Augmenting Computer-Aided Design Software With Multi-Functional Capabilities to Automate Multi-Process Additive Manufacturing

Bailey, Callum; Aguilera, Efrain; Espalin, David; Motta, José Maurício Santos Torres da; Fernández, Alfonso; Perez, Mireya A.; DiBiasio, Christopher M.; Pryputniewicz, Dariusz R.; MacDonald, Eric; Wicker, Ryan B.

doi:10.1109/access.2017.2781249

Cited by 16 publications

(13 citation statements)

References 14 publications

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“…Furthermore, inserting components into the printed part will likely affect the breakdown strength, given that the components will either create a pathway or obstruct the electric fields, as determined by the component's dielectric properties relative to the printed substrate. It should be stated that the embedding of electrical components has been previously demonstrated [16], [25] but not tested in regards to breakdown strength.…”

Section: B Ac and DC Hipot Testingmentioning

confidence: 99%

“…In pursuit of improved functionality, hybrid approaches have also been developed for material extrusion, to include the embedding of solid conductors within thermoplastic substrates [12]- [15] resulting in radiating elements for antennas [16], [17] and interconnect for embedded circuitry [18], [19]. Improved performance in interconnections was obtained through the use of solid conductive wires instead of conductive inks wherein exhibited lower resistivity (1.78 × 10 −8 • m for copper at 20 • C vs. 11.8 × 10 −8…”

Section: Introductionmentioning

confidence: 99%

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Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts With Embedded Wires for High Current-Carrying Applications

et al. 2019

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Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this paper describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to a 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this paper are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior. INDEX TERMS Multi 3D additive manufacturing, hybrid additive manufacturing, wire embedding, hipot testing, heat treatment, heat dissipation.

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Section: B Ac and DC Hipot Testingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts With Embedded Wires for High Current-Carrying Applications

et al. 2019

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“…Similarly, research on powder-based 3D printing with different color bindings [30] has resulted in products that produce plaster models in full-color 2 . Researchers have also investigated stereolithography setups with rotating carousels of resin vats [8] to produce multimaterial objects.…”

Section: Optical Materialsmentioning

confidence: 99%

“…In this context, researchers also explored techniques and supporting tools to embed conductive traces and capacitive pads in objects using dual-head extrusion printers and conductive filaments [26,28]. Alternatively, 3D printed channels can be filled manually using conductive paint [26], strips of coper [34] or automatically using special-purpose wire winding machinery [2]. Although these research efforts facilitate embedding of circuit traces in objects, seamlessly embedding electronic components in a fabricated object remains challenging.…”

Section: Embedding Existing Elements In Fabricated Objectsmentioning

confidence: 99%

StackMold: Rapid Prototyping of Functional Multi-Material Objects with Selective Levels of Surface Details

Valkeneers

Leen

Ashbrook

et al. 2019

Proceedings of the 32nd Annual ACM Symposium on User Interface Software and Technology

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An enormous thanks to Prof. Dr. Raf RAMAKERS for all his input and support in making this project happen. He provided me with very fast feedback on the work I did, helped with innovative ideas to solve problems and provided me with all the materials and tools that I required. Providing materials and tools is often taken for granted as the duty of the supervisor, but he was proactive in asking if other kinds of material or equipment where needed and when you asked to order a product, it was often ordered the same day. These little details make a big impact in the workflow of a project and me as a student felt supported. The same is true in the way he gave feedback and possible solutions on certain problems or ideas. He knows, and wants to know, in detail how a certain aspect of the software or process functions, which makes his ideas and feedback very practical and on point. Lastly a big thanks for the opportunity to turn this project into a paper. I probably didn't state this enough in person, but I am very glad that I was able to participate in the creation of a paper. I am very happy that i got to do it. Also a round of applause to Prof. Ph.D. Daniel ASHBROOK and Dany LEEN who both provided feedback on my work despite both being very busy. They also contributed on the paper about this project. A good portion of the pictures from this project are taken and edited by Dany. Thanks to the both of you. Lastly thanks to Jose Maria TIJERINA MUNOZ, or 'Chema', for helping me out on little things like problems with the lasercutter, casting resin, finding a tool, ... And my girlfriend Charlotte for having to put up with me when I needed to write(i don't like writing at all) or when I had no time while working the paper or around other deadlines.

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“…On the design side, we need tools that help us to explore the design space, unconstrained" [18] The open source FullControl GCode Designer software presented in this study directly addresses these needs by providing a generic framework for users to design the full manufacturing plan (print-path and print parameters) without constraint. Some relevant software has been developed to allow precise control for specific fields and applications, including: layerwise scaffold design for bioprinters [19], printing in well plates for bioprinters [20], graded scaffolds [21], fibre placement for carbon fibre reinforced printers [22][23][24], continuous extrusion for ceramics [11], controlled discontinuous extrusion for ceramics [13] and integration of multiple processes [25]. Additionally, scripts to translate CAD sketches or vector graphics into print-paths have been developed [26,27] as well as scripts for post-processing GCode generated by slicers [28].…”

Section: Introductionmentioning

confidence: 99%

FullControl GCode Designer: open-source software for unconstrained design in additive manufacturing

Gleadall¹

2021

Preprint

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A new concept is presented for the design of additive manufacturing procedures, which is implemented in open-source software called FullControl GCode Designer. In this new design approach, the user defines every segment of the print-path along with all printing parameters, which may be related to geometric and non-geometric factors, at all points along the print-path. Machine control code (GCode) is directly generated by the software, without the need for any programming skills and without using computer-aided design (CAD), STL-files or slicing software. Case studies are used to demonstrate the broad range of structures that can be designed using the software, including: precisely controlled specimens for printer calibration, parametric specimens for hardware characterisation utilising hundreds of unique parameter combinations, novel mathematically defined lattice structures, and previously inconceivable 3D geometries that are impossible for traditional slicing software to achieve. FullControl GCode Designer enables unconstrained freedom to create nonplanar 3D print-paths and break free from traditional restrictions of layerwise print-path planning. It also allows nozzle movements to be carefully designed - both during extrusion and while travelling between disconnected extrusion volumes - to overcome inherent limitations of the printing process or to improve capabilities for challenging materials. An industrial case study shows how explicit print-path design improved printer reliability, production time, and print quality for a production run of over 1,000 parts. FullControl GCode Designer offers a general framework for unconstrained design and is not limited to a particular type of structure or hardware; transferability to lasers and other manufacturing processes is discussed. Parametric design files use a few bytes or kilobytes of data to describe all details that are sent to the printer, which greatly improves shareability by eliminating any risk of errors being introduced during STL file conversion or due to different users having inconsistent slicer settings. Adjustable parameters allow GCode for revised designs to be produced instantly, instead of the laborious traditional routine using multiple software packages and file conversions. The FullControl design concept offers new opportunities for creative and high-precision use of additive manufacturing systems. It facilitates design for additive manufacturing (DfAM) at the smallest possible scale based on the fundamental nature of the process (i.e. assembly of individual extrusions). The software and source code are provided as supplementary data and ongoing updates will be available at www.fullcontrolgcode.com.

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Augmenting Computer-Aided Design Software With Multi-Functional Capabilities to Automate Multi-Process Additive Manufacturing

Cited by 16 publications

References 14 publications

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts With Embedded Wires for High Current-Carrying Applications

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts With Embedded Wires for High Current-Carrying Applications

StackMold: Rapid Prototyping of Functional Multi-Material Objects with Selective Levels of Surface Details

FullControl GCode Designer: open-source software for unconstrained design in additive manufacturing

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