Towards Early Estimation of Part Accuracy in Additive Manufacturing

Moroni, Giovanni; Syam, Wahyudin P.; Petrò, Stefano

doi:10.1016/j.procir.2014.03.194

Cited by 47 publications

(15 citation statements)

References 13 publications

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“…The aim of an optimal build orientation selection is to improve surface finish, increase part strength in a specific direction, reduce support material, minimize build time and maximize the geometric accuracy [54]. However, there are several factors that must be considered when selecting the build orientation in FDM systems [9, 51, 55-57]:…”

Section: Build Orientationmentioning

confidence: 99%

Design and Manufacturing Strategies for Fused Deposition Modelling in Additive Manufacturing: A Review

Medellín-Castillo

Zaragoza-Siqueiros

2019

Chin. J. Mech. Eng.

105

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Although several research works in the literature have focused on studying the capabilities of additive manufacturing (AM) systems, few works have addressed the development of Design for Additive Manufacturing (DfAM) knowledge, tools, rules, and methodologies, which has limited the penetration and impact of AM in industry. In this paper a comprehensive review of design and manufacturing strategies for Fused Deposition Modelling (FDM) is presented. Consequently, several DfAM strategies are proposed and analysed based on existing research works and the operation principles, materials, capabilities and limitations of the FDM process. These strategies have been divided into four main groups: geometry, quality, materials and sustainability. The implementation and practicality of the proposed DfAM is illustrated by three case studies. The new proposed DfAM strategies are intended to assist designers and manufacturers when making decisions to satisfy functional needs, while ensuring manufacturability in FDM systems. Moreover, many of these strategies can be applied or extended to other AM processes besides FDM.

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Section: Build Orientationmentioning

confidence: 99%

Design and Manufacturing Strategies for Fused Deposition Modelling in Additive Manufacturing: A Review

Medellín-Castillo

Zaragoza-Siqueiros

2019

Chin. J. Mech. Eng.

105

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“…MIP-SLA-built cylinders and cubes were used for checking the deviation models, while this model-build method was not comprehensive enough to cover all defect forms with obvious effects. Moroni et al (2014) proposed a methodology to estimate dimensional and geometric deviation of AM part features by analyzing the STereoLithography (STL) input file. This work mainly considered the incorporating confounding errors caused by the "stair-step" effect and shrinkage of FDM process.…”

Section: Additive Manufacturing Geometrical Quality Analysis and Estimentioning

confidence: 99%

Geometrical deviation identification and prediction method for additive manufacturing

Huang

Dantan

Etienne

et al. 2018

RPJ

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Purpose One major problem preventing further application and benefits from additive manufacturing (AM) nowadays is that AM build parts always end up with poor geometrical quality. To help improving geometrical quality for AM, this study aims to propose geometrical deviation identification and prediction method for AM, which could be used for identifying the factors, forms and values of geometrical deviation of AM parts. Design/methodology/approach This paper applied the skin model-based modal decomposition approach to describe the geometrical deviations of AM and decompose them into different defect modes. On that basis, the approach to propose and extend defect modes was developed. Identification and prediction of the geometrical deviations were then carried out with this method. Finally, a case study with cylinders manufactured by fused deposition modeling was introduced. Two coordinate measuring machine (CMM) machines with different measure methods were used to verify the effectiveness of the methods and modes proposed. Findings The case study results with two different CMM machines are very close, which shows that the method and modes proposed by this paper are very effective. Also, the results indicate that the main geometrical defects are caused by the shrinkage and machine inaccuracy-induced errors which have not been studied enough. Originality/value This work could be used for identifying and predicting the forms and values of AM geometrical deviation, which could help realize the improvement of AM part geometrical quality in design phase more purposefully.

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“…Typically, the CAD model is converted to a stereolithography (*.stl) file format where the designed geometries and surfaces are discretised into geometric meshes. A macro-level 'stair-case' effect can occur on part surfaces due this discretisation (Moroni et al, 2014). In addition it has been shown that melt pool dynamics have a large influence on sidewall dimensions for the finished parts (Lee and Farson, 2015).…”

Section: Geometrical Anomaliesmentioning

confidence: 99%

Powder-based additive manufacturing - a review of types of defects, generation mechanisms, detection, property evaluation and metrology

Taheri

Shoaib

Koester³

et al. 2017

IJASMM

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Powder-based additive manufacturing (AM) technologies have been evaluated for use in different fields of application (aerospace, medical, etc.). Ideally, AM parts should be at least equivalent, or preferably better quality than conventionally produced parts. Manufacturing defects and their effects on the quality and performance of AM parts are a currently a major concern. It is essential to understand the defect types, their generation mechanisms, and the detection methodologies for mechanical properties evaluation and quality control. We consider the various types of microstructural features or defects, their generation mechanisms, their effect on bulk properties and the capability of existing characterisation methodologies for powder based AM parts in this work. Methods of in-situ non-destructive evaluation and the influence of defects on mechanical properties and design considerations are also reviewed. Together, these provide a framework to understand the relevant machine and material parameters, optimise the process and production, and select appropriate characterisation methods.Abstract: Powder-based additive manufacturing (AM) technologies have been evaluated for use in different fields of application (aerospace, medical, etc.). Ideally, AM parts should be at least equivalent, or preferably better quality than conventionally produced parts. Manufacturing defects and their effects on the quality and performance of AM parts are a currently a major concern. It is essential to understand the defect types, their generation mechanisms, and the detection methodologies for mechanical properties evaluation and quality control. We consider the various types of microstructural features or defects, their generation mechanisms, their effect on bulk properties and the capability of existing characterisation methodologies for powder based AM parts in this work. Methods of in-situ non-destructive evaluation and the influence of defects on mechanical properties and design considerations are also reviewed. Together, these provide a framework to understand the relevant machine and material parameters, optimise the process and production, and select appropriate characterisation methods.Reference to this paper should be made as follows: Taheri, H., Shoaib, M.R.M., Koester, L., Bigelow, T.A., Collins, P.C. and Bond, L.J. (2017) 'Powder-based additive manufacturing -a review of types of defects, generation mechanisms, detection, property evaluation and metrology', Int. Institute of Aviation Technology conducting research on UAVs and designing and printing 3D parts for UAVs. His research interest areas include engineering mechanics, additive manufacturing and non-destructive testing.Lucas W. Koester received his PhD from the University of Nebraska at Lincoln studying wave propagation and scattering in polycrystalline media. His current and past research interests include wave propagation in polycrystalline media, defect scattering, and modelling with emphasis on additive manufacturing processes and materials.Powder-based additive...

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Towards Early Estimation of Part Accuracy in Additive Manufacturing

Cited by 47 publications

References 13 publications

Design and Manufacturing Strategies for Fused Deposition Modelling in Additive Manufacturing: A Review

Design and Manufacturing Strategies for Fused Deposition Modelling in Additive Manufacturing: A Review

Geometrical deviation identification and prediction method for additive manufacturing

Powder-based additive manufacturing - a review of types of defects, generation mechanisms, detection, property evaluation and metrology

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