Material handling and registration for an additive manufacturing-based hybrid system

Ambriz, Steven; Coronel, Jose L.; Zinniel, Bob; Schloesser, Ron; Kim, Chi Yen; Perez, Mireya A.; Espalin, David; Wicker, Ryan B.

doi:10.1016/j.jmsy.2017.07.003

Cited by 24 publications

(7 citation statements)

References 21 publications

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“…The 3D printing was accomplished by using a Multi 3D manufacturing system briefly described here. The interested reader can find a further description of the Multi 3D manufacturing system in [21], [25], and [26]. The Multi 3D machine consisted of an industrial MH50 six-axis robot (Yaskawa Motoman, Miamisburg, OH, USA) with several manufacturing stations within its reach including two production-grade Fortus 400mc Fused Deposition Modeling (FDM) machines (Stratasys, Eden Prairie, MN, USA) and a LC 3024 CNC machine (Techno CNC Systems, Ronkonkoma, NY, USA) capable of using multiple custom tools, including a wire embedding tool, machining spindle, pick-and-place end-effectors, and foil application tool as described in [26] and [27].…”

Section: Experiments a Fabricationmentioning

confidence: 99%

“…In the case of embedded electronics, the increased porosity, inability to effectively dissipate heat, and the mismatch in CTE, lead to distortion of the fabricated part. Subsequently, thermal deformation causes mechanical stress on the substrate material, leading to failure during long term operation [21]. Repair of fully encapsulated and embedded wires (and electrical components when present) is often not possible because access to each is prohibited by the encapsulating thermoplastic.…”

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: Experiments a Fabricationmentioning

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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“…The detailed procedure for all activities that must be done prior to the build is stated in the SOPs as indicated in Figure 2.2.1. the radio frequency identification technique (RFID) can be attached to a batch [12]. During the build process, only a small portion of the powder is transformed into a solid part and the rest of the powder is reused in consecutive builds with a sieving process and topping up of the new powder to prepare for the new build.…”

Section: Machine Setupmentioning

confidence: 99%

“…During the build process, only a small portion of the powder is transformed into a solid part and the rest of the powder is reused in consecutive builds with a sieving process and topping up of the new powder to prepare for the new build. There are numerous benefits of a powder traceability system that are mentioned in literature [12,13].…”

Section: Machine Setupmentioning

confidence: 99%

Implementing digital twinning in an additive manufacturing process chain

Thejane,

du Preez,

Booysen

2023

MATEC Web Conf.

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Additive manufacturing (AM) is defined as the process of joining materials layer by layer to produce a part. The Centre for Rapid Prototyping and Manufacturing (CRPM) of the Central University of Technology, Free State has successfully established an AM process chain to produce qualified medical implants. The process chain complies with the international standards ISO 13485:2016 and ISO 14971:2012, which certify the repeatability and reliability of processes. Despite the significant achievements CRPM has obtained in medical applications, efficiency in some areas can be improved through digital twinning approaches. The digital twin has comprehensive capabilities and allows real-time monitoring that can be used to improve different phases of AM processes. In this study, areas that need further improvement in the process chain, such as management information that flows between different users and processes for design and setting up AM machines, will be discussed. The study will further indicate how these areas can benefit from available advanced technologies such as augmented reality (AR) technology and digital twin data management. Further implementation of this approach is expected to confirm the potential of easy self-learning approaches and managing data more effectively for improving the AM process chain.

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“…Additive manufacturing (AM) refers to a set of advanced production technologies, used to build a component layer-by-layer, usually towards achieving a near-net shape component (Ambriz et al , 2017; Ribeiro et al , 1997; Rieger et al , 2017). This process starts from a computer-aided design (CAD) digital model that converts into a physical component through a series of coordinated and controlled movements of the heat source provided by the material deposition system.…”

Section: Introductionmentioning

confidence: 99%

The role of robotics in additive manufacturing: review of the AM processes and introduction of an intelligent system

Pires

Azar

Nogueira

et al. 2021

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Purpose Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology. Design/methodology/approach AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices. Findings The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically. Research limitations/implications This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors. Originality/value The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.

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Material handling and registration for an additive manufacturing-based hybrid system

Cited by 24 publications

References 21 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

Implementing digital twinning in an additive manufacturing process chain

The role of robotics in additive manufacturing: review of the AM processes and introduction of an intelligent system

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