This document discusses various design considerations for additive manufacturing with polymers. It addresses anisotropy in parts printed with different orientations. Wall thicknesses between 0.6-5mm are recommended depending on the application. Overhangs require support material which can be optimized by adjusting the support angle. Holes should be printed vertically for roundness. Ribs can reinforce walls, and superfluous material should be avoided to reduce printing time and potential warping. Font sizes as small as 8pt can be used on vertical surfaces.
This short presention is about the dirrefent types of boards used in building construction, furniture, and interior design.
This presentation is intended towards Architects/ Architecture Students/ Interior designers and Building construction technology enthusiasts.
This short presention is about the dirrefent types of boards used in building construction, furniture, and interior design.
This presentation is intended towards Architects/ Architecture Students/ Interior designers and Building construction technology enthusiasts.
It is not always easy to perform adhesive binding on soft cover brochures - and it is frequently a cause of complaint.
The problem is that the first and last pages are often not held effectively in place in the spine glue when they are opened. What's more, the top edge of the glue film can be seen around the notch − which is not a very pretty sight. The reasons behind this problem are many and varied - from the physical properties of the paper and glue themselves to incorrect material combinations or operating errors. But so, too, are the solutions. The most important of these are described below.
Lecture # 03 Design for Additive ManufacturingSolomon Tekeste
Design for Additive Manufacturing (DfAM)
DfAM - A generic term used to describe rules and parameters for a part design to be produced with an AM process
DfAM - is the practice of designing products to reduce or minimize manufacturing and assembly difficulties and costs,
DfAM aims
To take advantages of the unique AM technologies capabilities to design and optimize a product/component,
To utilize the characteristics of AM methods to improve the product/component functions according to the capability of the selected AM process.
In doing so, the designers should tailor their designs to maximize the advantages of AM methods, such as complex geometries and lightweight
Design Aspect and Design Consideration in AM
Design aspect
Any particular feature which can be quantified at the design phase.
Includes;
Geometric features of the part’s shape (overhangs, bores, channels, etc.)
Part’s programming parameters (layer thickness, orientation, etc.).
Design consideration
The result on the manufactured part
Specific properties of the process and quantified with certain key performance indicators.
These includes; surface roughness, accuracy, build time, etc.
Design Aspect and Design Consideration in AM
With conventional manufacturing processes, these aspects are mostly a concern for the production engineer rather than for the designer;
But, the significance of these aspects is high for the outcome in AM technologies.
I am John Nash . Currently associated with matlabassignmentexperts.com as a Matlab Homework Help Expert. After completing my Master's in Mechanical Engineering, University of Sydney, I was in search of an opportunity that would expand my area of knowledge hence I decided to help students with their homework. I have written several Design and Manufacturing Assignments to help students overcome numerous difficulties.
We have often come across the term resolution for images, which describes the detail of the image in image processing techniques. We also frequently use this term for differentiating TV screens and display quality, which is primarily based on their dimensions. Now, do we have a resolution for 3D prints?
It is not always easy to perform adhesive binding on soft cover brochures - and it is frequently a cause of complaint.
The problem is that the first and last pages are often not held effectively in place in the spine glue when they are opened. What's more, the top edge of the glue film can be seen around the notch − which is not a very pretty sight. The reasons behind this problem are many and varied - from the physical properties of the paper and glue themselves to incorrect material combinations or operating errors. But so, too, are the solutions. The most important of these are described below.
Lecture # 03 Design for Additive ManufacturingSolomon Tekeste
Design for Additive Manufacturing (DfAM)
DfAM - A generic term used to describe rules and parameters for a part design to be produced with an AM process
DfAM - is the practice of designing products to reduce or minimize manufacturing and assembly difficulties and costs,
DfAM aims
To take advantages of the unique AM technologies capabilities to design and optimize a product/component,
To utilize the characteristics of AM methods to improve the product/component functions according to the capability of the selected AM process.
In doing so, the designers should tailor their designs to maximize the advantages of AM methods, such as complex geometries and lightweight
Design Aspect and Design Consideration in AM
Design aspect
Any particular feature which can be quantified at the design phase.
Includes;
Geometric features of the part’s shape (overhangs, bores, channels, etc.)
Part’s programming parameters (layer thickness, orientation, etc.).
Design consideration
The result on the manufactured part
Specific properties of the process and quantified with certain key performance indicators.
These includes; surface roughness, accuracy, build time, etc.
Design Aspect and Design Consideration in AM
With conventional manufacturing processes, these aspects are mostly a concern for the production engineer rather than for the designer;
But, the significance of these aspects is high for the outcome in AM technologies.
I am John Nash . Currently associated with matlabassignmentexperts.com as a Matlab Homework Help Expert. After completing my Master's in Mechanical Engineering, University of Sydney, I was in search of an opportunity that would expand my area of knowledge hence I decided to help students with their homework. I have written several Design and Manufacturing Assignments to help students overcome numerous difficulties.
We have often come across the term resolution for images, which describes the detail of the image in image processing techniques. We also frequently use this term for differentiating TV screens and display quality, which is primarily based on their dimensions. Now, do we have a resolution for 3D prints?
