Additive Manufacturing of Bio and Synthetic Polymers

Additive manufacturing technology offers the ability to produce personalized products with lower development costs, shorter lead times, less energy consumed during manufacturing and less material waste. It can be used to manufacture complex parts and enables manufacturers to reduce their inventory, make products on-demand, create smaller and localized manufacturing environments, and even reduce supply chains. Additive manufacturing (AM), also known as fabricating three-dimensional (3D) and four-dimensional (4D) components, refers to processes that allow for the direct fabrication of physical products from computer-aided design (CAD) models through the repetitious deposition of material layers. Compared with traditional manufacturing processes, AM allows the production of customized parts from bio- and synthetic polymers without the need for molds or machining typical for conventional formative and subtractive fabrication.In this Special Issue, we aimed to capture the cutting-edge state-of-the-art research pertaining to advancing the additive manufacturing of polymeric materials. The topic themes include advanced polymeric material development, processing parameter optimization, characterization techniques, structure–property relationships, process modelling, etc., specifically for AM

Tolerance analysis approach based on the classification of uncertainty (aleatory / epistemic)

Uncertainty is ubiquitous in tolerance analysis problem. This paper deals with tolerance analysis formulation, more particularly, with the uncertainty which is necessary to take into account into the foundation of this formulation. It presents: a brief view of the uncertainty classification: Aleatory uncertainty comes from the inherent uncertain nature and phenomena, and epistemic uncertainty comes from the lack of knowledge, a formulation of the tolerance analysis problem based on this classification, its development: Aleatory uncertainty is modeled by probability distributions while epistemic uncertainty is modeled by intervals; Monte Carlo simulation is employed for probabilistic analysis while nonlinear optimization is used for interval analysis.“AHTOLA” project (ANR-11- MONU-013

Computer-Aided Conceptual Design Through TRIZ-based Manipulation of Topological Optimizations

Organised by: Cranfield UniversityIn a recent project the authors proposed the adoption of Optimization Systems [1] as a bridging element between Computer-Aided Innovation (CAI) and PLM to identify geometrical contradictions [2], a particular case of the TRIZ physical contradiction [3]. A further development of the research has revealed that the solutions obtained from several topological optimizations can be considered as elementary customized modeling features for a specific design task. The topology overcoming the arising geometrical contradiction can be obtained through a manipulation of the density distributions constituting the conflicting pair. Already two strategies of density combination have been identified as capable to solve geometrical contradictions.Mori Seiki – The Machine Tool Compan

Optimized normal and distance matching for heterogeneous object modeling

This paper presents a new optimization methodology of material blending for heterogeneous object modeling by matching the material governing features for designing a heterogeneous object. The proposed method establishes point-to-point correspondence represented by a set of connecting lines between two material directrices. To blend the material features between the directrices, a heuristic optimization method developed with the objective is to maximize the sum of the inner products of the unit normals at the end points of the connecting lines and minimize the sum of the lengths of connecting lines. The geometric features with material information are matched to generate non-self-intersecting and non-twisted connecting surfaces. By subdividing the connecting lines into equal number of segments, a series of intermediate piecewise curves are generated to represent the material metamorphosis between the governing material features. Alternatively, a dynamic programming approach developed in our earlier work is presented for comparison purposes. Result and computational efficiency of the proposed heuristic method is also compared with earlier techniques in the literature. Computer interface implementation and illustrative examples are also presented in this paper

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

Deep tillage tool optimization by means of finite element method: Case study for a subsoiler tine

Technologies and computer capacity currently available allow us to employ design software and numerical methods to solve complicated problems in very wide disciplines of engineering. It is also important for researches in agriculture. This study focused on obtaining optimum geometry parameters of a subsoiler tine by using computer aided engineering (CAE) applications. A field experiment was conducted to determine draft force of the subsoiler. The results from the experimental study were used in the finite element analysis (FEA) to simulate stress distributions on the subsoiler tine. The maximum equivalent stress of 432.49 MPa was obtained in the FEA. Visual investigations and FEA results showed that according to the tine’s material yield stress point of 355 MPa, plastic deformation was evident. Based on the FEA results, an optimization study was undertaken to obtain optimum geometry parameters without the occurrence of plastic deformation. According to the optimization study results, the optimum parameters of the tine geometry and maximum equivalent stress of 346.61 MPa were obtained. In addition to this, the total mass of the tine was reduced by about 0.367 kg

Thermal-induced defects and optimization of casting process

A casting process in the general industry is prone to produce varied defective parts, which happens majorly due to the factor of thermal and flow. These factors can cause major quality problems and drop in product performance during operational condition if left untreated.Thus, this paper presents these type of problems encountered in casting by applying analytical technique to forecast the behaviors of inclusions in molten material in a mold, determining the effect of parameter and process change during pouring, and analyze the pattern and provide the best decision in regards to the process of manufacturing. The use of computer-aided tool, also known as Manufacturing Analysis (in this case, an analysis of solidification and fluidity of molten material) technologies, is developed and utilized to enable a study on reduction of thermal–based defects in manufacturing on a casting product. Assessment is made based on temperature distribution, filling and solidification time, and the presence of porosity in a sample product, while optimization is performed on the same product but with different process parameters such as gate size, location, melt temperature and such. The results are varied with improvement in one area, but might worsen in another area. Thus, the final outcome is discussed and measured for its feasibility and possibility for multiple improvement process to be integrated together

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

Designing heterogeneous porous tissue scaffolds for additive manufacturing processes

A novel tissue scaffold design technique has been proposed with controllable heterogeneous architecture design suitable for additive manufacturing processes. The proposed layer-based design uses a bi-layer pattern of radial and spiral layers consecutively to generate functionally gradient porosity, which follows the geometry of the scaffold. The proposed approach constructs the medial region from the medial axis of each corresponding layer, which represents the geometric internal feature or the spine. The radial layers of the scaffold are then generated by connecting the boundaries of the medial region and the layer's outer contour. To avoid the twisting of the internal channels, reorientation and relaxation techniques are introduced to establish the point matching of ruling lines. An optimization algorithm is developed to construct sub-regions from these ruling lines. Gradient porosity is changed between the medial region and the layer's outer contour. Iso-porosity regions are determined by dividing the subregions peripherally into pore cells and consecutive iso-porosity curves are generated using the isopoints from those pore cells. The combination of consecutive layers generates the pore cells with desired pore sizes. To ensure the fabrication of the designed scaffolds, the generated contours are optimized for a continuous, interconnected, and smooth deposition path-planning. A continuous zig-zag pattern deposition path crossing through the medial region is used for the initial layer and a biarc fitted isoporosity curve is generated for the consecutive layer with C-1 continuity. The proposed methodologies can generate the structure with gradient (linear or non-linear), variational or constant porosity that can provide localized control of variational porosity along the scaffold architecture. The designed porous structures can be fabricated using additive manufacturing processes