The document discusses additive manufacturing (AM), also known as 3D printing. It defines AM as the process of joining materials layer by layer from a 3D model to create an object with minimal limitations. The document outlines seven main AM processes, describes current applications and trends, and identifies gaps in technology, materials, design, and education/training that need to be addressed for AM to realize its full potential, particularly for mass production applications. Recommendations include increased research in new materials, modeling, sensing, education, and university-industry collaboration.
FDM Process introduction (A part of Additive Manufacturing Technique OR Commonly Known as 3D Printing). 3D printing is an evolved manufacturing technique; it is comparatively better than conventional substractive manufacturing. There is minimum wastage of material because material is added only at those locations where it is required. To make 3D model you need a 3D printer and feeding material and obviously power source. Any thermoplastic material whose melting temperature lies in the range of 150-240 deg. C can be used in FDM based 3D printing.
Additive manufacturing (AM) is the industrial production name for 3D printing, a computer controlled process that creates three dimensional objects by depositing materials, usually in layers,is a transformative approach to industrial production that enables the creation of lighter, stronger parts and systems. ... As its name implies, additive manufacturing adds material to create an object.
FDM Process introduction (A part of Additive Manufacturing Technique OR Commonly Known as 3D Printing). 3D printing is an evolved manufacturing technique; it is comparatively better than conventional substractive manufacturing. There is minimum wastage of material because material is added only at those locations where it is required. To make 3D model you need a 3D printer and feeding material and obviously power source. Any thermoplastic material whose melting temperature lies in the range of 150-240 deg. C can be used in FDM based 3D printing.
Additive manufacturing (AM) is the industrial production name for 3D printing, a computer controlled process that creates three dimensional objects by depositing materials, usually in layers,is a transformative approach to industrial production that enables the creation of lighter, stronger parts and systems. ... As its name implies, additive manufacturing adds material to create an object.
this short ppt gives you a rough idea about the additive manufacturing process of stereolithography. This process is apart of 3d printing technologies around us. Also included is link to a video that will help you further.
Stereolithography (SLA) is the oldest 3D Printing technology used to manufactureaesthetically beautiful and proof of concept prototypes with smooth surface finish. We use photopolymer resins to manufacture the parts in SLA technology. The parts find applications in Automotive interiors, Industrial goods, Medical Devices industries etc.
This presentation is useful; for understanding the processes of rapid prototyping and its application.
Also this presentation includes the STL file format and problems with STL files.
Revolutionary and powerful technology with wide range of application.
The process involve quick building up of a prototype or working model for the purpose of testing the various design features, ideas, concepts, functionality, output and performance.
this short ppt gives you a rough idea about the additive manufacturing process of stereolithography. This process is apart of 3d printing technologies around us. Also included is link to a video that will help you further.
Stereolithography (SLA) is the oldest 3D Printing technology used to manufactureaesthetically beautiful and proof of concept prototypes with smooth surface finish. We use photopolymer resins to manufacture the parts in SLA technology. The parts find applications in Automotive interiors, Industrial goods, Medical Devices industries etc.
This presentation is useful; for understanding the processes of rapid prototyping and its application.
Also this presentation includes the STL file format and problems with STL files.
Revolutionary and powerful technology with wide range of application.
The process involve quick building up of a prototype or working model for the purpose of testing the various design features, ideas, concepts, functionality, output and performance.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
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Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
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Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
2. 2
CONTENTS
1. Introduction
2. What is additive manufacturing?
Functional principle
Advantages & disadvantages
Applications
3. AM Processes
4. Present conditions
5. AM - FutureAspects
6. Gaps & needs
7. Recommendations
8. Conclusion
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3. 3
Introduction
Manufacturing is a process in which raw materials are
transformed into finished goods.
Additive Manufacturing
• Technology that can make anything.
• Eliminates many constraints imposed by conventional
manufacturing
• Leads to more market opportunities.
• Increased applications such as 3D faxing sender scans a
3D object in cross sections and sends out the digital
image in layers, and then the recipient receives the
layered image and uses an AM machine to fabricate the
3D object.
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4. What is Additive Manufacturing?
4
The process of joining materials to make objects from three-
dimensional (3D) model data, usually layer by layer
Commonly known as “3D printing”
Manufacturing components with virtually no geometric limitations or
tools.
AM uses an additive process
Design for manufacturing to manufacturing for design
Distinguished from traditional subtractive machining techniques
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5. Functional principle
The system starts by applying a thin layer of the powder material to the
building platform.
