Katsaus lisäävän valmistuksen (aka 3D-tulostus) mahdollisuuksiin ja kustannuksiin metallisten tuotteiden valmistuksessa: Case jauhepetitekniikka

Suurelle yleisölle lisäävä valmistustekniikka eli ns. 3D-tulostustekniikka näyttäytyy lehtien otsikoissa ja artikkeleissa esiin pulpahtavana ”muotiaiheena”, mutta sekä muovien 3D-tulostustekniikka että metallienkin vastaava valmistustekniikka on ollut olemassa maailmalla ja Suomessa 80-luvun puolivälistä alkaen. Yhdysvalloissa ja Saksassa tekniikkaa käytetään valmistavassa teollisuudessa toiminnallisten osien tuotannossa. Esimerkiksi lentokoneen suihkumoottorien osia ja lääketieteellisiä välineitä tehdään metallijauheesta lisäävän valmistuksen avulla. Itse asiassa eräs menetelmä metalliesineiden valmistamiseksi lasersäteen avulla keksittiin Suomessa ja sitä myös kehiteltiin täällä, mutta teollisuudenala lähti aikanaan nousuun Saksassa. Lisäävä valmistus on tällä hetkellä maailmanlaajuisesti eräs kiinnostavista tuotantotekniikoista, jonka uskotaan muuttavan monia asioita tuotteiden suunnittelussa, toiminnoissa ja valmistuksessa. Tämä tekniikka ei kiinnosta pelkästään valmistavaa teollisuutta, vaan tietotekniikan, lääketieteen, koruvalmistuksen ja muotoilun osaajat sekä uusien liiketoimintamallien kehittäjät ja logistiikka operaattorit ovat teknologiasta kiinnostuneita. Suomelle 3D-tulostustekniikka on suuri mahdollisuus, sillä maassamme on vahva teollinen tieto- ja viestintätekniikkaosaaminen sekä lisäksi olemme maassamme erikoistuneet varsin vaativien teollisiin laitteiden valmistukseen. Eräät suurimmista mahdollisuuksista tällä tekniikalla ovat toimitusketjuihin liittyvät muutokset. Uutta on, että pienetkin yritykset ja organisaatiot voivat soveltaa tätä tekniikkaa valmistuksessa ja jopa kehitellä täysin uusia tuotteita. On myös arvioitu, että lisäävän valmistuksen merkitys valmistustapoihin ja toimitusketjuihin voi olla suurempi kuin koskaan aikaisemmin minkään teknologisen uudistuksen kohdalla. Lisäävästä valmistuksesta usein puhutaankin kolmantena teollisena vallankumouksena juuri tämän takia. 3D-tulostuksen kustannuksia tarkasteltaessa on tärkeätä huomata että vain sulatetun jauheen määrä ratkaisee, ei käytettävän geometrian monimutkaisuus. Tämä erottaa perinteisen ja lisäävän valmistuksen toisistaan. Perinteisesti kappaleen keventäminen on maksanut ”ylimääräistä”, kun taas lisäävässä valmistuksessa kappaleen keveys on jopa kustannusta alentava tekijä. Valmistettavan kappaleen korkeus on yksi kriittisimpiä kustannuksiin vaikuttavia tekijöitä. Tämän vuoksi useamman kappaleen valmistus yhdellä kertaa parantaa kannattavuutta huomattavasti. Samalla kertaa voi ja itse asiassa kannattaakin valmistaa keskenään erilaisia kappaleita. Perinteiset valmistustavat sen sijaan ovat nykyajan vaatimuksille liian hitaita; ne joustavat huonosti, kun kyseessä on pienet, asiakaslähtöiset erät. Trendi on globaalisti kohden yksilöllisiä asiakaslähtöisiä tuotteita, jolloin myös valmistustekniikoiden on oltava joustavia pysyäkseen näiden vaatimusten perässä. Lisäävä valmistus sopii erityisesti hyvin piensarjatuotantoon. Suuremmissa valmistuserissä kuitenkin perinteiset tekniikat ovat kustannustehokkaampia.

