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1 – 10 of 103
Article
Publication date: 27 July 2022

Donghua Zhao, Gaohan Zhu, Jiapeng He and Weizhong Guo

With the development of 3D printing or additive manufacturing (AM), curved layer fused deposition modeling (CLFDM) has been researched to cope with the flat layer AM inherited…

Abstract

Purpose

With the development of 3D printing or additive manufacturing (AM), curved layer fused deposition modeling (CLFDM) has been researched to cope with the flat layer AM inherited problems, such as stair-step error, anisotropy and the time-cost and material-cost problems from the supporting structures. As one type of CLFDM, cylindrical slicing has obtained some research attention. However, it can only deal with rotationally symmetrical parts with a circular slicing layer, limiting its application. This paper aims to propose a ray-based slicing method to increase the inter-layer strength of flat layer-based AM parts to deal with more general revolving parts.

Design/methodology/approach

Specifically, the detailed algorithm and implementation steps are given with several examples to enable readers to understand it better. The combination of ray-based slicing and helical path planning has been proposed to consider the nonuniform path spacing between the adjacent paths in the same curved layer. A brief introduction of the printing system is given, mainly including a 3D printer and the graphical user interface.

Findings

The preliminary experiments are successfully conducted to verify the feasibility and versatility of the proposed and improved slicing method for the revolving thin-wall parts based on a rotary 3D printer.

Originality/value

This research is early-stage work, and the authors are intended to explore the process and show the initial feasibility of ray-based slicing for revolving thin-wall parts using a rotary 3D printer. In general, this research provides a novel and feasible slicing method for multiaxis rotary 3D printers, making manufacturing revolving thin-wall and complex parts possible.

Article
Publication date: 20 October 2022

Donghua Zhao, Jiapeng He, Gaohan Zhu, Youcheng Han and Weizhong Guo

The rapid development of three-dimensional (3D) printing makes it familiar in daily life, especially the fused deposition modeling 3D printers. The process planning of traditional…

Abstract

Purpose

The rapid development of three-dimensional (3D) printing makes it familiar in daily life, especially the fused deposition modeling 3D printers. The process planning of traditional flat layer printing includes slicing and path planning to obtain the boundaries and the filling paths for each layer along the vertical direction. There is a clear division line through the whole fabricated part, inherited in the flat-layer-based printed parts. This problem is brought about by the seam of the boundary in each layer. Hence, the purpose of this paper is to propose a novel helical filling path generation with the ideal surface-plane intersection for a rotary 3D printer.

Design/methodology/approach

The detailed algorithm and implementation steps are given with several worked examples to enable readers to understand it better. The adjacent points obtained from the planar slicing are combined to generate each layer's helical points. The contours of all layers are traversed to obtain the helical surface layer and helical path. Meanwhile, the novel rotary four-degree of freedom 3D printer is briefly introduced.

Findings

As a proof of concept, this paper presents several examples based on the rotary 3D printer designed in the authors’ previous research and the algorithms illustrated in this paper. The preliminary experiments successfully verify the feasibility and versatility of the proposed slicing method based on a rotary 3D printer.

Originality/value

This paper provides a novel and feasible slicing method for multi-axis rotary 3D printers, making manufacturing thin-wall and complex parts possible. To further broaden the proposed slicing method’s application in further research, adaptive tool path generation for flat and curved layer printing could be applied with a combination of flat and curved layers in the same layer, different layers or even different parts of structures.

Article
Publication date: 30 March 2020

Donghua Zhao, Tianqi Li, Beijun Shen, Yicheng Jiang, Weizhong Guo and Feng Gao

The purpose of this paper is to design and develop a rotary three-dimensional (3D) printer for curved layer fused deposition modeling (CLFDM), and discuss some technical…

Abstract

Purpose

The purpose of this paper is to design and develop a rotary three-dimensional (3D) printer for curved layer fused deposition modeling (CLFDM), and discuss some technical challenges in the development.

Design/methodology/approach

Some technical challenges include, but are not limited to, the machine design and control system, motion analysis and simulation, workspace and printing process analysis, curved layer slicing and tool path planning. Moreover, preliminary experiments are carried out to prove the feasibility of the design.

