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Plastics are used today in many areas of the automotive, aerospace and mechanical engineering industries due to their lightweight potential and ease of processing. Additive manufacturing is applied more and more frequently, as it offers a high degree of design freedom and eliminates the need for complex tools. However, the application of additively manufactured components made of plastics have so far been limited due to their comparatively low strength. For this reason, processes that offer additional reinforcement of the plastic matrix using fibers made of high-strength materials have been developed. However, these components represent a composite of different materials produced on the basis of fossil raw materials, which are difficult to recycle and generally not biodegradable.
Therefore, this paper will explore the potential for new composite materials whose matrix consists of a bio-based plastic. In this investigation, it is assumed that the matrix is reinforced with a fibrous material made of natural fiber to significantly increase the strength. This potential material should offer a lightweight yet strong structure and be biodegradable after use under controlled conditions. Therefore, the state of the art in the use of bio-based materials in 3D printing is first presented. In order to determine the economic boundary conditions, the growth potentials for bio-based materials are analyzed. Also, the recycling prospects for bio-based plastics will also be highlighted. The greenhouse gas emissions and land use to be expected when using bio-based materials are also estimated. Finally, the degradability of the composites is discussed.
The Human-Robot-Collaboration (HRC) has developed rapidly in recent years with the help of collaborative lightweight robots. An important prerequisite for HRC is a safe gripper system. This results in a new field of application in robotics, which spreads mainly in supporting activities in the assembly and in the care. Currently, there are a variety of grippers that show recognizable weaknesses in terms of flexibility, weight, safety and price.
By means of Additive manufacturing (AM) gripper systems can be developed which can be used multifunctionally, manufactured quickly and customized. In addition, the subsequent assembly effort can be reduced due to the integration of several components to a complex component. An important advantage of AM is the new freedom in designing products. Thus, components using lightweight design can be produced. Another advantage is the use of 3D multi-material printing, wherein a component with different material properties and also functions can be realized.
This contribution presents the possibilities of AM considering HRC requirements. First of all, the topic of Human-Robot-Interaction with regard to additive manufacturing will be explained on the basis of a literature review. In addition, the development steps of the HRI gripper through to assembly are explained. The acquired knowledge regarding the AM are especially emphasized here. Furthermore, an application example of the HRC gripper is considered in detail and the gripper and its components are evaluated and optimized with respect to their function. Finally, a technical and economic evaluation is carried out. As a result, it is possible to additively manufacture a multifunctional and customized human-robot collaboration gripping system. Both the costs and the weight were significantly reduced. Due to the low weight of the gripping system only a small amount of about 13% of the load of the robot used is utilized.
Additive manufacturing (AM) or 3D printing (3DP) has become a widespread new technology in recent years and is now used in many areas of industry. At the same time, there is an increasing need for training courses that impart the knowledge required for product development in 3D printing. In this article, a workshop on “Rapid Prototyping” is presented, which is intended to provide students with the technical and creative knowledge for product development in the field of AM. Today, additive manufacturing is an important part of teaching for the training of future engineers. In a detailed literature review, the advantages and disadvantages of previous approaches to training students are examined and analyzed. On this basis, a new approach is developed in which the students analyze and optimize a given product in terms of additivie manufacturing. The students use two different 3D printers to complete this task. In this way, the students acquire the skills to work independently with different processes and materials. With this new approach, the students learn to adapt the design to different manufacturing processes and to observe the restrictions of different materials. The results of these courses are evaluated through feedback in a presentation and a questionnaire.
In addition to traditional methods in product development, the increasing availability of additive manufacturing AM technologies offer new opportunities in product development processes today. This contribution explores several ways in which AM can productively be used in education. New to this approach is amongst others that the students assemble and install the 3D-printers themselves. In two case studies is demonstrated how students in design education are able to autonomously research and realize technical possibilities and limitations of AM technologies, as well as economic constraints.