Näkökulmia 3D-tulostuksen opetukseen ja koulutukseen

Additive manufacturing, or 3D printing, is globally one of most interesting area in developing of manufacturing technologies. This technology is suitable for fabrication off industrial products and it interests actors in fields of computer sciences, economics, medical sciences and design&arts. Additive manufacturing is often referred as third industrial revolution: first revolution was invention of steam engines in 18th century and second was industrial revolution started by Henry Ford in 1920s. Companies should be able to test suitability of their products for additive manufacturing and 3D printing but also how much better products could be when products are totally re-designed so that all potential of this new technology can be utilized. This is where education has its importance; new generations who enter working life should be educated to know of additive manufacturing and 3D printing, its advantages but also of it limits. There has to be also possibility to educate industry and people already working there, so that industrial implementation could be done successfully. This is especially very valid for Finland. Education is strongly needed so that Finnish industry can maintain its competence in global markets. Role of education is extremely important when a new technology is industrially implemented. Additive manufacturing and 3D printing offers freedom to design new products, production and generally ways of doing things. Development, planning and execution of education for additive manufacturing and 3D printing is challenging as this area develops very fast. New innovations are coming almost every month. Planning of education for additive manufacturing and 3D printing requires collection pieces of data from various of sources. Additive manufacturing and 3D printing industry and its development has to be followed frequently, and material for additive manufacturing and 3D printing has to be renewed frequently.

Näin opetan lisäävää valmistusta ja 3D-tulostusta: Pohdintoja uuden teknologian opetuksesta ja koulutuksesta

Additive manufacturing (shortened as AM), or more commonly 3D printing, consists of wide variety of different modern manufacturing technologies. AM is based on direct printing of a digital 3D model to a final product which is fabricated adding material layer by layer. This is from where term additive manufacturing has its origin. It is not only material what is added, but it is also value, properties etc. which are added. AM enables production of different and even better products compared to conventional manufacturing technologies. An estimation of potential of additive manufacturing can be gathered by considering the potential of laser cutting, which is one of the most widely used modern manufacturing technologies. This technique has been used over 40 years, and whole market around this technology is at the moment c. four billion euros and yearly growth is around 10 %. One factor affecting this success of laser cutting is that laser cutting enables radical improvements to products made of flat sheet. AM and 3D printing will do the same for three dimensional parts. Laser devices, which are at the moment used in 3D printing, are globally at the moment only around 1% of all laser devices used in any fabrication technology, so even with a cautious estimate the potential growth of at least 100 % is coming in next few years. Role of education is very important, when this kind of modern technology is industrially implemented. When both generation entering to work life and also generation who has been a while in work life understands new technology, its potential and limitations, this is the point when also product design can be rethought Potential of product design is driving force for wide use of additive manufacturing and 3D printing. Utilization of additive manufacturing and 3D printing is also opportunity for Finland and Finnish industry. This technology can save Finnish manufacturing industry. This technique has stron potential, as Finland has traditionally strong industrial know-how and good ICT knowledge.

Dos bytes aos átomos: reflexões e experimentações artísticas sobre o universo da impressão 3D

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Von der Idee bis zum fertigen Produkt - 3D-Drucken mit der PolyJetTM -Technologie von OBJECT

Um mit den immer kürzer werdenden Produkteinführungszeiten Schritt halten zu können, die der harte Wettbewerb heute vorgibt, setzt die produzierende Industrie mehr und mehr auf das 3D-Drucken von Prototypen. Mit dieser Produktionsmethode lassen sich technische Probleme schon in der frühen Entwicklungsphase lösen. Dies spart Kosten und beschleunigt die Entwicklungsschritte. Die innovative PolyJetTM-Technologie von Objet setzt neue Maßstäbe im 3D-Drucken. 
Die Besonderheit: Modelle aus hauchdünnen Materialschichten. So können mit der 
PolyJetTM-Technologie detailgetreue Modelle extrem schnell, einfach und sauber realisiert werden – und das mit hervorragender Oberflächenqualität

3D Drucken und die Anwendungen

Eine zunehmende Anzahl von Artikeln in Publikumszeitschriften und Journalen rückt die direkte Herstellung von Bauteilen und Figuren immer mehr in das Bewusstsein einer breiten Öffentlichkeit. Leider ergibt sich nur selten ein einigermaßen vollständiges Bild davon, wie und in welchen Lebensbereichen diese Techniken unseren Alltag verändern werden. Das liegt auch daran, dass die meisten Artikel sehr technisch geprägt sind und sich nur punktuell auf Beispiele stützen. Dieser Beitrag geht von den Bedürfnissen der Menschen aus, wie sie z.B. in der Maslow’schen Bedürfnispyramide strukturiert dargestellt sind und unterstreicht dadurch, dass 3D Printing (oder Additive Manufacturing resp. Rapid Prototyping) bereits alle Lebensbereiche erfasst hat und im Begriff ist, viele davon zu revolutionieren.

