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Article
Publication date: 10 October 2018

Tugdual Amaury Le Néel, Pascal Mognol and Jean-Yves Hascoët

The purpose of this paper is to analyze the current state of the art manufacturing techniques using sand molds for the casting industry by the means of additive manufacturing…

1772

Abstract

Purpose

The purpose of this paper is to analyze the current state of the art manufacturing techniques using sand molds for the casting industry by the means of additive manufacturing (AM). In particular, this review will cover two families of 3D printing in regards to sand mold fabrication.

Design/methodology/approach

This paper will discuss the sand casting manufacturing processes of AM by binder jetting (3D printing) and selective laser sintering. Scientific articles, patents and case studies are analyzed. Topics ranging from the technology types to the economic implications are covered.

Findings

The review investigates new factors and methods for mold design, looking at mechanical properties and cost analysis as influenced by material selection, thermal characteristics, topological optimization and manufacturing procedure. Findings in this study suggest that this topic lacks vigorous scientific research and that the case studies by manufacturers thus far are not useful.

Research limitations/implications

As demonstrated by the limited data from previous published studies, a more comprehensive and conclusive analysis is needed due to the lack of interest and resources regarding the AM of sand molds.

Practical implications

This study is a useful tool for any researchers with an interest in the field of AM of sand molds.

Social implications

Key perspectives are proposed.

Originality/value

This review highlights current gaps in this field. The review goes beyond the scientific articles by curating patents and professional case studies.

Details

Rapid Prototyping Journal, vol. 24 no. 8
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 17 October 2016

Benoit Rosa, Pascal Mognol and Jean-Yves Hascoët

Direct metal deposition (DMD) with laser is an additive manufacturing process enabling rapid manufacturing of complex metallic and thin parts. However, the final quality of…

1036

Abstract

Purpose

Direct metal deposition (DMD) with laser is an additive manufacturing process enabling rapid manufacturing of complex metallic and thin parts. However, the final quality of DMD-manufactured surfaces is a real issue that would require a polishing operation. Polishing processes are usually based on abrasive or chemical techniques. These conventional processes are composed by many drawbacks such as accessibility of complex shapes, environmental impacts, high time consumption and cost, health risks for operators, etc. […] This paper aims to solve these problems and improve surface quality by investigating the laser polishing (LP) process.

Design/methodology/approach

Based on melting material by laser, the LP process enables the smoothing of initial topography. However, the DMD process and the LP processes are based on laser technology. In this context, the laser DMD process is used directly on the same machine for the polishing operation. Currently, few studies focus on LP of additive laser manufacturing surfaces, and it tends to limit the industrial use of additive manufacturing technology. The proposed study describes an experimental analysis of LP surfaces obtained by DMD process.

Findings

The investigation results in the improvement of a complete final surface quality, according to LP parameters. For mastering LP processes, operating parameters are modelled.

Originality/value

This experimental study introduces the LP of thin and complex DMD parts, to develop LP applications. The final objective is to create a LP methodology for optimizing the final topography and productivity time according to parts’ characteristics.

Details

Rapid Prototyping Journal, vol. 22 no. 6
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 20 October 2014

Pierre Muller, Jean-Yves Hascoet and Pascal Mognol

The purpose of this paper is to propose an evaluation of toolpaths for additive manufacturing of functionally graded materials (FGM) parts to ensure the manufacturing of parts in…

1677

Abstract

Purpose

The purpose of this paper is to propose an evaluation of toolpaths for additive manufacturing of functionally graded materials (FGM) parts to ensure the manufacturing of parts in compliance with the desired material distribution. The selection of an appropriate path strategy is critical when manufacturing FGM parts.

Design/methodology/approach

The selection of a path strategy is based on a process modeling and an additive laser melting (ALM) system control. To do that, some path strategies are selected, simulated and compared.

Findings

The comparison of some paths strategies was applied on a study case from the biomedical field. Test-parts were manufactured and analyzed. Results show a good correlation between the simulated and the deposited material distributions. The evaluation of toolpaths based on the process modeling and the system control was validated.

