THE DESIGN PROCESS OF AN OCCUPATIONALLY SAFE AND FUNCTIONAL 3D PRINTING LEARNING ENVIRONMENT FOR ENGINEERING EDUCATION

Learning environment is a physical environment which enables and supports interaction and learning of an individual. Practical learning happens usually in a physical learning environment allowing students to learn through using a certain technology when engineering education is in focus. 3D printing offers a low-cost and easy to access way to learn technology through different 3D printing technologies. There is lack of proper guidelines and solutions how to design practical and safe 3D printing learning environment in current literature. The design of a 3D printing environment consists of designing the physical environment and the operational model for the environment. The most important issue in the design work is the occupational safety of the environment including identifying different risks for health. This study presents a process of designing a 3D printing environment in Lapland University of Applied Sciences mechanical engineering degree programme (B.Sc. degree) including layout and operational planning from educational point of view. The study emphasizes the importance of connecting technology with learning in engineering. This study also includes an educational process model presenting the actions which the environment enables from educational point of view. Functionality of the environment refers to the possibility to learn by doing and work in the environment in a way that enables diverse learning possibilities. The process model presents how a 3D printing learning environment can be connected with other functions in a university or in a company and therefore be a part of a manufacturing chain from educational point of view. Article visualizations

INTRODUCING NOVEL LEARNING OUTCOMES AND PROCESS SELECTION MODEL FOR ADDITIVE MANUFACTURING EDUCATION IN ENGINEERING

Additive manufacturing (AM) is at the verge of being recognised as one of the main manufacturing methods among the traditional ones. The largest obstacle in using AM in the companies is the lack of knowledge about the possibilities of the technology. One sub-problem caused by this is the lack of qualified machine operators in companies due to the insufficient AM education. This indicates the need for strengthen the current AM education especially in the B.Sc. and M.Sc. levels in engineering education by emphasising the importance of AM in curriculum development. This study presents novel learning outcomes based on the needs of manufacturing industry and companies in Finland. A questionnaire was conducted to work-life representatives in order to map the requirements for AM education in the mechanical engineering degree of the Lapland University of Applied Sciences in Finland. The responds were collected as competences representing different areas of AM knowledge and the learning outcomes were derived from the responds. AM education must also provide a model for selecting the most suitable AM technology in order for students to learn the technological aspects. This study also presents a process selection model which can be used in AM education. The model allows the student to compare different AM technologies from different perspectives such as material, functionality and visual appearance point-of-view. Article visualizations

THE DESIGN PROCESS OF AN OCCUPATIONALLY SAFE AND FUNCTIONAL 3D PRINTING LEARNING ENVIRONMENT FOR ENGINEERING EDUCATION

Learning environment is a physical environment which enables and supports interaction and learning of an individual. Practical learning happens usually in a physical learning environment allowing students to learn through using a certain technology when engineering education is in focus. 3D printing offers a low-cost and easy to access way to learn technology through different 3D printing technologies. There is lack of proper guidelines and solutions how to design practical and safe 3D printing learning environment in current literature. The design of a 3D printing environment consists of designing the physical environment and the operational model for the environment. The most important issue in the design work is the occupational safety of the environment including identifying different risks for health. This study presents a process of designing a 3D printing environment in Lapland University of Applied Sciences mechanical engineering degree programme (B.Sc. degree) including layout and operational planning from educational point of view. The study emphasizes the importance of connecting technology with learning in engineering. This study also includes an educational process model presenting the actions which the environment enables from educational point of view. Functionality of the environment refers to the possibility to learn by doing and work in the environment in a way that enables diverse learning possibilities. The process model presents how a 3D printing learning environment can be connected with other functions in a university or in a company and therefore be a part of a manufacturing chain from educational point of view.</p

Review of Micro and Mesoscale simulation methods for Laser Powder Bed Fusion

Additive manufacturing (AM) is an advanced method of manufacturing complex parts layer by layer until the required design is achieved. Laser powder bed fusion (L-PBF) is used to produce parts with high resolution because of low layer thickness. L-PBF is based on laser beam and material interaction where the powder material is melted and then solidified. This occurs in a short time frame of the order of 0.02 seconds and makes the whole process challenging to be studied in real time. Studies have shown the development of numerical methods and the use of simulation software to understand the laser beam and material interaction. This phenomenon is key to understanding the material behavior under melting and mechanical properties of the part produced by L-PBF process as it is directly linked with the solidification of the melted powder material. A detailed study of the laser beam and material interaction is needed on a microscale and mesoscale level as it provides a better understanding and helps in the development of the given material for the L-PBF process. This review provides a comprehensive understanding of the background for the use of simulation in AM and the different simulation scales of feature under interest. The main conclusion from this review is the need to develop a methodology to use simulation at micro and mesoscale level to understand the laser beam and material interaction and improve the efficiency of the L-PBF process using this data

Introducing Novel Learning Outcomes and Process Selection Model for Additive Manufacturing Education in Engineering

Additive manufacturing (AM) is at the verge of being recognised as one of the main manufacturing methods among the traditional ones. The largest obstacle in using AM in the companies is the lack of knowledge about the possibilities of the technology. One sub-problem caused by this is the lack of qualified machine operators in companies due to the insufficient AM education. This indicates the need for strengthen the current AM education especially in the B.Sc. and M.Sc. levels in engineering education by emphasising the importance of AM in curriculum development. This study presents novel learning outcomes based on the needs of manufacturing industry and companies in Finland. A questionnaire was conducted to work-life representatives in order to map the requirements for AM education in the mechanical engineering degree of the Lapland University of Applied Sciences in Finland. The responds were collected as competences representing different areas of AM knowledge and the learning outcomes were derived from the responds. AM education must also provide a model for selecting the most suitable AM technology in order for students to learn the technological aspects. This study also presents a process selection model which can be used in AM education. The model allows the student to compare different AM technologies from different perspectives such as material, functionality and visual appearance point-of-view.</p

