3D Additive Manufacturing Symposium & Workshop

The IMI /3M BIC 3D Additive Manufacturing Symposium and Workshop was hosted by 3M Buckley Innovation Centre on March 17th 2015. The event was attended by the major players in precision engineering, 3D additive design and manufacturing: Representatives from EOS, Renishaw, HK 3D Printing IMI Plc Senior Management team, design engineers, programmers and academics from the University of Huddersfield School of Art Design & Architecture, 3M Buckley centre 3D printing management and designers shared their experiences and latest solutions to expand the potential of innovation and professional enterprise for design, prototyping and manufacturing. This publication showcases the keynote innovation presentations given at the IMI/3M BIC 3D Additive Manufacturing symposium. The main themes included focus on research, design, concept actualisation, prototyping, and engineering solutions. This is a unique visual documentary of the evolutions in additive manufacturing and provides a snaphsot of latest 3D technology solutions in 2015

Uncertainty evaluation associated with versatile automated gauging influenced by process variations through design of experiments approach

Recent advances in versatile automated gauging have enabled accurate geometric tolerance assessment on the shop floor. This paper is concerned with the uncertainty evaluation associated with comparative coordinate measurement using the design of experiments (DOE) approach. It employs the Renishaw Equator which is a software-driven comparative gauge based on the traditional comparison of production parts to a reference master part. The fixturing requirement of each production part to the master part is approximately ±1 mm for a comparison process with an uncertainty of ±2 μm. Therefore, a number of experimental designs are applied with the main focus on the influence of part misalignment from rotation between master and measure coordinate frames on the comparator measurement uncertainty. Other factors considered include measurement mode mainly in scanning and touch-trigger probing (TTP) and alignment procedure used to establish the coordinate reference frame (CRF) with respect to the number of contact points used for each geometric feature measured. The measurement uncertainty analysis of the comparator technique used by the Equator gauge commences with a simple measurement task using a gauge block to evaluate the three-dimensional (3D) uncertainty of length comparative coordinate measurement influenced by an offset by tilt in one direction (two-dimensional angular misalignment). Then, a specific manufactured measurement object is employed so that the comparator measurement uncertainty can be assessed for numerous measurement tasks within a satisfactory range of the working volume of the versatile gauge. Furthermore, in the second case study, different types of part misalignment including both 2D and 3D angular misalignments are applied. The time required for managing the re-mastering process is also examined. A task specific uncertainty evaluation is completed using DOE. Also, investigating the effects of process variations that might be experienced by such a device in workshop environments. It is shown that the comparator measurement uncertainties obtained by all the experiments agree with system features under specified conditions. It is also demonstrated that when the specified conditions are exceeded, the comparator measurement uncertainty is associated with the measurement task, the measurement strategy used, the feature size, and the magnitude and direction of offset angles in relation to the reference axes of the machine. In particular, departures from the specified part fixturing requirement of Equator have a more significant effect on the uncertainty of length measurement in comparator mode and a less significant effect on the diameter measurement uncertainty for the specific Equator and test conditions

Coincident beach surveys using UAS, vehicle mounted and airborne laser scanner: point cloud inter-comparison and effects of surface type heterogeneity on elevation accuracies

Reliable and consistent topographic data is key to a multitude of environmental manangement and research applications. Unmanned Aerial Systems (UAS) are fast establishing themselves as a promising additional remote sensing platform that provides high spatial resolution not only of topography but also surface types and coastal features together with comparatively low costs and high deployment flexibility. However, comprehensive information on the accuracy of UAS-based elevation models in comparison to other available surveying methodology is regulary limited to be referenced to individual methods. This paper addresses this shortcoming by comparing coincident beach surveys of three different point cloud generating methods: ATV mounted mobile laser scan (MLS), airborne LiDAR (ALS), and UAS. This was complemented by two RTK-GPS surveys on a pole with wheel attachment and mounted on an ATV. We present results in relation to elevation accuracies on a concrete control surface, the entire beach and for six different beach surface types together with how differences between point clouds propagate during the construction of gridded elevation models. Overall, UAS point cloud elevations were consistently higher than those of ALS (+0.063 m) and MLS (+0.087 m). However, these results for the entire beach mask larger and smaller differences related to the individual surface characteristics. For all surface types, UAS records higher (from 0.006 m for wet sand to 0.118 m for cobbles, average of 0.063 m) elevations than ALS. The MLS on the other hand, records predominantly lower elevation than ALS (-0.005 m for beach gravel to -0.089 m for soft mud, average of -0.025 m) except for cobbles, where elevations are 0.056 m higher. The comparison shows that all point cloud methods produce elevations that are suitable for monitoring changes in beach topography in the context of operational coastal management applications. However, due to the systematic differences between respective monitoring approaches, care needs to be taken when analysing beach topographies for the same area based on different methods. The eventual choice of monitoring method is therefore guided by a range of practical factors, including capital cost of the system and operating costs per survey area, conditions under which the system can operate, data processing time, and legal restrictions in the use of the system such as air safety regulations or limitation of ground access to areas with environmental protection

