Additive tooling for thermoforming a cowling of an UAV using binder jetting

Junk, Stefan; Schrock, Steffen; Schröder, Werner

doi:10.1063/1.5112677

Cited by 3 publications

(4 citation statements)

References 9 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…However, due to their high costs and the competition with conventional manufacturing, additively manufactured metal tools are mostly not economically viable. Although additive manufacturing can reduce manufacturing costs by up to 14% compared to conventional milling methods, the high costs of metal powder (167%) offset the savings [ 10 ]. For example, Leal et al [ 11 ] calculated significantly higher total production costs for stamping tool inserts fabricated by direct metal AM compared to such produced from laminated steel or by lost foam casting.…”

Section: Introductionmentioning

confidence: 99%

“…In the medical field, successful demonstrations and implementations were carried out for thermoforming plastic structures using molds made from calcium sulfate and gypsum powders and binder jetting technology [ 12 , 13 ]. Junk et al [ 10 ] explored the application of inkjet technology for thermoforming mold fabrication using polymer gypsum. A case study involving the production of an ABS fairing for an uncrewed aerial vehicle was conducted, aiming to integrate vacuum channels during manufacturing without the need for additional post-processing like drilling.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Influence of the Resin System and Sand Type on the Infiltration of 3D-Printed Sand Tools

2023

View full text Add to dashboard Cite

Binder jetting is a highly productive additive manufacturing (AM) method for porous parts. Due to its cost-effectiveness, it is used for large components and quantities ranging from prototyping to series production. Post-processing steps like sintering or infiltration are common in several applications to achieve high density and strength. This work investigates how 3D-printed sand molds can be infiltrated with epoxy resins without vacuum assistance to produce high-strength molds for thermoforming applications. Specimens 3D-printed from different sand types are infiltrated with resins of different viscosity and analyzed for infiltration velocity and depth. The infiltration velocities corresponded well with the correlation described in Washburn’s equation: The resins’ viscosities and the saturation level were decisive. Amongst the investigated sand types commonly used in foundries, sand type GS19 was found most suitable for infiltration. However, the sand type proved to be a less relevant influencing factor than the resins’ viscosities and quantities applied. Infiltration of topology-optimized 3D-printed sand tools up to a wall thickness of 20 mm for thermoforming applications was found to be feasible.

show abstract

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Influence of the Resin System and Sand Type on the Infiltration of 3D-Printed Sand Tools

2023

View full text Add to dashboard Cite

show abstract

“…Laser-sintered metal parts can be excluded due to their high costs. Although manufacturing costs can be reduced to as low as 14% compared to conventional tooling methods (milling), although this is offset by the high metal powder costs of 167% [ 10 ]. For the medical field, additive manufacturing of molds from calcium sulfate and gypsum powders was successfully demonstrated and even implemented for thermoforming of plastic structures [ 11 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

“…For the medical field, additive manufacturing of molds from calcium sulfate and gypsum powders was successfully demonstrated and even implemented for thermoforming of plastic structures [ 11 , 12 ]. In addition, Junk et al [ 10 ] reported the application of the inkjet technology for thermoforming mold fabrication out of polymer gypsum. This was tested for a case study, in which a fairing made of ABS for an unmanned aerial vehicle was produced.…”

Section: Introductionmentioning

confidence: 99%

3D Printed Sand Tools for Thermoforming Applications of Carbon Fiber Reinforced Composites—A Perspective

et al. 2021

View full text Add to dashboard Cite

Tooling, especially for prototyping or small series, may prove to be very costly. Further, prototyping of fiber reinforced thermoplastic shell structures may rely on time-consuming manual efforts. This perspective paper discusses the idea of fabricating tools at reduced time and cost compared to conventional machining-based methods. The targeted tools are manufactured out of sand using the Binder Jetting process. These molds should fulfill the demands regarding flexural and compressive behavior while allowing for vacuum thermoforming of fiber reinforced thermoplastic sheets. The paper discusses the requirements and the challenges and presents a perspective study addressing this innovative idea. The authors present the idea for discussion in the additive manufacturing and FRP producing communities.

show abstract

Development, Testing, and Thermoforming of Thermoplastics Reinforced with Surface-Modified Aramid Fibers for Cover of Electronic Parts in Small Unmanned Aerial Vehicles Using 3D-Printed Molds

Sonmez,

Pelin,

Pelin

et al. 2024

Polymers

View full text Add to dashboard Cite

This paper presents the development, characterization, and testing of PP/PE-g-MA composites with 10 and 15 wt% surface-modified aramid fibers, and aluminum-based pigment, as covers for a small drone body for collision protection. The successful fiber surface modification with SiO2 by the sol–gel method using TEOS was confirmed by FTIR, SEM, and EDS analyses. The composites were characterized by FTIR and SEM analyses and surface energy and water contact angle measurements and tested in terms of tensile, flexural, impact, and thermal properties. The materials exhibited hydrophobic character and compact and uniform morphostructures, with increased surface energy with fiber content owed to improved adhesion between modified fibers and the matrix. Compared to the control sample, composites with modified fibers showed an increase by 20% in tensile strength, and 36–52% in the modulus, and an increase by 26–33% in flexural strength and 30–47% in the modulus, with higher values at room temperature. Impact resistance of modified fiber composites showed an increase by 20–40% compared to the control sample, due to improved interaction between SiO2-modified fibers and maleic anhydride, which inhibits crack formation, allowing higher energies’ absorption. The composites were vacuum-thermoformed on 3D-printed molds as a two-part cover for the body of a drone, successfully withstanding the flight test.

show abstract

Additive tooling for thermoforming a cowling of an UAV using binder jetting

Cited by 3 publications

References 9 publications

Influence of the Resin System and Sand Type on the Infiltration of 3D-Printed Sand Tools

Influence of the Resin System and Sand Type on the Infiltration of 3D-Printed Sand Tools

3D Printed Sand Tools for Thermoforming Applications of Carbon Fiber Reinforced Composites—A Perspective

Development, Testing, and Thermoforming of Thermoplastics Reinforced with Surface-Modified Aramid Fibers for Cover of Electronic Parts in Small Unmanned Aerial Vehicles Using 3D-Printed Molds

Contact Info

Product

Resources

About