Additive manufacturing technologies : 3D printing, rapid prototyping, and direct digital manufacturing

This book covers in detail the various aspects of joining materials to form parts. A conceptual overview of rapid prototyping and layered manufacturing is given, beginning with the fundamentals so that readers can get up to speed quickly. Unusual and emerging applications such as micro-scale manufacturing, medical applications, aerospace, and rapid manufacturing are also discussed. This book provides a comprehensive overview of rapid prototyping technologies as well as support technologies such as software systems, vacuum casting, investment casting, plating, infiltration and other systems. This book also: Reflects recent developments and trends and adheres to the ASTM, SI, and other standards Includes chapters on automotive technology, aerospace technology and low-cost AM technologies Provides a broad range of technical questions to ensure comprehensive understanding of the concepts covered.

Improved manufacturing quality and bonding of laser machined microfluidic systems

Laser micro-machining offers a versatile tool for the rapid manufacturing of polymeric microfluidics systems, with a typical turn-around-time in the order of minutes. However, the chaotic nature of the thermal evaporative ablation process can yield a significant number of defects in the surface of the manufactured microchannels, in the form of residual condensed material. In this work we have investigated the use of solvent evaporation by which to not only laminate bond the laser machined structures but to remove a significant number of the defect formed by the condensation of residual polymer. Results are presented of the surface profiling of the bonded channel structures and demonstrations of the bonding of the microchips to produce autonomous capillary microchannels.

Geometric and material constraints in parametric modelling : the design to fabrication process

Parametric modelling, commonly used in the automotive and aerospace industries, has recently been adopted in the architecture and construction fields. The ability to design small repeatable components and apply them to a larger governing surface geometry is one area of parametric modelling that has great design potential. This two level modelling control, of component and overall surface, can allow designers to explore new types of form generation subject to parametric constraints. This paper reports on the design to fabrication process using repeatable components over a governing or carrier surface. The paper reports on our study of the requirements and possible solutions for successfully controlling a repeatable element, known as a Representative Volumetric Element (RVE), using geometric parameters of a larger governing surface geometry and material properties. This modelling process, coupled with Rapid
Manufacturing (RM) and Computer Numerically Controlled (CNC) machines has the potential to significantly reduce the interface between design and fabrication.

Rapid composite tube manufacture utilizing the quickstep™ process

In this study, a novel method for manufacturing composite tubes utilizing the Quickstep^TM process has been developed. Tubes manufactured from `quick-cure' Toray G83C prepreg have demonstrated highly repeatable axial crush behavior with an average specific energy absorption (SEA) of 86 kJ/kg. The cure cycle is optimized by comparing the results from compression, dynamic mechanical thermal analysis (DMTA), differential scanning calorimetry (DSC), and porosity testing. The tube lay-up is optimized using compression and porosity test results. The effect of changes in fiber-orientation on SEA is also investigated. Process development has resulted in a robust manufacturing method capable of producing fully cured, high performance composite tubes with a cure cycle of 7 min. This corresponds to a 95% reduction in time compared to an equivalent autoclave cycle.

Robust control applied to metal spraying for rapid tooling

The spray forming process is a novel method of rapidly manufacturing tools and dies for stamping and injection operations. The process sprays molten tool steel from a set of arc spray guns onto a ceramic former to build up a thick steel shell. The volumetric contraction that occurs as the steel cools is offset by a volumetric expansion taking place within the sprayed steel, which allows the dimensional accurate tools to be produced. To ensure that the required phase transformation takes place, the temperature of the steel is regulated during spraying. The sprayed metal acts both as a source of mass and a source of heat and by adjusting the rate at which metal is sprayed; the surface temperature profile over the surface of the steel can be controlled. The temperature profile is measured using a thermal imaging camera and regulated by adjusting the rate at which the guns spray the steel. Because the temperature is regulated by adjusting the feed rate to an actuator that is moving over the surface, this is an example of mobile control, which is a class of distributed parameter control. The dynamic system has been controlled using a PI controller before. The paper describes the application of H∞ tracking type controller as the desire was for the average temperature to follow a desired profile. A study on the controllability of the underlying system was aimed at.

A flow control methodology for the rapid generation of vehicle traffic models

This paper presents a conveyor-based methodology to model complex vehicle flows common to factory and distribution warehouse facilities. The AGV and human path modelling techniques available in many commercial discrete event simulation packages require extensive knowledge and time to implement even the simplest flow control rules for multiple vehicle interaction. Although discrete event simulation is accepted as an effective tool to model vehicle delivery movements, human paths and delivery schedules for modern assembly lines, the time to generate accurate models is a significant limitation of existing simulation-based optimisation methodologies. The flow control method has been successfully implemented using two commercial simulation packages. It provides a realistic visual representation, as well as accurate statistical results, and reduces the model development process cost.

