Science topic

Additive Manufacturing - Science topic

Explore the latest questions and answers in Additive Manufacturing, and find Additive Manufacturing experts.
Questions related to Additive Manufacturing
  • asked a question related to Additive Manufacturing
Question
3 answers
I have a gas atomised powder. I want to use it in laser powder bed fusion. I will use vibratory siever to sieve the powder. What sizes of sieves do I need?
Relevant answer
Answer
For sieving gas atomized powder for laser powder bed fusion, use these sieve sizes:
  1. Mesh 40 (425 µm): Removes oversized particles.
  2. Mesh 60 (250 µm): Captures larger agglomerates.
  3. Mesh 80 (180 µm): Refines powder size.
  4. Mesh 100 (150 µm): Ensures optimal particle range.
Consider a finer sieve (like Mesh 200) for very fine particles if needed. Adjust based on your specific powder and application requirements.
  • asked a question related to Additive Manufacturing
Question
3 answers
Hello,
I have a problem in classification of "Additive Manufacturing" techniques. There are several classification for Additive Manufacturing e.g. Powder, Extrusion, Resin etc.
Actually, I am OK with them, but I cannot find 3D Bioprinting. Is 3D Bioprinting a classifies branch of AM?
My problem is exactly classification of them.
Relevant answer
Answer
Dear Mohammad Hossein Khotanlou Please do recommend my answer if helpful.
3D bioprinting is a specialized subset of additive manufacturing (AM), focusing on the layer-by-layer fabrication of biological constructs using biomaterials and living cells. To classify 3D bioprinting within the broader context of additive manufacturing, we can explore its unique characteristics, applications, and techniques while comparing them to general AM processes. Here’s a structured approach to classify 3D bioprinting as part of additive manufacturing:
1. **Definition and Core Principles**
Additive Manufacturing (AM):
- AM, also known as 3D printing, refers to the process of creating objects by adding material layer by layer, based on digital models.
- Common materials include plastics, metals, ceramics, and composites.
3D Bioprinting:
- 3D bioprinting is a form of AM that specifically involves the creation of three-dimensional biological structures using bioinks, which are comprised of living cells, biomaterials, and other biological substances.
- The goal is to create tissue-like structures that mimic the natural biological environment.
2. **Classification Based on Materials**
AM Materials:
- Polymers: PLA, ABS, nylon.
- Metals: Titanium, stainless steel, aluminum.
- Ceramics:Alumina, zirconia.
- Composites: Fiber-reinforced polymers.
3D Bioprinting Materials:
- Bioinks: Hydrogels, extracellular matrix components, growth factors.
- Living Cells: Stem cells, differentiated cells, cell spheroids.
- Supporting Materials: Scaffolds, sacrificial materials.
3. **Techniques and Processes**
Common AM Techniques:
- Fused Deposition Modeling (FDM): Melting and extruding thermoplastic filaments.
- Selective Laser Sintering (SLS): Using lasers to sinter powdered material.
- Stereolithography (SLA): Curing liquid resin with UV light.
- Binder Jetting: Binding powder particles with a liquid binder.
3D Bioprinting Techniques:
- Extrusion-Based Bioprinting: Depositing bioinks through a nozzle layer by layer.
- Inkjet Bioprinting: Droplet-based deposition of bioinks.
- Laser-Assisted Bioprinting (LAB): Using laser pulses to transfer cells and materials.
- Stereolithography (SLA) for Bioprinting: Using light to crosslink bioinks, often for creating hydrogel scaffolds.
4. **Applications**
AM Applications:
- Prototyping: Rapid creation of prototypes for design validation.
- Manufacturing: Producing end-use parts in aerospace, automotive, and consumer goods.
- Tooling: Creating molds and tools for manufacturing processes.
3D Bioprinting Applications:
- Tissue Engineering: Creating tissue constructs for regenerative medicine.
- Drug Testing and Development: Fabricating tissue models for pharmaceutical testing.
- Medical Research: Studying disease mechanisms and tissue behavior.
- Organ Transplantation: Research into printing organs for transplantation.
5. **Technological Integration and Advancements**
AM Innovations:
- Multi-Material Printing: Combining different materials in a single print.
- Hybrid Manufacturing: Integrating AM with traditional manufacturing methods.
- Advanced Software: Enhanced CAD and simulation tools for design and optimization.
3D Bioprinting Innovations:
- Bioreactor Integration: Culturing printed tissues in bioreactors for maturation.
- Precision and Resolution: Improving the precision of cell placement and structural resolution.
- Custom Bioinks: Developing bioinks tailored to specific cell types and applications.
6. **Regulatory and Ethical Considerations**
AM Considerations:
- Standards: Adherence to manufacturing standards (ISO, ASTM).
- Quality Control: Ensuring consistent quality and performance of printed parts.
3D Bioprinting Considerations:
- Biocompatibility: Ensuring materials and constructs are safe for biological use.
- Ethics: Addressing ethical issues related to tissue and organ printing.
- Regulatory Approval: Navigating regulations for biomedical products (FDA, EMA).
Conclusion
By highlighting these distinctions and overlaps, we can classify 3D bioprinting as a specialized field within additive manufacturing, characterized by its use of bioinks and living cells to create biological structures. Its unique applications in medicine and biology further differentiate it from traditional AM processes, while still adhering to the core principles of layer-by-layer fabrication and digital design.
  • asked a question related to Additive Manufacturing
Question
6 answers
The AlSi7Mg sample was additive manufacturing by the PBF method and heat treated 480℃-6h and 550℃-6h.
When the residual stress of the top view and the side view(Figure) was measured by XRD, the following results were obtained.
As-built
Top : 47.4 MPa
Side : 134.9 MPa
480℃-6h
Top : -33.7 MPa
Side : 2.1 MPa
550℃-6h.
Top : -38.8 MPa
Side : -36.1 MPa
So, I have some questions about the results.
1. In case as-built sample, why is there such a big difference between Top and Side?
2. In case 480℃-6h heat treatment, after heat treatment, the Top changed greatly from tension to compression stress, but why didn't the Side change like this?
3. After heat treatment, Why tensile stress change to compressive stress?
Relevant answer
Answer
For this and to get some feedback, kindly refer to the preprint article given at the link; http://dx.doi.org/10.13140/RG.2.2.23849.40808
  • asked a question related to Additive Manufacturing
Question
5 answers
I am verymuch intreasted in doing research in the field of the Additive Manufacturing technology with 3D printing process. Because of that i would like to know about the clear details of the present updates and future trends in the field of the Additive Manufactuirng.
I am egarly wait and intreaated for the collobirative research work in the field of Additive Manufactuirng with 3D printing process.
Relevant answer
Answer
Different Additive Manufacturing (AM) techniques are actually gaining increasing interest in industry.
In my opinion, Big Area Additive Manufacturing (BAAM) has a great potential in aerospace and naval fields.
In this technique a single-screw extruder similar to the ones being used in plastic extrusion industry is used to selectively deposit thermoplastic materials layer-by-layer, as in conventional Fused Filament Fabrication (FFF) techniques.
The main advantages of BAAM are related to:
  • large format (printing volumes up to 7 meters cube)
  • high range of materials (e.g., fiber reinforced, bio-derived and recycled)
  • energy savings (no need to print with an heated chamber, if carbon fiber are used as reinforcing material)
  • reduced lead times (which is critical for aerospace) and material wastes
More considerations on the advantages of BAAM over FFF have been made in the following articles:
BAAM has been successfully applied to produce molds for horizontal axis wind turbines.
A second technique is Electronic Beam Additive Manufacturing (EBAM), which has been applied to manufacture large satellites:
Other important trends are: AI in 3D printing, 4D printing, soft robotics and self-healing materials.
Best regards,
AP
  • asked a question related to Additive Manufacturing
Question
1 answer
Dear Professors/Researchers,
Can you please suggest, the latest Additive Manufacturing & Casting Techniques used for Aerospace Applications?
Relevant answer
Answer
Among Additive Manufacturing (AM) techniques which are gaining increasing interest in aerospace industry there is Big Area Additive Manufacturing (BAAM).
It is also known more generally as Fused Granular Fabrication (FGF) or Pellet Additive Manufacturing (PAM).
In these techniques a single-screw extruder similar to the ones being used in plastic extrusion industry is used to selectively deposit thermoplastic materials layer-by-layer, as in conventional Fused Filament Fabrication (FFF) techniques.
