A Design for Additive Manufacturing Strategy for Dimensional and Geometrical Quality Improvement of PolyJet-Manufactured Glossy Cylindrical Features

Beltrán, Natalia; Álvarez, Braulio José Álvarez; Blanco, David; Peña, Fernando; Fernández, Pedro

doi:10.3390/polym13071132

Cited by 6 publications

(7 citation statements)

References 45 publications

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“…Additionally, the geometry is optimized using the surface modification method where selection criteria in the form of an algorithm are outlined for STL surfaces. Dimensional differences are compared in various studies 88,89,95,151 for various printing methods such as polyjet, fused deposition modeling, stereolithography, and powder bed fusion, and it was stated that polyjet technology resulted in a fine surface finish while fabricating the craniofacial skeleton. 150 .…”

Section: Printing Speed and Precisionmentioning

confidence: 99%

“…Polyjet printing reported a dimensional error of 2.14%, which was superior to stereolithography and powder bed fusion. A similar analysis 95 compares the dimensional variance of manufactured goods generated using various manufacturing techniques. Polyjet technology is generally associated with low printing speed as compared with other technologies 4,83,85,91,92 .…”

Section: Printing Speed and Precisionmentioning

confidence: 99%

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A review on polyjet 3D printing of polymers and multi-material structures

Patpatiya

Chaudhary²,

Shastri

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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This article investigates the state-of-the-art of polyjet 3D printing of polymers and multi-material structures, with an emphasis on its applications in a range of industrial domains, including aerospace, architecture, toy fabrication, and medical field. While significant research and development in the field of additively manufactured (AM) multi-material and reinforced composite structures have been carried out during the previous decade, the need of the hour is to utilize a single manufacturing platform which would not only help to govern the composition, shape, and characteristics of multi-material 3D printed objects at the microscopic level but would also help industries to replace the conventional AM manufacturing methods and optimize their mechanical performance. Significant advancements in polyjet 3D printing of fiber-reinforced and functionally graded structures with numerous modifications in material composition are reviewed, which may revolutionize the industrial sector. Numerous polyjet printing parameters such as accuracy, printing speed, photo-curing effect, build orientation, layer thickness, print angles, and post-processing are comprehensively discussed, and best outputs to optimize the mechanical performance and enhance the accuracy of the polyjet 3D printing products are highlighted. FEA (finite element analysis) models and analytical relations for multi-material 3D printed structures are presented to predict and enhance the overall performance of polyjet fabrication. Along with the benefits of polyjet manufacturing, a few of the limitations and challenges of polyjet AM are addressed which would benefit the reader to conduct further research in this field and enhance fabrication quality significantly. Vivid comparisons with other multi-material AM fabrication techniques such as FDM, SLA, and SLS with their brief discussion, merits, and demerits are done.

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Section: Printing Speed and Precisionmentioning

confidence: 99%

Section: Printing Speed and Precisionmentioning

confidence: 99%

A review on polyjet 3D printing of polymers and multi-material structures

Patpatiya

Chaudhary²,

Shastri

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

show abstract

“…while the maximum permissible limit of the repeatability range (R 0,MPL ) was 2.2 µm. The roundness profile verification strategy was defined following the methodology proposed in [50]: the relevant frequential components of geometrical deviations were calculated by means of the fast Fourier transform and the Nyquist criterion was used to determine the optimal scanning density for a reliable characterization of part geometry. As a result, nine cross-sections were digitized 4 mm apart from each other, whereas 18 points (one every 20 • ) were registered for each cross-section.…”

