Parametric Based Controller for Rapid Prototyping Applications

A methodology aiming at reproducing in Rapid Prototyping applications, exact parametric curves from CAD data is presented. The approach consists of converting the space-based parametric curves from the CAD system into time-base, such that the equations of the curve in terms of time are then fed to a controller directly. Optimization is used to solve the problem, which has both Rapid Prototyping process and scanning constraints. With information such as the equation of the curve, its first and second derivatives with respect to time, a real-time trajectory controller can be designed. The trajectory displays an increase in accuracy over traditional approaches using STL files, which is ofthe order of the chordal tolerance used to generate tessellations. The system model involves electrical and mechanical dynamics of the galvanometers and sensors. The controller, which acts on two mirrors, deflecting the laser beam of a stereolithography machine in the x and y directions respectively, should be easily substituted for current systems. Application of the methodology to freeform curves shows acceptable tracking and can be improved by judicious selection ofthe equation representing the spatial parameter as a function of time.Mechanical Engineerin

Folding Under Inequilibrium Conditions as a Possible Reason for Partial Irreversibility of Heat-Denatured Proteins: Computer Simulation Study

Using computer simulations we have studied possible effects of heating and cooling at different scan rates on unfolding and refolding of macromolecules. We have shown that even the simplest two-state reversible transition can behave irreversibly when an unfavorable combination of cooling rate, relaxation time and activation energy of refolding occurs. On the basis of this finding we suppose that apparent irreversibility of some proteins denatured by heat may result from slow relaxation on cooling rather than thermodynamic instability and/or irreversible alterations of the polypeptide chain. Using this kinetic reversible two-state model, we estimated the effects of the scan rate and kinetic parameters of the macromolecule on its unfolding–refolding process. A few recommendations are suggested on how to reach maximal possible recovery after denaturation if refolding appears to be under kinetic control

Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation

Among the many additive manufacturing (AM) processes for metallic materials, selective laser melting (SLM) is arguably the most versatile in terms of its potential to realize complex geometries along with tailored microstructure. However, the complexity of the SLM process, and the need for predictive relation of powder and process parameters to the part properties, demands further development of computational and experimental methods. This review addresses the fundamental physical phenomena of SLM, with a special emphasis on the associated thermal behavior. Simulation and experimental methods are discussed according to three primary categories. First, macroscopic approaches aim to answer questions at the component level and consider for example the determination of residual stresses or dimensional distortion effects prevalent in SLM. Second, mesoscopic approaches focus on the detection of defects such as excessive surface roughness, residual porosity or inclusions that occur at the mesoscopic length scale of individual powder particles. Third, microscopic approaches investigate the metallurgical microstructure evolution resulting from the high temperature gradients and extreme heating and cooling rates induced by the SLM process. Consideration of physical phenomena on all of these three length scales is mandatory to establish the understanding needed to realize high part quality in many applications, and to fully exploit the potential of SLM and related metal AM processes

Relating Operating Parameters between SLS Machines which have Different Scanner Geometries and Laser Spot Sizes

As the number of SLS machines in operation increases, the opportunities to share operating parameters with other SLS operators also increases. However, if the machines are not identical down to the spot size of the laser beam, the quality of parts made on each machine can be different. The most likely differences between two SLS machines are the laser spot size and the scanning radius of the optics. The total energy flux to the powder surface is a function of the spot size and the scan speed. The algorithms defined to correct for machine differences are verified both experimentally and numerically using a one-dimensional empirical SLS model.McDonald Observator

Modeling and control of a plastic film manufacturing web process

This paper is concerned with the modelling of aplastic film manufacturing process and the development and implementation of a model-based Cross-Directional (CD) controller. The model is derived from first-principles and some empirical relationships. The final validated nonlinear model could provide a useful off-line platform for developing control and monitoring algorithms.A new controller is designed which has a similar structureto that of Internal Model Control (IMC) with the addition ofan observer whose gain is designed to minimise process andmodel mis-match. The observer gain is obtained by solving amulti-objective optimisation problem through the application of a genetic algorithm. The controller is applied to the nonlinear model and simulation results are presented demonstrating improvements that can be achieved by the proposed controller over two existing CD controllers