Unobtainium

This practice based research project is a business collaboration supported by Renishaw and Hexagon Metrology which aims to explore the creative application of Additive Manufacturing technologies. The research will fuse additive and subtractive technologies in order to develop innovative solutions to increase the level of control over form and surface patterning of 3D printed metal objects. Renishaw (Est. 1973) is a UK global company with core skills in measurement, motion control, spectroscopy and precision machining. Renishaw’s products are used in applications as diverse as co-ordinate measurement, CAD/CAM dentistry, shape memory alloys and Additive Manufacturing. Additive Manufacturing (AM) is a term used to describe a range of processes which are capable of producing functional components or products in materials such as nylon, titanium, steel and some precious metals. AM is a development of Rapid Prototyping (RP) technology and is forecasted to supersede some traditional subtractive processes of manufacturing due to its ability to create complex geometries including internal structures and to reduce waste. The main applications for this developing technology are light weighting of components in aerospace and automotive and medical applications such as dental and cranial braces. Selective Laser Melting (SLM) is a new Additive Manufacture technology which has been developed by Renishaw, it is unique in the level of accuracy and surface detail that it can produce directly in metal. SLM will have a direct impact on reducing the wastage created through subtractive manufacturing processes and will be an important step towards achieving manufacturing that is very near 100% efficient. The current use of SLM is fairly traditional, aimed at manufacturing sectors such as aerospace however there is little exploration of its unique properties, creative practitioners could help in developing new understanding and applications enabled with direct metal production. Craft practitioners and designers have started to explore the creative application of these processes, Lionel Dean, Michael Eden, Nervous systems and Freedom Of Creation have all exploited these technologies to develop objects. Much of this work is limited to the creative application of the SLS and SLM manufacturing process and the new geometries it can enable; there remain opportunities to explore innovation through more direct engagement with the process and propriety software used to process files into an understandable format. The sub-contract model used to access such technology is problematic as it prevents craft practitioners from achieving exclusive control of the end aesthetic by requiring an intermediary (often a software engineer) to interpret their ideas; often this process has an overweighing influence on the final look and aesthetic language of the object. One of the major barriers of AM for the creative industries and individual craft practitioners is the limited range and control of surface quality; my project will address both of these issues. My practice is unique in the field of digital craft in that it seeks to engage with every part of the process to find innovative opportunities for new creative engagement. I have developed this unique practice due to the level of access of Falmouth’s unprecedented digital resources. ‘Unobtanium’ is a reference to my interest in military and bicycle manufacturing. Skunk Works, a branch of Lockheed who designed the SR -71 Blackbird spy plane used the term to refer to the metal (Titanium) which had been purchased from the Russians to build a supersonic spy plane. Sunglass manufacturer Oakley used the term in their advertising during the 90’s to highlight the level of innovation in their lense design and coatings. Aims • To create a showcase artefact for exhibition at Collect 2015 using advanced digital manufacturing processes at Renishaw and Falmouth University. The artefact will explore my interests of landscape and topology while demonstrating and expanding my acknowledged reputation for crafting innovative digital craft. • To develop a new hybrid prototyping process that will offer the potential to blend the unique advantages of Additive Manufacture and CNC milling. • To explore opportunities to commercialise any innovation on the above process with Renishaw • To disseminate the project learning through a paper, conference, documentation or public talk Objectives • I will develop physical test pieces and objects which reflect on ideas of landscape and topology. The use of both additive and reductive digital manufacturing processes will enable the design and manufacture of complex 3D geometries with highly detailed surface patterning. This fusion will balance the unique visual signatures of each process to create a new digital aesthetic. • To develop an indepth understanding of the unique process of Selective Laser Melting through collaborative dialogue with engineers at Renishaw • To develop an indepth knowledge of the specialist software module, Space structures. • To identify and explore opportunities for creative engagement, risk taking and play with software and hardware processes. • To test and develop a range of holding and alignment processes in order to accurately mill SLM parts • To develop a range of patterning and texture samples through CNC and Laser milling. • To develop an understanding of the particular machining qualities of different Titanium alloys with input from the CNC milling department at Renishaw. • To develop an understanding of a range of finishing process on titanium • To document and write reports on each stage of the project • To exhibit the project outcome at the International craft exhibition, Collect, Saatchi gallery in London, May 2015