Originality/value

Nowadays, FGM parts manufactured with ALM processes are not functional. To move from these samples to functional parts, it is necessary to have a global approach of the manufacturing procedure centered on the path planning. Few methodologies of path planning are adapted to FGM parts but are still limited.

Details

Rapid Prototyping Journal, vol. 20 no. 6
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 19 January 2010

Olivier Kerbrat, Pascal Mognol and Jean‐Yves Hascoet

The purpose of this paper is to propose a methodology to estimate manufacturing complexity for both machining and layered manufacturing. The goal is to take into account…

2108

Abstract

Purpose

The purpose of this paper is to propose a methodology to estimate manufacturing complexity for both machining and layered manufacturing. The goal is to take into account manufacturing constraints at design stage in order to realize tools (dies and molds) by a combination of a subtractive process (high‐speed machining) and an additive process (selective laser sintering).

Design/methodology/approach

Manufacturability indexes are defined and calculated from the tool computer‐aided design (CAD) model, according to geometric, material and specification information. The indexes are divided into two categories: global and local. For local indexes, a decomposition of the tool CAD model is used, based on an octree decomposition algorithm and a map of manufacturing complexity is obtained.

Findings

The manufacturability indexes values provide a well‐detailed view of which areas of the tool may advantageously be machined or manufactured by an additive process.

Originality/value

Nowadays, layered manufacturing processes are coming to maturity, but there is still no way to compare these new processes with traditional ones (like machining) at the early design stage. In this paper, a new methodology is proposed to combine additive and subtractive processes, for tooling design and manufacturing. A manufacturability analysis is based on an octree decomposition, with calculation of manufacturing complexity indexes from the tool CAD model.

Details

Rapid Prototyping Journal, vol. 16 no. 1
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 1 January 2006

Pascal Mognol, Denis Lepicart and Nicolas Perry

To discuss integration of the rapid prototyping environmental aspects with the primary focus on electrical energy consumption.

3161

Abstract

Purpose

To discuss integration of the rapid prototyping environmental aspects with the primary focus on electrical energy consumption.

Design/methodology/approach

Various manufacturing parameters have been tested on three rapid prototyping systems: Thermojet (3DS), FDM 3000 (Stratasys) and EOSINT M250 Xtended (EOS). The objective is to select sets of parameters for reduction of electrical energy consumption. For this, a part is manufactured in several orientations and positions in the chamber of these RP systems. For each test, the electrical power is noted. Finally, certain rules are proposed to minimize this electrical energy consumption during a job.

Findings

It is important to minimize the manufacturing time but there is no general rule for optimization of electrical energy consumption. Each RP system must be tested with energy consumption considerations under the spotlight.

Research limitations/implications

The work is only based on rapid prototyping processes. The objective is to take into consideration the complete life‐cycle of a rapid prototyped part: manufacturing of raw material as far as reprocessing of waste.

Practical implications

Reduction of electrical energy consumption to complete a job.

Originality/value

Currently, environmental aspects are not well studied in rapid prototyping.

Details

Rapid Prototyping Journal, vol. 12 no. 1
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 12 October 2018

Fabricio Leon Garcia, Virgínia Aparecida da Silva Moris, Andréa Oliveira Nunes and Diogo Aparecido Lopes Silva

The purpose of this paper is to overview the literature about the environmental performance of additive manufacturing (AM) and to evaluate the use of life cycle assessment (LCA…

787

Abstract

Purpose

The purpose of this paper is to overview the literature about the environmental performance of additive manufacturing (AM) and to evaluate the use of life cycle assessment (LCA) on these studies.

Design/methodology/approach

This study was based on the systematic literature review.

Findings

The investigation found that most authors were concerned about the energy consumption of the AM equipment, which is the subject studied by 87% of articles. In addition, 25% of the studies used LCA at least in some level, making a global environment assessment to evaluate the environmental impacts of AM. By analyzing research studies, it was possible to find signs that AM could be a lower environmental impact process, when compared with traditional manufacturing. However, this assumption is not valid in all cases because there are many variables that may affect environmental results.

Originality/value

Due to the increase on the usage of this type of technology by industries, studies on the environmental performance of this process became relevant.