The main advantages of BAAM are related to:
  • large format (printing volumes up to 7 meters cube)
  • high range of materials (e.g., fiber reinforced, bio-derived and recycled)
  • energy savings (no need to print with an heated chamber, if carbon fiber are used as reinforcing material)
  • reduced lead times (which is critical for aerospace) and material wastes
More considerations on the advantages of BAAM over FFF have been made in the following articles:
A generalized method aiming at predicting the polymer melt flow field in the metering zone of large-scale single-screw extruders
Analytical and Numerical Models of Thermoplastics: A Review Aimed to Pellet Extrusion-Based Additive Manufacturing
BAAM has been successfully applied to produce molds for horizontal axis wind turbines:
A second technique is Electronic Beam Additive Manufacturing (EBAM), which has been applied to manufacture large satellites:
Best regards,
AP
  • asked a question related to Additive Manufacturing
Question
4 answers
Hello everyone,
there seems to be a lack of resources, even though SLA additive manufacturing is widely used. Would anyone be so kind as to point me towards a source determining the Poisson's ratio of standard photopolymers in cured state? I'd be especially interested in Formlabs Clear resin and Formlabs Tough 2000. Their documentation does not provide a number, unfortunately, and literature results for other resins are surprisingly scarce as well.
Thank you all in advance.
Relevant answer
Answer
To answer my own question after almost two years, I investigated Formlabs Clear and Tough 2000 resins and found their Poisson ratios:
  • asked a question related to Additive Manufacturing
Question
1 answer
Hi every one
I have a model in Abaqus standard with Heat transfer. When I restart this model , Abaqus exit with this error:
"Unable to open the file <rank=0,arg_name=E:\ABQ
Model>Job-2.mdl"
How I can fix this error?
Thanks
Relevant answer
Answer
The disk space is not enough to handle it.
  • asked a question related to Additive Manufacturing
Question
4 answers
I am currently involved in research focused on defects detection within the Additive Manufacturing field, and I am seeking an international conference outside India but in Asian countries such as Singapore, Malaysia, Vietnam, Thailand, and the UAE. Please help me finding it.
The conference should meet the following criteria: Organized by reputable professional societies or bodies including ASME, SPIE, ISME, ISTAM, IMechE, IFToMM, IEEE, APS, ACM, ACS, IOP, Elsevier, Springer, IIAV, AMSI, CSIR laboratories, design society, CIRP, CADA, Japan Society of Kansei Engineering, International Association of Packaging Research Institute, Indian Society of Ergonomics, Usability Matters ORG (UMO), International Ergonomics Association, International Institute of Information Design, Vienna, and listed among the first 500 conferences in the Microsoft Conference Ranking.
Relevant answer
Answer
  • asked a question related to Additive Manufacturing
Question
5 answers
Global market size of additive manufacturing(AM) is still very low. AM is seen as a way to confront challenges by significantly reducing time-to-market and opening up new opportunities for the economy and society. There is still something preventing manufacturers (may be challenges like technical, financial, capability, design, IT integration etc.), from integrating AM technologies more generally into manufacturing process. Many analyses are limited when it comes to quantifying the environmental impact. Economical products are more attractive and demand and sales might be good though, but major difficulties is to factor impacts into business calculation?
Relevant answer
Answer
Dear Ashish Thakur please recommend my answer if helpful.
Scaling the adoption of Additive Manufacturing (AM) can indeed be challenging, and addressing the shortage of workforce skills is a crucial aspect of successful implementation. Here are some strategies that engineering management can adopt to handle the shortage of workforce skills in the context of AM:
1. **Invest in Training and Education:**
- Develop comprehensive training programs for existing employees to upskill them in AM technologies. This can include both theoretical knowledge and hands-on training. Consider partnering with educational institutions to provide specialized courses or certifications in AM.
2. **Recruitment and Talent Development:**
- Actively recruit individuals with a background in AM or related technologies. Look for candidates with experience in 3D printing, materials science, and computer-aided design (CAD). Additionally, invest in programs to develop talent internally by offering mentorship and career development opportunities.
3. **Collaborate with Educational Institutions:**
- Establish partnerships with universities, technical schools, and research institutions to influence curriculum development. This collaboration can help ensure that graduates are equipped with the necessary skills for AM. Consider offering internships or co-op programs to bridge the gap between academia and industry.
4. **Cross-Functional Training:**
- Encourage cross-functional training within the organization. Employees with expertise in traditional manufacturing methods can undergo training to understand and adopt AM technologies. This promotes a multidisciplinary approach, fostering collaboration between different departments.
5. **Knowledge Sharing and Collaboration:**
- Foster a culture of knowledge sharing within the organization. Encourage collaboration between teams working on AM projects and those focused on traditional manufacturing. This helps in the exchange of skills and expertise.
6. **Create Centers of Excellence:**
- Establish dedicated Centers of Excellence (CoE) for AM within the organization. These centers can serve as hubs of expertise, where employees can receive specialized training, work on AM projects, and share knowledge.
7. **Utilize External Training Resources:**
- Leverage external training resources, such as workshops, conferences, and online courses, to supplement internal training efforts. This can expose employees to the latest advancements in AM and provide opportunities for networking with industry experts.
8. **Employee Engagement and Recognition:**
- Recognize and reward employees who demonstrate a commitment to learning and adopting AM technologies. This can boost morale, create a positive learning environment, and motivate others to acquire new skills.
9. **Stay Informed on Industry Trends:**
- Engineering management should stay informed about the evolving landscape of AM technologies. Regularly assess the skills required in the industry and align training programs accordingly to ensure relevance and competitiveness.
10. **Continuous Improvement:**
- Establish a continuous improvement mindset within the organization. Regularly assess the effectiveness of training programs, solicit feedback from employees, and adjust strategies based on changing workforce needs and technological advancements.
Addressing the shortage of workforce skills in AM requires a holistic approach that combines training, recruitment, collaboration, and a commitment to ongoing learning and development. By strategically investing in workforce development, engineering management can position their teams for success in adopting and scaling AM technologies.
  • asked a question related to Additive Manufacturing
Question
2 answers
Ideas from artists flow through their hands to create art.
Ideas from designers not able to build from a sketch are drawn on paper or CAD programs and sent out to manufacturers or makers.
CAD design files have different views or perspectives. 3D CAD designs could be visualized in horizontal cross-sections to see internal features. Layered slices of CAD designs gave way to making models of 2D layer views and then 3D Models.
Makers wanted to imitate materials to make models more realistic. New machines had to be designed to automatically dispense existing materials for 3D models.
These 3D machine processes were labeled Additive Manufacturing Processes.
Some hand-held machine tools already existed for adding materials. (1) Hot-melt glue guns,
(2) inkjets or paint sprayers, (4)clothing and sheet laminators, (5) welding tools, etc.)
AM Processes chose materials based on tools for building 2D layers. The basic AM processes are computer automated (1) contact deposition with melted materials, (2)inkjet non-contact deposition with liquid materials, (3) Powder Bed, (4) Sheet lamination, (5)Welding or wire feed deposition and (6) Bath photopolymerization.
Patents have appeared with combinations of these processes. Powder "Binder Jetting", Laser Powder welding, Electron Beam powder welding, Liquid metal Jetting, Powder sintering in ovens, and others.
This discussion is about the basic AM Process of producing a solid single 3D layer vs producing a full finished 3D Model with "one" process. All of the above processes result in a solid 3D layer completion with one defined operation except Powder "Binder Jetting". The binder fluid is only water and a finished solid layer does not exist until the finished Binder Powder model is put into an oven and sintered. Binder Jetting is not a trademark but it is an AM Process and I believe it is identified incorrectly. It may never get changed but I need some input about this AM Process name.
3D Printing means producing a 3D object or any portion of the object as the process is performed. A partial layer is still a 3D model.
Think about it. Can I deposit "unsolidified" materials in small layered steps into a tray and put it into an oven, bake it, to be a finished pie and call it a 3D Printed Model?
Relevant answer
Answer
Dear James K. McMahon Please do recommend my answer if found useful.
Additive Manufacturing (AM), also known as 3D printing, refers to a set of technologies that build three-dimensional objects by adding material layer by layer. This approach stands in contrast to traditional subtractive manufacturing methods, where material is removed to create a final product. There are several additive manufacturing processes, each with its unique characteristics. Here's a discussion of some prominent additive manufacturing processes:
1. **Stereolithography (SLA):**
- SLA is one of the earliest 3D printing techniques. It uses a liquid photopolymer resin cured by ultraviolet (UV) light to build layers. A UV laser scans the resin surface, solidifying it layer by layer. SLA is known for producing high-resolution and detailed prints, making it suitable for prototyping and creating intricate models.
2. **Fused Deposition Modeling (FDM):**
- FDM is a widely used 3D printing method that employs a thermoplastic filament. The filament is heated and extruded through a nozzle, forming layers that solidify as they cool. FDM is popular for its accessibility, cost-effectiveness, and applicability to a wide range of materials. It's commonly used for rapid prototyping and producing functional parts.
3. **Selective Laser Sintering (SLS):**
- SLS utilizes a powdered material (typically nylon, polyamide, or metal) that is selectively fused together by a laser. The build platform lowers, and a new layer of powder is spread before the laser sinters the next cross-section. SLS is known for its ability to produce strong, functional parts, and it supports a variety of materials.
