittämään edullinen pienten kappaleiden painomuovauskone. Samalla kartoitettiin laitteelle soveltuvat parametrit ja rajoitukset. Laseravusteisella muovaamisella päästään kuparilla isompaan seinämän kaltevuuteen ja pinnalaatu pysyy hyvänä. Teräksellä laserista ei ollut juuri hyötyä ja alumiinilla muovattavuus kyllä parani, mutta pinnalaatu huononi. AM kappaleiden viimeistelykoneistuksessa tutkittiin muovisten kappaleiden viimeistely jyrsimällä, sekä metallikappaleiden automaattista hiontaa. Jyrsinnässä vertailtiin eri menetelmillä tehtyjä kappaleita, sekä mitattiin kappaleiden mittatarkkuutta ja geometrisia toleransseja. Huonosta kotitulostimella tehdystä kappaleesta on vaikea saada hyvää kappaletta vaikka se viimeisteltäisiin koneistamalla. Suurimmat ongelmat liittyvät kappaleiden vääntymiseen johtuen lämpöjännityksistä valmistusprosessin aikana. Kappaleiden automaattisessa hionnassa parhaat tulokset saatiin DMLS kappaleille käyttämällä hionta-aineena teräshauleja ja pyörittämällä niitä hiottavat kappaleen kanssa rummussa. Ra arvo parani tällöin noin seitsemästä mikrometristä kolmeen mikrometriin

Additive Manufacturing of Optically Transparent Glass

We present a fully functional material extrusion printer for optically transparent glass. The printer is composed of scalable modular elements able to operate at the high temperatures required to process glass from a molten state to an annealed product. We demonstrate a process enabling the construction of 3D parts as described by computer-aided design models. Processing parameters such as temperature, which control glass viscosity, and flow rate, layer height, and feed rate can thus be adjusted to tailor printing to the desired component, its shape, and its properties. We explored, defined, and hard-coded geometric constraints and coiling patterns as well as the integration of various colors into the current controllable process, contributing to a new design and manufacturing space. We report on performed characterization of the printed materials executed to determine their morphological, mechanical, and optical properties. Printed parts demonstrated strong adhesion between layers and satisfying optical clarity. This molten glass 3D printer demonstrates the production of parts that are highly repeatable, enable light transmission, and resemble the visual and mechanical performance of glass constructs that are conventionally obtained. Utilizing the optical nature of glass, complex caustic patterns were created by projecting light through the printed objects. The 3D-printed glass objects described here can thus be extended to implementations across scales and functional domains including product and architectural design. This research lies at the intersection of design, engineering, science, and art, representing a highly interdisciplinary approach.Massachusetts Institute of Technology. Department of Mechanical EngineeringGlass Art Society (Technology Advancing Glass Grant