PCPro a Novel Technology for Rapid Prototyping and Rapid Manufacturing

PCPro stands for Precise Cast Prototyping, which is a combination of casting technologies and milling. This method was developed at Fraunhofer IWS in Dresden, Germany. It is patented in Germany [1] and is applied in the USA under US 10/794,936. The main goal for this development was to shorten the process chain for making plastic prototypes accompanied by higher quality. The casting technology was integrated in a machining center in order to enable a high degree of automation and to avoid an external casting system. This means that Rapid Manufacturing can be easily implemented using such an automated combination of casting and machining. This article describes the PCPro method by means of the fabrication of sample parts. The advantages and the limitations in comparison to common Rapid Prototyping and Rapid Manufacturing process chains will be discussed. In addition, the manufacturing of a prototype machine is presented.Mechanical Engineerin

Possible explanations for different surface quality in laser cutting with 1 micron and 10 microns beams

In laser　cutting　of　thick　steel　sheets,　quality　difference　is　observed　between　cut　surfaces　obtained　with 1 micron and 10 micron laser beams. This paper investigates physical mechanisms for this interesting and important problem of the wavelength dependence. First, striation generation process is described, based on a 3D structure of melt flow on a kerf front, which was revealed for the first time by our recent experimental observations. Two fundamental processes are suggested to explain the difference in the cut surface quality: destabilization of the melt flow in the central part of the kerf front and downward displacement of discrete melt accumulations along the side parts of the front. Then each of the processes is analyzed using a simplified analytical model. The results show that in both processes, different angular dependence of the absorptivity of the laser beam can result in the quality difference. Finally we propose use of radial polarization to improve the quality with the 1 micron wavelength

Shared Metadata for Data-Centric Materials Science

The expansive production of data in materials science, their widespread sharing and repurposing requires educated support and stewardship. In order to ensure that this need helps rather than hinders scientific work, the implementation of the FAIR-data principles (Findable, Accessible, Interoperable, and Reusable) must not be too narrow. Besides, the wider materials-science community ought to agree on the strategies to tackle the challenges that are specific to its data, both from computations and experiments. In this paper, we present the result of the discussions held at the workshop on "Shared Metadata and Data Formats for Big-Data Driven Materials Science". We start from an operative definition of metadata, and what features a FAIR-compliant metadata schema should have. We will mainly focus on computational materials-science data and propose a constructive approach for the FAIRification of the (meta)data related to ground-state and excited-states calculations, potential-energy sampling, and generalized workflows. Finally, challenges with the FAIRification of experimental (meta)data and materials-science ontologies are presented together with an outlook of how to meet them

Langstroth hive construction with cement-vermiculite

Exfoliated vermiculite is a light-weight and cheap product that, because of its thermal resistance, has become a valuable insulating material. With regard to its use in beekeeping, this research tested whether the box for honey bees constructed with cement-vermiculite mortar (CVM) presents physical characteristics similar to those of wood. The experiment was carried out at Seropédica, RJ, Brazil, for eight months. The cement-vermiculite mortar was compared with a control material (pinewood), in the construction of Langstroth boxes and boards, in a completely randomized design, with respect to thermal control, thermal conductivity and its capacity to absorb and lose water. The production cost for a CVM box was estimated. There were no internal temperature differences between CVM and wooden boxes. Thermal conductivity values for CVM and pinewood were similar. CVM absorbed more water and lost water faster than pinewood. Since CVM boxes can be easily constructed, at a low cost and with similar characteristics as traditional boxes, made of wood, the material can be recommended for use in non-migratory beekeeping

Recent development in laminated tooling by multiple laser processing

The quick manufacturing of large metal forming tools, e.g. for car body parts, is a novel and promising application of the Metal-LOM technique. The acronym stands for "Metal Laminated Object Manufacturing", i.e. the metal variant of the established prototyping technique, which classically uses paper as build-up material. In the solution presented in horizontal or vertical layers by a specially developed software. Subsequently, steel sheets with a typical thickness of around 1 mm are cut according to these slices, stacked, and joined to a package. The steel slice are manufactured by high-speed laser cutting, and the joining technique can be laser welding, diffusion welding or other, mechnical/thermal combination techniques. In a laser integrated 5-axes CNC milling center, the active tool parts are clad with wear-resistant coatings by laser or plasma transferred arc cladding. Laser assisted plasma spraying is available for the tool's surface treatment as well. Also, smaller parts of the tools of complex shape can be produced by laser build-up welding directly onto the sheet package. In the end, the final contour of the tool is produced by CNC milling. The aims of the running research project are the reduction of tooling time from 16 to one week, tool dimensions in the meter-range and an application adapted tool life