Implementation of interdisciplinary student teams in design education for additive manufacturing
(2018)
Additive manufacturing (AM) technologies are becoming increasingly popular in all areas of product development. Therefore, it is imperative that students be taught Design for AM. However, due to the rapid development of new methods and materials for AM, it does not make sense to only teach particular design guidelines, as these can quickly become obsolete. Rather, students should acquire the competence to develop guidelines themselves, that take into account the current state of the art. Thus, they will be able to react to changing processes and new materials
in the future. In order to convey the independent development of design guidelines for additive manufacturing by students, a new concept was developed, which is presented in this contribution. In this process, the learning goal is worked out by a group of students on the basis of a practical
task. The group consists of an interdisciplinary team in order to combine different competencies and to provide different perspectives on the task. A case study will show the design and manufacture of a miniature aircraft using Fused Layer Modelling. The aim of the development is above all the design for additive manufacturing. In addition, a low use of resources in combination with lightweight construction should be achieved. In the implementation of the task, the students are confronted with challenging aerodynamic design of wings as well as with the economic evaluation of the development process. An examination of the level of knowledge before and after the case study examines the learning success.
Besides of conventional CAD systems, new, cloud-based CAD systems have also been available for some years. These CAD systems designed according to the principle of software as a service (SaaS) differ in some important features from the conventional CAD systems. Thus, these CAD systems are operated via a browser and it is not necessary to install the software on a computer. The CAD-data is stored in the cloud and not on a local computer or central server. This new approach should also facilitate the sharing and management of data. Finally, many of these new CAD systems are available as freeware for education purposes, so the universities can save license costs. This contribution examines newly developed, cloud-based CAD systems. In the context of a case study, the application of these new CAD systems are investigated in the training of engineers in design education. Thus, the students compare a conventional and a cloud-based CAD system as part of an exercise of designing and 3D modelling of a pinion shaft. Subsequently, the students manufacture a drawing with different views of the pinion shaft. This assessment evaluates different criteria such as user-friendliness, tutorial support and installation effort.
Additive manufacturing processes have evolved rapidly in recent years and now offer a wide range of manufacturing technologies and workable materials. This range from plastics and metals to paper and even polymer plaster composites. Due to the layer by layer structure of the components the additive processes have in comparison with conventional manufacturing processes the advantage of freedom of design, that means the simple implementation of complex geometries. Moreover, the additive processes provide the advantage of reduced consumption of resources, since essentially only the material is consumed, which is required for the actual component, since no waste in the form of chips is produced. In order to use these advantages, the potentials of additive manufacturing and the requirements of sustainable design must already be observed in the product development process. So the design of the components and products must be made so as little as possible construction and supporting material is required for the generative production and therefore little resources are consumed. Also, all steps of the additive manufacturing process must be considered properly, that includes the post processing. This allows components be designed so that for instance the effort for removing the support structure is considerably reduced. This leads to a significant reduction in manufacturing time and thus energy consumption. The implementation of these potentials in product development can be demonstrated by means of a multiple-stages model. A case study shows how this model is applied in the training of Master students in the field of product development. In a workshop the students work as a group while implementing the task of developing a miniature racing car under the rules of sustainable design in compliance with the boundary conditions for an additive manufacturing. In this case, Fused Deposition Modelling FDM using plastics as a building material is applied. The results show how the students have dealt with the different requirements and how they have implemented them in product development and in the subsequent additive manufacturing.
The integration of additive manufacturing processes into the teaching of students is an important prerequisite for the further dissemination of this new technology. In this context, the DfAM is of particular importance. For this reason, this paper presents an approach in which a connection is made between methodical product development and practical implementation by AM. Using a model racing car as an example, students independently develop significant improvements of particular assemblies. A final evaluation shows that the students have significantly improved their skills and competencies.
Today the methods of numerical simulation of sheet metal forming offer a great diversity of possibilities for optimization in product development and in process design. However, the results from simulation are only available as virtual models. Because there are any forming tools available during the early stages of product development, physical models that could serve to represent the virtual results are therefore lacking. Physical 3D-models can be created using 3D-printing and serve as an illustration and present a better understanding of the simulation results. In this way, the results from the simulation can be made more “comprehensible” within a development team. This paper presents the possibilities of 3D-colour printing with particular consideration of the requirements regarding the implementation of sheet metal forming simulation. Using concrete examples of sheet metal forming, the manufacturing of 3D colour models will be expounded upon on the basis of simulation results.
