Exploring Model-Based Engineering Concepts for Additive Manufacturing

Robust geometry and tolerance representations are needed in additive manufacturing for precise part specification and interoperability with downstream activities such as manufacturing, inspection, and long-term archiving. A disconnection exists between process-independent part geometry and tolerances, and process-dependent information requirements for additive manufacturing. Existing and emerging standards for part geometry (ASTM AMF, 3MF, ISO 10303 STEP) and tolerances (ASME Y14) contain information related to the additive manufacturing process. Details of the standards will be discussed, how their use and improvement can benefit the additive manufacturing process, and their integration into the model-based engineering paradigm.Mechanical Engineerin

STL 2.0: A Proposal for a Universal Multi-Material Additive Manufacturing File Format

The de-facto standard STL file format has served the rapid prototyping community for over two decades, but falls short with the advent of new technological developments such as the ability to handle multiple and graded materials, specify volumetric digital inkjet patterns and surface colors. We study a variety of requirements for additive fabrication technologies and propose a new compact XML-based file format. The new Additive Manufacturing File (AMF) format allows the resolution-independent specification of geometry and material properties. Regions may be defined geometrically either using a triangle mesh, using functional representations, or through a voxel bitmap. Each region is associated with a material, which may be defined as a base (single) material or hierarchically by a combination of other materials, either functionally (enabling smooth gradients) or voxel-wise (for arbitrary microstructure). Files can be self-contained or refer to external or online material libraries. With a simple conversion, the AMF file format is both forward and backwards compatible with the current standard STL format, and the flexibility of the XML structure enables additional features to be adopted as needed by CAD programs and future additive manufacturing processes. Code and examples are publicly available.Mechanical Engineerin

Design for additive manufacturing: trends, opportunities, considerations, and constraints

© 2016 CIRP. The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future challenges, and identifies promising directions for research and the exploitation of AM's full potential in industry

Flow-based fabrication: An integrated computational workflow for design and digital additive manufacturing of multifunctional heterogeneously structured objects

Structural hierarchy and material organization in design are traditionally achieved by combining discrete homogeneous parts into functional assemblies where the shape or surface is the determining factor in achieving function. In contrast, biological structures express higher levels of functionality on a finer scale through volumetric cellular constructs that are heterogeneous and complex. Despite recent advancements in additive manufacturing of functionally graded materials, the limitations associated with computational design and digital fabrication of heterogeneous materials and structures frame and limit further progress. Conventional computer-aided design tools typically contain geometric and topologic data of virtual constructs, but lack robust means to integrate material composition properties within virtual models. We present a seamless computational workflow for the design and direct digital fabrication of multi-material and multi-scale structured objects. The workflow encodes for and integrates domain-specific meta-data relating to local, regional and global feature resolution of heterogeneous material organizations. We focus on water-based materials and demonstrate our approach by additively manufacturing diverse constructs associating shape-informing variable flow rates and material properties to mesh-free geometric primitives. The proposed workflow enables virtual-to-physical control of constructs where structural, mechanical and optical gradients are achieved through a seamless design-to-fabrication tool with localized control. An enabling technology combining a robotic arm and a multi-syringe multi nozzle deposition system is presented. Proposed methodology is implemented and full-scale demonstrations are included

The Role Of System of Systems in Additive Manufacturing

The rapid growth in additive manufacturing technologies have brought various optimization techniques and methodologies to improve each phase that needs to be integrated and analyzed on system level to optimize the system performance. The challenges and limitations of each phase affect the system when integrated as a whole - creating a complex manufacturing environment that needs to be critically examined and managed. To have a better management of complex, emergent, and uncertain manufacturing system from design to recycling phase, a new way of thinking based on more holistic approach is necessary. In this paper, the system of systems paradigm (SoS) is introduced to treat additive manufacturing system as a whole and to present some SoS approaches that are based on holistic thinking. This paper provides a conceptual knowledge of SoS approach using systems principles, laws and approach emphasizing the characteristics and attributes of complex manufacturing system to the AM domain

The Role Of System of Systems in Additive Manufacturing

The rapid growth in additive manufacturing technologies have brought various optimization techniques and methodologies to improve each phase that needs to be integrated and analyzed on system level to optimize the system performance. The challenges and limitations of each phase affect the system when integrated as a whole - creating a complex manufacturing environment that needs to be critically examined and managed. To have a better management of complex, emergent, and uncertain manufacturing system from design to recycling phase, a new way of thinking based on more holistic approach is necessary. In this paper, the system of systems paradigm (SoS) is introduced to treat additive manufacturing system as a whole and to present some SoS approaches that are based on holistic thinking. This paper provides a conceptual knowledge of SoS approach using systems principles, laws and approach emphasizing the characteristics and attributes of complex manufacturing system to the AM domain

The exploitation of polymer based nanocomposites for additive manufacturing: a prospective review

Additive manufacturing (AM) is a well-known technology for making real three dimensional objects, based on metal, ceramic and plastic material used for various applications. The aim of this review is to explore and offer an insight in to the state of the art polymer based nanocomposites in to additive manufacturing applications. In context to this, the developing efforts and trends in nanocomposites development particularly for additive manufacturing processes were studied and summed up. The scope and limitations of nanocomposites into Stereolithography, selective laser sintering and fused deposition modeling was explored and highlighted. The review highlights widely accepted nanoparticles for range of applications including mechanical, electrical, flame retardance and crossing over into more biological with the use of polymer matrices. Acquisition of functional parts with limitations in regard to printing is highlighted. Overall, the review highlights successes, limitations and opportunities that the union of AM and polymer based nanocomposites can bring to science and technology