D. Dimitrov, W. van Wijck, K. Schreve and N. de Beer
The research was undertaken to characterise the three dimensional printing (3DP) process in term of the achievable dimensional and geometric accuracy.
Abstract
Purpose
The research was undertaken to characterise the three dimensional printing (3DP) process in term of the achievable dimensional and geometric accuracy.
Design/methodology/approach
New benchmark models were developed that represent characteristics needing to be investigated. The parts were fabricated in different materials. A program was written to measure the features on a numerically controlled coordinate measurement machine. Finally, a statistical analysis was done. The results are reported in terms of statistical parameters and international tolerance (IT) grades.
Findings
The paper provides general IT grades of the 3DP process for parts printed using different materials (powders).
Research limitations/implications
The research is limited to specific materials and equipment.
Practical implications
The data is very useful for designing products to be manufactured on 3DP machines applying either direct or indirect methods.
Originality/value
3DP is more and more used for rapid prototyping with great potential towards rapid manufacturing. Designers need to know the capability profile of the process they are going to use. There is a significant lack of published data on the 3DP process characteristics. This research was conducted to fill this gap and provide much needed accuracy information.
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D. Dimitrov, K. Schreve, A. Taylor and B. Vincent
The purpose of this paper is to demonstrate the use of three‐dimensional printing (3DP) process as a base technology for rapid manufacturing of components, larger than the…
Abstract
Purpose
The purpose of this paper is to demonstrate the use of three‐dimensional printing (3DP) process as a base technology for rapid manufacturing of components, larger than the machine's build volume. This extends the 3DP applications field beyond its existing domain. The paper gives process chains and design for manufacturing and assembly guidelines.
Design/methodology/approach
Several parameters influencing the process chains are identified and their interrelations investigated. Based on this study, new process chains are developed for specific functional and material requirements. The new process chains are validated with several case studies. Where applicable, the process chains are compared qualitatively with existing methods.
Findings
The results show that the new process chains are as fast as or faster than existing methods and have similar accuracy. The most significant advantage is a more geometric freedom. There is also more opportunity for checking physical models before making the final part. Some limitations to the processes are identified and given as design guidelines.
Research limitations/implications
A quantitative comparison of existing methods with the new process was not possible.
Practical implications
The study provides useful design for manufacturing guidelines.
Originality/value
This paper shows how 3DP technology, originally only conceived as a concept modeller, can be used to manufacture components that are larger than the rapid prototyping machine's build volume. It gives guidelines for designers wishing to follow a similar route.
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D. Dimitrov, K. Schreve and N. de Beer
This paper surveys the current state and capabilities of three dimensional printing (3DP). A comprehensive review of 3D Printing applications is presented. The scope of the…
Abstract
Purpose
This paper surveys the current state and capabilities of three dimensional printing (3DP). A comprehensive review of 3D Printing applications is presented. The scope of the applications includes design, manufacturing, the medical field and architecture.
Design/methodology/approach
A large variety of manufacturing applications such as rapid pattern making and rapid tooling using the 3DP process directly or as core technology, as well as further implications in design and engineering analysis, medicine, and architecture are presented and evaluated.
Findings
Some research issues are also discussed. An attempt, based on the state of the art, to show weaknesses and opportunities, and to draw conclusions about the future of this important process rounds up this paper.
Research limitations/implications
The scope of this research survey is limited to evaluation and comparison of processes that may be characterised as 3D printing technologies.
Practical implications
The study is very useful as a basis for matching evaluated 3D printing machine and process capabilities to user requirements, and forms a framework on which future comparative studies can build.
Originality/value
A comprehensive overview of the capabilities of 3DP processes is presented and evaluated. It shows the application of 3D printing beyond concept modelling. The paper is valuable for researchers as well as individuals, who require adequate and relevant comparative information during decision making.
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Quantifying and controlling the quality characteristics of parts produced by additive manufacturing (AM) processes has attracted significant interest in the research community…
Abstract
Purpose
Quantifying and controlling the quality characteristics of parts produced by additive manufacturing (AM) processes has attracted significant interest in the research community. However, to increase the sustainability of AM processes, such quality characteristics need to be assessed together with life cycle performance of AM processes such as energy and material consumption and manufacturing cost. Although a few studies have been performed for several quality characteristics, i.e. surface roughness and tensile strength, the relationship between dimensional performance and manufacturing cost is still not well known for AM processes.
Design/methodology/approach
In this paper, a comprehensive study of the dimensional performance and manufacturing cost of fused deposition modeling AM process is performed. Design of experiment technique is used, and the correlation of different cost components and the dimensional accuracy of parts are statistically studied.