Possibilities of CT Scanning as Analysis Method in Laser Additive Manufacturing

Nordic Laser Materials Processing Conference Volume: 78 Host publication title: 15th Nordic Laser Materials Processing Conference, Nolamp 15Laser additive manufacturing is an established and constantly developing technique. Structural assessment should be a key component to ensure directed evolution towards higher level of manufacturing. The macroscopic properties of metallic structures are determined by their internal microscopic features, which are difficult to assess using conventional surface measuring methodologies. X-ray microtomography (CT) is a promising technique for three-dimensional non-destructive probing of internal composition and build of various materials. Aim of this study is to define the possibilities of using CT scanning as quality control method in LAM fabricated parts. Since the parts fabricated with LAM are very often used in high quality and accuracy demanding applications in various industries such as medical and aerospace, it is important to be able to define the accuracy of the build parts. The tubular stainless steel test specimens were 3D modelled, manufactured with a modified research AM equipment and imaged after manufacturing with a high-power, high-resolution CT scanner. 3D properties, such as surface texture and the amount and distribution of internal pores, were also evaluated in this study. Surface roughness was higher on the interior wall of the tube, and deviation from the model was systematically directed towards the central axis. Pore distribution showed clear organization and divided into two populations; one following the polygon model seams along both rims, and the other being associated with the concentric and equidistant movement path of the laser. Assessment of samples can enhance the fabrication by guiding the improvement of both modelling and manufacturing process.Peer reviewe

Strategic application of digital tools to enhance lifecycle cost: product design and optimization in metal based powder bed fusion

Additive manufacturing (AM) has undergone different phases of technological changes from being a mere manufacturing method for consumer goods, prototyping, and tooling to industrial series production of functional end-use parts. The seven AM sub-categories allow the creation of unprecedented designs that are otherwise impossible using conventional manufacturing (CM) methods. The layer-by-layer approach to manufacturing enables the creation of metal components with hollows and overhangs, often requiring sacrificial support structures which are removed prior to or during the post-processing phase. Factors such as poor part quality, high investment cost, low material efficiency, and long manufacturing time hindered the widespread adoption of AM in the past. The adoption of laser-based powder bed fusion for metals was particularly hindered due to reasons such as the need for support structures, demand for post-processing, the numerous affecting processing parameters and the lack of understanding of the interaction between laser beam and material. Technological advances in AM have helped users reduce or omit some of the limitations to adoption, such as optimized support structures for better material efficiency. Simulation-driven tool is one means offering ways to time-efficient product development and more superior structural components amidst the raw material and cost reductions. This study elucidates how such benefits are feasible via using simulation tools. Simulation-driven optimization of the product design, process, and manufacturing is revealed to change the design, support structures and postprocessing required to bring parts to the required reliability. Virtual manufacturing planning also gives a prior understanding of how processing parameters such as laser scan velocity, laser power, scanning strategy, hatch distance and others can be controlled; to achieve optimal interaction between laser beam and material for the required part quality. Simulation-driven design for additive manufacturing (DfAM) allows for agile design optimizing with design parameters and rules, boosting resource efficiency and productivity. This research proposes a life cycle cost (LCC)driven DfAM tool, which potentially improves service life and life cycle cost. The results provide insight into the simulation-driven DfAM of laser-based PBF and demonstrate the potential for LCC-based approaches to enhance the confidence in adopting PBF for metals

Technical, Economic and Societal Effects of Manufacturing 4.0

Additive manufacturing (AM) is a relatively new manufacturing method that compiles different techniques to join materials together material on top of existing structure in order to make parts from 3D-model data—typically layer by layer. Additive manufacturing is a combination of different technologies such as CAD (computer-aided design), CAM (computer-aided manufacturing), laser and electron energy beam technology, CNC (computer numerical control) machining, and laser scanning. Some of these technologies existed already in the 1950s, but only in the 1980s the maturity of the different technologies enabled the creation of additive manufacturing. The term additive manufacturing substitutes historical terms, such as solid freeform fabrication, freeform fabrication,and rapid prototyping and it is also commonly called 3D-printing in nontechnical contexts and in colloquial language.</p

Data related to the microstructural identification and analyzing the mechanical properties of maraging stainless steel 13Cr10Ni1. 7Mo2Al0. 4Mn0. 4Si (commercially known as CX) processed by laser powder bed fusion method

The data available in this article presents the microstructural information achieved via scanning electron microscopy and electron backscatter diffraction to evaluate the microstructure of maraging stainless steel 13Cr10Ni1.7Mo2Al0.4Mn0.4Si, in its as-built and heat-treated conditions, fabricated by laser powder bed fusion. In addition, the statistical analysis of the defects is included to indicate the quality of the additively manufactured metal. Furthermore, true stress-logarithmic strain diagrams of the material with different types of post-processing are available, indicating the strain hardening behavior of the material. These diagrams were achieved via quasi-static tensile tests performed in conjunction with the digital image correlation technique. Finally, the sample designs, additive manufacturing parameters, and the heat treatment procedure carried out on the material are also available in this paper to guide future research and ensure the repeatability of the data in this data article and its linked research paper. The research paper investigates the effects of processing and post-processing parameters on the microstructure, surface quality, residual stress, and mechanical properties of 13Cr10Ni1.7Mo2Al0.4Mn0.4Si (conventionally known as CX developed by EOS GmbH) processed by laser powder bed fusion [1].</p