Development of an Automated Multiple Material Stereolithography Machine

An automated Multiple Material Stereolithography (MMSL) machine was developed by integrating components of a 3D Systems 250/50 stereolithography (SL) machine in a separate stand-alone system and adapting them to function with additional components required for MMSL operation. We previously reported retrofitting a 250/50 SL machine with multiple vats to accommodate multiple material fabrication for building a wide variety of multi-material models (Wicker et al., 2004). In the MMSL retrofit, spatial constraints limited the multiple vats located circumferentially on a vertical rotating vat carousel to cross-sectional areas of approximately 4.5-inches by 4.5-inches. The limited build size of the retrofitted 250/50 motivated the full development of a new system with multiple material build capabilities comparable to the build envelope of the original 250/50 machine. The new MMSL machine required fabrication of a large system frame, incorporating various 250/50 components and software, and adding a variety of new components and software. By using many existing components and software, the previous engineering development of 3D Systems could be directly applied to this new technology. Components that were transferred from an existing 250/50 to the MMSL machine included the complete optical system (including the optics plate with laser, mirrors, beam expander, scanning mirrors, and focusing lens), the rim assembly (including the laser beam profilers), the associated controllers (computer system, scanning mirror controller, power supply-vat controller) and the wiring harness. In addition to the new frame, the MMSL machine required the development of a new rotating vat carousel system, platform assembly, multi-pump filling/leveling system, and a custom LabVIEW® control system to provide automated control over the MMSL process. The overall operation of the MMSL system was managed using the LabVIEW® program, which also included controlling a new vat leveling system and new linear and rotational stages, while the 3D Systems software (Buildstation 4.0) was retained for controlling the laser scanning process. As a demonstration of MMSL technology, simple multi material parts were fabricated with vertically and horizontally oriented interfaces. The fully functional MMSL system offers enormous potential for fabricating a wide variety of multiple material functional devices.Mechanical Engineerin

A Traditional Approach to 3D Printing

Product Design has, since the 1980’s, developed beyond the remit of the traditional realisation of the object or product. That is Design is seen as a problem identification and solution methodology which can be applied to several contexts and needs (1). However there is still a need to be able to understand and realise an object. That is the knowledge of materials and how they are processed into components. Also in the last few years the possibilities for rapid prototyping and manufacture through 3D printing machines has become financially possible and creatively opens up new possibilities. Objects can be manufactured which were impossible a few years ago. We have taken a pragmatic approach which utilises the possibilities of 3D Printing to understand the complexity of manufacture through a design and build project. Whereas most student projects conclude with propositions few are carried through to validation. Although the more engineering based programmes do built and test prototypes, complexities of design for manufacture are usually left unresolved. Students are challenged to design, manufacture and assemble a working model of an Alarm Clock. Each component has to be designed against an understanding of a material and production process and then prototyped on a SD Printer. The final product is then assembled from these prototype components. Within this construct students learn about component design and product assemble while also negotiating the compromises needed between design and manufacture. There is rigour in the realisation of the final working models. The paper concludes with a reflection of the value of this project against the learning curve of student experience as a training for the product design profession. 1.T of Design, UK Design CouncilPeer reviewe

Concurrent Design and Manufacturing for Mechanical Systems

The conventional product development process employs a design-build-break philosophy. The sequentially executed product development process often results in a prolonged lead-time and an elevated product cost. The proposed concurrent design and manu facturing (CDM) paradigm employs physics-based computational methods together with computer graphics techniques for product de sign. This proposed approach employs Virtual Prototyping (VP) technology to support a cross-functional team in analyzing product per formance, reliability, and manufacturing cost early in the product development stage; and in conducting quantitative trade-off for design decision making. Physical prototypes of the product design are then produced using Rapid Prototyping (RP) technique primarily for de sign verification purposes. The proposed CDM approach holds potential for shortening the overall product development cycle, improving product quality, and reducing product cost. A software tool environment that supports CDM for mechanical systems is being built at the Concurrent Design and Manufacturing Research Laboratory (http://cdm.ou.edu) at the University of Oklahoma. A snapshot of the envi ronment is illustrated using a two-stroke engine example. This paper presents three unique concepts and methods for product develop ment : (1) bringing product performance, quality, and manufacturing cost together in early design stage for design considerations, (2) supporting design decision-making through a quantitative approach, and (3) incorporating rapid prototyping for design verification through physical prototypes.Yeshttps://us.sagepub.com/en-us/nam/manuscript-submission-guideline

Virtual reality for assembly methods prototyping: a review

Assembly planning and evaluation is an important component of the product design process in which details about how parts of a new product will be put together are formalized. A well designed assembly process should take into account various factors such as optimum assembly time and sequence, tooling and fixture requirements, ergonomics, operator safety, and accessibility, among others. Existing computer-based tools to support virtual assembly either concentrate solely on representation of the geometry of parts and fixtures and evaluation of clearances and tolerances or use simulated human mannequins to approximate human interaction in the assembly process. Virtual reality technology has the potential to support integration of natural human motions into the computer aided assembly planning environment (Ritchie et al. in Proc I MECH E Part B J Eng 213(5):461–474, 1999). This would allow evaluations of an assembler’s ability to manipulate and assemble parts and result in reduced time and cost for product design. This paper provides a review of the research in virtual assembly and categorizes the different approaches. Finally, critical requirements and directions for future research are presented

Principles for aerospace manufacturing engineering in integrated new product introduction

This article investigates the value-adding practices of Manufacturing Engineering for integrated New Product Introduction. A model representing how current practices align to support lean integration in Manufacturing Engineering has been defined. The results are used to identify a novel set of guiding principles for integrated Manufacturing Engineering. These are as follows: (1) use a data-driven process, (2) build from core capabilities, (3) develop the standard, (4) deliver through responsive processes and (5) align cross-functional and customer requirements. The investigation used a mixed-method approach. This comprises case studies to identify current practice and a survey to understand implementation in a sample of component development projects within a major aerospace manufacturer. The research contribution is an illustration of aerospace Manufacturing Engineering practices for New Product Introduction. The conclusions will be used to indicate new priorities for New Product Introduction and the cross-functional interactions to support flawless and innovative New Product Introduction. The final principles have been validated through a series of consultations with experts in the sponsoring company to ensure that correct and relevant content has been defined

Derivation of Power System Module Metamodels for Early Shipboard Design Explorations

The U.S. Navy is currently challenged to develop new ship designs under compressed schedules. These ship designs must necessarily incorporate emerging technologies for high power energy conversion in order to enable smaller ship designs with a high degree of electrification and next generation electrified weapons. One way this challenge is being addressed is through development of collaborative concurrent design environment that allows for design space exploration across a wide range of implementation options. The most significant challenge is assurance of a dependable power and energy service via the shipboard Integrated Power and Energy System (IPES). The IPES is largely made up of interconnected power conversion and distribution equipment with allocated functionalities in order to meet demanding Quality of Power, Quality of Service and Survivability requirements. Feasible IPES implementations must fit within the ship hull constraints and must not violate limitations on ship displacement. This Thesis applies the theory of dependability to the use of scalable metamodels for power conversion and distribution equipment within a collaborative concurrent design environment to enable total ship set-based design outcomes that result implementable design specifications for procurement of equipment to be used in the final ship implementation