A high-speed additive manufacturing approach for achieving high printing speed and accuracy

Abstract

<jats:p> The primary concern of the Industry 4.0 is the direct digital manufacturing of customized products on demand at high production speed, high accuracy with functional material property. Although the unique capabilities of existing additive manufacturing technologies make it suitable for direct digital manufacturing, there are numerous limitations which include low printing speed, less accuracy and repeatability, and a limited selection of materials for a particular application. Therefore, a high-speed additive manufacturing approach is proposed in this paper, that is capable of achieving high speed of production, high accuracy, and surface finish, and functional material property. For better understanding, authors describe those additive manufacturing technologies that are capable of achieving the aforementioned characteristics. For validation, samples of various dimensions were 3D printed on a selective laser sintering and a high-speed multijet fusion 3D printer. The results were compared in the context of printing speed, surface roughness (Ra), and hardness of printed parts. Results revealed that the multijet fusion process is significantly faster than its counterpart while sacrificing Ra to some extent but the hardness of printed parts is not changed significantly. The selective laser sintering-printed samples had a 15% lower Ra compared with multijet fusion samples. The results also revealed that the multijet fusion process might be able to print composite/multi-materials; however, more research needs to be done. </jats:p>

Beamless Metal Additive Manufacturing

“…These technologies are quite similar to High Speed Sintering (HSS) process [164]. HP's MJF, uses inkjet printheads to deposit both a fusing agent and a detailing agent onto a bed of powder before sintering them with a set of infrared lamps [165], while HSS does not use a detailing agent. HSS has not been used for true metal 3D printing, while infrared-assisted sintering of inkjet printed metal tracks on substrates have been reported [166].…”

Powder-Based 3D Printing for the Fabrication of Device with Micro and Mesoscale Features

“…It cools down the temperature of the powder bed. Detailing agent also reduces the thermal distortion in 3D-printed parts and improves the accuracy and detail of prints close to the fused boundary [ 106 , 107 ]. The extended melt and fusing time results in better fusing.…”

“…The HSS 3D-printing process also jets an infrared absorbing ink that polymerizes the powder under infrared heat [ 112 , 113 , 114 , 115 , 116 , 117 , 118 , 119 ]. However, HSS 3D-printing process does not use detailing agent or transforming agent to improve accuracy, print detail, color and change material property [ 107 , 120 ].…”

Buckling and Post-Buckling Behavior of Uniform and Variable-Density Lattice Columns Fabricated Using Additive Manufacturing

“…Additive manufacturing is defined as a “process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies, such as traditional machining” by the Additive Manufacturing (AM) Technology Standard F2792-10 [1]. Additive manufacturing allows multiple benefits over traditional manufacturing such as fabrication of complex geometries without the associated increase in cost, low material wastage, no tooling requirements, personalization and customization, and reduction in cost and time of manufacturing [2,3]. Although the aforementioned characteristics of AM technologies make it preferable over traditional manufacturing in some use cases, there are also several challenges in AM that restrict its extensive use in the manufacturing industry [3].…”