Evaluating the Quality Surface Performance of Additive Manufacturing Systems: Methodology and a Material Jetting Case Study

Udroiu, Răzvan; Braga, Ion Cristian; Nedelcu, Anișor

doi:10.3390/ma12060995

Cited by 74 publications

(44 citation statements)

References 32 publications

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“…The surface roughness of the mold has been measured using a Namicon TR-220 (Namicon Testing S.R.L., Otopeni, Romania) roughness tester, as per the ISO 4288 standard [ 49 ]. The roughness was measured perpendicular to the deposition direction, following a measurement procedure similar as in [ 50 ]. As is concluded in [ 51 ] the surface obtained by FDM technology is the surface composed of high peaks.…”

Section: Methodsmentioning

confidence: 99%

Novel Method for the Manufacture of Complex CFRP Parts Using FDM-based Molds

2020

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Fibre-reinforced polymers (FRP) have attracted much interest within many industrial fields where the use of 3D printed molds can provide significant cost and time savings in the production of composite tooling. Within this paper, a novel method for the manufacture of complex-shaped FRP parts has been proposed. This paper features a new design of bike saddle, which was manufactured through the use of molds created by fused deposition modeling (FDM), of which two 3D printable materials were selected, polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS), and these molds were then chemically and thermally treated. The novel bike saddles were fabricated using carbon fiber-reinforced polymer (CFRP), by vacuum bag technology and oven curing, utilizing additive manufactured (AM) molds. Following manufacture the molded parts were subjected to a quality inspection, using non-contact three-dimensional (3D) scanning techniques, where the results were then statistically analyzed. The statistically analyzed results state that the main deviations between the CAD model and the manufactured CFRP parts were within the range of ±1 mm. Additionally, the weight of the upper part of the saddles was found to be 42 grams. The novel method is primarily intended to be used for customized products using CFRPs.

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Section: Methodsmentioning

confidence: 99%

Novel Method for the Manufacture of Complex CFRP Parts Using FDM-based Molds

2020

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“…Additionally, if a circular model is lying down on the build platform and printed in glossy printing mode, then the surface quality is affected by some errors [41]. The experimental roughness (Ra) values for the PolyJet material jetting process are specified according to the finish type as follows: for matte finish in the range of 0.5-15 μm, and for the glossy finish in the range of 0.5-4 μm [42]. The dimensional accuracy and the quality of the surface of a circular artifact built in standing up position are not significantly influenced by the orientation and positioning on the build platform.…”

Section: Process Specifications Materials Artifact and Manufacturimentioning

confidence: 99%

System Performance and Process Capability in Additive Manufacturing: Quality Control for Polymer Jetting

Udroiu

Braga

2020

Polymers

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Polymer-based additive manufacturing (AM) gathers a great deal of interest with regard to standardization and implementation in mass production. A new methodology for the system and process capabilities analysis in additive manufacturing, using statistical quality tools for production management, is proposed. A large sample of small specimens of circular shape was manufactured of photopolymer resins using polymer jetting (PolyJet) technology. Two critical geometrical features of the specimen were investigated. The variability of the measurement system was determined by Gage repeatability and reproducibility (Gage R&R) methodology. Machine and process capabilities were performed in relation to the defined tolerance limits and the results were analyzed based on the requirements from the statistical process control. The results showed that the EDEN 350 system capability and PolyJet process capability enables obtaining capability indices over 1.67 within the capable tolerance interval of 0.22 mm. Furthermore, PolyJet technology depositing thin layers of resins droplets of 0.016 mm allows for manufacturing in a short time of a high volume of parts for mass production with a tolerance matching the ISO 286 IT9 grade for radial dimension and IT10 grade for linear dimensions on the Z-axis, respectively. Using microscopy analysis some results were explained and validated from the capability study.

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“…Confirmatory experiments were then performed based on the manufacturing of panels 2 and 3, in similar conditions as the initial experiment (temperature, humidity, same raw materials), to provide validation for the conclusions drawn during the analysis phase and also to confirm a stable process [31].…”

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confidence: 99%

A Novel Polymer Concrete Composite with GFRP Waste: Applications, Morphology, and Porosity Characterization

et al. 2020

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Composite materials reinforced with recycled fibers gather a great deal of interest with regards to construction applications. A novel polymer concrete composite was proposed, comprised of a surface layer and a structural composite reinforced with recycled glass fibers. The novel multi-material composite included a large amount of glass-fiber-reinforced polymer (GFRP) waste (30%), which is expected to help protect the environment. Large panels comprised of this polymer concrete composite, which reproduce the appearance of natural stone, were manufactured. A new methodology for porosity analysis of a large panel comprised of a multi-material composite was proposed, utilizing three-dimensional (3D) X-ray computed tomography (CT). The volume of pores was distributed between the constituent composite materials and then statistically analyzed. Homogeneous distribution of the pores within the novel multi-material composite was found. The observed mean porosities of the composite panel were 0.146% for the surface layer material and 31.3% for the structural composite material. The mean density of the panel, determined by the CT density method, was 1.73 g/cm 3 . The composite materials porosity provides a favorable effect for achieving lightweight structures. Using scanning electron microscopy (SEM) analysis, it was observed that a good connection interface between the constituent composite materials existed. possible recycling solutions regarding waste management of composite based products. At present, the main conventional recycling techniques for glass-fiber-reinforced polymer (GFRP) waste materials include incineration, thermal or chemical recycling, and mechanical recycling [1][2][3]. Mechanical recycling through grinding and milling processes is one of the most used techniques; additionally, due to the size reduction of the fibrous products, the recycling process itself does not contribute to atmospheric pollution and much simpler equipment is required as compared to other methods. From this process, the resulting fibers can then be incorporated into new composite materials.Within the construction field, polymeric composite materials are widely used (e.g., polymeric concrete composites), in which many industrial waste materials can be used as aggregates. One of the most commonly used aggregates for polymeric concretes is glass, which can be utilized in many different ways: glass fibers [4], glass dust, and inorganic waste in the form of coarse aggregates [5]. Polymer concretes produced with recycled materials and polyester resins provide aesthetic and structural benefits, as shown in a number of research studies [6,7]. GFRP waste materials incorporated into a polymer matrix are already used within many building materials, having the potential to reduce the environmental footprint of the materials used. Additional constituents of particulates in the polymeric matrix can be in the form of silica sand, calcium carbonate, mica, white cement, gypsum, perlite, or others [8,9]. The use of these materials enables the produ...

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Evaluating the Quality Surface Performance of Additive Manufacturing Systems: Methodology and a Material Jetting Case Study

Cited by 74 publications

References 32 publications

Novel Method for the Manufacture of Complex CFRP Parts Using FDM-based Molds

Novel Method for the Manufacture of Complex CFRP Parts Using FDM-based Molds

System Performance and Process Capability in Additive Manufacturing: Quality Control for Polymer Jetting

A Novel Polymer Concrete Composite with GFRP Waste: Applications, Morphology, and Porosity Characterization

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