Findings

A rotary 3D printer for CLFDM has been designed and developed. Moreover, this printer can function as a polar 3D printer for flat layer additive manufacturing (AM). Compared with flat layer AM, CLFDM weakens the staircase effect and improves geometrical accuracy and mechanical properties. Hence, CLFDM is more suitable for parts with curved surfaces.

Research limitations/implications

Double extruders have brought improved build speed. However, this paper is restricted to complex process planning and mechanical structures, which may lead to collisions during printing. Meanwhile, the rotation range of the nozzle is limited by mechanical structures, affecting the manufacturing capability of complex curved surfaces.

Originality/value

A novel rotary 3D printer, which has four degrees of freedom and double extruders, has been designed and manufactured. The investigation on the prototype has proved its capability of CLFDM. Besides, this rotary 3D printer has two working modes, which brings the possibility of flat layer AM and CLFDM.

Article
Publication date: 19 July 2021

Xiaojing Feng, Bin Cui, Yaxiong Liu, Lianggang Li, Xiaojun Shi and Xiaodong Zhang

The purpose of this paper is to solve the problems of poor mechanical properties, high surface roughness and waste support materials of thin-walled parts fabricated by…

Abstract

Purpose

The purpose of this paper is to solve the problems of poor mechanical properties, high surface roughness and waste support materials of thin-walled parts fabricated by flat-layered additive manufacturing process.

Design/methodology/approach

This paper proposes a curved-layered material extrusion modeling process with a five-axis motion mechanism. This process has advantages of the platform rotating, non-support printing and three-dimensional printing path. First, the authors present a curved-layered algorithm by offsetting the bottom surface into a series of conformal surfaces and a toolpath generation algorithm based on the geodesic distance field in each conformal surface. Second, they introduce a parallel five-axis printing machine consisting of a printing head fixed on a delta-type manipulator and a rotary platform on a spherical parallel machine.

Findings

Mechanical experiments show the failure force of the five-axis printed samples is 153% higher than that of the three-axis printed samples. Forming experiments show that the surface roughness significantly decreases from 42.09 to 18.31 µm, and in addition, the material consumption reduces by 42.90%. These data indicate the curved-layered algorithm and five-axis motion mechanism in this paper could effectively improve mechanical properties and the surface roughness of thin-walled parts, and realize non-support printing. These methods also have reference value for other additive manufacturing processes.

Originality/value

Previous researchers mostly focus on printing simple shapes such as arch or “T”-like shape. In contrast, this study sets out to explore the algorithm and benefits of modeling thin-walled parts by a five-axis machine. Several validated models would allow comparability in five-axis printing.

Details

Rapid Prototyping Journal, vol. 27 no. 7
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 4 September 2009

S. Vinodh, G. Sundararaj, S.R. Devadasan, D. Kuttalingam and D. Rajanayagam

The purpose of this paper is to investigate the adoption of rapid prototyping (RP) technology using three dimensional (3D) printer for infusing agility in traditional…

4113

Abstract

Purpose

The purpose of this paper is to investigate the adoption of rapid prototyping (RP) technology using three dimensional (3D) printer for infusing agility in traditional manufacturing environment.

Design/methodology/approach

The computer aided design (CAD) model of a knob of an electronics switch is developed using Pro/E software. Keeping this model as a reference, CAD models of new six knobs are developed. A 3D printer is used to build the prototypes of five of those CAD models. The receptivity of the practitioners over adopting CAD models and 3D printer for achieving agility is investigated.

Findings

The sensitisation of the industry captains and employees of traditional manufacturing sector is the imperative for exploiting the power of 3D printer and achieving mass customisation.

Originality/value

The paper reports an original research in which the practicality of using 3D printer is investigated with the objective of enabling the traditional manufacturing companies to imbibe agile characteristics.