Details

Rapid Prototyping Journal, vol. 24 no. 7
Type: Research Article
ISSN: 1355-2546

Keywords

Available. Open Access. Open Access
Article
Publication date: 28 September 2022

Yuxin Zhang, Wei Dong, Junyan Wang, Congcong Che and Lefei Li

Through this research study, the authors found that digital thread has made significant progress in the life cycle management of the US Air Force. The authors hope that by…

2752

Abstract

Purpose

Through this research study, the authors found that digital thread has made significant progress in the life cycle management of the US Air Force. The authors hope that by reviewing similar studies in the aerospace field, the meaning of digital thread can be summarized and applied to a wider range of fields. In addition, theoretically, the definition of digital twin and digital thread are not unified. The authors hope that the comparison of digital thread and digital twin will better enable scholars to distinguish between the two concepts. Besides, the authors are also looking forward that more people will realize the significance of digital thread and carry out future research.

Design/methodology/approach

Complete research about digital thread and the relevant concept of the digital twin is conducted. First, by searching in Google Scholar with the keyword “digital thread”, the authors filter results and save literature with high relevance to digital thread. The authors also track these papers’ references for more paper of digital thread and digital twin. After removing the duplicate and low-relevance literature, 72 digital thread-related literature studies are saved and further analyzed from the perspective of time development, application field and research directions.

Findings

Digital thread application in industries other than the aviation manufacturing industry is still relatively few, and the research on the application of digital thread in real industrial scenarios is mainly at the stage of framework design and design-side decision optimization. In addition, the digital thread needs a new management mechanism and organizational structure to realize landing. The new management mechanism and the process can adapt to the whole life cycle management process based on the digital thread, manage the data security and data update, and promote the digital thread to play a better effect on the organizational management.

Practical implications

Based on a review of digital thread, future research directions and usage suggestions are given. The fault diagnosis of high-speed train bogie as an example shows the effectiveness of the method and also partially demonstrates the advantages and effects brought by the digital thread connecting the data models at various stages.

Originality/value

This paper first investigates and analyzes the theoretical connotation and research progress of digital thread and gives a complete definition of digital thread from the perspective of the combination of digital thread and digital twins. Next, the research process of digital thread is reviewed, and the application fields, research directions and achievements in recent years are summarized. Finally, taking the fault diagnosis of high-speed train bogie as an example partially demonstrates the advantages and effects brought by the digital thread connecting the data models at various stages.

Details

Digital Transformation and Society, vol. 1 no. 2
Type: Research Article
ISSN: 2755-0761

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Article
Publication date: 1 August 2019

Elnaz Asadollahi-Yazdi, Julien Gardan and Pascal Lafon

This paper aims to provide a multi-objective optimization problem in design for manufacturing (DFM) approach for fused deposition modeling (FDM). This method considers the…

465

Abstract

Purpose

This paper aims to provide a multi-objective optimization problem in design for manufacturing (DFM) approach for fused deposition modeling (FDM). This method considers the manufacturing criteria and constraints during the design by selecting the best manufacturing parameters to guide the designer and manufacturer in fabrication with FDM.

Design/methodology/approach

Topological optimization and bi-objective optimization problems are suggested to complete the DFM approach for design for additive manufacturing (DFAM) to define a product. Topological optimization allows the shape improvement of the product through a material distribution for weight gain based on the desired mechanical behavior. The bi-objective optimization problem plays an important role to evaluate the manufacturability by quantification and optimization of the manufacturing criteria and constraint simultaneously. Actually, it optimizes the production time, required material regarding surface quality and mechanical properties of the product because of two significant parameters as layer thickness and part orientation.

Findings

A comprehensive analysis of the existing DFAM approaches illustrates that these approaches are not developed sufficiently in terms of manufacturability evaluation in quantification and optimization levels. There is no approach that investigates the AM criteria and constraints simultaneously. It is necessary to provide a decision-making tool for the designers and manufacturers to lead to better design and manufacturing regarding the different AM characteristics.

Practical implications

To assess the efficiency of this approach, a wheel spindle is considered as a case study which shows how this method is capable to find the best design and manufacturing solutions.

