Dimensional quality is still a major concern in additive manufacturing (AM) processes and its improvement is key to closing the gap between prototype manufacturing and industrialized production. Mass production requires the full working space of the machine to be used, although this arrangement could lead to location-related differences in part quality. The present work proposes the application of a multi-state machine performance perspective to reduce the achievable tolerance intervals of features of linear size in material extrusion (MEX) processes. Considering aspecific dimensional parameter, the dispersion and location of the distribution of measured values between different states are analyzed to determine whether the production should be treated as single-state or multi-state. A design for additive manufacturing strategy then applies global or local size compensations to modify the 3D design file and reduce deviations between manufactured values and theoretical values. The variation in the achievable tolerance range before and after the optimization of design is evaluated by establishing a target machine performance index. This strategy has been applied to an external MEX-manufactured cylindrical surface in a case study. The results show that the multi-state perspective provides a better understanding of the sources of quality variability and allows for a significant reduction in the achievable tolerance interval. The proposed strategy could help to accelerate the industrial adoption of AM process by reducing differences in quality with respect to conventional processes.

Flatbed scanners (FBSs) provide non-contact scanning capabilities that could be used for the on-machine verification of layer contours in additive manufacturing (AM) processes. Layer-wise contour deviation assessment could be critical for dimensional and geometrical quality improvement of AM parts, because it would allow for close-loop error compensation strategies. Nevertheless, contour characterisation feasibility faces many challenges, such as image distortion compensation or edge detection quality. The present work evaluates the influence of image processing and layer-to-background contrast characteristics upon contour reconstruction quality, under a metrological perspective. Considered factors include noise filtering, edge detection algorithms, and threshold levels, whereas the distance between the target layer and the background is used to generate different contrast scenarios. Completeness of contour reconstruction is evaluated by means of a coverage factor, whereas its accuracy is determined by comparison with a reference contour digitised in a coordinate measuring machine. Results show that a reliable contour characterisation can be achieved by means of a precise adjustment of image processing parameters under low layer-to-background contrast variability. Conversely, under anisotropic contrast conditions, the quality of contour reconstruction severely drops, and the compromise between coverage and accuracy becomes unbalanced. These findings indicate that FBS-based characterisation of AM layers will demand developing strategies that minimise the influence of anisotropy in layer-to-background contrast.

No abstract

No abstract

This paper presents a high-voltage power source to produce glow-discharge plasma in the frame of a specific application. The load has two well-differentiated types of behavior. To start the system, it is necessary to apply a high voltage, up to 15 kV, to produce air-dielectric breakdown. Before that, the output current is zero. Contrarily, under steady state, the output voltage is smaller (a few hundred volts) while the load requires current-source behavior to maintain a constant glow in the plasma. The amount of current must be selectable by the operator in the range 50 mA–180 mA. Therefore, very different voltage gains are required, and they cannot be easily attained by a single power stage. This work describes why the LC-parallel resonant topology is a good single stage alternative to solve the problem, and shows how to make the design. The step-up transformer is the key component of the converter. It provides galvanic isolation and adapts the voltage gain to the most favorable region of the LC topology, but it also introduces non-avoidable reactive components for the resonant net, determining their shape and, to some extent, their magnitude. In the paper, the transformer’s constructive details receive special attention, with discussion of its model. The experimental dynamic tests, carried out to design the control, show load behavior that resembles negative resistance. This fact makes any control loop prone to instability. To compensate this effect, a resistive ballast is proposed, eliminating its impact on efficiency with a novel filter design, based on an inductor, connected in series with the load beyond the voltage-clamping capacitor. The analysis includes a mathematical model of the filtering capacitor discharge through the inductor during the breakdown transient. The model provides insight into the dimensions of the inductor, to limit the discharge current peak and to analyze the overall performance on steady state. Another detail addressed is the balance among total weight, efficiency and autonomy, which appears if the filter inductor is substituted for a larger battery in autonomous operation. Finally, a comprehensive set of experimental results on the real load illustrate the performance of the power source, showing waveforms at breakdown and at steady state (for different output currents). Additionally, the detector’s constructive principles are described and its experimental performance is explored, showing results with two different types of metallic pollutants in water.