4. **Selective Laser Melting (SLM):**
- SLM is a metal additive manufacturing process where a high-powered laser selectively melts and fuses metallic powder particles layer by layer. This process is particularly well-suited for producing complex metal parts with high strength and precision. It finds applications in aerospace, healthcare, and automotive industries.
5. **Electron Beam Melting (EBM):**
- EBM is similar to SLM but uses an electron beam instead of a laser to melt and fuse metal powder. The high energy of the electron beam allows for the processing of refractory metals like titanium. EBM is known for producing fully dense metal parts with good mechanical properties.
6. **Digital Light Processing (DLP):**
- DLP is a 3D printing technique that uses a digital light projector to cure a liquid resin layer by layer. It shares similarities with SLA but cures entire layers simultaneously. DLP is known for its speed in comparison to some other resin-based methods.
7. **Binder Jetting:**
- In binder jetting, a liquid binder is selectively deposited onto a powder bed, bonding the powder particles together to form each layer. The process is repeated until the entire object is created. Binder jetting is used for both metal and sand casting applications.
These additive manufacturing processes have revolutionized the manufacturing industry by enabling rapid prototyping, customization, and the production of complex geometries that might be challenging or impossible with traditional manufacturing methods. Each process has its advantages and limitations, and the choice depends on factors such as material requirements, part complexity, and intended application.
  • asked a question related to Additive Manufacturing
Question
2 answers
Has anyone gone through the Wohler's report_2023 yet? Its pros and cons? What are the ways to obtain its e-copy? Its subscription is very costly for a normal researcher (around 750 USD per user). Any alternatives to get similar kind of data as that of the report?
Relevant answer
Answer
Thanks David A. Jones sir!!
  • asked a question related to Additive Manufacturing
Question
3 answers
Dear ResearchGate community,
I am currently exploring 3D printing of telecommunication antennas for deployment in rural areas of Nigeria. The 3D printer available to me utilizes PLA, which is susceptible to melting under prolonged sun exposure. I am seeking advice on suitable coatings to protect the antennas from sunlight.
Additionally, I would greatly appreciate recommendations for research papers that address similar challenges or provide insights into protective coatings for outdoor 3D printed structures as it'll be of immense help.
Thank you for your expertise and assistance.
Relevant answer
Answer
Hi, PLA is a terrible choice for this purpose. Can your printer work with some other material like ABS or PETG? PLA has a glass transition at around 60 °C, which means it will start to soften already at 50°C. These temperatures are easily reached on direct sun in hot climate. You must keep it cool. A reflective coating can help, but it will not solve the issue entirely.
  • asked a question related to Additive Manufacturing
Question
1 answer
Additive manufacturing (AM) and computer numerical control (CNC) machining are often seen as complementary rather than direct competitors. Each technology has its strengths and weaknesses, and their integration can offer unique advantages in various industrial applications. Need in-depth discussion on it?
Relevant answer
Answer
Dear Aqib Mashood Khan please recommend my answer
Additive manufacturing (AM) and subtractive manufacturing are often viewed as complementary rather than direct competitors. Each method has its strengths and limitations, and their suitability depends on the specific requirements of a given application. Here's an overview of their relationship:
1. **Complementary Nature:**
- **Prototyping and Complex Geometries:** Additive manufacturing is particularly advantageous for creating complex geometries and prototypes that may be challenging or expensive to produce using traditional subtractive methods.
- **Customization:** AM allows for easy customization and rapid prototyping, making it suitable for low-volume, high-complexity production.
2. **Strengths of Additive Manufacturing:**
- **Design Freedom:** AM enables designers to create intricate and complex structures that may be difficult or impossible to achieve with traditional machining.
- **Material Efficiency:** AM processes can be more material-efficient, generating less waste compared to subtractive manufacturing.
- **Rapid Prototyping:** AM is often faster for prototyping, allowing for quick iteration and design validation.
3. **Strengths of Subtractive Manufacturing:**
- **High Precision:** Subtractive manufacturing methods, such as CNC machining, are known for their high precision and tight tolerances.
- **Material Variety:** Subtractive methods can work with a wide range of materials, including metals, plastics, and composites.
- **Surface Finish:** Subtractive manufacturing often produces parts with excellent surface finishes, making them suitable for certain applications without additional post-processing.
4. **Hybrid Approaches:**
- **Combining Strengths:** In some cases, manufacturers use a hybrid approach, combining both additive and subtractive processes in a single workflow. For example, a part may be additively manufactured and then machined to achieve tight tolerances on critical features.
- **Post-Processing:** Additively manufactured parts may undergo post-processing, including machining, to achieve specific surface finishes or dimensional accuracy.
5. **Application-Specific Considerations:**
- **Cost and Volume:** The decision between additive and subtractive manufacturing often depends on factors such as production volume, cost considerations, and material requirements.
- **Material Properties:** The material properties required for a specific application can influence the choice between AM and subtractive manufacturing.
In summary, rather than being direct competitors, additive and subtractive manufacturing methods are often used complementarily within the broader scope of advanced manufacturing. The choice between them depends on factors such as design requirements, production volume, material properties, and cost considerations. Many manufacturers are adopting a hybrid approach, leveraging the strengths of both methods to optimize their production processes.
  • asked a question related to Additive Manufacturing
Question
6 answers
Anyone working with Abaqus additive manufacturing plugin. I need your guidance regarding error in AM simulation.
"Error in job Job-1: Toolpath-mesh intersection module: ERROR: Torch direction cannot be parallel to a segment.Event series-2_UMD_1"
How to resolve the problem?
Relevant answer
Answer
Thank you. I never use the AM_HeatsourceTrajectory_RuleID Event Series for my simulation, but as you can read from the ABQ manual:
"You must include a parameter table of type "ABQ_AM_EigenStrain_TrajectoryBased_Activation" in the table collection. Only one set of data must be defined.
Tables of type "ABQ_AM_MaterialDeposition", "ABQ_AM_MovingHeatSource", and "ABQ_AM_EigenStrain_TrajectoryBased_Activation" cannot refer to the same event series in an analysis."
Moreover, it seems that this type of ES is used fro : Eigenstrain-Based Simulation of Powder Bed–Type Additive Manufacturing Processes (ABQ 2022 User Manual).
What type of process do you want to represent? Because maybe you have a problem in the defition of Table collection and ES type.
  • asked a question related to Additive Manufacturing
Question
9 answers
Relevant answer
Answer
FDM would probably be the cheapest option. That being said if you are coming at it from a quality standpoint, You wont get better quality than resin printing. These machines do take more clean up but as something to go directly into the hands of a customer I think it would be a better bet for flexibles. Additionally, flexibles can be a bit easier and more reliable to print with resin printing machines. I'd look into DLP and SLA machines as well as FDM machines.
  • asked a question related to Additive Manufacturing
Question
2 answers
I use a DWS System's DS3000, a photosensitive monomer to disperse the nanoparticles in it and use the solution for SLA printing. But, because of its high viscosity, I cannot increase the particle concentration, which is my goal.
Relevant answer
Answer
Thank you very much for the response, Petr. I appreciate it.
  • asked a question related to Additive Manufacturing
Question
10 answers
I am doing the PDP test on the Magnesium alloy deposit. However, the minimum exposed area is not 1 cm^2. Can my result be justified? Can I keep the exposed area 0.5 cm^2?
Relevant answer
Answer
I answer to you as I have already done previously to a similar question.
Personally did electrochemical tests on different types of samples for research use, sometimes very small (uncoated, less than 1 cm2), incorporating them in cold resin followed by metallographic polishing and I still obtained significant results.
If possible, always work by comparison, so as to highlight the different behavior of the samples.
There are ASTM and ISO standards relating to electrochemical measurements on samples and cells and related methodology; some information you can find on the net.
I suggest you to have a look at the Gamry instruments notes, there are several, in particular I found the following very interesting:
-Rapid Electrochemical Assessment of Paint
My best regards, Pierluigi Traverso.
  • asked a question related to Additive Manufacturing
Question
4 answers
We found thin black areas of polygon shape in some fatigue fracture surfaces of LPBF 18Ni300 maraging steel over-aged at 585C (6 hours). The EDS analysis indicated the higher carbon fraction, but this is the carbon...
The photo and EDS results are enclosed.
Any comments will be appreciated.
Relevant answer
Answer
With carbon content 0.03% maximum it is not realistic to expect to see any sizable carbides. SEM image of a region is to poor to be of any use, but since you said you see black area, I would suspect that it is some organic contamination (more carbon, darker than surroundings).
  • asked a question related to Additive Manufacturing
Question
8 answers
Myself Nekin Joshua R. I like to do Fatigue compression test on 3D printed Polymer based Structure.
What is the ASTM Standard for Fatigue Compression test on 3D printed Polymer based Honeycomb structure?
What is the Specimen Size?
