Designing for Big Area Additive Manufacturing

Roschli, Alex; Gaul, Katherine T.; Boulger, Alex M.; Post, Brian; Chesser, Phillip; Love, Lonnie J.; Blue, Fletcher; Borish, Michael

doi:10.1016/j.addma.2018.11.006

Cited by 85 publications

(60 citation statements)

References 2 publications

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“…Such issues eventually result in a lack of reproducibility of the part quality over a prolonged production run [2], defects in the internal structure of the 3D-printed part [16], surface imperfections [17], or in the worst case a complete failure of the printing job due to filament buckling or annular backflow [14]. Another common cause for multiple processing attempts for the same component are novel, mostly unknown design constraints, such as the misuse of design parameters such as overhangs, support structures, bridges, cavities [18], or thin walls [19]. An additional underestimated problem is insufficient or over-adhesion during processing, which can result in extensive warpage or even damaged parts [20,21].…”

Section: Introductionmentioning

confidence: 99%

Mechanical Recyclability of Polypropylene Composites Produced by Material Extrusion-Based Additive Manufacturing

et al. 2019

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Due to a lack of long-term experience with burgeoning material extrusion-based additive manufacturing technology, also known as fused filament fabrication (FFF), considerable amounts of expensive material will continue to be wasted until a defect-free 3D-printed component can be finalized. In order to lead this advanced manufacturing technique toward cleaner production and to save costs, this study addresses the ability to remanufacture a wide range of commercially available filaments. Most of them either tend to degrade by chain scission or crosslinking. Only polypropylene (PP)-based filaments appear to be particularly thermally stable and therefore suitable for multiple remanufacturing sequences. As the extrusion step exerts the largest influence on the material in terms of temperature and shear load, this study focused on the morphological, rheological, thermal, processing, tensile, and impact properties of a promising PP composite in the course of multiple consecutive extrusions as well as the impact of additional heat stabilizers. Even after 15 consecutive filament extrusions, the stabilized additively manufactured PP composite revealed an unaltered morphology and therefore the same tensile and impact strength as the initial material. As the viscosity of the material of the 15th extrusion was nearly identical to that of the 1st extrusion sequence, the processability both in terms of extrusion and FFF was outstanding, despite the tremendous amount of shear and thermal stress that was undergone. The present work provides key insights into one possible step toward more sustainable production through FFF.

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Section: Introductionmentioning

confidence: 99%

Mechanical Recyclability of Polypropylene Composites Produced by Material Extrusion-Based Additive Manufacturing

et al. 2019

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“…Even regardless of build chamber size restriction, an extended amount of time is required for the manufacturing of large-sized objects [30]. Nevertheless, a technology called Big Area Additive Manufacturing (BAAM), which was developed in recent years, has overcome this limitation by being able to create large-scale parts [66]. Most of the design and application constraints of small-scale AM still apply to BAAM as well [67].…”

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confidence: 99%

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

et al. 2019

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Additive manufacturing (AM) or three-dimensional (3D) printing has introduced a novel production method in design, manufacturing, and distribution to end-users. This technology has provided great freedom in design for creating complex components, highly customizable products, and efficient waste minimization. The last industrial revolution, namely industry 4.0, employs the integration of smart manufacturing systems and developed information technologies. Accordingly, AM plays a principal role in industry 4.0 thanks to numerous benefits, such as time and material saving, rapid prototyping, high efficiency, and decentralized production methods. This review paper is to organize a comprehensive study on AM technology and present the latest achievements and industrial applications. Besides that, this paper investigates the sustainability dimensions of the AM process and the added values in economic, social, and environment sections. Finally, the paper concludes by pointing out the future trend of AM in technology, applications, and materials aspects that have the potential to come up with new ideas for the future of AM explorations.

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“…The embossing resolution of the extra-toolpath geometry was dependent upon the melt pool size response time and the print speed. The ability of this technique to control local bead geometry has interesting implications, particularly for a large-scale AM process like laser-wire DED, which requires a different set of design rules than the majority of AM processes and has traditionally been limited to lower resolution of component details [13,14]. It is anticipated that the technique can be used in the near future for volumetric defect mitigation in toolpaths where local overlap of adjacent beads is inadequate.The capability to emboss specific, secondary geometry means that part identification features, such as a serial number or QR code, could be permanently added to components during the printing process.…”

Section: Discussionmentioning

confidence: 99%

Beyond the Toolpath: Site-Specific Melt Pool Size Control Enables Printing of Extra-Toolpath Geometry in Laser-Wire Directed Energy Deposition

Gibson¹,

Richardson²,

Sundermann³

et al. 2019

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A variety of techniques have been utilized in metal additive manufacturing (AM) for melt pool size management, including modeling and feed-forward approaches. In a few cases, closed-loop control has been demonstrated. In this research, closed-loop melt pool size control for large-scale, laser-wire based Directed Energy Deposition is demonstrated with a novel modification: site-specific changes to the controller set-point were commanded at trigger points, the locations of which were generated by the projection of a secondary geometry onto the primary 3D-printed component geometry. The present work shows that, through this technique, it is possible to print a specific geometry that occurs beyond the actual toolpath of the print head. This is denoted as an extra-toolpath geometry and is fundamentally different from other methods of generating component features in metal AM. A proof-of-principle experiment is presented in which a complex oak leaf geometry was embossed on an otherwise ordinary double-bead wall made from Ti-6Al-4V. The process is introduced and characterized primarily from a controls perspective with reports on the performance of the control system, the melt pool size response, and the resulting geometry. The implications of this capability, which extend beyond localized control of bead geometry to the potential mitigations of defects and functional grading of component properties, are discussed.

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Designing for Big Area Additive Manufacturing

Cited by 85 publications

References 2 publications

Mechanical Recyclability of Polypropylene Composites Produced by Material Extrusion-Based Additive Manufacturing

Mechanical Recyclability of Polypropylene Composites Produced by Material Extrusion-Based Additive Manufacturing

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

Beyond the Toolpath: Site-Specific Melt Pool Size Control Enables Printing of Extra-Toolpath Geometry in Laser-Wire Directed Energy Deposition

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