Abstract. The University of Nantes has developed a 3D printing technique (BatiPrint3D TM ) dedicated to the construction of the walls of a house. This innovative on site construction technique is based on the deposition of two layers of expansive foam used as a formwork for a third concrete layer. It allows to build at the same time the structure and the insulation. This new construction technology has first been developed at the laboratory, but rapidly, we decided to deploy it on site, in order to demonstrate its technical viability. We present the technology Batiprint3D TM and the demonstrator Yhnova TM , a 95m² social dwelling built for the social landlord Nantes Métropole Habitat (NMH).
Purpose
The purpose of this paper is to present a novel methodology to produce a large boat hull with a foam additive manufacturing (FAM) process. To respond to shipping market needs, this new process is being developed. FAM technology is a conventional three-dimensional (3D) printing process whereby layers are deposited onto a high-pressure head mounted on a six-axis robotic arm. Traditionally, molds and masters are made with computer numerical control (CNC) machining or finished by hand. Handcrafting the molds is obviously time-consuming and labor-intensive, but even CNC machining can be challenging for parts with complex geometries and tight deadlines.
Design/methodology/approach
The proposed FAM technology focuses on the masters and molds, that are directly produced by 3D printing. This paper describes an additive manufacturing technology through which the operator can create a large part and its tools using the capacities of this new FAM technology.
Findings
The study shows a comparison carried out between the traditional manufacturing process and the additive manufacturing process, which is illustrated through an industrial case of application in the manufacturing industry. This work details the application of FAM technology to fabricate a 2.5 m boat hull mold and the results show the time and cost savings of FAM in the fabrication of large molds.
Originality/value
Finally, the advantages and drawbacks of the FAM technology are then discussed and novel features such as monitoring system and control to improve the accuracy of partly printed are highlighted.
Composite materials nowadays are used in a wide range of applications in aerospace, marine, automotive, surface transport and sports equipment markets. For example, all aircraft have the potential to incur damage and therefore require repairs. These shocks can impact the mechanical behavior of the structure in a different ways: adversely, irretrievable and, in some cases, in a scalable damage. It is therefore essential to intervene quickly on these parts to make the appropriate repairs without immobilizing the aircraft for too long. The scarfing repair operation involves machining or grinding away successive ply layers from the skin to create a tapered or stepped dish scarf profile around the damaged area. After the scarf profile is machined, the composite part is restored by applying multiple ply layers with the correct thickness and orientation to replace the damaged area. Once all the ply layers are replaced, the surface is heated under a vacuum to bond the new material. The final skin is ground smoothed to retrieve the original design of the part. Currently, the scarfing operations are performed manually. These operations involve high costs due to the precision, heath precautions and a lack of repeatability. In these circumstances, the use of automated solutions for the composite repair process could bring accuracy, repeatability and reduce the repair's time. The objective of this study is to provide a methodology for an automated repair process of composite parts, representative of primary aircraft structures.
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