CAD Files and European Design Law

Three-dimensional printing (“3DP”) is an additive manufacturing technology that starts with a virtual 3D model of the object to be printed, the so-called Computer-Aided-Design (“CAD”) file. This file, when sent to the printer, gives instructions to the device on how to build the object layer-by-layer. This paper explores whether design protection is available under the current European regulatory framework for designs that are computer-created by means of CAD software, and, if so, under what circumstances. The key point is whether the appearance of a product, embedded in a CAD file, could be regarded as a protectable element under existing legislation. To this end, it begins with an inquiry into the concepts of “design” and “product”, set forth in Article 3 of the Community Design Regulation No. 6/2002 (“CDR”). Then, it considers the EUIPO’s practice of accepting 3D digital representations of designs. The enquiry goes on to illustrate the implications that the making of a CAD file available online might have. It suggests that the act of uploading a CAD file onto a 3D printing platform may be tantamount to a disclosure for the purposes of triggering unregistered design protection, and for appraising the state of the prior art. It also argues that, when measuring the individual character requirement, the notion of “informed user” and “the designer’s degree of freedom” may need to be reconsidered in the future. The following part touches on the exceptions to design protection, with a special focus on the repairs clause set forth in Article 110 CDR. The concluding part explores different measures that may be implemented to prohibit the unauthorised creation and sharing of CAD files embedding design-protected products.

Caratterizzazione microstrutturale e frattografica di componenti in acciaio 316L prodotti tramite Selective Laser Melting

Il Selective Laser Melting è un processo di additive manufacturing che consiste nella realizzazione di componenti metallici tridimensionali, sovrapponendo strati di polvere, che viene via via fusa mediante una sorgente controllata di energia (laser). È una tecnica produttiva che viene utilizzata da più di 20 anni ma solo ora sta assumendo un ruolo rilevante nell’industria. È un processo versatile ma complesso che ad oggi permette di processare solo un numero limitato di leghe. Il presente lavoro di tesi riguarda in particolare lo studio, dal punto di vista microstrutturale, di componenti in acciaio inossidabile austenitico AISI-316L processato mediante Selective Laser Melting, attività svolta in collaborazione con il Gruppo di Tecnologia – Laser del Dipartimento di Ingegneria Industriale. Alla base dell’attività sperimentale è stata svolta anche un’ampia ricerca bibliografica per chiarire lo stato dell’arte sul processo e sulla lega in questione, la microstruttura, i difetti, le proprietà meccaniche e l’effetto dei parametri di processo sul componente finito. Le attività sperimentali hanno previsto una prima fase di caratterizzazione delle polveri di 316L, successivamente la caratterizzazione dei campioni prodotti tramite selective laser melting, in termini di microstruttura e difetti correlati al processo. Le analisi hanno rivelato la presenza di una microstruttura “gerarchica” costituita da melt pool, grani e celle submicrometriche. I difetti rinvenuti sono pori, delaminazione degli strati, particelle di polvere non fuse. Infine è stata eseguita la caratterizzazione frattografica dei campioni sottoposti a prove di trazione e di fatica a flessione rotante (attività condotte dal gruppo Laser) per identificare la morfologia di frattura e i siti di innesco della cricca di fatica.

DESIGN, FABRICATION, AND PERFORMANCE CHARACTERIZATION OF MULTIFUNCTIONAL STRUCTURES TO HARVEST SOLAR ENERGY FOR FLAPPING WING AERIAL VEHICLES

Flapping Wing Aerial Vehicles (FWAVs) have the capability to combine the benefits of both fixed wing vehicles and rotary vehicles. However, flight time is limited due to limited on-board energy storage capacity. For most Unmanned Aerial Vehicle (UAV) operators, frequent recharging of the batteries is not ideal due to lack of nearby electrical outlets. This imposes serious limitations on FWAV flights. The approach taken to extend the flight time of UAVs was to integrate photovoltaic solar cells onto different structures of the vehicle to harvest and use energy from the sun. Integration of the solar cells can greatly improve the energy capacity of an UAV; however, this integration does effect the performance of the UAV and especially FWAVs. The integration of solar cells affects the ability of the vehicle to produce the aerodynamic forces necessary to maintain flight. This PhD dissertation characterizes the effects of solar cell integration on the performance of a FWAV. Robo Raven, a recently developed FWAV, is used as the platform for this work. An additive manufacturing technique was developed to integrate photovoltaic solar cells into the wing and tail structures of the vehicle. An approach to characterizing the effects of solar cell integration to the wings, tail, and body of the UAV is also described. This approach includes measurement of aerodynamic forces generated by the vehicle and measurements of the wing shape during the flapping cycle using Digital Image Correlation. Various changes to wing, body, and tail design are investigated and changes in performance for each design are measured. The electrical performance from the solar cells is also characterized. A new multifunctional performance model was formulated that describes how integration of solar cells influences the flight performance. Aerodynamic models were developed to describe effects of solar cell integration force production and performance of the FWAV. Thus, performance changes can be predicted depending on changes in design. Sensing capabilities of the solar cells were also discovered and correlated to the deformation of the wing. This demonstrated that the solar cells were capable of: (1) Lightweight and flexible structure to generate aerodynamic forces, (2) Energy harvesting to extend operational time and autonomy, (3) Sensing of an aerodynamic force associated with wing deformation. Finally, different flexible photovoltaic materials with higher efficiencies are investigated, which enable the multifunctional wings to provide enough solar power to keep the FWAV aloft without batteries as long as there is enough sunlight to power the vehicle.