Apowerful laser beam then fuses the powder at exactly the points
defined by the computer-generated component design data.
Platform is then lowered and another layer of powder is applied.
Once again the material is fused so as to bond with the layer below at
the predefined points. 5
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6. ADVANTAGES
Freedom of design
Complexity for free
Potential elimination of tooling
Lightweight design
Elimination of production steps
DISADVANTAGES
Slow build rates
High production costs
Considerable effort required for application design
Discontinuous production process
Limited component size.
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7. Applications
AM has been used across a diverse array of
industries, including;
Automotive
Aerospace
Biomedical
Consumer goods and many others
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8. AM processes are classified into seven categories
1) V
at Photopolymerisation/Steriolithography
2) Material Jetting
3) Binder jetting
4) Material extrusion
5) Powder bed fusion
6) Sheet lamination
7) Directed energy deposition
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9. Vat photopolymerization/Steriolithography
• Laser beam traces a cross-section of the part pattern on
the surface of the liquid resin
• SLA's elevator platform descends
• A resin-filled blade sweeps across the cross section of the
part, re-coating it with fresh material
• Immersed in a chemical bath
Stereolithography requires the use of supporting structures
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10. Material Jetting
• Drop on demand method
• The print head is positioned above build platform
• Material is deposited from a nozzle which moves
horizontally across the build platform
• Material layers are then cured or hardened using
ultraviolet (UV) light
• Droplets of material solidify and make up the first layer.
• Platform descends
• Good accuracy and surface finishes
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11. Binder Jetting
• Aglue or binder is jetted from an inkjet style print head
• Roller spreads a new layer of powder on top of the previous
layer
• The subsequent layer is then printed and is stitched to the
previous layer by the jetted binder
• The remaining loose powder in the bed supports overhanging
structures
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12. Material Extrusion/FDM
• Fuse deposition modelling (FDM)
• Material is drawn through a nozzle, where it is heated and is then
deposited layer by layer
• First layer is built as nozzle deposits material where required onto
the cross sectional area.
• The following layers are added on top of previous layers.
• Layers are fused together upon deposition as the material is in a
melted state.
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13. Powder Bed Fusion
• Selective laser sintering (SLS)
• Selective laser melting (SLM)
• Electron beam melting (EBM)
No support structures required
PROCESS
• Alayer, typically 0.1mm thick of material
is spread over the build platform.
• The SLS machine preheats the bulk powder
material in the powder bed
• Alaser fuses the first layer
• Anew layer of powder is spread.
• Further layers or cross sections are fused
and added.
• The process repeats until the entire model is
created.
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14. Sheet Lamination
• Metal sheets are used
• Laser beam cuts the contour of each layer
• Glue activated by hot rollers
PROCESS
1. The material is positioned in place
on the cutting bed.
2. The material is bonded in place, over
the previous layer, using the
adhesive.
3. The required shape is then cut from
the layer, by laser or knife.
4. The next layer is added.
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15. Directed Energy Deposition
• Consists of a nozzle mounted on a multi axis arm
• Nozzle can move in multiple directions
• Material is melted upon deposition with a laser or electron
beam
PROCESS
1. A4 or 5 axis arm with nozzle moves
around a fixed object.
2. Material is deposited from the nozzle onto
existing surfaces of the object.
3. Material is either provided in wire or
powder form.
4. Material is melted using a laser, electron
beam or plasma arc upon deposition.
5. Further material is added layer by layer
and solidifies, creating or repairing new
material features on the existing object. 15
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16. Present Condition & Trends
TechnologyAnd Research
• The model data, usually in stereolithography (STL) format, is first
decomposed into a series of 2D, finitely thick cross sections, which
are then fed into anAM machine.
• Used directly and indirectly to produce prototype parts
• Reduce manufacturing and product costs
University–Industry Collaboration and Technology Transfer
More and more companies have begun usingAM technology to;
• Reduce time-to-market
• Increase product quality
• Improve product performance
• Costs
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17. • Metal-based AM processes have recently emerged in industrial
applications for manufacturing items such as automotive engines,
aircraft assemblies, power tools, and manufacturing tools including
jigs, fixtures, and drill guides
EducationAnd Training
• Educating the general public about AM empowers people to build
what they dream.
• FormalAM education has already been integrated into curricula at
different levels.
