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2023 | Buch

Innovative Product Development by Additive Manufacturing 2022

herausgegeben von: Roland Lachmayer, Behrend Bode, Stefan Kaierle

Verlag: Springer International Publishing

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik" , Springer Professional "Wirtschaft"

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Über dieses Buch

The book consists of a collection of papers from a corresponding conference regarding additive manufacturing. The yearly conference used to be held in German under the title "Konstruktion für die Additive Fertigung" and is held in English since last year.

The topics are

Specifications, potentials, and solutions Contributions to specifications on components and processes and methods for assessing the suitability of components and the application of additive manufacturing and finding solutions for concepts and design Design and optimization Contributions to the development and design of components, their design to ensure functional requirements and manufacturability, and methods and tools for optimization components Simulation, validation, and quality assurance Contributions to approaches for the computer-aided and physical validation of components, the testing of components and material, and measures to ensure quality aspects Process chain and business modelsContributions to their integration of additive manufacturing processes into existing processes and measures to increase value creation and the creation of new business models.

Inhaltsverzeichnis

Frontmatter

Do Additive Manufacturing Processes Enable More Sustainable Products? Circulation of Metallic Components Through Repair and Refurbishment by the Example of a Deep-Drawing Tool

Abstract

Resource-efficient circular economy strategies can make a significant contribution to increase the environmental sustainability of products. Repair and refurbishment of damaged or obsolete components can be achieved through the use of additive manufacturing (AM) processes. However, the analysis of existing application examples shows that the application potential of AM processes for the recycling of components is not yet fully exploited. Up to now, almost exclusively wear damage has been repaired. A structural repair as well as a refurbishment, i.e. a functional modernisation of a component, is hardly described in the literature so far. The AM process powder bed fusion by laser beam (PBF-LB) offers great potential for repairing filigree and complicated structures as well as refurbishing parts. However, potential users usually lack the know-how to use the process for repairing or refurbishing existing components. For users without the necessary experience, this article offers assistance through the detailed description of a process chain for the repair and refurbishment of a component. The component under consideration is a prototype of a deep-drawing die. Manufacturing defects occurred on this component, which were repaired using PBF-LB. Compared to manufacturing a new prototype, 83% less material was applied in the repair process and the build job required only about a third of the time. In addition, the prototype, which became obsolete with a new development status of the deep-drawing tool, was adapted to this new development status and thus used again. Since only conventional AM systems were used in the process chains, this article is particularly interesting for practitioners who want to use already existing AM systems for the repair and refurbishment of components. With the presented use case, this paper shows the potential for the broader use of a component repair and refurbishment by means of PBF-LB, especially in the context of product development processes. Finally, the discussion deals with the boundary conditions that have to be taken into account when deciding whether a component is suitable for metal additive repair and refurbishment.

Nicola Viktoria Ganter, Tobias Ehlers, Marcus Oel, Bernd-Arno Behrens, Philipp Müller, Sven Hübner, Philipp Althaus, Behrend Bode, Roland Lachmayer

Design and Optimization

Frontmatter

Automation in Active Surface-Based Design Generation for Additive Manufacturing

Abstract

This study presents an approach to support the optimisation of part candidates for additive manufacturing by the automated detection of relevant active surfaces. These active surfaces play a fundamental role for the definition of preserved geometries and design space in the Generative Design approach used for optimisation. A software tool is implemented that identifies active surfaces in parts or assemblies. Common types of active surfaces are recognised automatically based on geometric restrictions. Supplementary active surfaces can be considered individually by the user. The surfaces under consideration are analysed to derive key figures used for geometric reconstruction. Besides single part optimisation, this approach proves to be beneficial for consolidation of assemblies. The tool automatically distincts whether active surfaces exist as external interfaces or as internal interfaces in an assembly that can be consolidated. The active surfaces are automatically converted into solid bodies and transferred to the Generative Design software to generate optimised geometries for additive manufacturing.