Findings
The optimum process parameters for simultaneously optimizing the dimensional performance and manufacturing cost are identified. The analysis shows that as opposed to traditional manufacturing processes, obtaining a better dimensional performance is not necessarily associated with higher cost in the AM processes.
Originality/value
Almost no study and analysis for the combined dimensional performance and manufacturing cost has been performed for AM processes in the literature. It is known that within the context of traditional manufacturing processes, a natural trade-off governs the pursuit of higher dimensional performance and the manufacturing cost. However, as the AM process has a different nature compared with traditional manufacturing processes, the relationship between manufacturing cost and dimensional performance of parts has to be studied. Understanding this relationship will also help to establish a cost-optimal and sustainable tolerance allocation strategy in assemblies with AM components.
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Yogesh Patil, Milind Akarte, K. P. Karunakaran, Ashik Kumar Patel, Yash G. Mittal, Gopal Dnyanba Gote, Avinash Kumar Mehta, Ronald Ely and Jitendra Shinde
Integrating additive manufacturing (AM) tools in traditional mold-making provides complex yet affordable sand molds and cores. AM processes such as selective laser sintering (SLS…
Abstract
Purpose
Integrating additive manufacturing (AM) tools in traditional mold-making provides complex yet affordable sand molds and cores. AM processes such as selective laser sintering (SLS) and Binder jetting three-dimensional printing (BJ3DP) are widely used for patternless sand mold and core production. This study aims to perform an in-depth literature review to understand the current status, determine research gaps and propose future research directions. In addition, obtain valuable insights into authors, organizations, countries, keywords, documents, sources and cited references, sources and authors.
Design/methodology/approach
This study followed the systematic literature review (SLR) to gather relevant rapid sand casting (RSC) documents via Scopus, Web of Science and EBSCO databases. Furthermore, bibliometrics was performed via the Visualization of Similarities (VOSviewer) software.
Findings
An evaluation of 116 documents focused primarily on commercial AM setups and process optimization of the SLS. Process optimization studies the effects of AM processes, their input parameters, scanning approaches, sand types and the integration of computer-aided design in AM on the properties of sample. The authors performed detailed bibliometrics of 80 out of 120 documents via VOSviewer software.
Research limitations/implications
This review focuses primarily on the SLS AM process.
Originality/value
A SLR and bibliometrics using VOSviewer software for patternless sand mold and core production via the AM process.
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Tomaz Brajlih, Bogdan Valentan, Joze Balic and Igor Drstvensek
The purpose of this paper is to establish a general method for achievable speed and accuracy evaluation of additive manufacturing (AM) machines and an objective comparison among…
Abstract
Purpose
The purpose of this paper is to establish a general method for achievable speed and accuracy evaluation of additive manufacturing (AM) machines and an objective comparison among them.
Design/methodology/approach
First, a general schematic is defined that enables description of all currently available AM machines. This schematic is used to define two influential factors describing certain parts' properties regarding the machines' yield during manufacturing. A test part is defined, that will enable testing the influence of these factors on the speed and accuracy of manufacturing. A method for implementing and adapting test parts is established for individual machine's testing. This method was used to test four different machines that are predominantly used in Slovenia at the moment.
Findings
Research has proven that the machine's yield had a predominant influence on the achievable manufacturing speeds of all the tested machines. In addition, the results have shown different ranges of achievable manufacturing speeds for individually tested machines. Test parts' measurement results have shown comparable achievable accuracies for all the tested machines.
Research limitations/implications
Speed evaluation is based on a 2k factorial design that assumes the linearity among individual points of the experiment. This design was chosen to keep the method as simple and quick as possible, in order to perform testing on those machines otherwise used in industrial environments. Accuracy evaluation was limited by a rather small sample size of ten fabricated test parts per machine.
Practical implications
The presented evaluation method can be used on any existing or future type of AM machine, and their comparative placement regarding achievable manufacturing speed and accuracy.
Originality/value
The presented method can be used to evaluate a machine regardless of the AM technology on which it is based.
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Zhi Guo, Zhongde Shan, Feng Liu, Dong Du and Mengmeng Zhao
In this paper, the effects of the adhesive and curing agent contents on the tensile strength, bending strength, gas evolution and gas permeability of three-dimensional printed…
Abstract
Purpose
In this paper, the effects of the adhesive and curing agent contents on the tensile strength, bending strength, gas evolution and gas permeability of three-dimensional printed sand molds are studied. A strength model of the three-dimensional printed sand molds is proposed. The multi-material composite sand mold forming test is carried out. In addition, the mesostructure of the sand mold is studied.
Design/methodology/approach
The performances of three-dimensional printed sand mold such as tensile strength, bending strength, gas evolution and gas permeability are studied using the standard test methods. The mesostructure of the sand mold is studied by digital core technology.