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.

A MARKET-BASED APPROACH TO 3D PRINTING FOR ECONOMIC DEVELOPMENT IN GHANA

The purpose of this report is to create the foundation for further study of a market-based approach to 3D printing as an instrument for economic development in Ghana. The delivery of improved products and services to the most underserved markets is needed to spur economic activity and improve standards of living. The relationship between economic development and the advancement of technology is considered within the context of Ghana. An opportunity for market entry exists within both the bottom of the economic pyramid and the mid-segment market. 3D printing (additive manufacturing) has proven to be a disruptive technology that has demonstrated an ability to expedite the speed of innovations and create products that were previously not possible. An investigation of how 3D printers can be used to create improved products for the most underserved markets within Ghana is presented. Questions are asked to elucidate how and when adoption of 3D printers and 3D printed products may occur in the future. Based upon the existing barriers to adoption, 3D printing technology must improve before widespread adoption will occur in Ghana.

MULTISCALE MODELING OF LIQUID CRYSTALLINE/NANOTUBE COMPOSITES

The objective of this research is to synthesize structural composites designed with particular areas defined with custom modulus, strength and toughness values in order to improve the overall mechanical behavior of the composite. Such composites are defined and referred to as 3D-designer composites. These composites will be formed from liquid crystalline polymers and carbon nanotubes. The fabrication process is a variation of rapid prototyping process, which is a layered, additive-manufacturing approach. Composites formed using this process can be custom designed by apt modeling methods for superior performance in advanced applications. The focus of this research is on enhancement of Young's modulus in order to make the final composite stiffer. Strength and toughness of the final composite with respect to various applications is also discussed. We have taken into consideration the mechanical properties of final composite at different fiber volume content as well as at different orientations and lengths of the fibers. The orientation of the LC monomers is supposed to be carried out using electric or magnetic fields. A computer program is modeled incorporating the Mori-Tanaka modeling scheme to generate the stiffness matrix of the final composite. The final properties are then deduced from the stiffness matrix using composite micromechanics. Eshelby's tensor, required to calculate the stiffness tensor using Mori-Tanaka method, is calculated using a numerical scheme that determines the components of the Eshelby's tensor (Gavazzi and Lagoudas 1990). The numerical integration is solved using Gaussian Quadrature scheme and is worked out using MATLAB as well. . MATLAB provides a good deal of commands and algorithms that can be used efficiently to elaborate the continuum of the formula to its extents. Graphs are plotted using different combinations of results and parameters involved in finding these results

Ottimizzazione mediante codici di calcolo open source di componenti per il settore aerospaziale

Lo scopo della presente tesi è sviluppare un ambiente per l'ottimizzazione strutturale di componenti per applicazione aerospaziale utilizzando codici open-source. In particolare, il codice Salome viene utilizzato per il disegno automatico delle strutture, il programma Code Aster permette di effettuare l'analisi agli elementi finiti del componente, mentre Octave viene utilizzato per svolgere l'ottimizzazione basata su un algoritmo euristico e per integrare fra di loro i differenti codici. Le tecniche di ottimizzazione dei componenti stanno rivestendo sempre più importanza visto che le moderne tecniche di Additive Manufacturing permettono di realizzare strutture molto complesse che un tempo non era conveniente (o possibile) realizzare con asportazione di materiale. Nella prima parte della tesi si descrivono gli strumenti software utilizzati e la loro integrazione al fine di parametrizzare la generazione di geometrie ed effettuare in modo automatico analisi strutturali. Successivamente si descrivono tre casi di studio in cui la metodologia è stata sperimentata: un primo caso di validazione in cui si è applicato il metodo alla definizione della geometria di minimo peso per una trave a sbalzo con carico concentrato, un secondo test di ottimizzazione di un longherone per aeromobile, un terzo caso applicativo legato alla ottimizzazione di un serbatoio per fluidi in pressione da utilizzare su un satellite.

