Improving precision of material extrusion 3D printing by in-situ monitoring and predicting 3D geometric deviation using Conditional Adversarial Networks

The field of additive manufacturing, especially 3D printing, has gained growing attention in the research and commercial sectors in recent years. Notwithstanding that the capabilities of 3D printing have moved on to enhanced resolution, higher deposition rate, and a wide variety of materials, the crucial challenge of verifying that the component manufactured is within the dimensional tolerance as designed continues to exist. Material extrusion 3D printing has long been established for rapid prototyping and functional testing in many research and industry fields. However, its inconsistency and intrinsic defects (surface roughness and geometric inaccuracies) hinder its application in several areas, most notably “certify-as-you- build” small-batch prototyping and large-batch production.In this study, we present an approach to reduce both inconsistency and the 3D geometric inaccuracies of products fabricated by material extrusion.1. This work developed and demonstrated an approach for layer-by-layer mapping of 3D printed parts, which can be used for validation of printed models and in situ adjustment of print parameters. This in situ metrology system scans each layer at the time of printing, providing a 3D model of the as-printed part. A high-speed optical scanning system was integrated with a Material Extrusion type 3D printer to achieve in situ monitoring of dimensional inaccuracies during printing, which leaves the door open to implement a closed-loop feedback system to compensate geometric errors during printing in the future and fabricate “certify-as-you-build” products.2. This work trained machine learning algorithms with data from this scanning system and predicted 3D geometric inaccuracies in new designs. Eight Conditional Adversarial Networks (CAN) machine learning models were trained on a limited number of scanned profile images of different layers, consisting of less than 50 actual images and 50 generated images, to predict the 3D geometric deviations of freeform shapes. The generated images were produced by randomly combining and cropping the actual images without any distortion. These CAN models produced predictions where at least 44.4%, 87.6%, 99.2% of data were within �0.05 mm, �0.10 mm, �0.15 mm of the actual measured value, respectively.3. This work developed an Iterative Forward approach to redesign the Computer-Aided- Design model by reverse engineering using the trained machine learning models, allowing for compensation of print imperfection at the design stage, in advance of the first printing. The compensation algorithms with eight different sets of different parameters were evaluated. It has been proven that the Iterative Forward approach improved the geometric deviation of the predicted profiles by making compensation to the CAD model

From 3D Models to 3D Prints: an Overview of the Processing Pipeline

Due to the wide diffusion of 3D printing technologies, geometric algorithms for Additive Manufacturing are being invented at an impressive speed. Each single step, in particular along the Process Planning pipeline, can now count on dozens of methods that prepare the 3D model for fabrication, while analysing and optimizing geometry and machine instructions for various objectives. This report provides a classification of this huge state of the art, and elicits the relation between each single algorithm and a list of desirable objectives during Process Planning. The objectives themselves are listed and discussed, along with possible needs for tradeoffs. Additive Manufacturing technologies are broadly categorized to explicitly relate classes of devices and supported features. Finally, this report offers an analysis of the state of the art while discussing open and challenging problems from both an academic and an industrial perspective.Comment: European Union (EU); Horizon 2020; H2020-FoF-2015; RIA - Research and Innovation action; Grant agreement N. 68044

Towards early estimation of part accuracy in additive manufacturing

Additive manufacturing (AM) is becoming more diffused. In spite of its advantages: capability to manufacture complex internal feature and material efficiency, AM has inherent drawback from its layer-by-layer nature. "Staircase effect" is observed due to the slicing process of the computer model in which a rough surface from a theoretically smooth surface will be obtained. Hence, there will be a deviation of the produced part from its nominal model. A methodology to predict the deviation of computer model of an additive manufactured part after fabrication process is presented. A case study is proposed using cylindrical features due to its common real case application. Cylinder is a representation of pin-hole geometry. This geometry is an assembly feature which is very important to guarantee the parts can be assembled with their pair. The dimensional and geometric deviation of the cylindrical feature after fabrication is estimated and could be a useful information for the designer

A scalable parallel finite element framework for growing geometries. Application to metal additive manufacturing

