Dimensional and Geometrical Quality Enhancement in Additively Manufactured Parts: Systematic Framework and A Case Study

Abstract

In order to compete with traditional manufacturing processes, Additive Manufacturing (AM) should be capable of producing medium to large batches at industrial-degree quality and competitive cost-per-unit. This paper proposes a systematic framework approach to the problem of fulfilling dimensional and geometric requirements for medium batch sizes of AM parts, which has been structured as a three-step optimization methodology. Firstly, specific work characteristics are analyzed so that information is arranged according to an Operation Space (factors that could have an influence upon quality) and a Verification Space (formed by quality indicators and requirements). Standard process configuration leads to characterization of the standard achievable quality. Secondly, controllable factors are analyzed to determine their relative influence upon quality indicators and the optimal process configuration. Thirdly, optimization of part dimensional and/or geometric definition at the design level is performed in order to improve part quality and meet quality requirements. To evaluate the usefulness of the proposed framework under quasi-industrial condition, a case study is presented here which is focused on the dimensional and geometric optimization of surgical-steel tibia resection guides manufactured by Laser-Power Bed Fusion (L-PBF). The results show that the proposed approach allows for part quality improvement to a degree that matches the initial requirements.

A Design for Additive Manufacturing Strategy for Dimensional and Geometrical Quality Improvement of PolyJet-Manufactured Glossy Cylindrical Features

“…This recommended configuration includes factors like layer height, injector velocity/acceleration or UV lamp intensity. Otherwise, if the systematic framework described in [ 47 ] were applied, process configuration should have been optimized before the CAD optimization stage.…”

“…In a previous work, Beltrán [ 47 ] proposed a systematic framework for fulfilling dimensional and geometric tolerances of FoLS in AM processes. The proposed methodology was divided in several stages: The characterization of achievable quality, the optimization of process parameters, and the optimization of part design.…”

Estimation and Improvement of the Achievable Tolerance Interval in Material Extrusion Additive Manufacturing through a Multi-State Machine Performance Perspective

“…In a machine performance study, a series of parts are manufactured and measured. Each characteristic (X) is considered independently at a time, and the measured values for every i part (Xi) are used to determine the distribution The method proposed in this work is encompassed in the "design optimization" stage of the optimization framework described in [42]. More specifically, it could be applied as a previous step to a process capability analysis and serve as a guide for adjusting production to minimize the effect of machine-related inaccuracies.…”

“…The variation in the achievable tolerance range, before and after the optimization of design, is evaluated by establishing a target machine performance index. The method proposed in this work is encompassed in the "design optimization" stage of the optimization framework described in [42]. More specifically, it could be applied as a previous step to a process capability analysis and serve as a guide for adjusting production to minimize the effect of machine-related inaccuracies.…”

Special Issue of the Manufacturing Engineering Society 2019 (SIMES-2019)

“…In this Special Issue of the journal Materials, 29 contributions to cutting-edge advances in different fields of the manufacturing engineering have been collected. In particular, in additive manufacturing and 3D printing [4][5][6][7][8][9][10][11]; sustainable and green manufacturing [12][13][14][15][16]; metrology and quality in manufacturing [17][18][19][20][21]; advances and innovations in manufacturing processes [22][23][24][25]; manufacturing of new materials [26][27][28]; design, modeling, and simulation in manufacturing engineering [29,30] industry 4.0 [31] and manufacturing engineering and society [32]. Among all of them, the topic additive manufacturing and 3D printing stands out for the number of contributions it has had in this Special Issue showing the interest that this topic arouses, currently, among researchers, the industry and the public in general.…”