The emergence of battery electric vehicles : A NZ manufacturing opportunity?

Personal passenger transport faces several challenges in the coming decades: depletion of cheap oil reserves, increasing congestion, localised pollution, the need for reduced carbon emissions and the long term goal of sustainability. One way of solving some of these problems could be to introduce comfortable, energy efficient, battery electric vehicles.

Currently, hybrid vehicles have been presented as a means to reducing the transportation related oil demand. New developments in materials and technologies have made them, cleaner and safer as well as more fuel efficient. However, hybrids will only prolong the use of oil until alternatively fuelled vehicles are developed.

One long term alternative is the battery electric vehicle (BEV). A BEV designed to be light, aerodynamic with high efficiency drive train and latest battery technology would have a performance comparable to a typical internal combustion engine vehicle (ICEV). Recent developments in virtual engineering, rapid prototyping and advanced manufacturing might enable low-cost development of niche market BEV’s designed and built in New Zealand for export markets.

This work examines the collaborative development of a twin seat BEV using new materials and latest technologies by the University of Waikato’s Engineering Department and a group of NZ and foreign companies. The car will be used to research the potential of BEVs and will also compete in the Commuter Class of the World Solar Challenge in 2007.

MRP-production planning in agile manufacturing

The research studied a production planning problem in a manufacturing firm. Some production planning software was developed that enabled the efficient and rapid reproduction of an optimum production forecast. Not only was the production cost reduced but a significant length of planning time cn be saved using the software.

Rapid determination of protein contents in microencapsulated fish oil supplements by ATR-FTIR spectroscopy and partial least square regression (PLSR) analysis

Following the recent success in quantitative analysis of essential fatty acid compositions in a commercial microencapsulated fish oil (?EFO) supplement, we extended the application of portable attenuated total reflection Fourier transform infrared (ATR-FTIR) spectroscopic technique and partial least square regression (PLSR) analysis for rapid determination of total protein contents-the other major component in most commercial ?EFO powders. In contrast to the traditional chromatographic methodology used in a routine amino acid analysis (AAA), the ATR-FTIR spectra of the ?EFO powder can be acquired directly from its original powder form with no requirement of any sample preparation, making the technique exceptionally fast, noninvasive, and environmentally friendly as well as being cost effective and hence eminently suitable for routine use by industry. By optimizing the spectral region of interest and number of latent factors through the developed PLSR strategy, a good linear calibration model was produced as indicated by an excellent value of coefficient of determination R2 = 0.9975, using standard ?EFO powders with total protein contents in the range of 140-450 mg/g. The prediction of the protein contents acquired from an independent validation set through the optimized PLSR model was highly accurate as evidenced through (1) a good linear fitting (R2 = 0.9759) in the plot of predicted versus reference values, which were obtained from a standard AAA method, (2) lowest root mean square error of prediction (11.64 mg/g), and (3) high residual predictive deviation (6.83) ranked in very good level of predictive quality indicating high robustness and good predictive performance of the achieved PLSR calibration model. The study therefore demonstrated the potential application of the portable ATR-FTIR technique when used together with PLSR analysis for rapid online monitoring of the two major components (i.e., oil and protein contents) in finished ?EFO powders in the actual manufacturing setting.

The effect of a rapid heating rate, mechanical vibration and surfactant chemistry on the structure-property relationships of epoxy/clay nanocomposites

The role of processing conditions and intercalant chemistry in montmorillonite clays on the dispersion, morphology and mechanical properties of two epoxy/clay nanocomposite systems was investigated in this paper. This work highlights the importance of employing complementary techniques (X-ray diffraction, small angle X-ray scattering, optical microscopy and transmission electron microscopy) to correlate nanomorphology to macroscale properties. Materials were prepared using an out of autoclave manufacturing process equipped to generate rapid heating rates and mechanical vibration. The results suggested that the quaternary ammonium surfactant on C30B clay reacted with the epoxy during cure, while the primary ammonium surfactant (I.30E) catalysed the polymerisation reaction. These effects led to important differences in nanocomposite clay morphologies. The use of mechanical vibration at 4 Hz prior to matrix gelation was found to facilitate clay dispersion and to reduce the area fraction of I.30E clay agglomerates in addition to increasing flexural strength by over 40%.

Improved fracture toughness of fire resistant composites through rapid curing

A study on the effect of material and fracture properties of phenolic composites cured with reduced thermal cycle times. These reductions were achieved using various techniques. The work highlights significant reductions in manufacturing times are possible for this group of materials and conveniently can also lead to improved properties.