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1 – 10 of 497Mehrshad Mehrpouya, Daniel Tuma, Tom Vaneker, Mohamadreza Afrasiabi, Markus Bambach and Ian Gibson
This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It…
Abstract
Purpose
This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It reviews the emerging technologies in PBF multimaterial printing and summarizes the latest simulation approaches for modeling them. The topic of “multimaterial PBF techniques” is still very new, undeveloped, and of interest to academia and industry on many levels.
Design/methodology/approach
This is a review paper. The study approach was to carefully search for and investigate notable works and peer-reviewed publications concerning multimaterial three-dimensional printing using PBF techniques. The current methodologies, as well as their advantages and disadvantages, are cross-compared through a systematic review.
Findings
The results show that the development of multimaterial PBF techniques is still in its infancy as many fundamental “research” questions have yet to be addressed before production. Experimentation has many limitations and is costly; therefore, modeling and simulation can be very helpful and is, of course, possible; however, it is heavily dependent on the material data and computational power, so it needs further development in future studies.
Originality/value
This work investigates the multimaterial PBF techniques and discusses the novel printing methods with practical examples. Our literature survey revealed that the number of accounts on the predictive modeling of stresses and optimizing laser scan strategies in multimaterial PBF is low with a (very) limited range of applications. To facilitate future developments in this direction, the key information of the simulation efforts and the state-of-the-art computational models of multimaterial PBF are provided.
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Mojtaba Izadi, Aidin Farzaneh, Mazher Mohammed, Ian Gibson and Bernard Rolfe
This paper aims to present a comprehensive review of the laser engineered net shaping (LENS) process in an attempt to provide the reader with a deep understanding of the…
Abstract
Purpose
This paper aims to present a comprehensive review of the laser engineered net shaping (LENS) process in an attempt to provide the reader with a deep understanding of the controllable and fixed build parameters of metallic parts. The authors discuss the effect and interplay between process parameters, including: laser power, scan speed and powder feed rate. Further, the authors show the interplay between process parameters is pivotal in achieving the desired microstructure, macrostructure, geometrical accuracy and mechanical properties.
Design/methodology/approach
In this manuscript, the authors review current research examining the process inputs and their influences on the final product when manufacturing with the LENS process. The authors also discuss how these parameters relate to important build aspects such as melt-pool dimensions, the volume of porosity and geometry accuracy.
Findings
The authors conclude that studies have greatly enriched the understanding of the LENS build process, however, much studies remains to be done. Importantly, the authors reveal that to date there are a number of detailed theoretical models that predict the end properties of deposition, however, much more study is necessary to allow for reasonable prediction of the build process for standard industrial parts, based on the synchronistic behavior of the input parameters.
Originality/value
This paper intends to raise questions about the possible research areas that could potentially promote the effectiveness of this LENS technology.
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The purpose of this paper is to communicate a method to perform simultaneous topology optimization of component and support structures considering typical metal additive…
Abstract
Purpose
The purpose of this paper is to communicate a method to perform simultaneous topology optimization of component and support structures considering typical metal additive manufacturing (AM) restrictions and post-print machining requirements.
Design/methodology/approach
An integrated topology optimization is proposed using two density fields: one describing the design and another defining the support layout. Using a simplified AM process model, critical overhang angle restrictions are imposed on the design. Through additional load cases and constraints, sufficient stiffness against subtractive machining loads is enforced. In addition, a way to handle non-design regions in an AM setting is introduced.
Findings
The proposed approach is found to be effective in producing printable optimized geometries with adequate stiffness against machining loads. It is shown that post-machining requirements can affect optimal support structure layout.
Research limitations/implications
This study uses a simplified AM process model based on geometrical characteristics. A challenge remains to integrate more detailed physical AM process models to have direct control of stress, distortion and overheating.
Practical implications
The presented method can accelerate and enhance the design of high performance parts for AM. The consideration of post-print aspects is expected to reduce the need for design adjustments after optimization.
Originality/value
The developed method is the first to combine AM printability and machining loads in a single topology optimization process. The formulation is general and can be applied to a wide range of performance and manufacturability requirements.
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Anton Wiberg, Johan Persson and Johan Ölvander
This paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification of DfAM…
Abstract
Purpose
This paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification of DfAM methods and software. The focus is on the design engineer’s role in the DfAM process and includes which design methods and tools exist to aid the design process. This includes methods, guidelines and software to achieve design optimization and in further steps to increase the level of design automation for metal AM techniques. The research has a special interest in structural optimization and the coupling between topology optimization and AM.
Design/methodology/approach
The method used in the review consists of six rounds in which literature was sequentially collected, sorted and removed. Full presentation of the method used could be found in the paper.