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
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/
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.
TECHNICAL TRAINING MANUAL GENERAL FAMILIARIZATION COURSEDuvanRamosGarzon1
AIRCRAFT GENERAL
The Single Aisle is the most advanced family aircraft in service today, with fly-by-wire flight controls.
The A318, A319, A320 and A321 are twin-engine subsonic medium range aircraft.
The family offers a choice of engines
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
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.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
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.
2. CONTENT
Polymer AM
Anisotropy
Wall Thicknesses
Overhangs and Support Material
Holes
Ribs
Avoiding Superfluous Material
Font Sizes & Small Details
2
3. Polymers are materials made of long, repeating chains of molecules. The
materials have unique properties, depending on the type of molecules being
bonded and how they are bonded.
• Additive manufacturing (AM) encompasses a range of technologies that
allows physical components to be made from virtual 3D models by building
the component layer-upon-layer until the part is complete.
• Additive manufacturing uses data computer-aided-design (cad) software or
3d object scanners to direct hardware to deposit material, layer upon layer, in
precise geometric shapes
POLYMER
ADDITIVE MANUFACTURING
3
5. ANISOTROPY
• Anisotropy is the term used to describe the properties of a part in which the
mechanical properties of the part are not the same in all directions.
• With all additive manufacturing technologies, there is always a certain
amount of anisotropy in the vertical direction between the layers because the
mechanical strength of the bond between each layer can be somewhat weaker
than the mechanical strength within the layer itself
• In some am technologies anisotropy can be negligible or eliminated through
post-processing, but in some technology it is an issue that must be take into
account when designing a part, and when deciding on its print orientation.
• As all am technologies suffer from some level of anisotropy, special
consideration needs to be given to all aspects of the design that could suffer
from weakness because of print orientation
5
7. ANISOTROPY
• Some technologies, such as powder bed fusion, have some degree of
anisotropy but, as you get past a certain thickness, the anisotropy gets
minimized. This is due to the larger mass of plastic retaining the heat for
longer, which creates a better bond with the layer below.
• With powder bed fusion, screw bosses, below a diameter of about 6 mm,
for example, still exhibit some anisotropy, whereas it become negligible
for screw bosses with a diameter greater than 6 mm.
• As geometries becomes more complex, however, print orientation often
becomes a compromise between avoiding anisotropy while, at the same
time, achieving the best surface finish, and the best mechanical properties
for as many as features as possible.
7
7
8. WALL THICKNESS
• In 3D printing, wall thickness refers to the distance between one surface of
your part and the opposite sheer surface.
• It is possible to create thinner walls, how successfully they will print will
depend on the surface area of the wall, and the unsupported width to height
ratio.
• Large surface area flat thin walls will be hard to print without distortion
and depending on the am technology used, may divide into layers.
• A simple technique to avoid this problem, if the wall cannot be made
thicker, using ribs to strengthen the wall.
8
9. WALL THICKNESS
• The orientation in which the part is printed can be used to prevent large flat
walls from warping.
• Printing the part at a slight angle, typically above 10°can significantly
reduce the risk of distortion
*Printing the part at an angle may result in poorer surface finish than if it is
printed straight.
Range of wall thickness
• For light-weight consumer products : 0.6–2.5 mm
• For industrial heavy-duty industrial products : 3- 5 mm
9
10. WALL THICKNESS
• As with conventional injection molding, a general rule of thumb is to use
even wall thicknesses throughout the parts, as uneven wall thicknesses can
create part distortion.
• The design freedom allowed by AM, especially in comparison with
injection molding, makes it much easier to achieve such even wall
thicknesses throughout the part. This does not mean that there cannot be
uneven wall thicknesses, only that there should be a really good engineering
or functional reason for doing this.
• In some case, the orientation in which the part is printed can be used to
prevent large flat walls from warping.
• In the simple box example, if the part is printed in the horizontal position,
then there will be a large thin ‘sheet’ of polymer that gets melted, and may
try to curl up and cause warping, or could even cause the machine to crash.
In contrast, printing the part at a slight angle, typically above 10°, removes
such large flat areas and can drastically reduce the risk of distortion
10
10
12. OVERHANGS AND SUPPORT MATERIAL
• With polymer AM technologies, almost all technologies, the printed parts
require support material to support any overhanging features
• Support material is a sacrificial material that is utilized during the printing
process to allow any features that overhang,because it is not possible to print
in air without the material collapsing, and is removed after the part has
finished printing
Fig:Support material to allow overhanging features to be printed
12
13. OVERHANGS AND SUPPORT MATERIAL
• Most AM systems allow you to choose at what angle to use support
material.It take some trail to determine which angle is best to get best quality
part while minimizing the support material used.
• There is usually a support ‘angle’ option in your 3d printing software that
determines the angle in which the part requires support material.
External support and internal support:
Parts that have sections narrower than 45° must be supported. The support is
required to keep your part in place and prevent it from collapsing while being
printed
Fig: External support Fig: Internal support
13
14. OVERHANGS AND SUPPORT MATERIAL
• Some printers measure the support angle from the vertical, while others
measure it from the horizontal. It is thereforeimportant to be aware of how
each particular printer takes this measurement
• Choose the orientation that your part is printed into optimise support material
use but, in doing so, keep anisotropy in mind, as one print orientation may give
you less support material, but may weaken the part in certain undesirable
areas.
