Variable fused deposition modelling - concept design and tool path generation

Current Fused Deposition Modelling (FDM) techniques use fixed diameter nozzles to deposit a filament of plastic layer by layer. The consequence is that the same small nozzle, essential for fine details, is also used to fill in relatively large volumes. In practice a Pareto-optimal nozzle diameter is chosen that attempts to maximise resolution while minimising build time. This paper introduces a concept for adapting an additive manufacturing system, which exploits a variable diameter nozzle for the fused deposition of polymers. The variable nozzle allows the print resolution and the build speed to become independent variables which may be optimised. The paper discusses a concept design for the variable diameter nozzle to be fitted to a RapMan 3D printer and the software used to generate the tool paths for the extrusion head. The methodology involves the use of existing software solutions to gather basic data from STL files and generate the tool paths. A method for integrating the data and the deposition system is proposed. The challenges and possibilities of the technology are discussed as well as future research

A Review of State-of-the-Art Large Sized Foam Cutting Rapid Prototyping and Manufacturing Technologies.

Purpose – Current additive rapid prototyping (RP) technologies fail to efficiently produce objects greater than 0.5?m3 due to restrictions in build size, build time and cost. A need exists to develop RP and manufacturing technologies capable of producing large objects in a rapid manner directly from computer-aided design data. Foam cutting RP is a relatively new technology capable of producing large complex objects using inexpensive materials. The purpose of this paper is to describe nine such technologies that have been developed or are currently being developed at institutions around the world. The relative merits of each system are discussed. Recommendations are given with the aim of enhancing the performance of existing and future foam cutting RP systems. Design/methodology/approach – The review is based on an extensive literature review covering academic publications, company documents and web site information. Findings – The paper provides insights into the different machine configurations and cutting strategies. The most successful machines and cutting strategies are identified. Research limitations/implications – Most of the foam cutting RP systems described have not been developed to the commercial level, thus a benchmark study directly comparing the nine systems was not possible. Originality/value – This paper provides the first overview of foam cutting RP technology, a field which is over a decade old. The information contained in this paper will help improve future developments in foam cutting RP systems

Using the Finite Element Method to Determine the Temperature Distributions in Hot-wire Cutting.

Hot-wire cutting is a common material removal process used to shape and sculpt plastic foam materials, such as expanded polystyrene (EPS). Due to the low cost and sculpt-ability of plastic foams they are popular materials for large sized (> 1 m³) prototypes and bespoke visual artefacts. Recent developments in robotic foam sculpting machines have greatly increased the ability of hot-tools to sculpt complex geometrical surfaces bringing the subject into the realm of subtractive rapid prototyping/manufacturing. Nevertheless foam cut objects are not being exploited to their full potential due to the common perception that hot-wires are a low accuracy cutting tool. If greater accuracy for hot-wires can be obtained, it could provide a low cost method of producing high value functional engineering parts. Polystyrene patterns for lost foam casting are one such possibility. A nonlinear transient thermal finite element model was developed with the purpose of predicting the kerf width of hot-wire cut foams. Accurate predictions of the kerfwidth during cutting will allow the tool paths to be corrected off-line at the tool definition stage of the CAM process. Finite element analysis software (ANSYS) was used to simulate the hot-wire plastic foam cutting. The material property models were compiled from experimental data and commonly accepted values found in literature. The simulations showed good agreement with the experimental data and thus the model is thought to be reliable. The simulations provide an effective method of predicting kerf widths, under steady state cutting conditions. Limitations and further developments to the model are described

Electrospinning predictions using artificial neural networks

Electrospinning is a relatively simple method of producing nanofibres. Currently there is no method to predict the characteristics of electrospun fibres produced from a wide range of polymer/solvent combinations and concentrations without first measuring a number of solution properties. This paper shows how artificial neural networks can be trained to make electrospinning predictions using only commonly available prior knowledge of the polymer and solvent. Firstly, a probabilistic neural network was trained to predict the classification of three possibilities: no fibres (electrospraying); beaded fibres; and smooth fibres with > 80% correct predictions. Secondly, a generalised neural network was trained to predict fibre diameter with an average absolute percentage error of 22.3% for the validation data. These predictive tools can be used to reduce the parameter space before scoping exercises

Digital Footprints – Should We Be Worried? (36)

The internet is a big and unforgiving space. In this paper we explore what is the ‘digital footprint’ that we all leave as we move around the online world and how that might affect what happens in the offline world. In the past it was said that ‘today’s newspaper is tomorrow’s chip-paper’, but now what we post online is available today and tomorrow and for years to come. The question is ‘should we be worried about this’, how might it affect our reputation, are younger people sufficiently aware of what the future consequences of their online activities might be? How might we all ‘protect’ ourselves

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

Design of conformal cooling layers with self-supporting lattices for additively manufactured tooling

Additively manufactured (AM) conformal cooling channels are currently the state of the art for high performing tooling with reduced cycle times. This paper introduces the concept of conformal cooling layers which challenges the status quo in providing higher heat transfer rates that also provide less variation in tooling temperatures. The cooling layers are filled with self-supporting repeatable unit cells that form a lattice throughout the cooling layers. The lattices increase fluid vorticity which improves convective heat transfer. Mechanical testing of the lattices shows that the design of the unit cell significantly varies the compression characteristics. A virtual case study of the injection moulding of a plastic enclosure is used to compare the performance of conformal cooling layers with that of conventional (drilled) cooling channels and conformal (AM) cooling channels. The results show the conformal layers reduce cooling time by 26.34% over conventional cooling channels

The Role of Emancipatory Structure in StructurANTion: Informated Information Systems Development

This paper illustrates how the Emancipatory Structure within the StructurANTion theoretical framework may be called on by human and non-human actors to evoke radical change, even of the dissolution and replacement, of a humanchine network. This paper discusses the case of breast cancer surgery and the role information systems and technologies play in enabling this radical translation of an existing clinician-centric network to one in which the patient (female or male) rather than the clinician is the focal actor. The tools and techniques used to represent such informated networks and their emancipatory translations are also illustrated

Developing Credibility Guidelines for e-Government Website Design: An Empirical Study

Information Communication Technologies (ICTs) have changed how private sector business is conducted online. ICTs have also been adopted in the public sector, principally in terms of e-government. Users’ interaction with e-government can be influenced by a number of issues, notably e-government website credibility. Therefore, credibility is an important factor in e-government development, but one that has received little attention. This study has evaluated credibility of current e-government websites. The findings indicate a number of credibility problems, and suggest that current e-government websites need to improve their credibility. As such, this study has developed a set of credibility guidelines, which guide designers to develop credibility in e-government websites. The final goal is to develop more credible e-government that can generate greater users’ participation

Identifying and Classifying Processes (traditional and soft factors) that Support COTS Component Selection

COTS-Based Systems (CBS) development focuses on building large software systems by integrating previously existing software components. CBS success depends on successful evaluation and selection of Commercial-Off-The- Shelf (COTS) software components to fit customer requirements. Literature shows that successful selection of offthe- shelf systems to fit customer requirements remains problematic. This paper presents the outcome of a study aimed at using a social-technical approach to identify and classify processes (including traditional and soft factors) that support COTS software selection. The identified factors and lessons learnt from case study assisted in elaborating and further development of Social-Technical Approach to COTS Evaluation framework (STACE)