Relevant answer
Answer
you would be best using ASTM D638-22for this test
  • asked a question related to Additive Manufacturing
Question
5 answers
Whether the colour of the 3D printing filament affects the mechanical strength.
If affected, which one of the colours has a higher strength?
Relevant answer
Answer
Nekin Joshua This is a very important question that comes to our mind whenever we start to procure the raw filament for FDM-related experiments. I was also in the same situation trying to find out, a few years before.
Answer:
Yes, the colour of the 3D printing filament does affect various material properties including mechanical strength. The common colourants used in the filaments can be pigments, dyes, masterbatches, or pearlescent powders. In FDM 3D printing, where various colours of filament are used, it is possible that some of the colouring agents present in the filaments may also act as nucleating agents, thus, influencing the crystallization rate of the material being printed. The modified crystallization rate can result in variations in stiffness, strength, and other mechanical characteristics. Therefore, the impact of colouring agents on crystallization rate and mechanical strength can vary depending on the specific material and colouring agents used. Colourant additives in FDM filaments can also play a role in the gap size or the flow characteristics of the material during the printing process, thus showing different properties for different coloured filaments. Therefore, it is important to consider the composition of the raw filaments and conduct appropriate testing and analysis to assess the effects on material properties when using colored filaments in FDM 3D printing. For better results, consider the pure form of genuine pallets (Free from colourant) and create your own filaments to be used for experiments.
One of the important literature considering PLA and its various colours impacting the material properties is :
  • asked a question related to Additive Manufacturing
Question
1 answer
Hi everyone, My question is that: after downloading the file generateEventSeries.py and using it with the generated G-code from replicatorG, I got the following Error from Line 241 in Gcodereader.py "The Gcode data is not found as expected when looking for the first instance for the extruder/pump start" Traceback (most recent call last): File "D:\Ahmed PhD\ABAQUS AM\Code\generateEventSeries.py", line 68, in <module> import GcodeReader as myGcode File "D:\Ahmed PhD\ABAQUS AM\Code\GcodeReader.py", line 241 raise ValueError,"The Gcode data is not found as expected when looking for the first instance for the extruder/pump start" ^ SyntaxError: invalid syntax even when I used the gcode example from knowledge base, I have faced the same issue. I have attached the G-code file.
Relevant answer
Answer
The main purpose of converting G-code to an event series is to create a visual timeline of the 3D printer's movements. To do this, first you need to read the G-code and break it down into its individual commands. Each command has a point in time associated with it which can be used to create adjacent event points on the timeline. Then convert each command into its corresponding instructions by creating an event marker for each instruction. Finally, each event marker should be recorded into a table or created into a visual timeline.
  • asked a question related to Additive Manufacturing
Question
2 answers
I would like to know if there is someone currently doing research on Fused Granular Fabrication (FGF)/Pellet additive manufacturing (PAM)/Fused Pellet Manufacturing(FPM)?
Relevant answer
Answer
Currenty, I am finishing a PhD on FGF, with initeresting results.
Please see our Results, all published in peer-reviewed jourals:
Analytical and Numerical Models of Thermoplastics: A Review Aimed to Pellet Extrusion-Based Additive Manufacturing
10.3390/polym13183160
Modeling of extrusion-based additive manufacturing for pelletized thermoplastics: Analytical relationships between process parameters and extrusion outcomes
DOI: 10.1016/j.cirpj.2022.11.020
Best regards,
AP
  • asked a question related to Additive Manufacturing
Question
1 answer
I have 3 Odb. files from thermal analysis now I am trying to do sequentially coupled stress analysis but when I applied a predefined field I catch the error: Error in job Job-Mech1: Beginning step 5 in the output database G:/AM12/Job-3.odb cannot be found. Even though I select the right odb3. The rest of the 2 are fine but odb.file is giving an error. Any solution, please
Relevant answer
Answer
This error is likely due to the fact that the output database file for step 5 does not exist. The output database is the file that stores the results of the simulation. Check to make sure that the output database file exists in the specified location and try running the simulation again. If the file is missing, it may be necessary to re-run the simulation from step 5.
  • asked a question related to Additive Manufacturing
Question
5 answers
I prepared some samples by LAM and want to calculate temperature or heat generation at a point where laser beam is incident.
Relevant answer
Answer
this can be quite challenging as the thermal conductivity of powder can be regarded as air and back to bulk material when powders are molten. For FEM, regards powder before and after melting as a bulk material, then provide bulk with temperature dependent thermal properties. Heat transfer in pde toolbox in matlab can be good option.
  • asked a question related to Additive Manufacturing
Question
6 answers
Dear Scholars/Researchers,
Greetings of the day!
It gives us immense pleasure to announce that we are in the process of editing the book entitled “Additive Manufacturing of Bio-Implants - Design and Synthesis” for Springer.
Contributing book chapters are solicited in the following areas: • Additive manufacturing of biomaterials (such as Metallic, non-metallic, polymers, etc.) for various applications; • Development of Biomimetic Materials; • Medical Implants and Biomedical Device Design; • Biomechanical Characterization of additive manufactured Hard and Soft human Tissues; • Bioprinting and Nano-Biomaterials. • Corrosion performance of additive manufactured biomaterials • Biological Characteristics of additively manufactured biomaterials • Tribological characteristics of Additive manufactured biomaterials
•  Quality Assurance of additively manufactured bioimplants
I would like to invite you to contribute a Chapter to this book title. The 'Tentative Title' and 'Abstract' for the research contribution are invited on and before 20th April 2023. I look forward to hearing from you.
Book Title: “Additive Manufacturing of Bio-Implants - Design and Synthesis” Editors:
1. Dr. Amit Mahajan, Khalsa College of Engineering & Technology, Department of Mechanical Engineering, Amritsar, India 2. Dr. Sandeep Devgan, Khalsa College of Engineering & Technology Department of Mechanical Engineering, Amritsar, India 3. Dr. Redouane Zitoune, Institute Clement Ader, Toulouse University, Toulouse, France
Relevant answer
Answer
@ U. Ashok kumar
Dear sir,
I have sent an email on your respective email. But it is undelivered.
Kindly submit your abstract and title before 20thApril at amitmahajan291@gmail.com.
Thanks
  • asked a question related to Additive Manufacturing
Question
1 answer
Do you consider 3D printing/ Additive manufacturing for personalized products at scale?
Relevant answer
Answer
Shohin Aheleroff Yes, 3D printing/additive manufacturing is a great technology for producing personalized products at scale. With 3D printing, it is possible to create unique and customized products without incurring significant additional costs. This technology also enables on-demand production, reducing the need for inventory and allowing for faster product delivery times.
Moreover, 3D printing can be used to produce complex shapes and structures that are difficult or impossible to manufacture using traditional manufacturing techniques. This can be especially useful for medical implants, jewelry, and other products that require a high level of customization.
However, it is important to note that 3D printing has its limitations in terms of materials, size, and production speed. It is also not suitable for mass production of certain types of products. Nonetheless, as the technology continues to improve and new materials become available, 3D printing is expected to play an increasingly important role in the production of personalized products at scale.
  • asked a question related to Additive Manufacturing
Question
3 answers
Many functional gradient materials have been prepared, while most of them have gradient structure along a single direction. As the figure shows bellow, I'd like to prepare a CuCr specimen with component gradient distribution in the radial direction, but I don't know how to achieve it. What are possible ways of doing so?
Relevant answer
To prepare a CuCr specimen with a component gradient distribution in the radial direction, you could use a technique called centrifugal casting. Here are the steps:
  1. Prepare a mold that has a cylindrical shape with a diameter slightly larger than the desired final diameter of the specimen. The mold should also have a central rod that extends from the bottom to the top of the mold.
  2. Mix CuCr powder with a binder to create a slurry. The CuCr powder should have different particle sizes to create the desired gradient distribution. The slurry should have a viscosity that allows it to flow easily.
  3. Pour the slurry into the mold while it's spinning on a centrifugal casting machine. The centrifugal force will push the slurry to the outer walls of the mold, creating a cylindrical shape. The central rod in the mold will create a hollow center in the specimen.
  4. Control the speed of the spinning mold to create a gradient distribution in the radial direction. A higher speed will create a denser outer layer, while a lower speed will create a less dense inner layer.
  5. Once the slurry has solidified, remove the specimen from the mold and remove any excess material from the top and bottom of the specimen.
  6. Perform any necessary post-processing steps, such as heat treatment or machining, to create the final desired shape and properties of the specimen.
Centrifugal casting is a useful technique for creating specimens with gradient distributions in various materials, including metals, alloys, and composites.
  • asked a question related to Additive Manufacturing
Question
2 answers
Hello good people
I am simulating multipass multilayer additive manufacturing with ANSYS transient-thermal module. The problem is that the Gaussian heat source (APDL code) works fine with the first layer, but when it comes to the second layer, it does not work. The heat flux does not even initiate for the second layer. I tried generating the code with a different coordinate system for the second layer, but that didn’t work either. I also tried incorporating the ‘z’ or the height of the second layer in the equation. Unfortunately, it didn’t work. But when I put the heat sources for both layers in the same time step, it works for both layers; they don’t work in different time steps.
