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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.
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.
Today, thermoforming moulds are mostly produced using conventional mould-building technologies (e.g. milling and drilling) and are made of metal (e.g. aluminium or steel) or hardwood. The tools thus produced are very robust, but are only cost-effective in mass production. For the production of small batches of thermoformed parts, there is a need for moulds which can be produced quickly and economically. A new approach which significantly reduces the production time and cost is the 3D printing process (3DP). The use of this technology to produce thermoforming moulds offers many new options in the geometries which can be manufactured, and in manufacturing time and costs. In a case study of a thermoformed part (a scaled automotive model), the pre-processing of the CAD model of a mould is demonstrated. The mould can be printed within a few hours, and is sufficiently heat-resistant for moulding processes. The important advantages of moulds printed in 3D, in comparison to moulds built using conventional technologies, are the ability to create any shape of channels for the vacuum and the simplification in the production of tool mock-ups. This paper also discusses the economics of the technique, such as a comparison of material costs and manufacturing costs in relation to conventional production technologies and materials.
Experimental and numerical investigations into the forming of tailored strips and tailored tubes
(2008)
Through the application of tailored strips and tailored tubes, the wall thickness of components can be manufactured in a load-optimised manner. Thus, it is also possible to optimise component weight. Prior to the application of tailored products, wall thicknesses and the respective degree of deformation as well as the welding seam position can be determined in a FEM (finite element method) simulation. These results are then verified in test series on transfer presses and tube bending machines, with the necessary tool adaptations being determined in the process. This results in weight and cost reductions for deep-drawn components and tube sections. Moreover, this means that especially with regard to tubes, multiple sections can be combined in one component. A feasibility study shows that the level of possible weight and cost savings depends on the respective component geometry and load situation. Additional costs for the production of tailored products and - if necessary - tool modifications also need to be considered. Thus, the amount of savings possible for a part can only be determined on an individual basis.
Um medizinische Behandlungsverfahren in der Praxis besser verstehen und anwenden zu können, gewinnt die Visualisierung der Prozesse an immer größerer Bedeutung. Durch Anwendung der Computer-Simulationssoftware CST können elektromagnetische und thermische Simulationen zur Analyse verschiedener Herzrhythmusstörungen durchgeführt werden. Eine weitere Form der Visualisierung erfolgt durch haptische, dreidimensionale Druckmodelle. Diese Modelle können mit einem generativen Herstellungsverfahren, wie z. B. einem 3D-Drucker, in kürzester Zeit hergestellt werden.
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.
Zur Herstellung von Spritzgussformeinsätzen kommen in der Regel spanende Verfahren zum Einsatz. In den letzten Jahren hat sich allerdings auch die additive Herstellung dieser Werkzeuge als zweckmäßig erwiesen. In der Produktentwicklung spielt die Agilität heute eine immer wichtigere Rolle. Um mögliche Potentiale des Additive Tooling im Rahmen des Agile Prototyping und um Unterschiede zu den konventionellen Herstellverfahren aufzuzeigen, werden Angebote für die Fertigung mehrerer Formeinsätze durch eine CNC- und HSC-Fertigung, sowie durch additive Herstellung angefragt und hinsichtlich Beschaffungskosten und -zeiten miteinander verglichen. Zudem erfolgt eine Bewertung der technischen Unterschiede. Aus diesen beiden Betrachtungen kann schließlich ein Profil über die drei Herstellverfahren abgeleitet werden, welches bei der anwendungsfallspezifischen Verfahrensauswahl unterstützen soll.
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.
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.
Additive manufacturing (AM) and in particular the application of 3D multi material printing offers completely new production technologies thanks to the degree of freedom in design and the simultaneous processing of several materials in one component. Today's CAD systems for product development are volume-based and therefore cannot adequately implement the multi-material approach. Voxel-based CAD systems offer the advantage that a component can be divided into many voxels and different materials and functions can be assigned to these voxels. In this contribution two voxel-based CAD systems will be analyzed in order to simplify the AM on voxel level with different materials. Thus, a number of suitable criteria for evaluating voxel-based CAD systems are being developed and applied. The results of a technical-economic comparison show the differences between the voxel-based systems and disclose their disadvantages compared to conventional CAD systems. In order to overcome these disadvantages, a new method is therefore presented as an approach that enables the voxelization of a component in a simple way based on a conventional CAD model. The process chain of this new method is demonstrated using a typical component from product design. The results of this implementation of the new method are illustrated and analyzed.
PROBLEM TO BE SOLVED: To provide a method of producing a robot component, particularly a gripper, the method being capable of being applied multi-functionally and shortening a mounting time to a robot.
