Fabricate 2020

Fabricate 2020 is the fourth title in the FABRICATE series on the theme of digital fabrication and published in conjunction with a triennial conference (London, April 2020). The book features cutting-edge built projects and work-in-progress from both academia and practice. It brings together pioneers in design and making from across the fields of architecture, construction, engineering, manufacturing, materials technology and computation. Fabricate 2020 includes 32 illustrated articles punctuated by four conversations between world-leading experts from design to engineering, discussing themes such as drawing-to-production, behavioural composites, robotic assembly, and digital craft

TLC : une architecture photovoltaïque concentrée (CPV) au potentiel d’efficacité élevé à faible coût

Abstract: Human civilization has grown dependent on ready access to low-cost energy, but the fossil fuels that currently meet the bulk of humanity’s energy needs are causing environmental destruction, including potentially catastrophic global warming. Solar energy has to potential to halt global warming, and, if low enough in cost, to also bring the whole world’s population to a first world living standard. Silicon PV has dramatically reduced costs largely through decreasing the cost and increasing the efficiency of the silicon cells, but silicon is nearing its theoretical efficiency limits, and even if the cells were free, silicon PV would still be too expensive to meet these goals. Tandem CPV cells are roughly twice as efficient as silicon, but previous CPV designs have been unable to compete with silicon on cost in spite of the efficiency advantage. A new CPV architecture, called TLC for its trough, lens and cone concentration stages, proposed using initial concentration by a low-cost trough mirror to shrink the rest of an CPV module by 40X and thus reduce overall module costs. But before this PhD research project, TLC was only a paper study. This PhD research project was started to answer the question of whether TLC could work out as well as it appeared, or whether there were hidden flaws that precluded beating silicon PV on cost, or possibly even precluded TLC from working at all. Thesis chapter 3 details the main optical design aspects, and chapter 4 covers the design of the rest of the TLC module, including leading variations where there is more than one plausible way to achieve low cost and high reliability. The work included building a unified analytical model spreadsheet that linked known aspects of the TLC design together and estimated costs for a given design variation. Thesis chapter 5 covers the economics of the proposed design, with a focus on materials costs since these dominate PV overall costs, and a section on reliability since product lifetime strongly influences life-cycle cost. The work included building 3D-CAD models to refine the TLC design, and then the prototyping of individual parts and processes, and finally building a physical prototype of a TLC mini-module and putting it in sun. This physical confirmation was necessary because even after TLC has been “built” many times, in visualization, on paper, on spreadsheets, and then in COMSOL, until TLC was physically built, hidden flaws could arise at any time. Chapter 6 of this thesis covers the simulation and validation carried out to show that it is plausible that TLC can meet its cost targets. The conclusion of this thesis summarizes the overall project. The project was a success, producing a TLC design with high potential efficiency, very low materials cost, and low estimated process costs, with the potential to beat even the US Department of Energy’s goal for PV pricing in 2030. Ray-tracing a 3D model showed that the design could achieve high concentration with adequate acceptance angles, and tests showed that the prototyping cells were suitable for TLC’s massively parallel microcell-array receiver configuration. The project also successfully tested the proposed manufacturing process for molding semi-dense arrays of tertiary optical elements on the back of a lens tile and assembled a TLC mini module which was tested on sun at the focus of a trough mirror. Four papers have already been published, with a fifth paper accepted, as result of this work.La civilisation humaine est devenue de plus en plus dépendante d'un accès facile à une énergie à faible coût, mais les combustibles fossiles qui répondent actuellement à la majeure partie des besoins énergétiques de l'humanité causent la destruction de l'environnement, y compris un réchauffement climatique potentiellement catastrophique. L'énergie solaire a le potentiel d'arrêter le réchauffement climatique et, si son coût est suffisamment bas, d'amener également la population mondiale entière à un niveau de vie du premier monde. Les coûts de photovoltaïque (PV) à base de silicium ont été considérablement réduits en grande partie en diminuant le prix et en augmentant l'efficacité des cellules en silicium, cependant l’utilisation de silicium a ses limites d'efficacité théoriques, et même si les cellules étaient gratuites, la PV à base de silicium serait encore trop chère pour atteindre ces objectifs. Les cellules de photovoltaïque concentré (CPV) Tandem sont environ deux fois plus efficaces que celles à base de silicium, mais malgré l'avantage de leur efficacité, les architectures des années précédentes de CPV n'ont pas été en mesure de rivaliser avec le silicium en termes de coût. Une nouvelle architecture CPV, appelée TLC (Trough-Lens-Cone) utilise la concentration initiale par un miroir parabolique à faible coût combiné avec un module CPV de 40X et ainsi réduire les coûts globaux du module. Avant ce projet de recherche de doctorat, TLC n'était qu'une étude sur papier. Cette thèse a pour but de répondre à la question de savoir si l’approche TLC pouvait fonctionner aussi bien qu'elle était apparue, ou s'il y avait des défauts cachés qui empêchaient de battre le silicium PV sur le coût, ou pourrait même empêcher la TLC de fonctionner. Ce travail comprenait la construction d'un modèle de tableur unifié qui reliait les aspects connus de la conception TLC et les coûts estimés pour une variation de conception donnée. Nous présentons également la construction de modèles 3D-CAD pour raffiner la conception TLC, puis le prototypage de pièces individuelles et de processus, et enfin la construction d'un prototype physique d'un mini-module TLC qui est mis au soleil. Cette validation physique était nécessaire car même après que TLC ait été théoriquement et numériquement « construit » à plusieurs reprises soit, en visualisation, sur papier, sur des feuilles de calcul, puis dans COMSOL, avant que TLC soit physiquement construit, des défauts cachés pouvaient survenir à tout moment. La mise en œuvre de ce projet a réussi, produisant une conception TLC cohérente qui avait un rendement élevé avec un coût des matériaux très bas et des faibles coûts estimatifs de processus, avec un potentiel de battre même l’objectif du département américain de l'énergie pour la tarification du silicium photovoltaïque en 2030. Le suivi de raies (Ray-tracing) avec un modèle 3D a montré que la conception pouvait atteindre une concentration élevée avec des angles d'acceptation adéquats. Les tests ont également montré que les cellules de prototypage ont été bien adaptées à la nouvelle configuration de TLC de récepteur à matrice de microcellules massivement parallèle. Le projet a également testé avec succès le processus de fabrication proposé pour le moulage de réseaux semi-denses d'éléments optiques tertiaires à l'arrière d'un carreau de lentille. Le projet a également réussi à assembler un mini-module TLC et à tester sous le soleil avec le focus d'un miroir parabolique. Quatre articles ont déjà été publiés, avec un cinquième article accepté, à la suite de ce travail