This work introduces an innovative parallel, fully-distributed finite element framework for growing geometries and its application to metal additive manufacturing. It is well-known that virtual part design and qualification in additive manufacturing requires highly-accurate multiscale and multiphysics analyses. Only high performance computing tools are able to handle such complexity in time frames compatible with time-to-market. However, efficiency, without loss of accuracy, has rarely held the centre stage in the numerical community. Here, in contrast, the framework is designed to adequately exploit the resources of high-end distributed-memory machines. It is grounded on three building blocks: (1) Hierarchical adaptive mesh refinement with octree-based meshes; (2) a parallel strategy to model the growth of the geometry; (3) state-of-the-art parallel iterative linear solvers. Computational experiments consider the heat transfer analysis at the part scale of the printing process by powder-bed technologies. After verification against a 3D benchmark, a strong-scaling analysis assesses performance and identifies major sources of parallel overhead. A third numerical example examines the efficiency and robustness of (2) in a curved 3D shape. Unprecedented parallelism and scalability were achieved in this work. Hence, this framework contributes to take on higher complexity and/or accuracy, not only of part-scale simulations of metal or polymer additive manufacturing, but also in welding, sedimentation, atherosclerosis, or any other physical problem where the physical domain of interest grows in time

Energy management system for biological 3D printing by the refinement of manifold model morphing in flexible grasping space

The use of 3D printing, or additive manufacturing, has gained significant attention in recent years due to its potential for revolutionizing traditional manufacturing processes. One key challenge in 3D printing is managing energy consumption, as it directly impacts the cost, efficiency, and sustainability of the process. In this paper, we propose an energy management system that leverages the refinement of manifold model morphing in a flexible grasping space, to reduce costs for biological 3D printing. The manifold model is a mathematical representation of the 3D object to be printed, and the refinement process involves optimizing the morphing parameters of the manifold model to achieve desired printing outcomes. To enable flexibility in the grasping space, we incorporate data-driven approaches, such as machine learning and data augmentation techniques, to enhance the accuracy and robustness of the energy management system. Our proposed system addresses the challenges of limited sample data and complex morphologies of manifold models in layered additive manufacturing. Our method is more applicable for soft robotics and biomechanisms. We evaluate the performance of our system through extensive experiments and demonstrate its effectiveness in predicting and managing energy consumption in 3D printing processes. The results highlight the importance of refining manifold model morphing in the flexible grasping space for achieving energy-efficient 3D printing, contributing to the advancement of green and sustainable manufacturing practices.Comment: 33 pages, 10 figures, Journa

Modeling, Simulation and Data Processing for Additive Manufacturing

Additive manufacturing (AM) or, more commonly, 3D printing is one of the fundamental elements of Industry 4.0. and the fourth industrial revolution. It has shown its potential example in the medical, automotive, aerospace, and spare part sectors. Personal manufacturing, complex and optimized parts, short series manufacturing and local on-demand manufacturing are some of the current benefits. Businesses based on AM have experienced double-digit growth in recent years. Accordingly, we have witnessed considerable efforts in developing processes and materials in terms of speed, costs, and availability. These open up new applications and business case possibilities all the time, which were not previously in existence. Most research has focused on material and AM process development or effort to utilize existing materials and processes for industrial applications. However, improving the understanding and simulation of materials and AM process and understanding the effect of different steps in the AM workflow can increase the performance even more. The best way of benefit of AM is to understand all the steps related to that—from the design and simulation to additive manufacturing and post-processing ending the actual application.The objective of this Special Issue was to provide a forum for researchers and practitioners to exchange their latest achievements and identify critical issues and challenges for future investigations on “Modeling, Simulation and Data Processing for Additive Manufacturing”. The Special Issue consists of 10 original full-length articles on the topic

Predicting Geometric Errors and Failures in Additive Manufacturing

Additive manufacturing is a process that has facilitated the cost effective production of complicated designs. Objects fabricated via additive manufacturing technologies often suffer from dimensional accuracy issues and other part specific problems such as thin part robustness, overhang geometries that may collapse, support structures that cannot be removed, engraved and embossed details that are indistinguishable. In this work we present an approach to predict the dimensional accuracy per vertex and per part. Furthermore, we provide a framework for estimating the probability that a model is fabricated correctly via an additive manufacturing technology for a specific application. This framework can be applied to several 3D printing technologies and applications. In the context of this paper, a thorough experimental evaluation is presented for binder jetting technology and applications.Comment: This version has been published in the Rapid Prototyping Journal (2023

Auralization of Air Vehicle Noise for Community Noise Assessment

This paper serves as an introduction to air vehicle noise auralization and documents the current state-of-the-art. Auralization of flyover noise considers the source, path, and receiver as part of a time marching simulation. Two approaches are offered; a time domain approach performs synthesis followed by propagation, while a frequency domain approach performs propagation followed by synthesis. Source noise description methods are offered for isolated and installed propulsion system and airframe noise sources for a wide range of air vehicles. Methods for synthesis of broadband, discrete tones, steady and unsteady periodic, and a periodic sources are presented, and propagation methods and receiver considerations are discussed. Auralizations applied to vehicles ranging from large transport aircraft to small unmanned aerial systems demonstrate current capabilities