Research Towards High Speed Freeforming

Additive manufacturing (AM) methods are currently utilised for the manufacture of prototypes and low volume, high cost parts. This is because in most cases the high material costs and low volumetric deposition rates of AM parts result in higher per part cost than traditional manufacturing methods. This paper brings together recent research aimed at improving the economics of AM, in particular Extrusion Freeforming (EF). A new class of machine is described called High Speed Additive Manufacturing (HSAM) in which software, hardware and materials advances are aggregated. HSAM could be cost competitive with injection moulding for medium sized medium quantity parts. A general outline for a HSAM machine and supply chain is provided along with future required research

Automated software for streamlining optimisation of resource planning for an additive manufacturing system

Abstract. The use of additive manufacturing (AM) systems in scale production has rapidly increased in recent years. The growing tendency to adopt AM technologies into established manufacturing systems has led to research that considers the optimisation of both process and resource planning. In order to maximise the outputs of such a production process, planning must be conducted rigorously. This paper proposes an automated software tool, called EasyPlan, which streamlines the optimisation of resource planning. The algorithm is developed using LabVIEW and is demonstrated for an AM component from the medical industry. For the evaluation process, parameters such as stock levels, delivery terms and technical charts of the products are provided. A user friendly interface is developed, making EasyPlan versatile to all types of environments

Automated software for streamlining optimisation of resource planning for an additive manufacturing system

Abstract. The use of additive manufacturing (AM) systems in scale production has rapidly increased in recent years. The growing tendency to adopt AM technologies into established manufacturing systems has led to research that considers the optimisation of both process and resource planning. In order to maximise the outputs of such a production process, planning must be conducted rigorously. This paper proposes an automated software tool, called EasyPlan, which streamlines the optimisation of resource planning. The algorithm is developed using LabVIEW and is demonstrated for an AM component from the medical industry. For the evaluation process, parameters such as stock levels, delivery terms and technical charts of the products are provided. A user friendly interface is developed, making EasyPlan versatile to all types of environments

Multivariable Regression Analysis for Optimised Mass Calculation of MEX 3D Printed Parts

Since its introduction in the early 1990s Material Extrusion (MEX) has become the most popular additive manufacturing technology for a variety of applications. One of the reasons of its popularity amongst users is the affordability of the equipment, materials and the open source software. Given the large variety of combinations optimisation of MEX process parameters can be quite elaborate. The paper provides a method for optimisation of mass calculation using multivariable regression analysis. Layer thickness, printing temperature and printing speed were considered the independent variables for a two level factorial experimental program. DOE was used to plan 12 sets of programs, out of which four were found to have significant models. The four models were validated through measured and calculated responses

Geometry Optimisation of Tools used in Milling of Spherical Surfaces

In this paper, the authors show an original methodology for optimisation of tool geometry used in the milling of spherical surfaces. This methodology is based on thorough theoretical research, which highlights the kinematic characteristics of spherical surface generation by milling. These characteristics lead to the conclusion that the constructive angles of tools used in spherical surface milling must have the same values on both cutting edges. In this paper, a practical design methodology of these tools is also presented, both for exterior spherical milling, and for interior spherical milling

Additive manufacturing technology and material selection for direct manufacture of products based on computer aided design geometric feature analysis

eveloped in a Visual Basic programming environment that aids in the selection of materials processed using additive manufacturing (AM) technologies. AM technologies such as selective laser sintering (SLS) and fused deposition modelling (FDM) have limitations on the materials available to them and each system has factors that limit the geometric freedom of the components that they can produce. Thus, materials capable of being processed on these types of technology can be selected through a method of traversing the geometric features of a computer aided design (CAD) model and performing an analysis of each individual feature’s attributes. The algorithm developed for this research uses data based on minimum feature size and a model bounding box as criteria in the selection of suitable materials. Through integration with an existing commercially available CAD software package, a component can be automatically analysed for its geometric feature properties and attributes, returning suitable AM systems and material information for selection by the operator. A number of case studies are presented that highlight the successful operation of the AM technology and material selection tool that has been developed

Additive manufacturing technologies and functional analysis used in product development optimization

Market leadership is achieved only by the fastest, most productive and best value global producers that use product performance, cost, quality and reliability as assets. Product innovation is an essential factor to companies that want to be competitive, so to improve and modernise finished products or productive systems, a lot of methods, organising and rationalising techniques are used. The authors propose to approach a product’s lifecycle with technical functional analysis (FA) for better understanding of the consumers needs and eliminating unnecessary costs, taking into consideration the specific characteristics of additive manufacturing (AM) technologies. Amongst the most important advantages brought together by the two concepts are customer focus, high quality final products, energy efficiency, low material waste, production speed and time-to-market, manufacturing complex geometries, low costs etc. Merging FA with the opportunities offered by AM technologies creates a synergistic effect, enabling development of new standards of innovation, performance and sustainable competitive advantage

Research on deploying technical functional analysis for additive manufacturing of a surgical device for intravitreal interventions

This paper presents a methodology on designing for additive manufacturing applications using technical functional analysis tools. The methodology is applied to the re-design of a device for intravitreal interventions. The present research leads to significant improvements in product functionality and reduction of manufacturing costs. The unique and innovative design of the product had encouraging reviews after laboratory and in vivo testing. Fatigue simulations were deployed for both prototyping materials and biocompatible materials, in the hopes of series production. Results of the current study are being used by a commercial company in the United Kingdom to support the launch of a new competitive product

Functional analysis for the development of bio-medical products

The engineer nowadays needs to possess knowledge that will enable the design of more diverse and cheaper products, but of higher quality, which reach the market faster, and do not pollute. These requirements are the effect of globalization, competition, reduction of the life-cycle of a product, managing the environmental issues, increasing computing power related to communication networks etc. The present paper proposes research applying technical functional analysis for the development of a surgical device manufactured from biocompatible silicone rubber. The vacuum surgical device is a treatment instrument for skin ulcers resistant to antibiotics and difficult to treat because of other connected diseases. The product is fabricated by open mould casting in a selective laser sintered (additive manufactured) mould, obtained after performing functional analysis. Functional analysis is applied to establish the optimum mould concept and the technological process of manufacturing it. Additive manufacturing is used for both the intermediary functional prototype production of the mould and the zero series mould