• With the part below, for example, if it is printed facing upwards, very little
supportmaterial is used, whereas if it is printed upside down, the inside will be
filled with material, which requires labour to remove after the part is printed,
and wastes material.
Fig: Support material to allow overhanging features to beprinted
14
14
16. 16
• Some AMsoftware also allows you to set the surface area below which no
support material is required.
• The benefit of this is that some material is saved and a slightly shorter print
time is achieved. Moreover, this approach can also result in less support
material to remove from holes.
• The risk is that, if the surface area is too high, there may be some sagging of
material on the top surfaces of the overhangs
OVERHANGS AND SUPPORT MATERIAL
Fig: Setting the surface area below which support material is not required
16
18. HOLES
• With AM technologies, print orientation can greatly affect the roundness of
holes. To achieve the roundest possible holes, it is always best to have the
holes printed in the vertical direction.
• Holes printed in the horizontal position will suffer both from the stair-step
effect and from some sagging that may make the holes slightly elliptical.
• Holes are also often very slightly undersized, but this can easily be
compensated for in cad by oversizing the holes by about 0.1 mm or by
running a drill through the hole after printing to make it the precise
required size.
• The smallest achievable hole diameter depends heavily on the thickness of
the material they are going through.
• In general, however, for most walls that are around 2 mm thick, a 0.5 mm
diameter hole is achievable. 18
19. RIBS
• Most polymer AM materials are slightly less rigid than their injection
molded counterparts. This means that large surface areas and walls can be
quite flexible, and can sometimes develop some distortion during the
printing or cooling down process.
• The simplest way to make walls more rigid, and to minimize the risk of
distortion is to design the part with ribs to reinforce large thin areas.
The general guideline for adding ribs to a 3d printed polymer part are:
• For a given stiffness : it is better to increase the number of ribs instead of
their height.
• For very thick ribs :it is better to core them out, so as to avoid large masses
of material that can cause distortion, and are more expensive to print.
• Shelling the rib to an even wall thickness (making it hollow) and printing it
filled with support material shown in figure in next slide
19
21. RIBS
Thickness of ribs: 75% of wall thickness
Height of ribs: <3× thickness
Rib spacing: >2× thickness
Always fillet the point where ribs meet the
wall
Fig: General guidelines for adding ribs
21
22. AVOIDING SUPERFLUOUS MATERIAL
• With conventional subtractive manufacturing, we strive to have the machine
do as little cutting work as possible so, in our design, we leave any material
that does not hinder the function of the part, as removing it would cost time
and money.
• With am the more unnecessary material there is, the more work the am
system has to do, and the longer the part will take to make, and the more it
will cost.
• Large masses of superfluous material can also have a detrimental effect on
the part, as they may cause the part to distort and warp on cooling.
• When designing am parts, it is therefore important to avoid having large
masses of material that serve no functional purpose, as they slow down
production time,increase part weight, and can cause part deformation.
22
23. AVOIDING SUPERFLUOUS MATERIAL
• The very simplest approach to this, also described in the economics of AM section, is
to ‘shell’ the thicker sections of the part.
• This will minimise print time and cost. But a decision also needs to be made as to
whether to leave the excess material (unsintered powder, liquid photopolymer resin, or
support material, etc.) inside the shelled part, or to design in‘salt-shaker’ holes so that
the excess material can be removed.
• To remove internal support material, larger holes may be necessary
Fig: Shelled part with salt-shaker holes to remove thick sections from the
part and allow material inside the part to be removed
23
24. SMALL DETAILS
The minimum size for small detail to still be visible is determined by the
printer’s resolution.
When detail dimensions are below the minimum, the printer may not be able to
accurately replicate them.
Details that are too small can also be smoothed over in the polishing or sanding
process. To ensure details come out clearly, make them larger than the indicated
minimum.
Typically, for most polymer am technologies, details are visible down to about
0.5 mm (though in some cases they can be as small as 0.2 mm high × 0.2 mm
wide), but this must be tested for each model of printer.
Also, surfaces that are in contact with support material may not be possible to
reproduce with as fine a detail as those surfaces that do not require support
material. 24
25. FONT SIZE
For many AM technologies, the smallest legible font size is, counterintuitively,
on the sides of the part. Relatively small text can be added to the vertical sides
of a part,but it can be relatively poor on top surfaces.
Fonts, and other small details, can either be sunk into thewall
(debossed) of the part or can project from the wall of the part
(embossed).
In general, it may be preferable to have them sunk into thewalls of the
part for two reasons:
1. It removes material form the part which means a slightly reduced
print time.
2. It reduces the risk of the font or details being sanded off during post
processing.
25
26. However, there is no problem with using printed fonts, if required. But
greater care may need to be taken during the part post-processing.
General font size:
• A font size that usually works on all surfaces is 14pt, and at least
0.4mm(0.016 in.)In depth.
• On vertical surfaces one can go down to about an 8pt font
FONT SIZE
26