Design for Additive Manufacturing, to produce assembled products, by SLS

The paper presents a new methodology on how to design a product, which could be produced directly as an assembly, instead of manufacturing all individual parts, to be assembled after words, in a classical manner. A detailed case study is presented, on how the product’s structure could be simplified, the number of the components being drastically reduced. The theoretical Design for Assembly (DFA) methodology was tested and validated, by manufacturing the physical products, using the Selective Laser Sintering (SLS) machine

Design for Additive Manufacturing, to produce assembled products, by SLS

The paper presents a new methodology on how to design a product, which could be produced directly as an assembly, instead of manufacturing all individual parts, to be assembled after words, in a classical manner. A detailed case study is presented, on how the product’s structure could be simplified, the number of the components being drastically reduced. The theoretical Design for Assembly (DFA) methodology was tested and validated, by manufacturing the physical products, using the Selective Laser Sintering (SLS) machine

Research on the mechanical behaviour of an airplane component made by selective laser melting technology

The main objective of the presented research consists in the redesign of an airplane component to decrease its weight, without affecting the mechanical behaviour of the component, at the end. Femap NX Nastran and ANSYS FEA programs were used for the shape optimization and for the estimation of the mechanical behaviour of a fixing clamp that was used to sustain the hydraulic pipes that are passing through an airplane fuselage, taking into consideration two types of raw materials – Ti6Al4V and AlSi12 powder from which this component could be manufactured by using the selective laser melting (SLM) technology. Based on the obtained results, the airplane component was finally manufactured from titanium alloy using the SLM 250 HL equipment that is available at SLM Solutions GmbH company from Luebeck, in Germany

Research on the mechanical behaviour of an airplane component made by selective laser melting technology

The main objective of the presented research consists in the redesign of an airplane component to decrease its weight, without affecting the mechanical behaviour of the component, at the end. Femap NX Nastran and ANSYS FEA programs were used for the shape optimization and for the estimation of the mechanical behaviour of a fixing clamp that was used to sustain the hydraulic pipes that are passing through an airplane fuselage, taking into consideration two types of raw materials – Ti6Al4V and AlSi12 powder from which this component could be manufactured by using the selective laser melting (SLM) technology. Based on the obtained results, the airplane component was finally manufactured from titanium alloy using the SLM 250 HL equipment that is available at SLM Solutions GmbH company from Luebeck, in Germany

Preliminary study on occurrence of composite material delamination processed by abrasive water jet cutting

The paper presents a preliminary experimental study on processing composite materials (CFRP) using abrasive water jet cutting (AWJC) process, analysing the possibilities of occurrence of material delamination. AWJC is a proper solution for cutting CFRP because of reduced interface temperature, high flexibility, low mechanical loading and reduced cutting forces. Cutting CFRP using AWJC involves several challenges like material delamination due to the high velocity impact of the jet. To understand the delamination, three experimental tests were made: in the first test the cutting and the drilling was made with high water pressure (350 MPa), in the second test the cutting was made with high water pressure and for drilling was used low water pressure (200 MPa) and in last test a pre-drilled hole was used. Within those experiments was observed the CFRP delamination appears just during the drilling, not during the cutting. By decreasing the water jet pressure, the jet energy is decreased and in this way the delamination decrease

Basic research on lattice structures focused on the reliance of the cross sectional area and additional coatings

This scientific survey is about periodic lattice structures which are made by Selective Laser Melting (SLM). Selective laser melting is based on Additive Manufacturing. The increased use and increasing demand of lattice structures in different fields of applications forms the necessity of a closer look on complex structures. Lattice structures can be found in different fields of applications for example in lightweight applications, filters and heat exchangers. Because of the expanding of application areas and thus arising requirements, the quality improvement is indispensable. Additive manufacturing and especially the SLM process enable the manufacturing of highly complex shapes and structures. Further it allows the integration of lightweight structures within to be manufactured applications. These high performance structures and applications need specific boundary and process conditions [1-3]. The main aim of this survey is an extraction of important parameters concerning the shape of lattices. A first focus will be on mechanical properties and the therefore necessary tensile tests

Basic research on lattice structures focused on the reliance of the cross sectional area and additional coatings

This scientific survey is about periodic lattice structures which are made by Selective Laser Melting (SLM). Selective laser melting is based on Additive Manufacturing. The increased use and increasing demand of lattice structures in different fields of applications forms the necessity of a closer look on complex structures. Lattice structures can be found in different fields of applications for example in lightweight applications, filters and heat exchangers. Because of the expanding of application areas and thus arising requirements, the quality improvement is indispensable. Additive manufacturing and especially the SLM process enable the manufacturing of highly complex shapes and structures. Further it allows the integration of lightweight structures within to be manufactured applications. These high performance structures and applications need specific boundary and process conditions [1-3]. The main aim of this survey is an extraction of important parameters concerning the shape of lattices. A first focus will be on mechanical properties and the therefore necessary tensile tests

Education packed in technology to promote innovations: Teaching Additive Manufacturing based on a rolling Lab

3D Printing is about to revolutionize the way we design and produce future products. This causes not just immense research and development activities worldwide but requires intensive education and training efforts. As 3D Printing is an ideal tool to set up a decentralized production, it is one key to integrate even rural and under-industrialized parts of the country into high tech education and professional training needed. But how to reach the relevant groups - pupils from schools as well as professional staff of preferably companies? Remembered the old proverb: “If the mountain won’t come to the prophet, the prophet must go to the mountain” the plan of a mobile 3D printing lab was born. Based on our experiences, we designed the technical infrastructure and the educational approach to adopt Additive Manufacturing courses to a short term comprehensive teaching. To create a fully equipped workplace for every participant, we redesigned a double-decker bus. The paper addresses the strategy behind the bus, the infrastructure in detail, the developed courses taught and the resonance on this project. Looking forward, the paper gives a sneak preview on the further development in terms of specialized courses to be given in the bus as well as in the frame of accompanying activities such as engineering design of parts, application of new materials for Additive Manufacturing such as metals and follow-up production like plastic injection molding

Education packed in technology to promote innovations: Teaching Additive Manufacturing based on a rolling Lab

3D Printing is about to revolutionize the way we design and produce future products. This causes not just immense research and development activities worldwide but requires intensive education and training efforts. As 3D Printing is an ideal tool to set up a decentralized production, it is one key to integrate even rural and under-industrialized parts of the country into high tech education and professional training needed. But how to reach the relevant groups - pupils from schools as well as professional staff of preferably companies? Remembered the old proverb: “If the mountain won’t come to the prophet, the prophet must go to the mountain” the plan of a mobile 3D printing lab was born. Based on our experiences, we designed the technical infrastructure and the educational approach to adopt Additive Manufacturing courses to a short term comprehensive teaching. To create a fully equipped workplace for every participant, we redesigned a double-decker bus. The paper addresses the strategy behind the bus, the infrastructure in detail, the developed courses taught and the resonance on this project. Looking forward, the paper gives a sneak preview on the further development in terms of specialized courses to be given in the bus as well as in the frame of accompanying activities such as engineering design of parts, application of new materials for Additive Manufacturing such as metals and follow-up production like plastic injection molding