SOLUTION: A method of producing a robot component, particularly a finger 5, applied to robotics by a three-dimensional printing method of this invention comes not to require other production processes such as attachment of a cover, etc. with a separate sensor or a material (soft, in many cases), etc., by simultaneously printing at least one sensor 7 by multi-material printing while printing the robot component.
Die Erfindung betrifft ein Verfahren zum 3D-Druck eines Roboterelements, insbesondere eines Fingers 5, zum Einsatz in der Robotik, bei dem mittels Multimaterialdruck wenigstens ein Sensor 7 während des Drucks des Roboterelements mitgedruckt wird. Weiterhin betrifft die Erfindung ein Betätigungs- oder Greifelement, insbesondere Finger 5 für einen Roboter, das durch ein derartiges Verfahren hergestellt wurde.
A method for 3D printing of a robot element, more particularly a finger for use in robotics. At least one sensor is concomitantly printed by means of multi-material printing during the printing of the robot element. A gripping element produced by a method of this kind includes a number of printed layers of robot element material and a concomitantly printed sensor.
In 4D printing an additively manufactured component is given the ability to change its shape or function under the influence of an external stimulus. To achieve this, special smart materials are used that are able to react to external stimuli in a specific way. So far, a number of different stimuli have already been investigated and initial applications have been impressively demonstrated, such as self-folding bodies and simple grippers. However, a methodical specification for the selection of the stimuli and their implementation was not yet in the foreground of the development.
The focus of this work is therefore to develop a methodical approach with which the technology of 4DP can be used in a solution- and application-oriented manner. The developed approach is based on the conventional design methodology for product development to solve given problems in a structured way. This method is extended by specific approaches under consideration of the 4D printing and smart materials.
To illustrate the developed method, it is implemented in practice using a problem definition in the form of an application example. In this example, which represents the recovery of an object from a difficult-to-access environment, the individual functions of positioning, gripping and extraction are implemented using 4D printing. The material extrusion process is used for additive manufacturing of all components of the example. Finally, the functions are successfully tested. The developed approach offers an innovative and methodical approach to systematically solve technical complex problems using 4DP and smart materials.
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.
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.
In 4D printing, an additively manufactured component is given the ability to change its shape or function in an intended and useful manner over time. The technology of 4D printing is still in an early stage of development. Nevertheless, interesting research and initial applications exist in the literature. In this work, a novel methodical approach is presented that helps transfer existing 4D printing research results and knowledge into solving application tasks systematically. Moreover, two different smart materials are analyzed, used, and combined following the presented methodical approach to solving the given task in the form of recovering an object from a poorly accessible space. This is implemented by self-positioning, grabbing, and extracting the target object. The first smart material used to realize these tasks is a shape-memory polymer, while the second is a polymer-based magnetic composite. In addition to the presentation and detailed implementation of the methodical approach, the potentials and behavior of the two smart materials are further examined and narrowed down as a result of the investigation. The results show that the developed methodical approach contributes to moving 4D printing closer toward a viable alternative to existing technologies due to its problem-oriented nature.
In addition to traditional methods in product development, the increasing availability of two new technologies, namely additive manufacturing AM (e.g. 3D-printing) and reverse engineering RE by means of 3D-scanning, offer new opportunities in product development processes today. However, to date only very few approaches exist those include these new technologies systematically in the education of students in the field of product development. This paper explores several ways in which AM and RE can productively be used in education. New to this approach is, on the one hand, that the students assemble and install the 3Dprinters themselves, and on the other hand, that they are introduced to an approach that combines 3D-scanning followed by 3D-printing. In different case studies is demonstrated that students in design education are able to autonomously research and realize technical possibilities and limitations of these technologies, as well as economic parameters and constraints.
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.
Additive Manufacturing and Reverse Engineering have increasingly been gaining in importance over the past years. This paper investigates the current status of the implementation of these new technologies in design education and also identifies current shortcomings. Then it develops two new approaches for the teaching of the necessary expertise for the design of 3D-printed components and illustrates these with case studies. First, a workshop is presented in which students gain a broad understanding for the functionalities of additive manufacturing and the creative possibilities and limits of this process, through the assembly and installation of a 3D-printer. A second new approach is the combination of reverse engineering and 3D-printing. Thereby, students learn how to deal with this complex process chain. The result of these new approaches can e.g. be seen in the design guidelines for Additive Manufacturing, which were developed by the students themselves. At the same time, the students are able to estimate opportunities and limits of both technologies. Finally, the success of the new course contents and form is reviewed by an evaluation by the students.