Conception of a YBCO Superconducting ZFC-Magnetic Bearing Virtual Prototype

This paper presents the conception of an original superconducting Frictionless Zero Field Cooling bearing virtual prototype. In previous work also shown in this conference, a viability study of a Zero Field Cooling-superconducting bearing concept was conducted. It showed that the virtual prototype is feasible. Moreover, the simulation studies showed that a Zero Field Cooling superconducting track provides not only effective lateral stability but also higher levitation forces than the commonly used Field Cooling tracks. In this paper the new Zero Field Cooling -bearing virtual prototype is modeled in 3D. The virtual prototype was designed having in mind: i) a future implementation in high density polyurethane, for low temperature robustness; ii) future manufacturing in a three axes CNC milling machine and; iii) future implementation of some parts using an additive manufacturing technique.

Ethanol Production from Hardboard Manufacturing Process Wastewater: Methods for Improving Product Yields from Hemicellulose Hydrolysates

Waste effluents from the forest products industry are sources of lignocellulosic biomass that can be converted to ethanol by yeast after pretreatment. However, the challenge of improving ethanol yields from a mixed pentose and hexose fermentation of a potentially inhibitory hydrolysate still remains. Hardboard manufacturing process wastewater (HPW) was evaluated at a potential feedstream for lignocellulosic ethanol production by native xylose-fermenting yeast. After screening of xylose-fermenting yeasts, Scheffersomyces stipitis CBS 6054 was selected as the ideal organism for conversion of the HPW hydrolysate material. The individual and synergistic effects of inhibitory compounds present in the hydrolysate were evaluated using response surface methodology. It was concluded that organic acids have an additive negative effect on fermentations. Fermentation conditions were also optimized in terms of aeration and pH. Methods for improving productivity and achieving higher ethanol yields were investigated. Adaptation to the conditions present in the hydrolysate through repeated cell sub-culturing was used. The objectives of this present study were to adapt S. stipitis CBS6054 to a dilute-acid pretreated lignocellulosic containing waste stream; compare the physiological, metabolic, and proteomic profiles of the adapted strain to its parent; quantify changes in protein expression/regulation, metabolite abundance, and enzyme activity; and determine the biochemical and molecular mechanism of adaptation. The adapted culture showed improvement in both substrate utilization and ethanol yields compared to the unadapted parent strain. The adapted strain also represented a growth phenotype compared to its unadapted parent based on its physiological and proteomic profiles. Several potential targets that could be responsible for strain improvement were identified. These targets could have implications for metabolic engineering of strains for improved ethanol production from lignocellulosic feedstocks. Although this work focuses specifically on the conversion of HPW to ethanol, the methods developed can be used for any feedstock/product systems that employ a microbial conversion step. The benefit of this research is that the organisms will the optimized for a company's specific system.

THE USE OF LIFE-CYCLE ANALYSIS TO REDUCE THE ENVIRONMENTAL IMPACT OF MATERIALS IN MANUFACTURING

This thesis is composed of three life-cycle analysis (LCA) studies of manufacturing to determine cumulative energy demand (CED) and greenhouse gas emissions (GHG). The methods proposed could reduce the environmental impact by reducing the CED in three manufacturing processes. First, industrial symbiosis is proposed and a LCA is performed on both conventional 1 GW-scaled hydrogenated amorphous silicon (a-Si:H)-based single junction and a-Si:H/microcrystalline-Si:H tandem cell solar PV manufacturing plants and such plants coupled to silane recycling plants. Using a recycling process that results in a silane loss of only 17 versus 85 percent, this results in a CED savings of 81,700 GJ and 290,000 GJ per year for single and tandem junction plants, respectively. This recycling process reduces the cost of raw silane by 68 percent, or approximately $22.6 and $79 million per year for a single and tandem 1 GW PV production facility, respectively. The results show environmental benefits of silane recycling centered around a-Si:H-based PV manufacturing plants. Second, an open-source self-replicating rapid prototype or 3-D printer, the RepRap, has the potential to reduce the environmental impact of manufacturing of polymer-based products, using distributed manufacturing paradigm, which is further minimized by the use of PV and improvements in PV manufacturing. Using 3-D printers for manufacturing provides the ability to ultra-customize products and to change fill composition, which increases material efficiency. An LCA was performed on three polymer-based products to determine the CED and GHG from conventional large-scale production and are compared to experimental measurements on a RepRap producing identical products with ABS and PLA. The results of this LCA study indicate that the CED of manufacturing polymer products can possibly be reduced using distributed manufacturing with existing 3-D printers under 89% fill and reduced even further with a solar photovoltaic system. The results indicate that the ability of RepRaps to vary fill has the potential to diminish environmental impact on many products. Third, one additional way to improve the environmental performance of this distributed manufacturing system is to create the polymer filament feedstock for 3-D printers using post-consumer plastic bottles. An LCA was performed on the recycling of high density polyethylene (HDPE) using the RecycleBot. The results of the LCA showed that distributed recycling has a lower CED than the best-case scenario used for centralized recycling. If this process is applied to the HDPE currently recycled in the U.S., more than 100 million MJ of energy could be conserved per annum along with significant reductions in GHG. This presents a novel path to a future of distributed manufacturing suited for both the developed and developing world with reduced environmental impact. From improving manufacturing in the photovoltaic industry with the use of recycling to recycling and manufacturing plastic products within our own homes, each step reduces the impact on the environment. The three coupled projects presented here show a clear potential to reduce the environmental impact of manufacturing and other processes by implementing complimenting systems, which have environmental benefits of their own in order to achieve a compounding effect of reduced CED and GHG.

