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For some years now, additive manufacturing (AM) has offered an alternative to conventional manufacturing processes. The strengths of AM are primarily the rapid implementation of ideas into a usable product and the ability to produce geometrically complex shapes. It has also significantly advanced the lightweight design of products made of plastic. So far, the strength of printed components made of polymers is previously very limited.
Recently, new AM processes have become available that allow the embedding of short and also long fibers in polymer matrix. Thus, the manufacturing of components that provide a significant increase in strength becomes possible. In this way, both complex geometries and sophisticated applications can be implemented. This paper therefore investigates how this new technology can be implemented in product development, focusing on sports equipment. An extensive literature research shows that lightweight design plays a decisive role in sports equipment. In addition, the advantages of AM in terms of individualized products and low quantities can be fully exploited.
An example of this approach is the steering system for a seat sled used by paraplegic athletes in the Olympic discipline of Nordic paraskiing. A particular challenge here is the placement and alignment of the long carbon fibers within the polymer matrix and the verification of the strength by means of Finite-Element-Analysis (FEA). In addition, findings from bionics are used to optimize the lightweight design of the steering system. Using this example, it can be shown that the weight of the steering system can be drastically reduced compared to conventional manufacturing. At the same time, a number of parts can be saved through function integration and thus the manufacturing and assembly effort can be reduced significantly.
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.
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.
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.
Fusion 360 – kurz und bündig
(2020)
Dieses Lehrbuch ermöglicht dem Anfänger in der 3D-Modellierung einen schnellen Einstieg in die Arbeit mit dem cloudbasierten CAD-System Autodesk® Fusion 360TM. Der Schwerpunkt liegt dabei auf den grundlegenden Funktionen zur Modellierung von Einzelteilen und dem Zusammenbau von Produkten, sowie in der Erstellung von einfachen technischen Zeichnungen. Dabei werden bei jedem Schritt die besonderen Anforderungen an eine 3D-Druck-gerechte Gestaltung erläutert und umgesetzt. Somit ist das Ergebnis dieser „Schritt für Schritt“-Anleitung die vollständige Modellierung eines Miniatur-Automobils, das am 3D-Drucker in ein reales Modell umgesetzt werden kann. Das didaktische Konzept ist so ausgelegt, dass alle Schritte für ein Selbststudium geeignet sind. Die vorliegende Auflage wurde komplett überarbeitet, sie basiert auf der neuen Benutzeroberfläche User Interface (UI) und enthält ein neues Kapitel zum CNC-Blechbiegen.
Dieses Lehrbuch ermöglicht dem Anfänger in der 3D-Modellierung einen schnellen Einstieg in die Arbeit mit dem cloudbasierten praxisorientierten CAD-System Onshape. Dabei werden bei jedem Schritt die besonderen Anforderungen an eine 3D-Druck-gerechte Gestaltung erläutert und umgesetzt. Somit ist das Ergebnis dieser „Schritt für Schritt“-Anleitung die vollständige Modellierung eines Miniatur-Automobils, das am 3D-Drucker in ein reales Modell umgesetzt werden kann. Die aktuelle Auflage wurde zugunsten besserer Lesbarkeit in ein größeres Format gebracht, die Inhalte wurden neu gegliedert und aktualisiert und um das Kapitel „Blechbauteile für CNC-Biegen" erweitert.
The ability to change aerodynamic parameters of airfoils during flying can potentially save energy as well as reducing the noise made by the unmanned aerial vehicles (UAV) because of sharp edges of the airfoil and its rudders. In this paper, an approach for the design of an adaptive wing using a multi-material 3D printer is shown. In multi-material 3D printing, up to six different materials can be combined in one component. Thus, the user can determine the mixture and the spatial arrangement of this “digital material” in advance in the pre-processing software. First, the theoretical benefits of adaptive wings are shown, and already existing adaptive wings and concepts are explicated within a literature review. Then the additive manufacturing process using photopolymer jetting and its capabilities to print multiple materials in one part are demonstrated. Within the scope of a case study, an adaptive wing is developed and the necessary steps for the product development and their implementation in CAD are presented. This contribution covers the requirements for different components and sections of an adaptive wing designed for additive manufacturing using multiple materials as well as the single steps of development with its different approaches until the final design of the adaptive wing. The developed wing section is simulated, and qualitative tests in a wind tunnel are carried out with the wing segment. Finally, the additively manufactured wing segment is evaluated under technical and economic aspects.
The fast and cost-effective manufacturing of tools for thermoforming is an essential requirement to shorten the development time of products. Thus, additive processes are used increasingly in tooling for thermoforming of plastic sheets. However, a disadvantage of many additive methods is that they are highly cost-intensive, since complex systems based on laser technology and expensive metal powders are needed. Therefore, this paper examines how to work with favorable additive methods, e.g. Binder Jetting, to manufacture tools, which provide sufficient strength for thermoforming. The use of comparatively low-priced inkjet technology for the layer construction and a polymer plaster as material can be expected to result in significant cost reductions. Based on a case study using a cowling (engine bonnet) for an Unmanned Aerial Vehicle (UAV), the development of a complex tool for thermoforming is demonstrated. The object in this study is to produce a tool for a complex-shaped component in small numbers and high quality in a short time and at reasonable costs. Within the tooling process, integrated vacuum channels are implemented in additive tooling without the need for additional post-processing (for example, drilling). In addition, special technical challenges, such as the demolding of undercuts or the parting of the tool are explained. All process steps from tool design to the use of the additively manufactured tool are analyzed. Based on the manufacturing of a small series of cowlings for a UAV made of plastic sheets (ABS), it is shown, that the Binder Jetting offers sufficient mechanical and thermal strength for additive tooling. In addition, an economic evaluation of the tool manufacturing and a detailed consideration of the required manufacturing times for the different process steps are carried out. Finally, a comparison is made with conventional and alternative additive methods of tooling.