C. Hauser, M. Dunschen, M. Egan and C. Sutcliffe
The purpose of this paper is to report on software development in which mathematical algorithms apply geometric transformations to digitised images in preparation for layer…
Abstract
Purpose
The purpose of this paper is to report on software development in which mathematical algorithms apply geometric transformations to digitised images in preparation for layer manufacturing by printing a binder onto a rotating powder substrate.
Design/methodology/approach
Spiral growth manufacturing (SGM) is a high‐speed rapid manufacturing technique in which objects are built up, layer by layer, by simultaneously depositing, levelling and selectively consolidating thin powder layers onto a rotating build platform. Consolidation occurs by infiltrating the powder layer with a binding agent deposited in droplet form using inkjet technology. During each rotation, the build platform falls away from a stationary doctor blade and print head assembly. This gives a continuous spiralled layer of powder with a constant layer pitch. To faithfully print digitised images onto a rotating substrate, polar and linear transformations have to be applied.
Findings
In support of this work, dimensional accuracy measurements of transformed printed images are reported and the measured results were found to be within ±0.2 mm of their predicted size. The experimental work is briefly extended to the printing of transformed images, using an aqueous binder, onto plaster powder to demonstrate the build speed capabilities of SGM. Primitive multiple layer parts built at speeds of 10 layers/min are reported.
Practical implications
From a practical standpoint, SGM has the potential to increase build speed by an order of magnitude over existing commercial rapid prototyping/manufacturing systems.
Originality/value
There is no commercial system available that allows high‐speed simultaneous deposition and processing of powder material and so this method could have implications in large batch manufacture.
Details
Keywords
Guillermo Zañartu‐Apara and Jorge Ramos‐Grez
The purpose of this paper is to study the effect of different parameters (layer thickness, jetted binder volume per layer and type of binder and temperature) on the mechanical…
Abstract
Purpose
The purpose of this paper is to study the effect of different parameters (layer thickness, jetted binder volume per layer and type of binder and temperature) on the mechanical properties of parts made with an experimental 3D printing (3DP) process. This 3DP device built for this project is based on the spiral growth manufacturing (SGM) device previously introduced by Hauser et al. at The University of Liverpool. It differs from the common 3DP in that it generates the different parts using only one rotating piston instead of two non‐rotating ones.
Design/methodology/approach
Several parts are produced using this device according to an experimental design, repeating each run three times. The experimental machine is able to make every part needed without major issues, demonstrating that it is possible to build a functional device using common and standard components.
Findings
Experimental analysis of the printed parts shows that the layer thickness has the highest effect on apparent density, hardness and fracture strength of the parts made.
Originality/value
Empirical information is provided about mechanical behavior (e.g. apparent density, hardness and fracture strength) of parts made under different processing factors (e.g. binder type, layer thickness, quantity of binder and chamber temperature) using a SGM‐based 3DP experimental device.