How can I modify my code so that it works for the SECOND LAYER in the SECOND TIME STEP or any layer after the first layer?
The APDL code is mentioned below-
*DIM,HEAT_FLX1,TABLE,6,24,1,,,,0
!
! Begin of equation: 4e7*exp(-3*(({X}-0.05)^2+({Y}-0.01*{TIME})^2)/0.005^2)
*SET,HEAT_FLX1(0,0,1), 0.0, -999
*SET,HEAT_FLX1(2,0,1), 0.0
*SET,HEAT_FLX1(3,0,1), 0.0
*SET,HEAT_FLX1(4,0,1), 0.0
*SET,HEAT_FLX1(5,0,1), 0.0
*SET,HEAT_FLX1(6,0,1), 0.0
*SET,HEAT_FLX1(0,1,1), 1.0, -1, 0, 0, 0, 0, 0
*SET,HEAT_FLX1(0,2,1), 0.0, -2, 0, 1, 0, 0, -1
*SET,HEAT_FLX1(0,3,1),   0, -3, 0, 1, -1, 2, -2
*SET,HEAT_FLX1(0,4,1), 0.0, -1, 0, 3, 0, 0, -3
*SET,HEAT_FLX1(0,5,1), 0.0, -2, 0, 1, -3, 3, -1
*SET,HEAT_FLX1(0,6,1), 0.0, -1, 0, 0.05, 0, 0, 2
*SET,HEAT_FLX1(0,7,1), 0.0, -3, 0, 1, 2, 2, -1
*SET,HEAT_FLX1(0,8,1), 0.0, -1, 0, 2, 0, 0, -3
*SET,HEAT_FLX1(0,9,1), 0.0, -4, 0, 1, -3, 17, -1
*SET,HEAT_FLX1(0,10,1), 0.0, -1, 0, 0.01, 0, 0, 1
*SET,HEAT_FLX1(0,11,1), 0.0, -3, 0, 1, -1, 3, 1
*SET,HEAT_FLX1(0,12,1), 0.0, -1, 0, 1, 3, 2, -3
*SET,HEAT_FLX1(0,13,1), 0.0, -3, 0, 2, 0, 0, -1
*SET,HEAT_FLX1(0,14,1), 0.0, -5, 0, 1, -1, 17, -3
*SET,HEAT_FLX1(0,15,1), 0.0, -1, 0, 1, -4, 1, -5
*SET,HEAT_FLX1(0,16,1), 0.0, -3, 0, 1, -2, 3, -1
*SET,HEAT_FLX1(0,17,1), 0.0, -1, 0, 0.005, 0, 0, 0
*SET,HEAT_FLX1(0,18,1), 0.0, -2, 0, 2, 0, 0, -1
*SET,HEAT_FLX1(0,19,1), 0.0, -4, 0, 1, -1, 17, -2
*SET,HEAT_FLX1(0,20,1), 0.0, -1, 0, 1, -3, 4, -4
*SET,HEAT_FLX1(0,21,1), 0.0, -1, 7, 1, -1, 0, 0
*SET,HEAT_FLX1(0,22,1), 0.0, -2, 0, 4e7, 0, 0, -1
*SET,HEAT_FLX1(0,23,1), 0.0, -3, 0, 1, -2, 3, -1
*SET,HEAT_FLX1(0,24,1), 0.0, 99, 0, 1, -3, 0, 0
! End of equation: 4e7*exp(-3*(({X}-0.05)^2+({Y}-0.01*{TIME})^2)/0.005^2)
!-->
sf, s1, hflux, %HEAT_FLX1%
Relevant answer
Answer
Thank you for your response. I created a new parameter, 'time_elapsed' as you recommended here. Unfortunately, the laser source still works only on the first time step. It doesn't work in any other time step, even if I select it to run on other time steps specifically.
Could you please suggest how you would do it?
Best,
Tan
  • asked a question related to Additive Manufacturing
Question
5 answers
Could anyone suggest me a good research paper in Additive Manufacturing to study and learn more about it?
Relevant answer
Answer
hi sir seasonal wishes.. i would like to suggest "Additive Manufacturing Technology" book by Hari Prasad for your basic understanding. later on u try with Progress in Additive Manufacturing or 3D printing journals.
  • asked a question related to Additive Manufacturing
Question
12 answers
Dear professors and Experts,
According to recent research and articles, it seems that materials science and engineering is going to have a critical role of the future of science and even engineering. As you all know it's a vast field of research. I would like to have your opinions in this regard. What will be the next of materials science? Which branches will do well and is critical than others?
Please let me find your awesome answers.
Best regards
Relevant answer
Answer
Hello,
I believe that science is moving from continuum mechanics to particle mechanics. Here, depending on the size of the particles, I expect major breakthroughs across the whole range of particle sizes. Up to now, even particle mechanics in the micro to centimeter range is mostly modeled by continuum mechanics. Of course, with respect to the rapid development of DEM methods. This will allow the modelling of particles with respect to their sizes and the digitalization of the field. I wish you a lot of success in finding new properties of particles and their collectives.
Prof. Dr. Jiří Zegzulka, TU Ostrava
  • asked a question related to Additive Manufacturing
Question
2 answers
The residual stress of the additive manufactured aluminum alloy was measured using neutron diffraction (refer to the picture below for the sample shape).
The residual stress result measured by neutron diffraction method is shown in the figure below.
According to the results of several papers, LD and TD values show similar results, and ND values show different results.
However, my experimental results showed that the LD and ND results were similar, but the TD results were different.
These results do not explain well, please suggest any possibility.
Relevant answer
Answer
hello,
as you pointed out in most of the case ND (in building direction )has different valuse than in LD and TD. Some more contexct will be reqiuired to explain this: was the sample still attached to the base plate or not and if it has been subjected to any heat treatment as well. Also first thing to check will be if the measured direction and direction presented are same ( some times this might happen ). Also try to get the stress balanced if you have done cross-sectional measurements.
Texture might be another aspect to be considerd here. AM compontes are highly influnce by the processing parameters as well.
hope this helps
  • asked a question related to Additive Manufacturing
Question
3 answers
What are all the materials available for FDM type 3D printing. And Please share the Strength, Energy absorption characteristics of each material by comparing.
Relevant answer
Answer
FDM 3D printing materials are ABS, PLA, and their various blends. More advanced FDM printers can also print with other specialized materials that offer properties like higher heat resistance, impact resistance, chemical resistance, and rigidity
  • asked a question related to Additive Manufacturing
Question
4 answers
Greetings everyone
I am trying to etch some additively manufactured CuCrZr alloys but i am not able to get the melt pool can anyone give me some suggestions
I have tried with FeCl3 HCL combinations but no satisfactory results
any suggestions would be helpful
Relevant answer
Answer
This is the result itr was not etching actually Egor Terentyev
  • asked a question related to Additive Manufacturing
Question
1 answer
What are the critical rules to pay attention during manufacturing masterbatch especially when working with inorganic nanoparticles? What should be considered in order to achieve the homogenously dispersion in the polymer matrix without destroying the screw and the polymer?
Relevant answer
Answer
1. Use a high-shear mixing element in the extruder to ensure that the particles are evenly dispersed.
2. Use a low screw speed to reduce the risk of particle breakage.
3. Use a low temperature setting to prevent thermal degradation of the particles.
4. Use a low back pressure setting to reduce the risk of particle agglomeration.
5. Use a vacuum system to remove air from the extruder barrel and reduce the risk of particle oxidation.
6. Use a cooling system to reduce the risk of thermal degradation of the particles.
7. Use a filter system to remove any particles that may have been damaged during the extrusion process.
8. Use a pelletizing system to ensure that the particles are evenly distributed in the masterbatch.
  • asked a question related to Additive Manufacturing
Question
1 answer
Additively Manufactured Metal Lattice Structures
Relevant answer
Answer
There are several test programs that can be developed to enhance understanding of the impact-dynamic mechanical properties of metal lattice structures. These are just some of them and the only common ones I know but is more than adequate. Do note that it is important to note the application of the item.
  1. Impact testing: In this type of test, a load is applied to the metal lattice structure in the form of a sudden impact. This can be done using a drop weight or a pendulum impact tester. The impact force and energy absorbed by the structure can be measured and used to determine its dynamic properties.
  2. Dynamic compression testing: This test is similar to impact testing, but instead of an impact force, a dynamic compressive load is applied to the structure. This can be done using a dynamic testing machine or a servo-hydraulic testing machine. The results can be used to determine the dynamic properties of the metal lattice structure, such as its dynamic yield strength and modulus of elasticity.
  3. Vibration testing: This type of test involves applying a sinusoidal excitation to the metal lattice structure and measuring its response. The results can be used to determine the natural frequencies and modal shapes of the structure, as well as its dynamic stiffness and damping properties.