Findings
A sand mold strength model based on the resin adhesive content, curing agent content and sand mold compactness are obtained. Two types of multi-material composite three-dimensional printed sand molds are proposed. An increase in the curing agent content in the sand mold widens the mesoscopic characteristic size distribution of the sand mold, and large-sized mesostructures appear, resulting in a decrease in the sand mold bearing capacity.
Practical implications
Process parameters that affect the performance of three-dimensional printed sand mold are revealed. The sand mold bearing curve provides a reference for the ultimate design of three-dimensional printed sand mold.
Originality/value
The paper deals with experimental work on the performance and mesostructure of multi-material composite three-dimensional printed sand mold with different contents of adhesive and curing agent. That gives a perspective on future designs of sand mold based on these principles.
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Yang Guo, Huseini S. Patanwala, Brice Bognet and Anson W.K. Ma
This paper aims to summarize the latest developments both in terms of theoretical understanding and experimental techniques related to inkjet fluids. The purpose is to provide…
Abstract
Purpose
This paper aims to summarize the latest developments both in terms of theoretical understanding and experimental techniques related to inkjet fluids. The purpose is to provide practitioners a self-contained review of how the performance of inkjet and inkjet-based three-dimensional (3D) printing is fundamentally influenced by the properties of inkjet fluids.
Design/methodology/approach
This paper is written for practitioners who may not be familiar with the underlying physics of inkjet printing. The paper thus begins with a brief review of basic concepts in inkjet fluid characterization and the relevant dimensionless groups. Then, how drop impact and contact angle affect the footprint and resolution of inkjet printing is reviewed, especially onto powder and fabrics that are relevant to 3D printing and flexible electronics applications. A future outlook is given at the end of this review paper.
Findings
The jettability of Newtonian fluids is well-studied and has been generalized using a dimensionless Ohnesorge number. However, the inclusion of various functional materials may modify the ink fluid properties, leading to non-Newtonian behavior, such as shear thinning and elasticity. This paper discusses the current understanding of common inkjet fluids, such as particle suspensions, shear-thinning fluids and viscoelastic fluids.
Originality/value
A number of excellent review papers on the applications of inkjet and inkjet-based 3D printing already exist. This paper focuses on highlighting the current scientific understanding and possible future directions.
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S. Vinodh, G. Sundararaj, S.R. Devadasan, D. Kuttalingam and D. Rajanayagam
The purpose of this paper is to investigate the adoption of rapid prototyping (RP) technology using three dimensional (3D) printer for infusing agility in traditional…
Abstract
Purpose
The purpose of this paper is to investigate the adoption of rapid prototyping (RP) technology using three dimensional (3D) printer for infusing agility in traditional manufacturing environment.
Design/methodology/approach
The computer aided design (CAD) model of a knob of an electronics switch is developed using Pro/E software. Keeping this model as a reference, CAD models of new six knobs are developed. A 3D printer is used to build the prototypes of five of those CAD models. The receptivity of the practitioners over adopting CAD models and 3D printer for achieving agility is investigated.
Findings
The sensitisation of the industry captains and employees of traditional manufacturing sector is the imperative for exploiting the power of 3D printer and achieving mass customisation.
Originality/value
The paper reports an original research in which the practicality of using 3D printer is investigated with the objective of enabling the traditional manufacturing companies to imbibe agile characteristics.
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Wanbin Pan, Hongyi Jiang, Shufang Wang, Wen Feng Lu, Weijuan Cao and Zhenlei Weng
This paper aims to detect the printing failures (such as warpage and collapse) in material extrusion (MEX) process effectively and timely to reduce the waste of printing time…
Abstract
Purpose
This paper aims to detect the printing failures (such as warpage and collapse) in material extrusion (MEX) process effectively and timely to reduce the waste of printing time, energy and material.
Design/methodology/approach
The approach is designed based on the frequently observed fact that printing failures are accompanied by abnormal material phenomena occurring close to the nozzle. To effectively and timely capture the phenomena near the nozzle, a camera is delicately installed on a typical MEX printer. Then, aided by the captured phenomena (images), a smart printing failure predictor is built based on the artificial neural network (ANN). Finally, based on the predictor, the printing failures, as well as their types, can be effectively detected from the images captured by the camera in real-time.
Findings
Experiments show that printing failures can be detected timely with an accuracy of more than 98% on average. Comparisons in methodology demonstrate that this approach has advantages in real-time printing failure detection in MEX.
Originality/value
A novel real-time approach for failure detection is proposed based on ANN. The following characteristics make the approach have a great potential to be implemented easily and widely: (1) the scheme designed to capture the phenomena near the nozzle is simple, low-cost, and effective; and (2) the predictor can be conveniently extended to detect more types of failures by using more abnormal material phenomena that are occurring close to the nozzle.