• Educational materials on rapid prototyping have long been a part of
manufacturing engineering courses
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18. AM - Future Aspects
TechnologyAnd Research
• “ Third industrial revolution “
• The cost effective mass customization of complex products
• Reduced material waste and energy consumption
• Adapt new product designs without the additional expenses
• In the biomedical field,AM can be used to fabricate tissue scaffolds
that are biocompatible, biodegradable, and bio-absorbable
Education & Training
• AM holds great potential for promoting science, technology,
engineering, and mathematics (STEM) education
• The availability of low-cost 3D printing equipment is creating the
opportunity for AM-enabled, hands-on labs in primary, secondary,
and postsecondary schools across the nation
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20. Material
• Intensive materials research and development is needed
• In metallurgy, it takes about 10 years to develop a new alloy, including the
determination of various critical properties such as fatigue strength. This
time frame also applies to developing new materials forAM
• Even with existing materials, advancements are needed
Design
• V
ariousAM-oriented design tools must be developed
• CAD systems should be re-invented to overcome its limitations
Modeling, Sensing, Control, and Process Innovation
• Difficult to predict the microstructures and fatigue properties resulting from
AM processes
• The sensing ofAM processes may require fast in situ measurements of the
temperature, cooling rate, and residual stress
Characterization and Certification
• Real production environments and practices are much more rigorous
than those for prototyping purposes.
• The existing AM systems are still predominantly based on rapid
prototyping machine architectures
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21. University–Industry Collaboration and Technology
Transfer.
• To compete with conventional mass production processes,AM
technology must advance significantly in order to drastically reduce
the cost of fabrication, improve the performance of fabricated parts
• The price of materials for AM would need to drop substantially in
order to achieve sufficient return on investment to make AM for
mass production a reality
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23. Education & Training
While numerousAM education resources and training materials are
available, there is still no readily applicable, proven model forAM
education and training
Taking full advantage ofAM will require;
• Educating the current workforce
• Recruiting a new generation of students
• Developing proper design tools
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24. Recommendations
Technology and Research.
Materials
• Development of new materials forAM processes
• Formation and mixing of materials in desired forms and with desired properties
Design
• Methods and tools for simultaneous multifunctional
• Product design andAM process design
Modeling
• Robust physics-based mathematical models of temperature, stress etc.
• Prediction of microstructures and fatigue properties resulting from extreme
heating and cooling rates inAM processes
Sensing and control
• Fast-response sensors for detecting defects and phase transformations
• Integrated real time sensing and closed-loop control ofAM processes
• The production costs, manufacturing time, and part defects must be reduced
drastically in order forAM to become hugely successful.
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25. University–Industry Collaboration and Technology
Transfer
• Collaborations incentivized by federal funding programs
• Increased federal research and development (R&D) support
Education and Training
Teaching Factory
In the teaching factory, students are exposed directly to a
manufacturing enterprise where they design products to meet
customer needs and manufacture their designed products for the
market.
Other Training Efforts
Promotion of public awareness
Use of the Internet
Establishment of publicly accessibleAM facilities
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26. CONCLUSION
• The process of joining materials to make objects from three-
dimensional (3D) model data, usually layer by layer
• Traditional subtractive machining techniques rely on the removal of
material by methods such as cutting or milling
• Has many advantages over traditional manufacturing processes
• Seven processes ofAM
• AM is on the verge of shifting from a pure rapid prototyping
technology
• Manufacturing metal components with virtually no geometric
limitations or tools offers new ways to increase product performance
or establish new processes and revenue streams
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27. References
Base Journal ; Additive Manufacturing: Current State, Future Potential, Gaps and
Needs, and Recommendations
1. ASTM, 2009, ASTM International Committee F42 on Additive
Manufacturing Technologies,ASTM F2792–10 Standard Terminology for
Additive Manufacturing Technologies,ASTM, West Conshohocken, PA.
2. Wohlers Associates, Inc., 2013, Wohlers Report 2013: Additive
Manufacturing and 3D Printing State of the Industry, Wohlers Associates,
Fort Collins, CO.
3. Bourell, D. L., Beaman, J. J., Leu, M. C., and Rosen, D. W., 2009, “ABrief
History of Additive Manufacturing and the 2009 Roadmap for Additive
Manufacturing: Looking Back and Looking Ahead,” Proceedings of
RapidTech 2009: US-TURKEY Workshop on Rapid Technologies, Istanbul,
Turkey, Sept. 24–25, pp. 1–8.
4. Google
5. Wikipedia
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