Marcel Winkler, Georg Jacobs, Jo Gessert, Christian Konrad, Stefan Keßler

Innovative Product Development by Additive Manufacturing 27. September 2022

Influence of Joining Zone Geometry on Material Distribution in Electrochemically Produced Component Joints in Additive Manufacturing

Abstract

In additive manufacturing, differential design is becoming increasingly important as a complementary design method to integral design. Consequently, the need for component connections increases. In preliminary investigations, electrochemical metal deposition has been shown to be promising as a joining method. In this publication, the process preparation steps are improved. Subsequently, the influence of geometry parameters on the material distribution in the joining zone is considered using specimen made of AlSi10Mg. For this purpose, characterizing features of the finished joint are identified and the effect of geometry on these features is investigated. In addition, a brief comparison of the effect of geometry on the tensile strength of a purely material bonded joint is drawn. An opposite behavior between improved tensile strength and reduction of material agglomeration is found. Finally, suggestions are given for improving the joint by modifying part design and process based on the current state of research.

Kris Rudolph, Melina Kübler, Marco Noack, Eckhard Kirchner

Powder Residuals in Metal Laser Powder Bed Fusion – Review: Kinds of Residuals and Consideration in Process

Abstract

Additive manufacturing (AM) is known as a manufacturing technology, which can create complex geometries or functionalities that are not achievable by traditional production approaches. Many examples demonstrate additive manufactured complex components with curved inner channels for conformal cooling, lattice structures for lightweight application, or porous structures for medical implants. These components are only operative if the residual powder has been sufficiently removed. Therefore, powder removal is a necessary post-processing step, but the detailed description of this topic is often neglected in research articles. This paper presents a literature review on the topic of residual powder in metal laser powder bed fusion (PBF-LB/M). It deals with different kinds of residuals, from large loose powder quantities to individual semi-melted particles, as well as the process steps in which the residuals were considered.

Laura Wirths, Matthias Bleckmann, Patrick Lurtz, Kristin Paetzold, Philipp Höfer

Approach for Rapid Fabrication of Individual Bone Replacement Structures by Designing Additively Prefabricated CPC Models

Abstract

Customized bone replacement structures offer the potential to build up missing bone areas. However, additive manufacturing of calcium phosphate cement (CPC) structures is limited due to the material behavior. The aim is to separate the functionalization and shaping. Thus, prefabricated CPC-prefabs, which show different porosity as functionalization, are to be manufactured additively. The individual shaping will be carried out by milling (CAD/CAM). Several CPC-prefabs are developed, which differ in the mapping of the transition geometry from porous to dense phase as well as in the overall size. Therefore, categorized datasets of mandibular scans are analyzed and the cross-sectional contour of the bone is determined. Mathematical regression is used to determine a parametrically described average contour, which is used to design the prefab models. First single phase prefab demonstrators have been additively manufactured and subjected to initial milling tests. The feasibility in principle of the intended process has thus been demonstrated.

P. Sembdner, H. Pohlmann, A. Wendler, J. B. Matschke, L. Kroschwald, S. Holtzhausen, A. Hutsky, D. Ellmann, G. Lauer, K. Paetzold

Characterization of Additive Manufactured Structures for the Development of Foam-Replacement Cushions

Abstract

For an ergonomic and healthy sitting posture, the distribution of the seat load in the contact zone through a soft seat cushion is essential. Conventional polyurethane (PUR) foams have only a very limited ability to adapt the distribution of the seat load in the seat cushion to the individual person. In this paper, a potential analysis is conducted to show the extent to which a replacement model for PUR foams can be realized using thermoplastic polyurethane (TPU) materials in the fused-deposition modeling (FDM) process. Based on fundamental experiments and consideration of manufacturing restrictions, suitable structure families and types are investigated and characterized. The characterization is based on standards for foam testing. Grading and design parameters are presented for the use of the foam replacement model in cushioned units. This allows the replacement of PUR foam and also a customer-specific hardness grading in the context of a mass customization process chain.