Originality/value

A multi-criteria decision-making approach as the main contribution is developed to analyze FDM technology and its attributes, criteria and drawbacks. It completes the DFAM approach for FDM through a bi-objective optimization problem which deals with finding the best manufacturing parameters by optimizing production time and material mass because of the product mechanical properties and surface roughness.

Details

Rapid Prototyping Journal, vol. 25 no. 5
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 6 August 2019

Corentin Douellou, Xavier Balandraud and Emmanuel Duc

The purpose of this paper is to develop a numerical approach inspired by Geometrical Product Specifications (GPS) standards for the assessment of geometrical defects appearing…

297

Abstract

Purpose

The purpose of this paper is to develop a numerical approach inspired by Geometrical Product Specifications (GPS) standards for the assessment of geometrical defects appearing during Additive Manufacturing (AM) by Laser Beam Melting (LBM).

Design/methodology/approach

The study is based on finite element (FE) simulations of thermal distortions, then an assessment of flatness defects (warping induced by the high-residual stresses appearing during the manufacturing) from the deformed surfaces provided by simulation, and finally the correction of the calculated flatness defects from preliminary comparison between simulated and experimental data.

Findings

For an elementary geometrical feature (a wall), it was possible to identify the variation in the flatness defect as a function of the dimensions. For a complex geometry exhibiting a significant flatness defect, it was possible to improve the geometric quality using the numerical tool.

Research limitations/implications

To the best of the author’s knowledge, this work is the first attempt using a numerical approach inspired by GPS standards to identify variations in thermal distortions caused by LBM, which is an initial step toward optimization. This paper is mainly focused on flatness defect assessment, even though the approach is potentially applicable for all types of geometrical defects (shape, orientation or position defects).

Practical implications

The study opens prospects for the optimization of complex parts elaborated using LBM, based on the minimization of the geometric defects caused by thermal distortions.

Social implications

The prospects in terms of shape optimization will extend the potential to benefit from the new possibilities offered by LBM additive manufacturing.

Originality/value

Unlike the usual approach, the proposed methodology does not require any artifacts or comparisons with the computer-aided-design (CAD) model for geometrical distortion assessment. The present approach opens up the possibility of performing metrology from FE simulation results, which is particularly promising in the AM field.

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Article
Publication date: 4 June 2021

Luis Lisandro Lopez Taborda, Heriberto Maury and Jovanny Pacheco

There are many investigations in design methodologies, but there are also divergences and convergences as there are so many points of view. This study aims to evaluate to…

1259

Abstract

Purpose

There are many investigations in design methodologies, but there are also divergences and convergences as there are so many points of view. This study aims to evaluate to corroborate and deepen other researchers’ findings, dissipate divergences and provide directing to future work on the subject from a methodological and convergent perspective.

Design/methodology/approach

This study analyzes the previous reviews (about 15 reviews) and based on the consensus and the classifications provided by these authors, a significant sample of research is analyzed in the design for additive manufacturing (DFAM) theme (approximately 80 articles until June of 2017 and approximately 280–300 articles until February of 2019) through descriptive statistics, to corroborate and deepen the findings of other researchers.

Findings

Throughout this work, this paper found statistics indicating that the main areas studied are: multiple objective optimizations, execution of the design, general DFAM and DFAM for functional performance. Among the main conclusions: there is a lack of innovation in the products developed with the methodologies, there is a lack of exhaustivity in the methodologies, there are few efforts to include environmental aspects in the methodologies, many of the methods include economic and cost evaluation, but are not very explicit and broad (sustainability evaluation), it is necessary to consider a greater variety of functions, among other conclusions

Originality/value

The novelty in this study is the methodology. It is very objective, comprehensive and quantitative. The starting point is not the case studies nor the qualitative criteria, but the figures and quantities of methodologies. The main contribution of this review article is to guide future work on the subject from a methodological and convergent perspective and this article provides a broad database with articles containing information on many issues to make decisions: design methodology; optimization; processes, selection of parts and materials; cost and product management; mechanical, electrical and thermal properties; health and environmental impact, etc.

Details

Rapid Prototyping Journal, vol. 27 no. 5
Type: Research Article
ISSN: 1355-2546

Keywords

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