Conference Agenda

Thermal history is critical to part performance and reliability in material-extrusion additive manufacturing. Using encoders and an infrared camera, we developed a method to generate thermal clouds, where each node has its distinct spatio-thermal data. Filters removed up to 20.68% of the data while preserving relevant thermal features. This study enables in-situ process monitoring that establishes the basis for part certification, particularly for high-performance polymers, and for predicting material strength from thermal clouds.

This study evaluates the repeatability of print results in FDM through tests made with a generatively designed robotic limb. Five specimen were printed in two build orientations each with the same other process parameters. Deviations were measured via 3D scanning and CMM on both outer surfaces and functional features. Measured deviations exhibit small mean values and a clear orientation-dependent variability. As findings highlight deterministic effects in the propagation of deviations, design guidelines to improve repeatability of 3D prints are formulated as a result.

Individualisation in military equipment aims to improve performance by aligning design with soldier-specific needs. Existing DfAM methodologies lack structured integration of user variability and iterative evaluation in defence contexts. This study develops an iterative DfAM process linking anthropometric input, additive strategy, constraints, and performance assessment. Demonstrated through a helmet liner case, three iterations addressed geometry, manufacturability, and impact-response behaviour within regulatory limits.

We experimentally characterise the effect of layer temperature on the mechanical properties of PA6-CF manufactured by MEX. Ultimate tensile strength (UTS) and tensile modulus was investigated across layer temperatures ranging from 67 °C to 165 °C. UTS increased from 7.55 MPa at 67 °C to 36.04 MPa at 165°, while tensile modulus increased from 1.6 GPa at 67°C to 4.0 GPa at 140 °C. Measurements on a manufactured component show in-process layer temperatures between 88 °C and 123 °C. These findings quantify the attainable performance window and implications for functional component design.