  4. Fatigue testing: This test is used to determine the number of cycles the metal lattice structure can withstand before failure. The test can be performed under different loading conditions, such as cyclic tension, compression, or torsion.
  5. Charpy impact testing: This test is used to determine the impact toughness of the metal lattice structure by measuring the energy absorbed during a test sample of it is broken with a single impact blow.
  6. Finite Element Analysis: can also be used to simulate the impact response of metal lattice structure, and can help to predict the behavior of the structure under different loading conditions. This can be used to optimize the design of the structure before it is built, or to evaluate the performance of an existing structure.
  • asked a question related to Additive Manufacturing
Question
4 answers
Ultem material has the melting point is 426 degree Celsius. Is it possible to print Ultem material in FDM 3D printer. I am having Creality Ender 3Max type FDM printer. Is any other printers can print Ultem material?
Relevant answer
Answer
Ultem is a material that can be printed by some FDM machines, however these are typically classed as high temperature FDM machines. The main differences being they have a heated chamber, heated build platform and increased nozzle temperature range.
It can be printed however not all standard FDM machines will have the capability required.
  • asked a question related to Additive Manufacturing
Question
2 answers
Myself Nekin Joshua R. I like to do my research in Biomimic structures like Nacre, Auxetic, Conch Shell, Hexagonal cellular structure, Hourglass structure, Bouligand Structure.
And 3D print the structures in FDM and like to test the mechanical properties, Ballistic performance, Impact test.
I need to select any one bimimic structure and need to analyze. Please help me to identify which one structure has more energy absorbing property and Armor applications.
Please tell me which one structure I can select.
Relevant answer
Answer
There are several biomimetic structures that are known for their energy absorbing properties and potential use in armor applications. Some structures that you may want to consider include:
  1. Nacre: Nacre, also known as mother-of-pearl, is a material that is found in the shells of some mollusks. It is known for its high toughness and energy absorbing properties, making it a potentially useful material for armor applications.
  2. Auxetic materials: Auxetic materials are materials that exhibit a negative Poisson's ratio, meaning that they expand in the lateral direction when stretched. This property makes them highly energy absorbent and they have been explored for use in armor applications.
  3. Conch shell: The conch shell is a type of shell that is known for its toughness and energy absorbing properties. It has a complex microstructure that is thought to contribute to its mechanical properties, making it a potential candidate for use in armor applications.
  4. Hexagonal cellular structure: Materials with a hexagonal cellular structure, such as honeycombs, are known for their high energy absorption and have been explored for use in armor applications.
  5. Hourglass structure: Materials with an hourglass structure, such as those found in some sea urchin spines, have been shown to have excellent energy absorbing properties and may be useful in armor applications.
  6. Bouligand structure: Materials with a Bouligand structure, such as those found in some marine animal shells, have been shown to have high energy absorbing properties and may be useful in armor applications.
To answer your question, the specific biomimetic structure that is most suitable for use in armor applications will depend on the specific requirements of the application (where and how will it be used specifically?) and the properties that are most important, such as energy absorption, toughness, and weight. I recommend conducting further research and analysis to determine which structure is the best fit for your specific needs.
  • asked a question related to Additive Manufacturing
Question
4 answers
Hello everyone,
I am trying to generate an algorithm that can roughly estimate the support's volume of an stl file at a specific orientation. Does anyone have any ideas where and how to start? I am trying to do this in Python but based on what I read, this can be a GPU computational and geometrical design problem. So I am not sure if Python is a good place to start. I appreciate any ideas/responses. Thank you.
  • asked a question related to Additive Manufacturing
Question
7 answers
For a master's thesis on design optimization for additive manufacturing, I'm looking for ideas.
Relevant answer
Answer
I would recommend to think about design features that can only manufactured additively and not by conventional/subtractive methods. You could evaluate the pro’s and con’s of the different designs.
  • asked a question related to Additive Manufacturing
Question
6 answers
Textbooks about the managerial aspects of Digital Transformation and Industry 4.0 for academic teaching with exercises and case studies.
Relevant answer
Answer
Dear All,
Please access the link below for your reference on the 10 Must-Read Digital Transformation Books in 2022.
You can customize your options on this subject.
Good luck to your careers!
  • asked a question related to Additive Manufacturing
Question
2 answers
Dear colleagues,
Trying to tackle the problem of path planning and G-code modification/generation in metal additive manufacturing, I would be grateful to hear about your experience in this field. The path planner methods and their pros and cons, how to generate a link between path planner and G-code modifier, the capabilities of such method in online programming, and so on...
It would be great to get to know where can I start to make everything optimal.
Relevant answer
Answer
Hi Reza,
We at IIT Guwahati use a CAM package, "PowerMill," along with our algorithms to generate the G-codes for different AM systems (CNC - WAAM, Robotic - WAAM, and FDM). Soon we shall try to use the same platform for powder-bed fusion also.
  • asked a question related to Additive Manufacturing
Question
1 answer
Need suggestions about SCI-Q1 fast publication journal which is unpaid, and can accept 20 pages MS regarding Additive manufacturing?
Relevant answer
Answer
Dear Ray Tahir Mushtaq,
The following publication compares the most important additive manufacturing journals:
  • asked a question related to Additive Manufacturing
Question
3 answers
I am working on lattice structures. I saw in some papers that they used nTopolgy software to achieve the structures' stiffness matrix. unfortunately, I do not have access to this software.
You may guide me from which software or what solution I can get this matrix.
I look forward to your kind reply. Sincerely yours
Relevant answer
You may use the numerical homogenisation method:
  • asked a question related to Additive Manufacturing
Question
6 answers
Hello,
I am doing an additive manufacturing simulation in ABAQUS/CAE 2017.
I have two working subroutines: DFLUX and UEPACTIVATIONVOL which both do their jobs correctly in separate models. I need to combine them but for my moving surface flux, the surface I define in the model does not work due to the activating elements during the analysis form the UEPACTIVATIONVOL. (The surface I define in the GUI for the heat flux does not exist at t = 0 since the elements are inactive)
Is there a way to define the top element face as a surface and change that in a subroutine for my DFLUX subroutine to call so the heat source will be applied on the surface of elements on one layer and then apply to the elements top face on the next layer?
Thanks in advance for your help!
Shaun
Relevant answer
Answer
Manik Patil You as well. Best of luck!
  • asked a question related to Additive Manufacturing
Question
1 answer
Does Big Area Additive Manufacturing (BAAM) demonstrate any plastic deformation before crack initiation?
Relevant answer
Answer
There's a thesis that may answer your question here:
  • asked a question related to Additive Manufacturing
Question
2 answers
Hello,
I am trying to simulate a laser path to understand various mechanical effects because of using a DED to build a cube of 15mm*15mm*15mm in ANSYS workbench using DED Process extension(attached) for Tungsten.
The extension enables Transient thermal followed by static structural, although I am not sure how to set up the process. I could not find any leads on the ansys on the setup unlike for the moving heat source (many sources available)... I was wondering if anyone can share how to enable the process.
Relevant answer
Answer
I am also trying to incorporate the laser in the ansys..but it's very difficult to find any source
  • asked a question related to Additive Manufacturing
Question
6 answers
XPS analysis was performed for O 1s , and the following results were obtained.
I can see C=O, C-O, Al2O3 bond.
but, I don't know why C=O / C-O bonds are exist, what C=O / C-O bonds means.
Please interpret this result.
Relevant answer
Answer
Sc Park There always appears to be a large amount of C on a surface - could be from absorbed CO2 in the atmosphere in your case leading to carbonate formation on the surface. Other theories are that organic matter in the atmosphere also contribute to (or are the majority of) the C found on surfaces. I would Ar+ etch 15 atomic layers or so to see what you then obtain.
  • asked a question related to Additive Manufacturing
Question
1 answer
Hello everyone,
I am trying to model the process stage (Gate to Gate) of FDM on SimaPro. I understand that I need to decide upon my inputs and outputs as well as system boundary before doing that. I am trying to do this properly and was wondering if anyone can advise more on this methodology (i.e., how to decide upon the values for the raw material input and electricity?, etc...).
Any response is very much appreciated. Thank you.
Useful Article: Methodology for systematic analysis and improvement of manufacturing unit process life-cycle inventory (UPLCI) —CO2PE! initiative (cooperative effort on process emissions in manufacturing). Part 1: Methodology description.
Relevant answer
Answer
For FDM SimaPro modelling in gate-to-gate first you should have clear system boundaries based on the research scope. I would like to suggest the following research articles for in-depth study:
Hope them helps you
Best regards,
Shuraik
  • asked a question related to Additive Manufacturing
Question
6 answers
AlSi10Mg powder was made by gas-atomizing.
and this powder has poor flowability.
so, I tried to dry the AlSi10Mg powder on vacuum, but it doesn't work.