Findings
Existing DfAM research has been divided into three main groups – component, part and process design – and based on the review of existing DfAM methods, a proposal for a DfAM process has been compiled. Design support suitable for use by design engineers is linked to each step in the compiled DfAM process. Finally, the review suggests a possible new DfAM process that allows a higher degree of design automation than today’s process. Furthermore, research areas that need to be further developed to achieve this framework are pointed out.
Originality/value
The review maps existing research in design for additive manufacturing and compiles a proposed design method. For each step in the proposed method, existing methods and software are coupled. This type of overall methodology with connecting methods and software did not exist before. The work also contributes with a discussion regarding future design process and automation.
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Francois Du Rand, André Francois van der Merwe and Malan van Tonder
This paper aims to discuss the development of a defect classification system that can be used to detect and classify powder bed surface defects from captured layer images without…
Abstract
Purpose
This paper aims to discuss the development of a defect classification system that can be used to detect and classify powder bed surface defects from captured layer images without the need for specialised computational hardware. The idea is to develop this system by making use of more traditional machine learning (ML) models instead of using computationally intensive deep learning (DL) models.
Design/methodology/approach
The approach that is used by this study is to use traditional image processing and classification techniques that can be applied to captured layer images to detect and classify defects without the need for DL algorithms.
Findings
The study proved that a defect classification algorithm could be developed by making use of traditional ML models with a high degree of accuracy and the images could be processed at higher speeds than typically reported in literature when making use of DL models.
Originality/value
This paper addresses a need that has been identified for a high-speed defect classification algorithm that can detect and classify defects without the need for specialised hardware that is typically used when making use of DL technologies. This is because when developing closed-loop feedback systems for these additive manufacturing machines, it is important to detect and classify defects without inducing additional delays to the control system.
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Shubhi Gupta, Govind Swaroop Pathak and Baidyanath Biswas
This paper aims to determine the impact of perceived virtuality on team dynamics and outcomes by adopting the Input-Mediators-Outcome (IMO) framework. Further, it also…
Abstract
Purpose
This paper aims to determine the impact of perceived virtuality on team dynamics and outcomes by adopting the Input-Mediators-Outcome (IMO) framework. Further, it also investigates the mediating role of team processes and emergent states.
Design/methodology/approach
The authors collected survey data from 315 individuals working in virtual teams (VTs) in the information technology sector in India using both offline and online questionnaires. They performed the analysis using Partial Least Squares Structural Equation Modelling (PLS-SEM).
Findings
The authors investigated two sets of hypotheses – both direct and indirect (or mediation interactions). Results show that psychological empowerment and conflict management are significant in managing VTs. Also, perceived virtuality impacts team outcomes, i.e. perceived team performance, team satisfaction and subjective well-being.
Research limitations/implications
The interplay between the behavioural team process (conflict management) and the emergent state (psychological empowerment) was examined. The study also helps broaden our understanding of the various psychological variables associated with teamwork in the context of VTs.
Practical implications
Findings from this study will aid in assessing the consequences of virtual teamwork at both individual and organisational levels, such as guiding the design and sustainability of VT arrangements, achieving higher productivity in VTs, and designing effective and interactive solutions in the virtual space.
Social implications
The study examined the interplay between behavioural team processes (such as conflict management) and emergent states (such as psychological empowerment). The study also theorises and empirically tests the relationships between perceived virtuality and team outcomes (i.e. both affective and effectiveness). It may serve as a guide to understanding team dynamics in VTs better.
Originality/value
This exploratory study attempts to enhance the current understanding of the research and practice of VTs within a developing economy.
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Diqian Ren, Jun-Ki Choi and Kellie Schneider
Because of the significant differences in the features and requirements of specific products and the capabilities of various additive manufacturing (AM) solutions, selecting the…
Abstract
Purpose
Because of the significant differences in the features and requirements of specific products and the capabilities of various additive manufacturing (AM) solutions, selecting the most appropriate AM technology can be challenging. This study aims to propose a method to solve the complex process selection in 3D printing applications, especially by creating a new multicriteria decision-making tool that takes the direct certainty of each comparison to reflect the decision-maker’s desire effectively.
Design/methodology/approach
The methodology proposed includes five steps: defining the AM technology selection decision criteria and constraints, extracting available AM parameters from the database, evaluating the selected AM technology parameters based on the proposed decision-making methodology, improving the accuracy of the decision by adopting newly proposed weighting scheme and selecting optimal AM technologies by integrating information gathered from the whole decision-making process.
Findings
To demonstrate the feasibility and reliability of the proposed methodology, this case study describes a detailed industrial application in rapid investment casting that applies the weightings to a tailored AM technologies and materials database to determine the most suitable AM process. The results showed that the proposed methodology could solve complicated AM process selection problems at both the design and manufacturing stages.
