Efficient three dimensional modelling of additive manufactured textiles

Purpose – To investigate, develop and validate a three dimensional modelling strategy for the efficient generation of conformal textile data suitable for Additive Manufacture. Design/methodology/approach – A series of Additive Manufactured textiles samples were modelled using currently available Computer Aided Design software to understand the limitations associated with the generation of conformal data. Results of the initial three dimensional modelling processes informed the exploration and development of a new dedicated efficient modelling strategy that was tested to understand its capabilities. Findings – The research demonstrates the dramatically improved capabilities of the developed three dimensional modelling strategy, over existing approaches by accurately mapping complex geometries described as STL data to a mapping mesh without distortion and correctly matching the orientation and surface normal. Originality/value – To date the generation of data for AM textiles has been seen as a manual and time-consuming process. The research presents a new dedicated methodology for the efficient generation of complex and conformal Additive Manufactured textile data that will underpin further research in this area

Design tool for enhanced new product development in low income economies

In order to alleviate poverty throughout the World government and nongovernment organisations provide aid in the form of essential household products. These products typically include cook stoves, water filters and LED lights. However, evidence suggests that these products are not always suitable for Low Income Economies (LIEs) which has resulted in a number of high profile product failures. In response to the growing need for appropriate New Product Development (NPD), this paper presents the development of a tool to assist industrial designers create appropriate and long lasting solutions for those in poverty. Data was collected from the analysis of existing products, a survey, interviews with NGOs & industrial designers and a field trip to Myanmar. The results were used to identify attributes required for effective, long‐lasting product design. This was used to create a tool for designers which was found to enhance understanding of appropriate NPD for LIEs

Meeting the expectation of industry: an integrated approach for the teaching of mechanics and electronics to design students

This paper examines the traditional engineering-based provision delivered to Product Design and Technology (B.Sc.) undergraduates at the Loughborough Design School and questions its relevancy against the increasing expectations of industry. The paper reviews final-year design projects to understand the level of transference of engineering-based knowledge into design practice and highlights areas of opportunity for improved teaching and learning. The paper discusses the development and implementation of an integrated approach to the teaching of Mechanics and Electronics to formalise and reinforce the key learning process of transference within the design context. The paper concludes with observations from the delivery of this integrated teaching and offers insights from student and academic perspectives for the further improvement of engineering-based teaching and learning

Additive manufactured textiles for high-performance stab resistant applications

A series of nanocrystalline copper metallised and non-metallised Laser Sintered (LS) Nylon (PA2200) samples using the EOS P100 Formiga system, were stab tested to current Home Office Scientific Development Branch (HOSDB) Knife Resistance (KR) 2007 standards, to ascertain their stab resistant characteristics. The research demonstrated that while a sample thickness of 8mm virgin PA2200 was required for a successful stab test, this figure was significantly reduced to 5.6mm using a 50:50 mix of virgin and recycled PA2200. A further significant reduction in sample thickness to 4.5mm was also recorded for samples manufactured from virgin PA2200, metallised in a 150μm layer of nanocrystalline copper. The results of the stab testing series were then utilised to develop a non-metallised, scale Additive Manufactured (AM) textile manufactured from a 50:50 recycled and virgin PA2200 mix. Results indicated a successful AM textile-like design, with little or no penetration during stab testing at the HOSDB KR1 standard

Utilising Additive Manufacturing technology for the development of knife resistant soft body armour to UK performance requirements

Utilising Additive Manufacturing technology for the development of knife resistant soft body armour to UK performance requirement

A performance assessment of a developed mesh-generating algorithm: A computer-aided design modelling process to support progression within additive manufacturing

Developments in Additive Manufacturing (AM) technologies and associated processes have increased the limits of attainable design complexity, yet Computer-Aided Design (CAD) tools that may utilise these new potentials have not advanced as rapidly. Research detailed in this paper addresses aspects of automatic geometric design that may support the generation of high resolution, functional, three-dimensional (3D) textures. A 3D CAD model of a surface with complex curvature was modelled to be systematically populated with points using a developed mesh-generation algorithm. Following the successful generation of a mesh the distances between points were analysed, throughout the process, to measure the performance of the algorithm. Equidistance between points was achieved and, if the algorithm was used as intended, would provide an essential foundation for successive texture application processes with minimal manual input required

Finite-element modelling of mechanical behaviour of rapid manufactured textiles

Novel textile-like linked structures, realised using a rapid manufacturing (RM) process, have been proposed and developed recently. Various potential applications exist, and in most cases the mechanical performance must be evaluated. The present paper outlines a method to solve this problem by employing finite-element (FE) techniques at two scales, using the results of analysis at the meso-scale (the scale of the repeating unit) to provide equivalent non-linear spring behaviour for each textile link at the macro-scale. Validation with experimental test data from each scale was performed and these results are presented. Initial results overestimated mechanical performance. Microscopy suggested that this may be due to edge porosity in the specimens, and the dimensions of the FE models were adjusted accordingly as an initial approach to account for this. Predictions incorporating this modification exhibited excellent agreement with experimental measurements. The current work demonstrates both a technique, which could be automated for use in the design environment, and the potential value of developing an integrated process simulation to provide local material property data for the FE model

Additive manufactured textiles for high-performance stab resistant applications

Purpose – The purpose of this paper is to ascertain the stab resistance characteristics of a series of planar and articulated laser sintered (LS) samples, in accordance with the United Kingdom Home Office Scientific Development Branch (HOSDB) Body Armour Standard – Publication 39/07. Design/methodology/approach – A series of LS planar samples were manufactured using an EOS P100 Formiga system, manufactured from 100 per cent virgin or a 50:50 mix of recycled and virgin Nylon (PA2200), ranging in thickness from 1-10 mm. All planar samples were stab tested to the HOSDB knife-resistance (KR) level one impact energy of 24 Joules, using an in-house manufactured HOSDB guided rail drop test impact rig and standardised knives. Penetration through the underside of each sample was measured and recorded. These results were then used to develop an articulated, additive manufactured (AM) scale textile – LS from a 50:50 mix of recycled and virgin PA2200 powder. These samples were then tested using the aforementioned impact rig and stab impact energy. Findings – The research demonstrated that while virgin PA2200 sample required a minimum thickness of 8mm to achieve stab-resistance below the HOSDB maximum penetration limit of 7 mm, this figure can be reduced to 5.6mm when manufacturing LS planar samples from a 50:50 mix of virgin and recycled PA2200. Results from stab testing the articulated samples indicated a successful AM textile-like design, with a maximum knife penetration of 1.6mm – below the 7mm HOSDB limit. Originality/value – The paper describes a unique application of AM technologies for the manufacture of high-performance stab resistant AM textiles. Keywords Textile technology, Protective clothing, Advanced manufacturing technologies, Laser sintering, High-performance, Stab resistant, Additive manufactured textile, Body armour, Home Office Scientific Development Branch, United Kingdo

Underwired brassieres

Underwired brassiere

AMBA – Additive Manufactured Body Armour

Utilising graphical generative algorithms and Additive Manufacturing technology for the development of knife resistant flexible body armour to UK performance requirements