Modellgestützte und hierarchische Prozesskettenbetrachtung für die additive Fertigung

Additive Fertigungsverfahren eignen sich für die wirtschaftliche Herstellung von Bauteilen im Bereich kleiner bis mittlerer Stückzahlen, da keine Formen oder Spezialwerkzeuge notwendig sind. Die erzielbaren Eigenschaften sind oftmals bereits ausreichend, um einen Einsatz auch in Serienanwendungen zu ermöglichen. Verbunden mit den Vorteilen der Technologie bezüglich einer hohen Flexibilität, sowohl während der Konstruktion als auch der Fertigung, können sich durch eine konsequente Nutzung finanzielle Einsparmöglichkeiten entlang des gesamten Produktlebenszyklus ergeben. Bezüglich der Wirtschaftlichkeit der Verfahren herrscht oftmals noch Unklarheit, da geeignete Methoden fehlen, um diese zu bewerten. Bestehende Methoden und Werkzeuge zur Bewertung der Wirtschaftlichkeit konventioneller Fertigungsverfahren sind dabei für die additive Fertigung nicht direkt nutzbar. In dem Artikel wird eine Methode zur modellgestützten Abbildung einer gesamten additiven Fertigungskette vorgestellt, welche auch die Wechselwirkungen zwischen den einzelnen Prozesskettengliedern berücksichtigen soll. Eine konkrete Aussage bezüglich der Wirtschaftlichkeit der additiven Fertigung soll somit ermöglicht werden.

Auslegung, Konstruktion und Fertigung von strömungsmechanischen Funktionsprototypen mittels Rapid Manufacturing

Bei der Fertigung von Funktionsbauteilen für Strömungsversuche spielt das Design und die Komplexität der Bauteilgeometrie eine wesentliche Rolle. Ziel der interdisziplinären Zusammenarbeit der Lehrstühle Strömungsmaschinen, Rechnereinsatz in der Konstruktion und Fertigungstechnik mit dem Rapid Technology Center (RTC) an der Universität Duisburg-Essen ist es, das Potenzial der additiven Fertigungsverfahren bei der Herstellung von Funktionsprototypen für strömungsmechanische Anwendungen effektiv zu nutzen. An verschiedenen, auf dieser Kooperation beruhenden, Best Practise Beispielen wird gezeigt wie das Laser-Sintern in die Prozesskette zur Herstellung von Laufrädern u. Ä. in unterschiedlichen Größenordnungen integriert werden kann. In diesem Zusammenhang werden auch die Vorüberlegungen (z. B. durch Simulation), Wechselwirkungen und Folgeprozesse, die mit dieser Fertigungstechnologie verbunden sind, aufgezeigt.

Auslegung, Konstruktion und Fertigung von strömungsmechanischen Funktionsprototypen mittels Rapid Manufacturing

Bei der Fertigung von Funktionsbauteilen für Strömungsversuche spielt das Design und die Komplexität der Bauteilgeometrie eine wesentliche Rolle. Ziel der interdisziplinären Zusammenarbeit der Lehrstühle Strömungsmaschinen, Rechnereinsatz in der Konstruktion und Fertigungstechnik mit dem Rapid Technology Center (RTC) an der Universität Duisburg-Essen ist es, das Potenzial der additiven Fertigungsverfahren bei der Herstellung von Funktionsprototypen für strömungsmechanische Anwendungen effektiv zu nutzen. An verschiedenen, auf dieser Kooperation beruhenden, Best Practise Beispielen wird gezeigt wie das Laser-Sintern in die Prozesskette zur Herstellung von Laufrädern u. Ä. in unterschiedlichen Größenordnungen integriert werden kann. In diesem Zusammenhang werden auch die Vorüberlegungen (z. B. durch Simulation), Wechselwirkungen und Folgeprozesse, die mit dieser Fertigungstechnologie verbunden sind, aufgezeigt.