Carl Steinnagel, Cem Bastimar, Paul Christoph Gembarski, Stefan Plappert, Patrik Müller, Roland Lachmayer

Manufacturing and Build Quality

Frontmatter

Challenges in Quality Management of Additively Manufactured Metal Spare Parts in Low-Volume Production

Abstract

The expectations towards metal Additive Manufacturing (AM) as an enabling technology to manufacture sparne parts are rapidly growing. The technology enables low-volume production at a reasonable cost. Several advantages of AM compared to conventional manufacturing processes, for example, a shortening of manufacturing time are presented in literature studies. However, to implement AM in the industry for a long-term perspective, process characteristics need to be analysed and adapted. Hereby, Quality Management (QM) remains a critical aspect that needs to be considered. Especially, machines and systems used in the aerospace and defense industry are underlying strict regulations. Military equipment frequently operates in harsh environments - thus unexpected inspections and maintenance are mandatory. Because of the long service time of the systems the demand for spare parts increases. This paper points out current challenges for additively manufactured spare parts in low-volume production. In particular, challenges in the process- and quality management are addressed. Current literature research and experience of conducted experiments are considered.

Patrick Lurtz, Laura Wirths, Kristin Paetzold

Resource-Efficient Sintering Supports for the Metal Binder Jetting Process

Abstract

As one of the additive manufacturing processes, metal binder jetting enables a resource-efficient and more cost-effective production of highly complex metal components. However, shrinkage of approx. 20% occurs during the sintering process, which often leads to undesirable component deformation and thus to component defects due to relative movement between the component and sintering base and the associated frictional forces. One way of minimizing this distortion is to use co-shrinking sintering supports. These are support structures that are manufactured using the same process and material as the components. However, this type of support structure can only be used once, which results in significantly higher material consumption and process time. To increase resource efficiency and reduce production costs, lightweight sintering supports were developed and analyzed, which are presented in this work. Initial results show a material saving of up to 73% for the sintering supports.

Heiko Blunk, Niklas Huber

Product Redesign for Hybrid Additive Manufacturing Driven by Product Architecture Transformation - A Methodological Proposal

Abstract

The implementation of additive manufacturing enables the re-thinking of a product architecture towards an optimized design and functional integration. This study builds upon existing function-oriented part identification methods. These approaches have been further developed towards identifying and evaluating potential product redesigns for powder bed (Laser Powder Bed Fusion), powder spray (Cold Spray), and hybrid additive manufacturing. Our method is capable of analyzing complex industrial product structures. The feasibility of the method is demonstrated for a gas turbine combustion unit.

Veronica Molina, Otto Maier, Dietmar Göhlich

Advanced Temperature Sense and Control Methods for Selective Laser Sintering

Abstract

The selective laser sintering (SLS) process is very temperature sensitive, so slight temperature changes can lead do inhomogeneous prints with varying mechanical properties. The laser power is kept at a fixed value while printing because most SLS printers assume a constant temperature in the building volume on the powder surface. The assumption of an even temperature distribution is incorrect in a lot of cases. In this chapter a modular system for the monitoring and controlling of laser based double scanner systems is presented. Also very fast signals (e.g. temperature) can be processed and used for a process control (e.g. controlled laser power). Current strategies for temperature control of the sensitive SLS process are often based on slow thermal cameras or single scanner pyrometry. In a novel approach, a highly dynamic double scanner system is used to position the measuring beam of a high speed pyrometer independently from the laser spot. FPGA technology (Field Programmable Gate Array) is used to manipulate scanner trajectories in real time and to process the pyrometer data. With this approach, new measurement and control strategies are possible.

C. Zander, J. Düsing, G. Hohenhoff, P. Jäschke, L. Overmeyer, S. Kaierle

Backmatter

Titel: Innovative Product Development by Additive Manufacturing 2022
herausgegeben von: Roland Lachmayer
Behrend Bode
Stefan Kaierle
Verlag: Springer International Publishing
Electronic ISBN: 978-3-031-27261-5
Print ISBN: 978-3-031-27260-8
DOI: https://doi.org/10.1007/978-3-031-27261-5

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