Prospect of Making Ceramic Shell Mold by Ceramic Laser Fusion

Manufacturing prototypical castings by conventional investment casting not only takes several weeks, but also is prohibitively expensive. Z Corporation in USA, EOS GmbH and IPT in Germany employ the techniques of 3DP and SLS respectively to make directly ceramic shell molds for metal castings. Although those techniques dramatically reduce time expenditure and production cost, each layer cannot be thinner than 50 µm because of using powder to pave layers. The dimensional accuracy and roughness of the castings still cannot meet the specification of precision casting. Therefore, in this paper the ceramic laser fusion (CLF) was used to pave layers. Each layer can be thinner than 25 µm, so that the step effect can be diminished and the workpiece surface can be smoother; drying time will be shortened dramatically. Moreover, the inherent solid-state support formed by green portion has the capability of preventing upward and downward deformation of the scanned cross sections. In order to make shell mold which meets the roughness requirement (Rq=3.048µm) of the precision casting, following issues have to be further studied: (1) design a proper ceramic shell mold structure, (2) design a paving chamber for paving a complete green layer which can be easily collapsed, (3) cut down drying time, (4) optimize laser scanning process parameters with the smallest distortion, (5) eliminate sunken area, (6) reduce layer thickness to less than13µm, (7) control power to guarantee the energy uniformly absorbed by workpiece, and (8) develop a method which can directly clean green portion in cavity from gate.Mechanical Engineerin

Modelling the primary drying step for the determination of the optimal dynamic heating pad temperature in a continuous pharmaceutical freeze-drying process for unit doses

In the pharmaceutical industry, traditional freeze-drying of unit doses is a batch-wise process associated with many disadvantages. To overcome these disadvantages and to guarantee a uniform product quality and high process efficiency, a continuous freeze-drying process is developed and evaluated. The main differences between the proposed continuous freeze-drying process and traditional freeze-drying can be found firstly in the freezing step during which the vials are rotated around their longitudinal axis (spin freezing), and secondly in the drying step during which the energy for sublimation and desorption is provided through the vial wall by conduction via an electrical heating pad. To obtain a more efficient drying process, the energy transfer has to be optimised without exceeding the product and process limits (e.g. cake collapse, choked flow). Therefore, a mechanistic model describing primary drying during continuous lyophilisation of unit doses based on conduction via heating pads was developed allowing the prediction of the optimal dynamic power input and temperature output of the electric heating pads. The model was verified by experimentally testing the optimal dynamic primary drying conditions calculated for a model formulation. The primary drying endpoint of the model formulation was determined via in-line NIR spectroscopy. This endpoint was then compared with the predicted model based endpoint. The mean ratio between the experimental and model based predicted drying time for six verification runs was 1.05 +/- 0.07, indicating a good accordance between the model and the experimental data

Establishment of surface functionalization methods for spore-based biosensors and implementation into sensor technologies for aseptic food processing

Aseptic processing has become a popular technology to increase the shelf-life of packaged products and to provide non-contaminated goods to the consumers. In 2017, the global aseptic market was evaluated to be about 39.5 billion USD. Many liquid food products, like juice or milk, are delivered to customers every day by employing aseptic filling machines. They can operate around 12,000 ready-packaged products per hour (e.g., Pure-Pak® Aseptic Filling Line E-PS120A). However, they need to be routinely validated to guarantee contamination-free goods. The state-of-the-art methods to validate such machines are by means of microbiological analyses, where bacterial spores are used as test organisms because of their high resistance against several sterilants (e.g., gaseous hydrogen peroxide). The main disadvantage of the aforementioned tests is time: it takes at least 36-48 hours to get the results, i.e., the products cannot be delivered to customers without the validation certificate. Just in this example, in 36 hours, 432,000 products would be on hold for dispatchment; if more machines are evaluated, this number would linearly grow and at the end, the costs (only for waiting for the results) would be considerably high. For this reason, it is very valuable to develop new sensor technologies to overcome this issue. Therefore, the main focus of this thesis is on the further development of a spore-based biosensor; this sensor can determine the viability of spores after being sterilized with hydrogen peroxide. However, the immobilization strategy as well as its implementation on sensing elements and a more detailed investigation regarding its operating principle are missing. In this thesis, an immobilization strategy is developed to withstand harsh conditions (high temperatures, oxidizing environment) for spore-based biosensors applied in aseptic processing. A systematic investigation of the surface functionalization’s effect (e.g., hydroxylation) on sensors (e.g., electrolyte-insulator semiconductor (EIS) chips) is presented. Later on, organosilanes are analyzed for the immobilization of bacterial spores on different sensor surfaces. The electrical properties of the immobilization layer are studied as well as its resistance to a sterilization process with gaseous hydrogen peroxide. In addition, a sensor array consisting of a calorimetric gas sensor and a spore-based biosensor to measure hydrogen peroxide concentrations and the spores’ viability at the same time is proposed to evaluate the efficacy of sterilization processes

The AzTEC mm-Wavelength Camera

AzTEC is a mm-wavelength bolometric camera utilizing 144 silicon nitride micromesh detectors. Herein we describe the AzTEC instrument architecture and its use as an astronomical instrument. We report on several performance metrics measured during a three month observing campaign at the James Clerk Maxwell Telescope, and conclude with our plans for AzTEC as a facility instrument on the Large Millimeter Telescope.Comment: 13 pages, 15 figures, accepted for publication in Monthly Notice