Originality/value
This research proposes a unique multicriteria decision-making solution, which employs an exclusive weightings calculation algorithm that converts the decision-maker's subjective priority of the involved criteria into comparable values. The proposed framework can reduce decision-maker's comparison duty and potentially reduce errors in the pairwise comparisons used in other decision-making methodologies.
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The purpose of this study is to examine the direct impact of social intelligence and collective self- efficacy on two components of service providers’ performance: extra-role…
Abstract
Purpose
The purpose of this study is to examine the direct impact of social intelligence and collective self- efficacy on two components of service providers’ performance: extra-role performance and intra-role one. The study also investigates the indirect effect of social intelligence on service providers’ performance and its components via the mediating role of collective self-efficacy.
Design/methodology/approach
This study was undertaken to develop a conceptual framework that integrates social intelligence, collective self-efficacy and service provider’s performance constructs in one framework. Data was collected from 220 physicians in the Egyptian governmental hospitals. Confirmatory factor analysis explored the latent structure of the research constructs. The current study used structural equation modelling to test the research model hypotheses.
Findings
The study finds that social intelligence was positively associated with service providers’ performance. The results also support the significant effect of social intelligence on the two main dimensions of service provider’s performance: extra-role (contextual) performance and intra-role (task) performance. Moreover, the results indicate that social intelligence competences provide a basis for collective self-efficacy and service providers’ performance for physicians in the Egyptian governmental hospitals.
Research limitations/implications
This study collected data based on a cross-sectional design, so further studies could test the theoretical model by using longitudinal studies’ data, which give the study results more accuracy of results and support generalizing the results. This study considers the synergistic effects between social intelligence and collective self-efficacy on service providers’ performance and sheds new light on bringing new drivers for developing extra- and intra-role dimensions of service provider performance in service literature.
Originality/value
This study is one of the first studies that integrate social intelligence and collective self-efficacy with service providers’ performance and its dimensions in one framework. This study contributes to knowledge by integrating the social exchange theory with the cognitive theory in one study.
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Maximilian Kunovjanek and Christian Wankmüller
The COVID-19 pandemic caused global supply disruptions and shortages that resulted in countries battling over desperately needed (medical) supplies. In this mayhem, additive…
Abstract
Purpose
The COVID-19 pandemic caused global supply disruptions and shortages that resulted in countries battling over desperately needed (medical) supplies. In this mayhem, additive manufacturing (AM) provided relief to the strained healthcare systems and manufacturing environments by offering an alternative way to rapidly produce desired products. This study sheds light on how AM was used globally in response to the COVID-19 pandemic.
Design/methodology/approach
The study undertakes a systematic and content-centric review of 289 additively manufactured products made in response to the COVID-19 pandemic. Additionally, quantitative frequency-based text mining and various descriptive analyses were applied that support the investigation of the subject under regard.
Findings
Results show that AM was primarily used in the medical domain for the production of standard medical items, such as personal protective equipment (PPE) but also for non-obvious and new applications (e.g. swab simulator, rapid diagnostic kits, etc.). Also, certain paradigm shifts were observed, as the effective move to mass production and the mitigation of problems related to certification and standardization emerged as prominent management prospects. Nevertheless, various obstacles arose and remained in the path of lasting AM success, especially with respect to print quality, raw material supply and technological versatility.
Originality/value
Due to the actuality of the topic under investigation, no comparable study has so far been conducted. The systematic review provides a conclusive and precise foundation for further analysis and subsequent discussions. Additionally, no comparable study mapping such a wide array of different AM products exists today.
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Nils O.E. Olsson, Ali Shafqat, Emrah Arica and Andreas Økland
The purpose of this paper is to study the introduction of 3D-printing of concrete in the construction sector.
Abstract
Purpose
The purpose of this paper is to study the introduction of 3D-printing of concrete in the construction sector.
Design/Methodology/Approach
A survey was conducted to collect professional view on ongoing innovations in the construction sector, including 3D-printing. Participants were selected among the members of Norwegian networks for project and construction management research.
Findings
The survey highlighted effective leadership, collaboration with partners and industry-academia collaboration as primary enablers of innovation. Few of the respondents to the survey have used 3D-printing technologies.
Research Limitations/Implications
It is difficult to obtain representative samples in this type of research, including this study. The study can be seen as a snapshot of attitudes in the sector.
Practical Implications
3D-printing appear as a potentially interesting technology, especially for unstandardized construction components. Further work is needed to materialise the expectation for technological development in the construction sector.
Originality/Value
Most research on 3D-printing has focused on demonstrating technical potential. This study adds a practitioners’ perspective, with a large dose of pragmatism.
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