Section: Experimental Procedure: Case Studymentioning

confidence: 99%

Estimation and Improvement of the Achievable Tolerance Interval in Material Extrusion Additive Manufacturing through a Multi-State Machine Performance Perspective

et al. 2021

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Dimensional quality is still a major concern in additive manufacturing (AM) processes and its improvement is key to closing the gap between prototype manufacturing and industrialized production. Mass production requires the full working space of the machine to be used, although this arrangement could lead to location-related differences in part quality. The present work proposes the application of a multi-state machine performance perspective to reduce the achievable tolerance intervals of features of linear size in material extrusion (MEX) processes. Considering aspecific dimensional parameter, the dispersion and location of the distribution of measured values between different states are analyzed to determine whether the production should be treated as single-state or multi-state. A design for additive manufacturing strategy then applies global or local size compensations to modify the 3D design file and reduce deviations between manufactured values and theoretical values. The variation in the achievable tolerance range before and after the optimization of design is evaluated by establishing a target machine performance index. This strategy has been applied to an external MEX-manufactured cylindrical surface in a case study. The results show that the multi-state perspective provides a better understanding of the sources of quality variability and allows for a significant reduction in the achievable tolerance interval. The proposed strategy could help to accelerate the industrial adoption of AM process by reducing differences in quality with respect to conventional processes.

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“…For instance, the use of Digital Twins (DT), successfully applied in many fields related to Industry 4.0 (Tao et al , 2019; Leng et al , 2021), makes it possible by using a twin virtual machine (Kadir et al , 2011; Iñigo et al , 2021). However, in the case of AM, it is most common to use mathematical computer models to predict machine errors and compensate for them by one of the following procedures: modifying the original design of the part (Lyu et al , 2017; Beltrán et al , 2021); modifying the stereolithography (STL) model of the part (Wang and Chang, 2008; Cajal et al , 2016); and correcting the G-code that will be run on the machine control (Tong et al , 2008; Majarena et al , 2017). …”

Section: Introductionmentioning

confidence: 99%

“…Among these methods, the first two are the most recommendable as they allow for the tool path compensation, and not only for the target positions reached by the forming element during manufacture. As the geometry included in the STL file consists of triangles, its modification only involves the correction of the triangle vertices and their normal vectors (Tong et al , 2004) avoiding the need for complicated geometric transformations in the original computer aided design model (Beltrán et al , 2021).…”

Section: Introductionmentioning

confidence: 99%

Virtual-point-based geometric error compensation model for additive manufacturing machines

Zapico

Peña

Valiño

et al. 2022

RPJ

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Purpose The lack of geometric and dimensional accuracy of parts produced by additive manufacturing (AM) is directly related to the machine, material and process used. This paper aims to propose a method for the analysis and compensation of machine-related geometric errors applicable to any AM machine, regardless of the manufacturing process and technology used. Design/methodology/approach For this purpose, an error calculation model inspired by those used in computerized numerical control machines and coordinate measuring machines was developed. The error functions of the model were determined from the position deviations of a set of virtual points that are not sensitive to material and process errors. These points were obtained from the measurement of an ad hoc designed and manufactured master artefact. To validate the model, off-line compensation was applied to both the original designed artefact and an example part. Findings The geometric deviations in both cases were significantly smaller than those found before applying the geometric compensation. Dimensional enhancements were also achieved on the example part by using a correction parameter available in the three-dimensional printing software, whose value was adjusted from the measurement of the geometrically compensated master artefact. Research limitations/implications The errors that persist in the part derive from both material and process. Compensation for these type of errors requires a detailed analysis of the influencing parameters, which will be the subject of future research. Originality/value The use of the virtual-point-based error model increases the quality of additively manufactured parts and can be used in any AM system.

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A Design for Additive Manufacturing Strategy for Dimensional and Geometrical Quality Improvement of PolyJet-Manufactured Glossy Cylindrical Features

Cited by 6 publications

References 45 publications

A review on polyjet 3D printing of polymers and multi-material structures

A review on polyjet 3D printing of polymers and multi-material structures

Estimation and Improvement of the Achievable Tolerance Interval in Material Extrusion Additive Manufacturing through a Multi-State Machine Performance Perspective

Virtual-point-based geometric error compensation model for additive manufacturing machines

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