Virtuelle Modell "begreifbar" Machen - Darstellung von Simulationsergebnissen mittels 3D-Farbdruck
(2016)
Today, Additive Manufacturing (AM) is an important part of teaching for the education of future engineers. Therefore, a variety of approaches have been developed in recent years on how to bring the design for additive manufacturing (DfAM) into university teaching. In a detailed literature review, the advantages and disadvantages of the previous approaches are considered and analysed. Based on this, an extended approach is presented in which students analyse and optimize a given product with respect to additive manufacturing. In doing so, the students have to solve challenging tasks in optimization in product development with the help of methodical approaches and practically implement their developed solutions with state-of-the-art additive processes. To work on this task, the students have two different 3D printers at their disposal, which work with different processes and materials. Thus, the students learn to adapt the design to different manufacturing processes and to consider the restrictions of different materials. The assessment of the results from this course is done through feedback and a written survey.
The present-day methods of numerical simulation offer a great variety of options for optimizing metal forming processes. Although it is possible to simulate complex forming processes, the results are typically available only as 2D projections on screens. Some forming processes have reached a level of complexity beyond the level of spatial sense, which makes it necessary to use physical 3D representations to develop a deeper understanding of the material flow, microstructural processes, process and design limits, or to design the required tooling. Physical 3D models can be produced in a short amount of time using 3D printing, and indexed with a wide range of colors. In this paper, the additive manufacturing of 3D color models based on simulation results are explored by means of examples from metal forming. Different 3D-printing processes are compared on the basis of quality as well as technical and economic criteria. Other examples from the fields joining by upset-bulging of tubes and microstructure simulation are also analyzed. This paper discusses the possibilities offered by the rapid progress and wide availability of 3D printers for the design and optimization of complex metal forming processes.
As a reaction to the increasing market dynamics and complex requirements, today’s products need to be developed quickly and customized to the customer’s individual needs. In the past, CAD systems are mainly used to visualize the model that the product designer creates. Generative Design shifts the task of the CAD program by actively participating in the shaping process. This results in more design options and the complexity of the shapes and geometries increases significantly. This potential can be optimally exploited through the combination of Generative Design with Additive Manufacturing (AM). Artificial intelligence and the input of target parameters generate geometries, for example, by creating material for stressed areas, which in turn develops biomorphic shapes and thus significantly reduces the consumption of resources. This contribution aims at the evaluation of existing applications in CAD systems for generative design. Special attention is paid to the requirements in design education and easy access for students. For this purpose, three representative CAD systems are selected and analyzed with the help of a comprehensive example of mass reduction. The aim is to perform an individual result analysis in order to assess the application based on various criteria. By using different materials, the influence of the material for the generation is investigated by comparing the material distribution. By comparing the generated models, differences of the CAD systems can be identified and possible fields of application can be presented. By specifying the manufacturing parameters for the generation of the models, the feasibility of AM can be guaranteed without having to modify the results. The physical implementation of the example by means of Fused Deposition Modeling demonstrates this in an exemplary way and examines the interface of the Generative Design and AM. The results of this contribution will enable an evaluation of the different CAD systems for Generative Design according to technical, visual and economic aspects.
Additive manufacturing enables the production of lightweight and resilient components with extensive design freedom. In the low-cost sector, material extrusion (e.g. Fused Deposition Modeling - FDM) has been the main method used to date. Thus, robust 3D printers and inexpensive 3D materials (polymer filaments) can be used. However, the printing times for FDM are very long and the quality of the dimensions and surfaces is limited. Recently, new processes from the field of Vat polymerization have entered the market. For example, masked stereolithography (mSLA) offers a significant improvement in component quality and build speed through the use of resins and large-area curing at still reasonable costs. Currently, there is only limited knowledge available on the optimal design of components using this young process. In this contribution, design guidelines are developed to determine the possibilities and limitations of mSLA from a design point of view. For this purpose, a number of test geometries are designed and investigated to obtain systematic insights into important design features, such as wall thickness, grooves and holes. In addition, typical problems in additive manufacturing, such as the design of overhangs and fits or the hollowing of components, are investigated. The evaluation of practical 3D printing tests thus provides important parameters that can be transferred to design guidelines of components for additive manufacturing using mSLA.