Details

Journal of Manufacturing Technology Management, vol. 20 no. 7
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 17 May 2021

Vivek Kumar Tiwary, Arunkumar P. and Vinayak R. Malik

Three-dimensional (3D) printing, one of the important technological pillars of Industry 4.0, is changing the landscape of future manufacturing. However, the limited build volume…

Abstract

Purpose

Three-dimensional (3D) printing, one of the important technological pillars of Industry 4.0, is changing the landscape of future manufacturing. However, the limited build volume of a commercially available 3D printer is one inherent constraint, which holds its acceptability by the manufacturing business leaders. This paper aims to address the issue by presenting a novel classification of the possible ways by which 3D-printed parts can be joined or welded to achieve a bigger-sized component.

Design/methodology/approach

A two-step literature review is performed. The first section deals with the past and present research studies related to adhesive bonding, mechanical interlocking, fastening and big area additive manufacturing of 3D printed thermoplastics. In the second section, the literature searches were focused on retrieving details related to the welding of 3D printed parts, specifically related to friction stir welding, friction (spin) welding, microwave and ultrasonic welding.

Findings

The key findings of this review study comprise the present up-to-date research developments, pros, cons, critical challenges and the future research directions related to each of the joining/welding techniques. After reading this study, a better understanding of how and which joining/welding technique to be applied to obtain a bigger volume 3D printed component will be acquired.

Practical implications

The study provides a realistic approach for the joining of 3D printed parts made by the fused deposition modeling (FDM) technique.

Originality/value

This is the first literature review related to joining or welding of FDM-3D printed parts helping the 3D printing fraternity and researchers, thus increasing the acceptability of low-cost FDM printers by the manufacturing business leaders.

Details

Rapid Prototyping Journal, vol. 27 no. 4
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 19 June 2019

Christopher-Denny Matte, Michael Pearson, Felix Trottier-Cournoyer, Andrew Dafoe and Tsz Ho Kwok

The purpose of this paper is to introduce a novel technique for printing with multiple materials using the DLP method. Digital-light-processing (DLP) printing uses a digital…

Abstract

Purpose

The purpose of this paper is to introduce a novel technique for printing with multiple materials using the DLP method. Digital-light-processing (DLP) printing uses a digital projector to selectively cure a full layer of resin using a mask image. One of the challenges with DLP printing is the difficulty of incorporating multiple materials within the same part. As the part is cured within a liquid basin, resin switching introduces issues of cross-contamination and significantly increased print time.

Design/methodology/approach

The material handling challenges are investigated and addressed by taking inspiration from automated storage and retrieval systems and using an active cleaning solution. The material tower is a compact design to facilitate the storage and retrieval of different materials during the printing process. A spray mechanism is used for actively cleaning excess resin from the part between material changes.

Findings

Challenges encountered within the multi-material DLP technology are addressed and the experimental prototype validates the proposed solution. The system has a cleaning effectiveness of over 90 per cent in 15 s with the build area of 72 inches, in contrast to the previous work of 50 per cent cleaning effectiveness in 2 min with only 6 inches build area. The method can also hold more materials than the previous work.

Originality/value

The techniques from automated storage and retrieval system is applied to develop a storage system so that the time complexity of swapping is reduced from linear to constant. The whole system is sustainable and scalable by using a spraying mechanism. The design of the printer is modular and highly customizable, and the material waste for build materials and cleaning solution is minimized.

Details

Rapid Prototyping Journal, vol. 25 no. 5
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 17 August 2015

Benjamin Weiss, Duane W. Storti and Mark A. Ganter

The purpose of this paper is to explore the improvements in speed and precision achievable using straightforward closed-loop control for the gantry motion in additive…

1765

Abstract

Purpose

The purpose of this paper is to explore the improvements in speed and precision achievable using straightforward closed-loop control for the gantry motion in additive manufacturing machines. The authors designed and built an economically viable demonstration system to quantify the performance improvement.

Design/methodology/approach

The authors develop and evaluate a low-cost closed-loop controller for the X and Y axes of an entry-level three-dimensional (3D) printer. The system developed captures and compensates for the dynamics of the motor and the belt-driven stage and detects mechanical errors, such as skipped motor steps.