Applications of Additive Manufacturing for Norwegian Oil and Gas Industries

The additive manufacturing or 3D printing (3DP) technologies have undergone exponential expansion, particularly in the previous couple of decades. Additive manufacturing technologies have paved the way for easy component manufacturing in large-scale and high-performance businesses. The introduction of desktop 3D printers has established 3DP as a reliable technique for generating prototypes and direct parts from CAD files. This technology is employed in an industrial setting for a range of purposes, including the invention and manufacture of customized and task-specific tools. This thesis looks at the benefits and drawbacks of deploying a 3D printer on an offshore facility to encourage on-site part manufacture, save operating costs, and reduce downtime. The thesis proposes ways for speeding and simplifying the creation of customized products. The approaches utilized were aimed to discover flaws and opportunities in offshore platforms' 3D printing processes. It also includes a comparative examination of production procedures, which will aid in decision-making. Furthermore, the technical structure of the proposed method would outline a path for developing prototype designs and tools to address identified difficulties. The proposed ideas and produced technologies could have a positive impact on the oil and gas industries' operations. The thesis also goes over the equipment needed for post-processing printed parts, as well as their availability on offshore platforms. The reliability issues associated with 3D printed parts are also addressed, which will improve RAMS analysis of printed parts

Specifying a hybrid, multiple material CAD system for next-generation prosthetic design

For many years, the biggest issue that causes discomfort and hygiene issues for patients with lower limb amputations have been the interface between body and prosthetic, the socket. Often made of an inflexible, solid polymer that does not allow the residual limb to breathe or perspire and with no consideration for the changes in size and shape of the human body caused by changes in temperature or environment, inflammation, irritation and discomfort often cause reduced usage or outright rejection of the prosthetic by the patient in their day to day lives. To address these issues and move towards a future of improved quality of life for patients who suffer amputations, Loughborough University formed the Next Generation Prosthetics research cluster. This work is one of four multidisciplinary research studies conducted by members of this research cluster, focusing on the area of Computer Aided Design (CAD) for improving the interface with Additive Manufacture (AM) to solve some of the challenges presented with improving prosthetic socket design, with an aim to improve and streamline the process to enable the involvement of clinicians and patients in the design process. The research presented in this thesis is based on three primary studies. The first study involved the conception of a CAD criteria, deciding what features are needed to represent the various properties the future socket outlined by the research cluster needs. These criteria were then used for testing three CAD systems, one each from the Parametric, Non Uniform Rational Basis Spline (NURBS) and Polygon archetypes respectively. The result of these tests led to the creation of a hybrid control workflow, used as the basis for finding improvements. The second study explored emerging CAD solutions, various new systems or plug-ins that had opportunities to improve the control model. These solutions were tested individually in areas where they could improve the workflow, and the successful solutions were added to the hybrid workflow to improve and reduce the workflow further. The final study involved taking the knowledge gained from the literature and the first two studies in order to theorise how an ideal CAD system for producing future prosthetic sockets would work, with considerations for user interface issues as well as background CAD applications. The third study was then used to inform the final deliverable of this research, a software design specification that defines how the system would work. This specification was written as a challenge to the CAD community, hoping to inform and aid future advancements in CAD software. As a final stage of research validation, a number of members of the CAD community were contacted and interviewed about their feelings of the work produced and their feedback was taken in order to inform future research in this area