How can I improve flowability AlSi10Mg powder for Additive Manufacturing?
and, Why AlSi10Mg powder's flowability is so poor?
Relevant answer
Answer
Your powder contains particles of different sizes. One speaks here of a wide particle size distribution. This is bad for flowability, since the finest particles tend to form lumps. In order to improve the flowability of the powder you have to remove the finest particles from the powder. There are basically two ways of doing this: wet sieving (vibration sieving machine) with a 20-30 micrometer sieve or compressed air screening using a cyclone screener.
  • asked a question related to Additive Manufacturing
Question
1 answer
I created 50 interactions(welding-1 to welding-50) such that half of the region was reactivated through these interaction,which was previously deactivated , through the following code:
Tol=.00000000001
Speed=0.01
for i in range (1,51):
mdb.models['Model-2'].ModelChange(activeInStep=True,createStepName='welding_'+str(i),includeStrain=False,name='welding_'+str(i),region=Region(
elements=mdb.models['Model-2'].rootAssembly.instances['Part-1-1'].elements.getByBoundingBox(-Tol+Speed*(i-1),-Tol,-Tol,Tol+Speed*i,.0025+Tol,Tol+0.002)),
regionType=ELEMENTS)
But when I tried to view region reactivated in any of these newly created interaction,following error showed up,"At least part of the region of the selected interaction has been suppressed,deleted or excuded or is a part of reference representation".I am unable to understand the error.The deactivated region is a cuboid with X coordinate ranging from (0,0.5) ,Y coordinate ranging from (0,0.0025),Z coordinate value from (0,0.004).The direction of welding is positive X axis.Through these interactions I am trying to reactivate lower half of this cuboid with Z axis of the reactivated region ranging from (0,0.002) and range of X and Y coordinate being the same as that of the deactivated region.I have attached an image of abaqus model.
Relevant answer
Answer
Hi Atul,
I have the same problem in my modeling. could you finally resolve this error or not? I would appreciate it if you can share with me what you have done.
Regards,
Hossein
  • asked a question related to Additive Manufacturing
Question
4 answers
I am working on ceramic resins. I First mixed the ceramic with surfactant and a solvent. Ballmilled for 1 hours. To facilitate chemisoprtion i kept the solution in oven for 130 degree for 180 minutes. I found the white ceramic powder the turned brown in colour. I would like to know the reason for the outcome.
Relevant answer
Answer
neutral
based on the composition of material surface
  • asked a question related to Additive Manufacturing
Question
3 answers
I am planning to measuring residual stress using Nanoindentation.
And I need the stress-free sample for reference.
The sample that I want to measure is AlSi10Mg , makes Additive Manufacturing.
so, how to make stree-free sample?
heat treatment? , how can i decide to proper heat treatment temperature?
Electric Discharge Machining?
Relevant answer
Answer
It is quite hard to produce a truly stress-free sample. Stress relief annealing of AlSi10Mg is tricky as you might change the hardness of your samples, see Mertens, et al 2015 - THERMAL TREATMENTS OF AlSi10Mg PROCESSED BY LASER BEAM MELTING (Hardness was reduced by ~ 10 % due to the 250°C/2h heat treatment)
Non precipitation hardenable alloys are typically annealed at 200°C till 300°C and then slowly cooled e.g. in the furnace (GDA Merkblatt W7). Whereby, a higher temperature should be able to achieve a lover stress level. If your samples have the capability of a precipitation hardening and your residual stress is related to a fast cooling steep, "up-hill quenching" (e.g. -196°C and then heating up in a steam bath) might be suitable. (see ASM Handbook vol. 4 Heat Treatment)
The proper temperature depends on the condition (amount of Mg and Si in solution or/and the precipitations) of your samples.
Every machining (even EDM) is able to introduce residual stresses close to the surface. Therefore, you might be better of with a chemical enchant or rather electrolytic polishing before the testing and after your stress relief treatment.
  • asked a question related to Additive Manufacturing
Question
3 answers
Dear Researchers, Need to fabricate specimen from CNT powder using additive manufacturing technique and What could be suitable process for fabrication. Any vendors available for specimen preparation.
Thanks in advance
Relevant answer
  • asked a question related to Additive Manufacturing
Question
24 answers
Metal AM/3D Printing processes have seen massive R&D efforts over the last few years, which have helped improve the indsutrialisation efforts of AM processes. I would be very interested to hear everyone's thoughts on what the topics are, that need to be investigated and developed over the next 5 years by those in research.
Relevant answer
Answer
Actually, Powder Bed Fusion (PBF) is an advanced AM technology that has matured over an extended period of research and industrial development. This technology development has enabled wide uptake of commercial applications of PBF technology, particularly for the production of high-value products that are not technically feasible with traditionally manufacturing processes.
  • asked a question related to Additive Manufacturing
Question
15 answers
Hi all, i would like to know what are some of the key considerations one has when it comes to purchasing metal powders for printing? Price point is definitely a consideration, how about quality? or even availability of powder sizes or availability of small batch like (10kg?) is that a challenge in purchase of powders? any other challenges when you face when it comes to purchasing metal powders?
Relevant answer
Answer
Actually, Metal powders used in AM processes are typically microscopic in size (< 100 µm) and often pose toxicity, reactivity, combustibility and instability hazards. Dust clouds, formed for example by the accidental swirling of powders, have the potential to catch fire and explode under certain conditions.
  • asked a question related to Additive Manufacturing
Question
16 answers
What are advantages of smart factories?
I've recently published the following article in the Korea Times.
And how do you feel about smart factories? Please be as specific as possible when expressing your comments.
What are advantages of smart factories?
Humanity has come a long way from its earliest traces of civilization. Through industrialization, advancement has been brought to the world like never before. The introduction of human labor and later on machines were heightened to a great emphasis, being the main fuel of the economy. Manufacturing became a core concept in terms of civilization during the height of capitalism; a necessity in providing for the needs of citizens in terms of products, services and jobs among others. It is probably right to say that humanity's current habits revolve around the whims and ways of capitalism. Despite the fact that humanity has highly benefited from different stages of industrialization, it has also revealed how it can be perilous and detrimental to citizens throughout the years in different aspects. One of the dangers that capitalism and intensive labor pose toward workers would be the tendency of burnout from excessive and inhumane workloads. Burnout can also come from repetitive tasks, whereas humans are naturally inclined to look for new things to explore and experience from time to time. More so, labor workers also frequently encounter the risks of unjust labor treatment, particularly in relation to wages, benefits and regulations. Amid the introduction of artificial intelligence (AI) technology during the current Industrial Revolution (IR), the same issues regarding the negative sides of labor and capitalism maintain their prevalence. This is where the idea of smart factories enters. In the simplest sense, a smart factory is a manufacturing site wherein the traditional workload is combined with smart machinery powered by huge data and technological systems. Smart factories are factories that are highly improved, innovated, and advanced, branching out as a contribution of IR 4.0. One of the great benefits that smart factories introduce would be the ability to shorten the duration and costs of operations in manufacturing. This is because it is highly flexible in adapting with the usual processes that happen in the factory through the means of storage and analysis of huge data. In doing so, the manufacturing processes became more efficient and effective, lessening the workload that employees are usually tasked with. A smart factory provides for the reduction of manufacturing process times and costs by adapting and optimizing operations as well as storing and analyzing vast amounts of data in real time. This leads to a more flexible, efficient, and autonomous production by encouraging workers to focus on improving processes rather than on mundane jobs, resulting in high value. Smart factories gradually gear up society for IR 5.0, with the goal of creating a people-centered economy rather than a task-centric economy. As smart factories aim to lessen the workloads of human workers, it allows them to have more time for other fundamental things that comprise their lives, other than their jobs and careers. Smart factories give hope for individuals to have more time for recreation and leisure, as well as time spent with family, friends, and meeting new individuals instead of working for eight hours straight. A smart factory strategy does not equate to a total replacement and retrenchment of employees with machines. Rather, it would employ the fusion of the work and effort of both humans and smart technology-powered machines. It adapts a system that is highly-digitalized wherein real-time data is optimized. Smart machines or smart robots can be programmed with repetitive and routine tasks that are usually compiled by the human workforce. Simply put, it brings forth a workplace and lifestyle for individuals that is both sustainable and humane. It is well known that the height of capitalism involves intense competition within and outside of firms and companies. With that being said, the utilization of smart factories and artificial intelligence allows the opportunity for robots to be those involved in the competitions instead of relying on humans. This can be done in the way that smart robots will be mainly responsible for the heavy processes done during production. Thus, they will be liable for the quality of the manufactured goods which are the foundation of a company's competency compared to other companies. In turn, this would relieve the human workforce from the added pressure that is embedded in the production process for the obvious reasons that they are held responsible for the product quality and output. Through smart robots, quality products and their output can be made, which will be the basis for the reputation of the company's name. External influences such as the macroeconomy and the pressure it places on a firm and its employees can play a significant role in fostering a toxic workplace. Smart factories give us a chance to save humanity and society by providing a realistic, attainable and considerate alternative for the people. Such an approach would provide the steps for a healthier and more sustainable lifestyle for humans in terms of realigning their relationship with work. Lastly, it promotes a society that looks out for the well-being of its citizens, instead of looking at them as mere workers. Rushan Ziatdinov (ziatdinov.rushan@gmail.com) is a professor in the Department of Industrial Engineering at Keimyung University, Daegu.
