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D225: ADVANCEMENTS IN DESIGN AND MATERIALS FOR ADDITIVE MANUFACTURING
Time:
Tuesday, 21/May/2024:
10:45am - 12:30pm
Session Chair: Tino Stanković, ETH Zurich, Switzerland
Location:Congress Hall Konavle
Presentations
Analysing shrinkage compensation in additive manufacturing: a comparative study of reverse engineering and gauge-based methods
Alessio Zanini, Marco Marconi, Gianluca Rubino
Università degli Studi della Tuscia, Italy
Additive Manufacturing has transformed modern manufacturing with its well-known advantages. However, shrinkage remains a critical challenge, causing dimensional inaccuracies that should be properly compensated to assure geometric fidelity. This study aims to assess the reliability of a Reverse Engineering (RE) technique for dimensional compensation. A gauge-based measurement approach has been used to validate the RE method. Results confirm that the RE method is promising, while highlighting the intrinsic errors of the RE technique, and suggesting ways to evaluate and prevent them.
Optical and mechanical testing of 3D printed parts made of high-viscosity silicone to identify process parameters and design advice for 3D printing and printer development
Joel Schön, Robin Löffler, Michael Koch
Technische Hochschule Nürnberg Georg Simon Ohm, Germany
The additive manufacturing of parts made from close-to-production materials poses a great challenge. One example are highly viscous silicones, as used in injection moulding. For small production quantities, the manufacturing of injection moulds is uneconomical. This paper presents tensile specimens printed with an in-house developed dispensing system, which are analysed for air cavities (micro-CT scans) and mechanical properties. Based on the results, advice for the design and slicing parameters of parts using high-viscosity silicones in AM by means of material extrusion are developed.
Design and evaluation of non-planar material extrusion on a 3-axis printer
Samuel Bengtsson, Axel Nordin, Jože Tavčar
Lund University, Sweden
The use of material extrusion (MEX) has increased rapidly due to the affordability of 3D printers. This has led to a growing demand for improved print quality, high fidelity, strength, or fast print times. In this study, a non-planar approach for better surface quality is investigated. The hardware of a 3-axis MEX printer was developed together with testing new software for non-planar slicing. The aim was to identify the most influential parameter combinations using design of experiments. A novel method for measuring surface quality was presented together with future research work.
Exploring high-stiffness pellets as filaments in fused filament fabrication
Martin Lilletvedt Rasmussen1, Simen Gjethammer Grønvik1, Henrik H. Øvrebø1, Ben Hicks2, Chris Snider2, Martin Steinert1, Christer W. Elverum1, Sindre Wold Eikevåg1,2
1Norwegian University of Science and Technology, Norway; 2University of Bristol, United Kingdom
In Fused Filament Fabrication, there is increasing interest in the potential of composite filaments for producing complex and load-bearing components. Carbon fibre-filled polyamide currently has highest available strength and stiffness, but promising variants are not in filament form. This paper investigates filament production of commercially available, high-filled PA-CF pellets by modifying a tabletop filament extruder. We show filament production is possible by improving cooling. The FFF printed specimens show an average UTS of 135.5 MPa, higher than most commercially available filaments.
An analytic cost model for bound metal deposition
Mikhailo Sartini, Iacopo Bianchi, Alessio Vita, Michele Germani, Marco Mandolini
Università Politecnica delle Marche, Italy
Metal material extrusion is a family of metal additive manufacturing that includes atomic diffusion additive manufacturing (ADAM) and bound metal deposition (BMD). In the literature, there are just a few cost models for ADAM and no one for BMD. The paper presents an analytic cost model for BMD. It considers the entire process: pre-processing, printing and post-processing. The total manufacturing cost is split into material, machine, labour, energy and consumables items. The cost model validation on a 3D-printed part determined an accuracy of 98%.
