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This study aims to develop a data fusion method for powder-bed fusion (PBF) process monitoring based on process image information. The data fusion method can help improve process condition identification performance, which can provide guidance for further PBF process monitoring and control system development.

Design of reliable process monitoring systems is an essential approach to solve PBF built quality. A data fusion framework based on support vector machine (SVM), convolutional neural network (CNN) and Dempster-Shafer (D-S) evidence theory are proposed in the study. The process images which include the information of melt pool, plume and spatters were acquired by a high-speed camera. The features were extracted based on an appropriate image processing method. The three feature vectors corresponding to the three objects, respectively, were used as the inputs of SVM classifiers for process condition identification. Moreover, raw images were also used as the input of a CNN classifier for process condition identification. Then, the information fusion of the three SVM classifiers and the CNN classifier by an improved D-S evidence theory was studied.

The results demonstrate that the sensitivity of information sources is different for different condition identification. The feature fusion based on D-S evidence theory can improve the classification performance, with feature fusion and classifier fusion, the accuracy of condition identification is improved more than 20%.

An improved D-S evidence theory is proposed for PBF process data fusion monitoring, which is promising for the development of reliable PBF process monitoring systems.

In rapid prototyping, such as SLA (stereolithography apparatus) and FDM (fused deposition modelling), the orientation of the part during fabrication is critical as it can affect part accuracy, reduce the production time, and minimize the requirement for supports and, thus, the cost of building the model. Presents a multi‐objective approach for determining the optimal part‐building orientation. Considers different objectives such as part accuracy and building time. Objective functions have been developed based on known sources of errors affecting part accuracy and the requirements of good orientations during the building of a model. The objective functions employ weights assigned to various surface types affecting part accuracy. The primary objective is to attain the specified accuracy achievable with the process. The secondary objective is to minimize the building time. Gives examples to illustrate the algorithm for deriving the optimal orientation which can assure better part quality and higher building efficiency.

Path generation is an important factor that affects the quality and efficiency of most laminated manufacturing processes such as SLS, SLA and FDM. This paper introduces an efficient path generation algorithm. The principle of the algorithm and its implementation are presented. A comparative study is used to analyze the effectiveness of this method. The results of comparison on both path length and processing time between the traditional method and the proposed method are discussed.

A geometric benchmark part is proposed, designed and fabricated for the performance evaluation of rapid prototyping machines/processes. The benchmark part incorporates key shapes and features of better‐known benchmark parts. It also includes new geometric features, such as freeform surfaces, certain mechanical features and pass‐fail features that are increasingly required or expected of RP processes/systems. The part is suitable for fabrication on a typical RP machines. In this paper, the application of the benchmark part is demonstrated using relatively common RP processes. The ability of the benchmark part to determine achievable geometric features and accuracy by the aforementioned RP processes is presented and discussed.

This study aims to further the understanding of support structures and the likely impacts on maraging steel MS1 parts fabricated by selective laser melting (SLM) at 45°, 60° and 75° building angles.

Two groups of samples, one group with support structures and the other group without support structures, were designed with the same specifications and printed under the same conditions by SLM at 45°, 60° and 75° building angles. Differences in dimensional accuracy, surface roughness, Vickers microhardness, residual stress and microstructure were compared between groups.

The results showed that with support structures, more accurate dimension and slightly higher Vickers microhardness could be obtained. Larger compressive stress dominated and was more uniformly distributed on the supporting surface. Without support structures, the dimension became more precise as the building angle increased and alternating compressive and tensile stress was unevenly distributed on the supporting surface. In addition, the surface roughness of the outer surface decreased with the increase of the built angle, regardless of the support structures. Furthermore, whether the building angle was 45°, 60° or 75°, the observed microstructures revealed that the support structures altered the orientation of the molten pool and the direction of grain growth.

This paper studies the influence of support structures on the workpieces printed at different building angles. Support structures affect the residual stress distribution, heat dissipation rate and microstructure of the parts, and thus affecting the printing quality. Therefore, it is necessary to balance the support strategy and printing quality to better apply or design the support structures in SLM.