Investigation into the Influence of Build Parameters on Failure of 3D Printed Parts

Additive manufacturing, including fused deposition modeling (FDM), is transforming the built world and engineering education. Deep understanding of parts created through FDM technology has lagged behind its adoption in home, work, and academic environments. Properties of parts created from bulk materials through traditional manufacturing are understood well enough to accurately predict their behavior through analytical models. Unfortunately, Additive Manufacturing (AM) process parameters create anisotropy on a scale that fundamentally affects the part properties. Understanding AM process parameters (implemented by program algorithms called slicers) is necessary to predict part behavior. Investigating algorithms controlling print parameters (slicers) revealed stark differences between the generation of part layers. In this work, tensile testing experiments, including a full factorial design, determined that three key factors, width, thickness, infill density, and their interactions, significantly affect the tensile properties of 3D printed test samples.

Characterization of a 3D-printed low-cost flexible dielectric material for the realization of innovative WPT wearable applications

The aim of this thesis is to demonstrate that 3D-printing technologies can be considered significantly attractive in the production of microwave devices and in the antenna design, with the intention of making them lightweight, cheaper, and easily integrable for the production of wireless, battery-free, and wearable devices for vital signals monitoring. In this work, a new 3D-printable, low-cost resin material, the Flexible80A, is proposed as RF substrate in the implementation of a rectifying antenna (rectenna) operating at 2.45 GHz for wireless power transfer. A careful and accurate electromagnetic characterization of the abovementioned material, revealing it to be a very lossy substrate, has paved the way for the investigation of innovative transmission line and antenna layouts, as well as etching techniques, possible thanks to the design freedom enabled by 3D-printing technologies with the aim of improving the wave propagation performance within lossy materials. This analysis is crucial in the design process of a patch antenna, meant to be successively connected to the rectifier. In fact, many different patch antenna layouts are explored varying the antenna dimensions, the substrate etchings shape and position, the feeding line technology, and the operating frequency. Before dealing with the rectification stage of the rectenna design, the hot and long-discussed topic of the equivalent receiving antenna circuit representation is addressed, providing an overview of the interpretation of different authors about the issue, and the position that has been adopted in this thesis. Furthermore, two rectenna designs are proposed and simulated with the aim of minimizing the dielectric losses. Finally, a prototype of a rectenna with the antenna conjugate matched to the rectifier, operating at 2.45 GHz, has been fabricated with adhesive copper on a substrate sample of Flexible80A and measured, in order to validate the simulated results.

Design, fabrication and mechanical characterization of a structural node made using Wire and Arc Additive Manufacturing (WAAM) technology

Additive Manufacturing (AM), also known as “3D printing”, is a recent production technique that allows the creation of three-dimensional elements by depositing multiple layers of material. This technology is widely used in various industrial sectors, such as automotive, aerospace and aviation. With AM, it is possible to produce particularly complex elements for which traditional techniques cannot be used. These technologies are not yet widespread in the civil engineering sector, which is slowly changing thanks to the advantages of AM, such as the possibility of realizing elements without geometric restrictions, with less material usage and a higher efficiency, in particular employing Wire-and-Arc Additive Manufacturing (WAAM) technology. Buildings that benefit most from AM are all those structures designed using form-finding and free-form techniques. These include gridshells, where joints are the most critical and difficult elements to design, as the overall behaviour of the structure depends on them. It must also be considered that, during the design, the engineer must try to minimize the structure's own weight. Self-weight reductions can be achieved by Topological Optimization (TO) of the joint itself, which generates complex geometries that could not be made using traditional techniques. To sum up, weight reductions through TO combined with AM allow for several potential benefits, including economic ones. In this thesis, the roof of the British Museum is considered as a case study, analysing the gridshell structure of which a joint will be chosen to be designed and manufactured, using TO and WAAM techniques. Then, the designed joint will be studied in order to understand its structural behaviour in terms of stiffness and strength. Finally, a printing test will be performed to assess the production feasibility using WAAM technology. The computational design and fabrication stages were carried out at Technische Universität Braunschweig in Germany.