Additive manufacturing with plastics enables the production of lightweight and resilient components with a high degree of design freedom. In the low-cost sector, Material Extrusion as Fused Layer Modeling (FLM) has so far been the leading method, as it offers simple 3D printers and a variety of inexpensive 3D materials. However, printing times for 6FLM are very long and dimensional accuracy and surface finish are rather poor. Recently, new processes from the field of Vat Polymerization have appeared on the market, such as masked Stereolithography (mSLA), which offer a significant improvement in component quality and build speed at equally favorable machine costs.
This paper therefore analyzes the technical and economic capabilities of the two competing additive processes. For this purpose, the achievable dimensional and surface qualities are determined using a test specimen which represents various important geometry elements. In addition, the machine and material costs are determined and compared with each other. Finally, the resulting environmental impact is determined in the form of the CO2 footprint. In order to optimize the strength of the printed components, material properties of the tensile specimens produced additively with mSLA are determined. The use of ABS-like resins will also be investigated to determine optimal processing settings.
Various Rapid Prototyping methods have been available for the production of physical architectural models for a few years. This paper highlights in particular the advantages of 3D printing for the production of detailed architectural models. In addition, the current challenges for the creation and transfer of data are explained. Furthermore, new methods are being developed in order to improve both the technical and economic boundary conditions for the application of 3DP. This makes the production of models with very detailed interior rooms possible. The internal details are made visible by dividing the complex overall model into individual models connected by means of an innovative plug-in system. Finally, two case studies are shown in which the developed methods are applied in order to implement detailed architectural models. Additional information about manufacturing time and costs of the architectural models in the two case studies is given.
Various rapid prototyping methods have been available for the production of physical architectural models for a few years. This paper highlights in particular the advantages of 3D printing and Fused Layer Modeling for the production of detailed architectural models. In addition, the current challenges for the creation and transfer of CAAD-data are explained. Furthermore, new methods are being developed in order to improve both the technical and economic boundary conditions for the application of 3DP und FLM. This makes the production of models with very detailed interior rooms possible. The internal details are made visible by dividing the complex overall model into individual models connected by means of an innovative plug-in system. In addition, three case studies are shown in which the developed methods are applied in order to implement detailed architectural models. Finally manufacturing time and costs of the architectural models in the three case studies are compared.
Additive manufacturing is a rapidly growing manufacturing process for which many new processes and materials are currently being developed. The biggest advantage is that almost any shape can be produced, while conventional manufacturing methods reach their limits. Furthermore, a lot of material is saved because the part is created in layers and only as much material is used as necessary. In contrast, in the case of machining processes, it is not uncommon for more than half of the material to be removed and disposed of. Recently, new additive manufacturing processes have been on the market that enables the manufacturing of components using the FDM process with fiber reinforcement. This opens up new possibilities for optimizing components in terms of their strength and at the same time increasing sustainability by reducing materials consumption and waste. Within the scope of this work, different types of test specimens are to be designed, manufactured and examined. The test specimens are tensile specimens, which are used both for standardized tensile tests and for examining a practical component from automotive engineering used in student project. This project is a vehicle designed to compete in the Shell Eco-marathon, one of the world’s largest energy efficiency competitions. The aim is to design a vehicle that covers a certain distance with as little fuel as possible. Accordingly, it is desirable to manufacture the components with the lowest possible weight, while still ensuring the required rigidity. To achieve this, the use of fiber-reinforced 3D-printed parts is particularly suitable due to the high rigidity. In particular, the joining technology for connecting conventionally and additively manufactured components is developed. As a result, the economic efficiency was assessed, and guidelines for the design of components and joining elements were created. In addition, it could be shown that the additive manufacturing of the component could be implemented faster and more sustainably than the previous conventional manufacturing.