The Integration of CAD/CAM and Rapid Prototyping in Product Development: A Review

Matta, A.K.; Raju, D. Ranga; Suman, K. N. S.

doi:10.1016/j.matpr.2015.07.319

Cited by 54 publications

(33 citation statements)

References 45 publications

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“…To date, additive manufacturing applied to metal rapid casting tooling applications has received little research focus or made significant industrial impact, other than in the early product development stages for prototypes and small-size polymer mould tooling (Matta, Ranga Raju and Suman, 2015).…”

Section: Traditional Foundry Moulds Compared To Printed Mouldsmentioning

confidence: 99%

3D sand printing for automotive mass production applications

Hackney

Wooldridge

2017

IJRAPIDM

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Abstract:Additive manufacturing (AM) of metallic products is seen by many to be commercially viable for only small and highly complex components, manufactured with difficult to machine materials using heat sintering process. In the automotive manufacturing sector, metal hard tooling is often required to produce mass produced components, and the tools are typically bespoke, large in size, inflexible and complex. Conventionally these tools have either been machined from solid billets or near-net-shape cast and then machined to get final size. Rapid casting technologies (RCT) use AM 3D sand printing process to manufacture sand mould tools used to create the production tooling. Adopters of this technology can achieve an increasingly agile and robust production process, RCT can also rewrite the design hand book for casting design. The research findings demonstrate that RCT can be successfully applied within the automotive industry, achieving considerable cost and time savings whilst improving quality and product flexibility.Keywords: rapid casting technology; rapid tooling; 3D sand printing; sand casting.Reference to this paper should be made as follows: Hackney, P.M. and Wooldridge, R. (201X) '3D sand printing for automotive mass production applications', Int. J. Rapid Manufacturing, Vol. XX, No. YY, pp.XXX-XXX.Biographical notes: Philip M. Hackney is a senior member of the Department of Mechanical and Construction Engineering management team, managing several programmes both at Northumbria and Validated programmes at other HEI institutions worldwide. Hackney first started researching rapid prototyping in 1996, with the development of casting tools from the LOM process and later using the ZCast process awarded him a PhD in 2007, with over 30 published papers and a research group of 6 PhD students under his supervision. His current research interests include shop floor scheduling using genetic algorithms, additive manufacturing of polyurethane foams and sand printing of AM.Richard Wooldridge is currently a PT PhD Student at Northumbria University, following completing an MSc in Advanced Manufacturing Engineering at Loughborough University. He has developed and managed a major automotive Rapid Product Development Centre, at the forefront of commercialisation of industrial applications of AM, for over a decade.This paper is a revised and expanded version of a paper entitled [title] presented at [date/year and place where held].

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Section: Traditional Foundry Moulds Compared To Printed Mouldsmentioning

confidence: 99%

3D sand printing for automotive mass production applications

Hackney

Wooldridge

2017

IJRAPIDM

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“…The accuracy and geometrical fidelity of 3D-printed objects is researched in many works and for over 20 years [11,12] due to the necessity to produce objects that match their digital models closely for the use as prototypes (Rapid Prototyping, (RP) [13,14]), consumer products (Rapid Manufacturing, (RM) [15]) or tools (Rapid Tooling, (RT) [16]). …”

Section: Accuracymentioning

confidence: 99%

Scanned Image Data from 3D-Printed Specimens Using Fused Deposition Modeling

Baumann

Eichhoff

Roller

2017

Data

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Abstract:This dataset provides high-resolution 2D scans of 3D printed test objects (dog-bone), derived from EN ISO 527-2:2012. The specimens are scanned in resolutions from 600 dpi to 4800 dpi utilising a Konica-Minolta bizHub 42 and Canon LiDE 210 scanner. The specimens are created to research the influence of the infill-pattern orientation; The print orientation on the geometrical fidelity and the structural strength. The specimens are printed on a MakerBot Replicator 2X 3D-printer using yellow (ABS 1.75 mm Yellow, REC, Moscow, Russia) and purple ABS plastic (ABS 1.75 mm Pink Lion&Fox, Hamburg, Germany). The dataset consists of at least one scan per specimen with the measured dimensional characteristics. For this, software is created and described within this work. Specimens from this dataset are either scanned on blank white paper or on white paper with blue millimetre marking. The printing experiment contains a number of failed prints. Specimens that did not fulfil the expected geometry are scanned separately and are of lower quality due to the inability to scan objects with a non-flat surface. For a number of specimens printed sensor data is acquired during the printing process. This dataset consists of 193 specimen scans in PNG format of 127 objects with unadjusted raw graphical data and a corresponding, annotated post-processed image. Annotated data includes the detected object, its geometrical characteristics and file information. Computer extracted geometrical information is supplied for the images where automated geometrical feature extraction is possible.

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“…With the use of this technology it is possible to fabricate prototypes with minimum material consumption and satisfactory accuracy [3]. Therefore, AM technologies are promising in reducing production costs and time, while maintaining relatively high quality of final products [4] in comparison to traditional manufacturing. Another advantage of this technology is the wide range of materials which can be used ____________ Tychanicz-Kwiecien, M., et al: Performance of Thermal Insulation Fabricated by … S1080 THERMAL SCIENCE: Year 2019, Vol.…”

Section: Introductionmentioning

confidence: 99%

“…As far as thermoplastics are concerned, these materials are often applied in fused filament fabrication (FFF) method, which is one of the AM technologies. In the FFF method, thin layers of molten thermoplastic material (filament) are pushed through the movable, heated extrusion nozzle and placed alternately on the print surface to form a final prototype [4][5][6][7][8][9]. The material used as filament is heated up barely above the melting temperature.…”

Section: Introductionmentioning

confidence: 99%

Performance of thermal insulation fabricated by rapid prototyping technology

2019

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Nowadays, 3-D printing technology is very often applied in industry due to design cycles shortening and surface quality improvement when comparing to conventional manufacturing technologies. In order to adapt 3-D printed materials as thermal barriers, it is necessary to determine its thermophysical properties. As far as thermal insulation is concerned, the lowest thermal conductivity is required and therefore the crucial parameter of the material is the porosity. This paper presents the results of experimental investigation of effective thermal conductivity of thermal barriers with variable porosity fabricated by the fused filament fabrication technology. Also the numerical study was presented. The commercial code-COMSOL multiphysics was used to model the coupled heat transfer. The model was than validated by comparing the numerical and experimental results. For each sample the density and thermal conductivity were determined experimentally. The influence of the size and shape of the cell on the formation of free convection was investigated in particular. The effect of the conduction and radiation on temperature and velocity profiles within the enclosure has been analyzed. In addition, the dominant heat transfer mechanisms as a function of density have been identified.

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The Integration of CAD/CAM and Rapid Prototyping in Product Development: A Review

Cited by 54 publications

References 45 publications

3D sand printing for automotive mass production applications

3D sand printing for automotive mass production applications

Scanned Image Data from 3D-Printed Specimens Using Fused Deposition Modeling

Performance of thermal insulation fabricated by rapid prototyping technology

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