Coupling 3D visualisation to qualitative assessment of built environment designs

Geographical information systems (GIS) coupled to 3D visualisation technology is an emerging tool for urban planning and landscape design applications. The utility of 3D GIS for realistically visualising the built environment and proposed development scenarios is much advocated in the literature. Planners assess the merits of proposed changes using visual impact assessment (VIA). We have used Arcview GIS and visualisation software: called PolyTRIM from the University of Toronto, Centre for Landscape Research (CLR) to create a 3D scene for the entrance to a University campus. The paper investigates the thesis that to facilitate VIA in planning and design requires not only visualisation, but also a structured evaluation technique (Delphi) to arbitrate the decision-making process. (C) 2001 Elsevier Science B.V. All rights reserved.

Current approaches and future perspectives on strategies for the development of personalized tissue engineering therapies

Personalized tissue engineering and regenerative medicine (TERM) therapies propose patient-oriented effective solutions, considering individual needs. Cell-based therapies, for example, may benefit from cell sources that enable easier autologous set-ups or from recent developments on IPS cells technologies towards effective personalized therapeutics. Furthermore, the customization of scaffold materials to perfectly fit a patientâ s tissue defect through rapid prototyping technologies, also known as 3D printing, is now a reality. Nevertheless, the timing to expand cells or to obtain functional in vitrotissue substitutes prior to implantation prevents advancements towards routine use upon patient´s needs. Thus, personalized therapies also anticipate the importance of creating off-the-shelf solutions to enable immediately available tissue engineered products. This paper reviews the main recent developments and future challenges to enable personalized TERM approaches and to bring these technologies closer to clinical applications.

Consumer Attitudes on Aroma Printing

Olfactory packaging is an emerging technology which uses the aromatic capsules to release various scents. Normally, manufacturers add these aromatic capsules in the printing ink, the label or packaging material itself. When the aromatic capsules meet suitable release triggers, the scents will be released. The common release triggers are external forces, temperature changes, humidity changes and so on. The aim for this Masters of Science Thesis is to understand the aroma printing technology from literature and make market research for this kind of technology. The main target is to collect the current technology principle of aroma packaging and figure out how they are implemented on products with those. In addition, an investigation is made about consumers' attitudes from Chinese and Finnish market through the questionnaire, and the market potential is analyzed as well. The key points researched in this work are: the general attitudes on aroma printing technology, market potential and economic possibilities. This thesis specifies the main technologies used in aroma printing, the solutions of products with aroma packaging and the original results of the questionnaires. It also includes analysis of the acceptance of Chinese and Finnish consumers, what are their opinions of the aroma printing technology and the products packed by aroma printing technology. In addition, various factors which impact the market is discussed in the thesis. At last, some comparisons are made from the point of views of similarities and differences between Chinese and Finnish market.

Characterization Of Process Efficiency Improvement In Laser Additive Manufacturing

Laser additive manufacturing (LAM), known also as 3D printing, has gained a lot of interest in past recent years within various industries, such as medical and aerospace industries. LAM enables fabrication of complex 3D geometries by melting metal powder layer by layer with laser beam. Research in laser additive manufacturing has been focused in development of new materials and new applications in past 10 years. Since this technology is on cutting edge, efficiency of manufacturing process is in center role of research of this industry. Aim of this thesis is to characterize methods for process efficiency improvements in laser additive manufacturing. The aim is also to clarify the effect of process parameters to the stability of the process and in microstructure of manufactured pieces. Experimental tests of this thesis were made with various process parameters and their effect on build pieces has been studied, when additive manufacturing was performed with a modified research machine representing EOSINT M-series and with EOS EOSINT M280. Material used was stainless steel 17-4 PH. Also, some of the methods for process efficiency improvements were tested. Literature review of this thesis presents basics of laser additive manufacturing, methods for improve the process efficiency and laser beam – material- interaction. It was observed that there are only few public studies about process efficiency of laser additive manufacturing of stainless steel. According to literature, it is possible to improve process efficiency with higher power lasers and thicker layer thicknesses. The process efficiency improvement is possible if the effect of process parameter changes in manufactured pieces is known. According to experiments carried out in this thesis, it was concluded that process parameters have major role in single track formation in laser additive manufacturing. Rough estimation equations were created to describe the effect of input parameters to output parameters. The experimental results showed that the WDA (width-depth-area of cross-sections of single track) is correlating exponentially with energy density input. The energy density input is combination of the input parameters of laser power, laser beam spot diameter and scan speed. The use of skin-core technique enables improvement of process efficiency as the core of the part is manufactured with higher laser power and thicker layer thickness and the skin with lower laser power and thinner layer thickness in order to maintain high resolution. In this technique the interface between skin and core must have overlapping in order to achieve full dense parts. It was also noticed in this thesis that keyhole can be formed in LAM process. It was noticed that the threshold intensity value of 106 W/cm2 was exceeded during the tests. This means that in these tests the keyhole formation was possible.