Findings

The system produces path-following precision improvements of 40 and 75 per cent for two different sample trajectories. Correcting for skipped steps increases reliability and allows for more aggressive tuning of motion parameters; time savings of up to 25 per cent are seen by doubling acceleration rate.

Research limitations/implications

The system presented provides an appropriate platform for further investigation into more complex, application-specific controllers and inclusion of more details of the printer dynamics that could produce still greater improvements in speed and accuracy.

Practical implications

The performance, low cost (40 USD/axis) and applicability to the majority of sub-2000USD 3D printer designs make this work of practical significance.

Originality/value

The CNC machining industry has for many years used similar approaches, but application to 3D printers has not been explored in the literature. This paper demonstrates the value of even a simple controller applicable to almost any 3D printer, while maintaining cost-effectiveness of the solution in a competitive market.

Article
Publication date: 27 September 2023

Veera Harsha Vardhan Jilludimudi, Daniel Zhou, Eric Rubstov, Alexander Gonzalez, Will Daknis, Erin Gunn and David Prawel

This study aims to collect real-time, in situ data from polymer melt extrusion (ME) 3D printing and use only the collected data to non-destructively identify printed parts that…

Abstract

Purpose

This study aims to collect real-time, in situ data from polymer melt extrusion (ME) 3D printing and use only the collected data to non-destructively identify printed parts that contain defects.

Design/methodology/approach

A set of sensors was created to collect real-time, in situ data from polymer ME 3D printing. A variance analysis was completed to identify an “acceptable” range for filament diameter on a popular desktop 3D printer. These data were used as the basis of a quality evaluation process to non-destructively identify spatial regions of printed parts in multi-part builds that contain defects.

Findings

Anomalous parts were correctly identified non-destructively using only in situ collected data.

Research limitations/implications

This methodology was developed by varying the filament diameter, one of the most common reasons for print failure in ME. Numerous other printing parameters are known to create faults in melt extruded parts, and this methodology can be extended to analyze other parameters.

Originality/value

To the best of the authors’ knowledge, this is the first report of a non-destructive evaluation of 3D-printed part quality using only in situ data in ME. The value is in improving part quality and reliability in ME, thereby reducing 3D printing part errors, plastic waste and the associated cost of time and material.

Article
Publication date: 28 January 2020

Yuan-Min Lin, Hsuan Chen, Chih-Hsin Lin, Pin-Ju Huang and Shyh-Yuan Lee

The purpose of this study is to develop resin composite materials composed of polycaprolactone (PCL) acrylates and hydroxyapatite (HA) nanoparticles for ultraviolet digital light…

Abstract

Purpose

The purpose of this study is to develop resin composite materials composed of polycaprolactone (PCL) acrylates and hydroxyapatite (HA) nanoparticles for ultraviolet digital light projection (DLP) three-dimensional (3D) printing technique.

Design/methodology/approach

Two PCL-based triacrylates, namely, glycerol-3 caprolactone-triacrylate (Gly-3CL-TA) and glycerol-6 caprolactone-triacrylate (Gly-6CL-TA) were synthesized from ring-opening polymerization of ε-caprolacton monomer in the presence of glycerol and then acrylation was performed using acryloyl chloride. 3D printing resins made of Gly-3CL-TA or Gly-6CL-TA, 5% HA and 3% of photoinitiator 2,4,6-Trimethylbenzoyl-diphenyl-phosphineoxide were then formulated. The surface topography, surface element composition, flexural strength, flexural modulus, cytotoxicity and degradation of the PCL-based scaffolds were then characterized.

Findings

Resin composite composed of Gly-3CL-TA or Gly-6CL-TA and 5% (w/w) of HA can be printed by 405 nm DLP 3D printers. The former has lower viscosity and thus can form a more uniform layer-by-layer structure, while the latter exhibited a higher flexural strength and modulus after being printed. Both composite materials are non-cytotoxic and degradable.

Originality/value

This study provides a direction of the formulation of environment-friendly resin composite for DLP 3D printing. Both resin composites have huge potential in tissue engineering applications.

Details

Rapid Prototyping Journal, vol. 26 no. 5
Type: Research Article
ISSN: 1355-2546

Keywords

1 – 10 of 103