This paper presents a new approach for the teaching of competence in additive manufacturing to engineering students in product development. Particularly new to this approach is the combination of the students' autonomous assembly and commissioning of a 3D-printer, and the independent development of guidelines for this new technology regarding the design of components. This way the students will be able to gain first practical experiences with the data preparation, the additive manufacturing process itself and also the required post-treatment of the 3D-printed parts. To allow the students a significantly deeper insight into the functioning of 3D-printing, the workshop Rapid Prototyping developed a new approach in the course of which the students first assemble a construction kit for a 3D-printer themselves and then commission the printer. This enables the students to gain a better understanding of the functionality and configuration of additive manufacturing. In a next step, the students used the 3D-printers they constructed themselves to produce components which they take from a database. Finally, the experiences of the students in the course of the workshop will be evaluated to review the effectiveness of the new approach.
In addition to traditional methods in product development, the increasing availability of two new 3D digital technologies, namely digital manufacturing (3D-printing) and digitizing of surfaces (3D-scanning), offer new opportunities in product development processes today. With regard to the systematic implementation of these technologies in the education of students in the field of product development, however, only a small number of approaches exist so far. This paper explores several ways in which 3D digital technologies can productively be used in design education. The innovative aspects here include that the students assemble and install the 3D-printers themselves, and that they are introduced to an approach that combines 3D-scanning followed by 3D-printing.
4D printing (4DP) is an evolutionary step of 3D printing, which includes the fourth dimension, in this case the time. In different time steps the printed structure shows different shapes, influenced by external stimuli like light, temperature, pH value, electric or magnetic field. The advantage of 4DP is the solution of technical problems without the need for complex internal energy supply via cables or pipes. Previous approaches to 4D printing with magnetoresponsive materials only use materials with limited usability (e.g. hydrogels) and complex programming during the manufacturing process (e.g. using magnets on the nozzle). The 4D printing using unmagnetized particles and the later magnetization allows the use of a standard 3D printer and has the advantage of being easily reproducible and relatively inexpensive for further application. Therefore, a magnetoresponsive feedstock filament is produced which shows elastic and magnetic properties. In a first step, pellets are produced by compounding polymer with magnetic particles. In a second step, those pellets are extruded in form of filament. This filament is printed using a conventional printing system for Material Extrusion (MEX-TRB/P). Various prototypes have been printed, deformed and magnetized, which is called programming. In comparison to shape memory polymers (SMP) the repeatability of the movement is better. The results show the possibilities of application and function of magnetoresponsive materials. In addition, an understanding of the behaviour of this novel material is achieved.
Purpose
This study aims to investigate a systematic approach to the production and use of additively manufactured injection mould inserts in product development (PD) processes. For this purpose, an evaluation of the additive tooling design method (ATDM) is performed.
Design/methodology/approach
The evaluation of the ATDM is conducted within student workshops, where students develop products and validate them using AT-prototypes. The evaluation process includes the analysis of work results as well as the use of questionnaires and participant observation.
Findings
This study shows that the ATDM can be successfully used to assist in producing and using AT mould inserts to produce valid AT prototypes. As a reference for the implementation of AT in industrial PD, extracts from the work of the student project groups and suitable process parameters for prototype production are presented.
Originality/value
This paper presents the application and evaluation of a method to support AT in PD that has not yet been scientifically evaluated.
Due to globalization and the resulting increase in competition on the market, products must be produced more and more cheaply, especially in series production, because buyers expect new variants or even completely new products in ever shorter cycles. Injection molding is the most important production process for manufacturing plastic components in large quantities. However, the conventional production of a mold is extremely time-consuming and costly, which creates a contradiction to the fast pace of the market. Additive tooling is an area of application of additive manufacturing, which in the field of injection molding is preferably used for the prototype production of mold inserts. This allows injection molding tools to be produced faster and more cheaply than through the subtractive manufacturing of metal tools. Material Jetting processes using polymers (MJT-UV/P), also called Polyjet Modeling (PJM), have a great potential for use in additive tooling. Due to the poorer mechanical and thermal properties compared to conventional mold insert materials, e.g. steel or aluminum, the previously used design principles cannot be applied. Accordingly, new design guidelines are necessary, which are developed in this paper. The necessary information is obtained with the help of a systematic literature research. The design guidelines are mapped in a uniform design guide, which is structured according to the design process of injection molds. The guidelines do not only refer to the constructive design of the injection mold or the polymer mold insert, but to the entire design process and describe the four phases of planning, conception, development and realization. Particular attention is paid to the special geometric designs of a polymer mold insert and the thermomechanical properties of the mold insert materials. As a result, design guidelines are available that are adapted to the special requirements of additive tooling of molds inserts made of plastics for injection molding.