Accuracy and building time are two important concerns in rapid prototyping (RP). Usually there exists a trade‐off between these two aspects pertaining to model building in RP. The use of variable thickness slicing can satisfy these two requirements to some extent. Introduces an adaptive variable thickness slicer implemented on a solid CAD modeller. The slicer employs a genetic algorithm to find the minimum layer thickness allowed at referenced height with a given cusp height tolerance. By introducing the variable thickness slicing technique, the optimal orientation for part building in RP systems is considered. Seeks to obtain the optimal orientation with adaptive slicing for part building in stereolithography (SLA) systems. Takes into consideration building time, accuracy and stability of the part when determining the optimal orientation. Results show that the proposed approach gives an effective and practical solution for building parts with curved surfaces.

To identify the effects of laser scan speed and scan spacing on surface morphology, microstructure and structure evolution in direct laser sintering of Cu‐based metal powder.

Scanning electron microscope, differential thermal analyser (DTA) and X‐ray diffractometer were used to examine the microstructure of the sintered parts.

It was found that the decrease of the scan speed and scan spacing could lead to densification due to solute‐reprecipitation mechanism. The formation of oxide Cu₂O is sensitive to the scan spacing due to the lack of Cu₃P protection under the re‐heating condition if using small scan spacing. Furthermore, the result shows that there exist two mechanisms in determining the phosphor distribution. During the laser sintering, concentration diffusion acts as the main mechanism at a fast scan speed and a large scan spacing while solute‐reprecipitation acts as the main mechanism at a low scan speed and small scan spacing.

This paper discloses the influence of process parameters on microstructure evolution and the mechanism of densification in direct laser sintering Cu‐based metal powder. It offers practical help to the researchers who are interested in direct laser sintering metal powder.

The feasibility of building copper‐based electrodes for electrical discharge machining (EDM) via laser cladding is investigated as an application of rapid prototyping (RP). Two material systems‐Cu/W (with and without nickel) and Cu/B₄C (with and without nickel) in certain compositions are selected for the experimental investigation. The laser claddings are realised via a 3000 W CO₂ laser with suitable parameters. The micro‐structures of the electrodes are analysed with a SEM. The performance of the EDM electrodes is examined in terms of machining rate and wear rate.

Rapid prototypes formed using stereolithography (SL) method have to undergo post‐curing to increase their strength and rigidity. This study attempts to reduce, if not eliminate, post‐cure distortion by characterising curing behaviours. Curing (both heat and UV initiated) characteristics of an acrylic‐based photopolymer under actual fabrication conditions were studied using Raman spectroscopy as well as differential scanning calorimetry (DSC) and differential scanning photo‐calorimetry (DSP). Specimens of single photopolymer lines were created using a SL machine. Raman spectroscopy was used to quantify the curing percentage at different areas on the cross‐section of these lines. Curing percentages before and after post‐curing were also obtained from the experiments. Difference in percentage of post‐curing gave an indication of the distortions faced. It was found that uncured and partially cured resins trapped within the photopolymer resulted in inhomogeneity of curing in the specimens causing shrinkage and distortion.

Fabricating functionally graded scaffolds to mimic the complex spatial distributions of the composition, micro-structure and functionality of native tissues will be one of the key objectives for future tissue engineering research. This study aims to create a scaffold to mimic functionally-graded tissue using a hybrid process, which incorporated electrospun polycaprolactone (PCL) and electrosprayed hydroxyapatite (HA) in a simple pathway.

The PCL and HA were dispensed simultaneously from different positions to form a layer on a rotational mandrel, and a gradient construct was achieved by adjusting dispensing rates of both materials.

The morphology of scaffolds changed gradually from one layer to another layer with the change of the dispensing conditions of the two materials. The elemental distribution analysis revealed that C/Ca ratio linearly increased with certain dispensing rate ratio of PCL:HA. In addition, the thickness, mechanical properties (i.e. ultimate tensile stress and Young’s modulus), surface roughness and water contact angle of each layer changed accordingly with the variation of dispensing rate of PCL and HA, and the diameter distributions of PCL fibres and HA particles did not vary significantly.

This study showed the hybrid process has the potential to be used in fabrication of scaffold with functionally graded structure for tissue engineering applications, especially for mimicking the nature of the native 3D tendon–bone interface.