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1 – 2 of 2Sigmund Arntsønn Tronvoll, Sebastian Popp, Christer Westum Elverum and Torgeir Welo
This paper aims to present the mathematical foundation of so-called advance algorithms, developed to compensate for defects during acceleration and deacceleration of the print…
Abstract
Purpose
This paper aims to present the mathematical foundation of so-called advance algorithms, developed to compensate for defects during acceleration and deacceleration of the print head in filament-based melt extrusion additive processes. It then investigates the validity of the mathematical foundation, its performance on a low-cost system and the effect of changing layer height on the algorithm’s associated process parameter.
Design/methodology/approach
This study starts with a compilation and review of literature associated with advance algorithms, then elaborates on its mathematical foundation and methods of implementation. Then an experiment displaying the performance of the algorithm implemented in Marlin machine firmware, Linear Advance 1.0, is performed using three different layer heights. The results are then compared with simulations of the system using Simulink.
Findings
Findings suggests that advance algorithms following the presented approach is capable of eliminating defects because of acceleration and deacceleration of the print head. The results indicate a layer height dependency on the associated process parameter, requiring higher compensation values for lower layer heights. It also shows higher compensation values for acceleration than deacceleration. Results from the simulated mathematical model correspond well with the experimental results but predict some rapid variations in flow rate that is not reflected in the experimental results.
Research limitations/implications
As there are large variations in printer design and materials, deviation between different setups must be expected.
Originality/value
To the best of authors’ knowledge, this study is the first to describe and investigate advance algorithms in academic literature.
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Keywords
Jørgen Blindheim, Christer W. Elverum, Torgeir Welo and Martin Steinert
This paper proposes the combination of rapid prototyping and physical modelling as a set-based concept evaluation method in the early stage of new product development.
Abstract
Purpose
This paper proposes the combination of rapid prototyping and physical modelling as a set-based concept evaluation method in the early stage of new product development.
Design/methodology/approach
The concept evaluation method is applied in a case study of a new metal additive manufacturing process for aluminium, where a set of four extruder concepts has been modelled and evaluated. Rapid prototyping was used to produce plastic models of the different designs, and plasticine feedstock material was used to physically model the metal flow during operation. Finally, the selected concept has been verified in full-scale for processing of aluminium feedstock material.
Findings
The proposed method led to several valuable insights on critical factors that were unknown at the outset of the development project. Overall, these insights enabled concept exploration and concept selection that led to a substantially better solution than the original design.
Research limitations/implications
This method can be applied for other projects where numerical approaches are not applicable or capable, and where the costs or time required for producing full-scale prototypes are high.
Practical implications
Employing this method can enable a more thorough exploration of the design space, allowing new solutions to be discovered.
Originality/value
The proposed method allows a design team to test and evaluate multiple concepts at lower cost and time than what is usually required to produce full-scale prototypes. It is, therefore, concluded to be a valuable design strategy for the early development stages of complex products or technologies.
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