Der effektive Einsatz von Energie ist vor dem Hintergrund von begrenzten Ressourcen und der Forderung nach einer Reduzierung der bei der Energiegewinnung entstehenden Umweltbelastungen von wachsender Bedeutung. Für die noch relativ junge Gruppe der generativen Fertigungsverfahren liegen bis heute kaum Untersuchungen zum Energieverbrauch vor. Deshalb werden in diesem Beitrag zwei weit verbreitete Rapid-Prototyping-Verfahren (3D-Drucken und Fused Deposition Modeling) hinsichtlich ihres Energieverbrauchs untersucht und verglichen. Zudem werden Maßnahmen zur Steigerung der Energieeffizienz aufgezeigt und Einsparmöglichkeiten genannt.
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.
Application of Polymer Plaster Composites in Additive Manufacturing of High-Strength Components
(2015)
Today, 3D-printing with polymer plaster composites is a common method in Additive Manufacturing. This technique has proven to be especially suitable for the production of presentation models, due to the low cost of materials and the possibility to produce color-models. But nowadays it requires refinishing through the manual application of a layer of resin. However, the strength of these printed components is very limited, as the applied resin only penetrates a thin edge layer on the surface. This paper develops a new infiltration technique that allows for a significant increase in the strength of the 3D-printed component. For this process, the components are first dehydrated in a controlled two-tier procedure, before they are then penetrated with high-strength resin. The infiltrate used in this process differs significantly from materials traditionally used for infiltration. The result is an almost complete penetration of the components with high-strength infiltrate. As the whole process is computer-integrated, the results are also easier to reproduce, compared to manual infiltration. On the basis of extensive material testing with different testing specimen and testing methods, it can be demonstrated that a significant increase in strength and hardness can be achieved. Finally, this paper also considers the cost and energy consumption of this new infiltration method. As a result of this new technology, the scope of applicability of 3D-printing can be extended to cases that require significantly more strength, like the production of tools for the shaping of metals or used for the molding of plastics. Furthermore, both the process itself and the parameters used are monitored and can be optimized to individual requirements and different fields of application.
A variety of different additive manufacturing processes have been available for the last three decades. Some of these technologies are very energy-intensive, e.g. laser technology and the manufacture of metal powder. In many areas, the detailed investigation of the energy and material consumption of these new manufacturing methods is still in the beginning. This paper investigates energy and material consumption using 3D colour printing (3DP) as an example. The specific energy required for the layering can be determined from this. This then forms the basis for a comparison of the specific energy consumption with other generative (e.g. Fused Layer Modelling—FLM) and also conventional production processes (e.g. milling and grinding). Thus process selection is facilitated by introducing the specific energy for layering. In addition several variables, in which resource consumption can be reduced are also investigated and compared. For example the influence of the geometry or the positioning of the 3D-printed part in the design space on the consumption are investigated. But also the measuring of different batch sizes is compared. Using the results found, the use of 3D printing can initially be optimized so that less energy, resources and manufacturing time are required.
Dieser Beitrag stellt die Möglichkeiten des 3D-Druckes unter der Berücksichtigung von Mensch-Roboter-Kollaborations-Anforderungen dar. Dabei werden die Vorteile mit besonderem Fokus auf die zusätzliche Gestaltungsfreiheit erläutert. Anhand von Beispielen wird der Stand der Technik bereits eingesetzter Sensorik sowie deren Notwendigkeit in Greifsystemen erläutert. Im weiteren Verlauf dieses Beitrags werden allgemeine Verfahren für die additive Verarbeitung von leitfähigen Materialien vorgestellt. Daran angeknüpft sind Beispiele speziell zur 3D-gedruckten Sensorik. Abgerundet wird der Beitrag mit einem Ausblick bezüglich 3D-gedruckter Sensorik in MRK-Greifsystemen.
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.
Various methods of Digital Manufacturing (DM) have been available for the manufacturing of physical architectural models for several years. This paper highlights the advantages of 3D printing for digital manufacturing of detailed architectural models. In particular, the representation of architectural details and textures is treated. Furthermore, two new methods are being developed in order to improve the conditions for the application of digital manufacturing of architectural models.
Besides of conventional CAD systems, new, cloudbased 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. The chances and risks of cloud-based systems will first be analyzed in this paper. Then two leading cloud-based CAD systems will be researched. During the process, the technical performance range these new systems offer for the product development will be initially checked and reviewed. For this purpose, various criteria are worked out and the CAD software is evaluated using these criteria. In addition, the criteria are weighted by their importance for design education. This allows one to conclude which capabilities the different CAD system offers for use in education.
Fusion 360 – kurz und bündig
(2019)
Dieses Lehrbuch ermöglicht dem Anfänger in der 3D-Modellierung einen schnellen Einstieg in die Arbeit mit dem cloudbasierten CAD-System Autodesk® Fusion 360™. Der Schwerpunkt liegt dabei auf den grundlegenden Funktionen zur Modellierung von Einzelteilen und 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.