Relevant answer
Answer
Smart factories optimize efficiency and productivity by extending the capabilities of both manufacturing devices and people. By focusing on creating an agile, iterative production process through data collection, smart factories can aid decision-making processes with stronger evidence. https://tulip.co/glossary/what-is-a-smart-factory-and-what-it-means-for-you/
  • asked a question related to Additive Manufacturing
Question
4 answers
We have done some of our own work with early DIY 3D printers that for new users showed failure rates as high as 20%. I know from our own experience it is much lower now - but have you seen or published average failure rates of plastic 3D printers - either in industry or from your own labs?
Relevant answer
Answer
I've been doing 3D FDM (PLA) printing since 2012. In this particular case, main flailure ou flaws are misalignment of mechanical assembly, from housing to gears and bolted parts. Besides, of course, wear of the extruder nozzle and its cleaning, which we must remember is not eternal. I recommend changing the nozzle every 50-60 hours of printing, having gone through many cleanings.
One thing that cannot be overlooked are gear head fixing screws on stepper motors, these are called cotter pins, they are headless screws inserted into gear body. Due to the "jumps" of printing pieces with right angles (Dirac delta effect - unit step impulse). These tiny screws loosen over time and can often "disappear" given their tiny size. I always recommend retightening along with the rest of structure.
As for 3D printing failure, I think main reason is quality and color of PLA plastic used. I've noticed during these 10 years that I have fewer problems with transparent (natural), white and light gray plastics. Colors with a lot of pigmentation more often clog the extruder nozzle. I also prefer to use unheated tables.
I realized over time that 3D printer needs to stay in a power-on with no air circulation. Mild air displacement temperature changes during a long print (30-60h) change quality of finish.
Another important factor is alignment adjustment of assembly and extruder with table. It must be calibrated every 20 hours of printing, including a raft on first layer to check if the alignment is still good!
I think these are the tips, and it really is sad and annoying when a crash ou failure occurs, but keeping in mind what I said earlier, it's easier to avoid failures!
Good luck!
My best regards,
Filipe
  • asked a question related to Additive Manufacturing
Question
3 answers
Ansys 19.2 R2 and 2020 R1 versions of Additive Manufacturing Workbench is convenient for powder-based Additive Manufacturing processing. However, in this workbench, there is a machine parameter setting dialogue box and this parameter setting dialogue box has not included the laser power parameter. Without laser power, the powder material will not melt. So, how to add laser power in the machine parameter setting?
Thank you very much for your cooperation
Relevant answer
Answer
In Ansys Additive Manufacturing System there is no provision for setting laser power, the scan strategy also can not be controlled. The system adds material and heat all at once for each element layer i.e., instead of applying heat flux, the system sets the entire layer to the melt temperature.
For controlling the laser power and scan strategy you can use element death and birth technique in ansys workbench and apply heat flux on the elements for specific time depending on your scanning speed.
Thanks,
Ankit
  • asked a question related to Additive Manufacturing
Question
5 answers
If yes, please contact me.
We are looking for partners in joint research.
Relevant answer
Answer
Our system can process either wires up to 2.2 mm diameter or rods up to 10 mm diameter. Just need to select machine configuration during order registration.
Other methods of raw material supply in our area of interest for joint research are e.g. induction melting of larger rods or pellets incl. alloying or AM scrap reuse (so called re-powder).
As in my initial question: We are looking for partners in joint research in different areas – feedstock input and melting, material characterization after alloying, powder applications (e.g. cermetal / MMC, inter-metallics), scale-up and full automatization for industrial scale production, system integration with printers and others research topics.
  • asked a question related to Additive Manufacturing
Question
11 answers
Dear Colleagues,
If you are researcher who is studying or already published on Industry 4.0 or digital transformation topic, what is your hottest issue in this field?
Your answers will guide us in linking the perceptions of experts with bibliometric analysis results.
Thanks in advance for your contribution.
  • asked a question related to Additive Manufacturing
Question
6 answers
Hello dear colleagues,
I want to reproduce the surface topography of metal additive manufacturing samples in CAD and CAE environments. What is the best way to capture surface topography and how can I reproduce it?
Any recommendation is appreciated in advance.
Best regards,
Hamidreza
Relevant answer
Answer
Hi, If you want to capture all the surface features (pores, cavities) generated during the LPBF process, especially Rv surface roughness with high resolution, use a laser scanning confocal microscope.
See our paper:
"Enhancement of electrical conductivity and corrosion resistance by silver shell‑copper core coating of additively manufactured AlSi10Mg alloy"
  • Surface and Coatings Technology 403(C):126426
  • DOI:10.1016/j.surfcoat.2020.126426
  • asked a question related to Additive Manufacturing
Question
4 answers
I am interested in removing defects during metal LPBF like orientation adjustment, residual stresses, cracks, part failure, etc.
Relevant answer
Answer
For predictive simulation of these processes, we use Autodesk Netabb (https://www.autodesk.de/products/netfabb/features), which works great but is cost-intensive. We also use the Simulia Abaqus "AM Modeler" Plugin (https://info.simuleon.com/blog/using-abaqus-to-simulate-additive-manufacturing-printing-an-optimized-hip-implant) which costs less and also delivers good results for this process. These simulations might potentially help you to reduce the thermal and stress-induced defects and deformations in your parts. Further, it might support you to improve your support structure placement (if required for your process).
When considering micro-defects and the quality of the material after manufacturing, you should specify the type of defects that should be "removed". Maybe a simulation would not be appropriate and you should consider an In-Line process monitoring and control for your process, combined with a proper "Design of Experiments". The data achieved by this procedure could be used to improve the simulations mentioned above by considering your materials and machines constraints.
  • asked a question related to Additive Manufacturing
Question
8 answers
As we all know the best particle size for SLM is around 40um.
I was looking for a lab scale machine to produce my needed metal powders and I found ATO Lab Atomizer machine, although the company claims that the output powder of the machine is suitable for SLM but in its catalogue it is mentioned that the particle sizes are between 20 and 120um.
I am curious to know can I use that powder for SLM AD?
and also how many percent of that powder is under 50um?!
they did not share any size distribution graph!
Relevant answer
Answer
Dear Mrs. Cheng,
As for ultrasonic atomization by itself, ultrasonic frequency is the most important factor. You could take o look at our new paper on technology.
You could also take a look at the PSD we have obtained at the rePowder device by AMAZEMET for two different frequencies. As the inventor of both the abovementioned devices, I would suggest taking an in-depth look at the material feedstock used by both setups.
Best regards,
Łukasz Żrodowski
  • asked a question related to Additive Manufacturing
Question
3 answers
Hello!
I'm starting a Thesis on the topic of Additive Manufacturing with the combination of flexible manufacturing/process build control. Can anyone suggest any research topic I can work on? Any reference paper or Thesis would be appreciated. Also, can you suggest which software I'll have to use in this research topic? Ansys?
Relevant answer
Answer
Hi Daniyal,
are you starting a master' thesis ? Will it then be for 6 months ? Some topics you could work on. Will it be on Metal AM ?
1. Guidelines for enabling in process monitoring and control of AM ( Metal or Polymer) processes.
2. Studying and comparing different post process treatments for enabling flexible/hybrid manufacturing with AM.
3. Studying and developing different digital error detection and quality control methodologies for AM.
There has been research done in all these fields, you can find some for example like
Good luck with your thesis!
  • asked a question related to Additive Manufacturing
Question
9 answers
My intention is to be able to see by LOM, the melt pools produced by the additive manufacturing process, and also the grain formation.
Any help or advice would be appreciated!
  • asked a question related to Additive Manufacturing
Question
4 answers
Hello,
I am working on a project "Structural simulation of 3D printed part - PLA material - FDM method" and for that I am doing simulation in ABAQUS AM modeler but I got stuck in the middle.
I got the error "EVENT SERIES data error". I do not know how to generate event series from .gcode file. Please someone land me any example file or the way to generate a event series file fr that?
Thank you!
Relevant answer
Answer
In AM model tab, you can find data setup, model setup, and simulation setup. Different data structure include parameter table, property table, and event series.
If you want define data in time and space dependent, you need event series. It is a combination of amplitude curve and path. Within event series, you must define field variables. The structure consists of
Time-1, x1, y1, z1
Filed value-1 (..., ...)
Time-2, x2, y2, z2
Filed value-2 (..., ...)
There are predefined event series also.