Energy and raw material consumption analysis of powder bed fusion: case study: CNC machining and laser additive manufacturing

Laser additive manufacturing (LAM), known also as 3D printing, is a powder bed fusion (PBF) type of additive manufacturing (AM) technology used to manufacture metal parts layer by layer by assist of laser beam. The development of the technology from building just prototype parts to functional parts is due to design flexibility. And also possibility to manufacture tailored and optimised components in terms of performance and strength to weight ratio of final parts. The study of energy and raw material consumption in LAM is essential as it might facilitate the adoption and usage of the technique in manufacturing industries. The objective this thesis was find the impact of LAM on environmental and economic aspects and to conduct life cycle inventory of CNC machining and LAM in terms of energy and raw material consumption at production phases. Literature overview in this thesis include sustainability issues in manufacturing industries with focus on environmental and economic aspects. Also life cycle assessment and its applicability in manufacturing industry were studied. UPLCI-CO2PE! Initiative was identified as mostly applied exiting methodology to conduct LCI analysis in discrete manufacturing process like LAM. Many of the reviewed literature had focused to PBF of polymeric material and only few had considered metallic materials. The studies that had included metallic materials had only measured input and output energy or materials of the process and compared to different AM systems without comparing to any competitive process. Neither did any include effect of process variation when building metallic parts with LAM. Experimental testing were carried out to make dissimilar samples with CNC machining and LAM in this thesis. Test samples were designed to include part complexity and weight reductions. PUMA 2500Y lathe machine was used in the CNC machining whereas a modified research machine representing EOSINT M-series was used for the LAM. The raw material used for making the test pieces were stainless steel 316L bar (CNC machined parts) and stainless steel 316L powder (LAM built parts). An analysis of power, time, and the energy consumed in each of the manufacturing processes on production phase showed that LAM utilises more energy than CNC machining. The high energy consumption was as result of duration of production. Energy consumption profiles in CNC machining showed fluctuations with high and low power ranges. LAM energy usage within specific mode (standby, heating, process, sawing) remained relatively constant through the production. CNC machining was limited in terms of manufacturing freedom as it was not possible to manufacture all the designed sample by machining. And the one which was possible was aided with large amount of material removed as waste. Planning phase in LAM was shorter than in CNC machining as the latter required many preparation steps. Specific energy consumption (SEC) were estimated in LAM based on the practical results and assumed platform utilisation. The estimated platform utilisation showed SEC could reduce when more parts were placed in one build than it was in with the empirical results in this thesis (six parts).

Sulautetun ohjausjärjestelmän kehittäminen 3D-tulostimelle

Kandidaatintyössä tutkittiin Adam Klodowskin tutkimuksessa käytetyn menetelmän soveltuvuutta 3D-tulostimen mekanismiin. Tutkimustyö liittyy RepRap-projektiin, jonka tavoitteena on valmistaa 3D-tulostin 3D-tulostetuista osista. Mekaniikasta oli luotu matemaattinen malli, jota tutkittiin simuloinnin avulla. Työssä toteutettiin täysin yksilöity sulautettu ohjausjärjestelmä kyseiselle mekanismille ja tutkittiin järjestelmän soveltuvuutta käytäntöön. Tavoitteena oli vähentää komponenttien lukumäärää ja pienentää laitteiston vaatimaa tilaa.