Refine
Year of publication
- 2022 (9) (remove)
Document Type
- Conference Proceeding (7)
- Book (2)
Conference Type
- Konferenzartikel (7)
Has Fulltext
- no (9)
Is part of the Bibliography
- yes (9)
Keywords
- Additive Manufacturing (2)
- Lightweight design (2)
- 3D printing (1)
- 3D-Drucken (1)
- 3D-Modellierung (1)
- Additive Tooling (1)
- Additive manufacturing (1)
- Blechbiegemodul (1)
- CAD (1)
- CNC-Biegen (1)
Institute
Open Access
- Closed (4)
- Open Access (3)
- Closed Access (2)
- Diamond (2)
- Bronze (1)
In the development of new vehicles, increasing customer comfort requirements and rising safety regulations often result in an increase in weight. Nevertheless, in order to be able to meet the demand for reduced fuel consumption, it is necessary within product development process to implement complex and filigree lightweight structures. This contribution therefore addresses the potential of generatively developed components for fiber-reinforced additive manufacturing (FRAM). Currently, several commercial systems for this application are available on the market. Therefore, a comparison of the systems is first made to determine a suitable system. Then, a highly stressed and safety-relevant chassis component of a race car is generatively designed and manufactured using FRAM. A matrix with short fiber reinforcement and additional long fiber reinforcement with carbon fibers is applied. Finally, tensile tests are carried out to check the mechanical properties. In addition, relevant properties such as weight and cost are obtained in order to be able to compare them with conventionally developed and manufactured components.
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.
This paper presents a method for supporting the application of Additive Tooling (AT)-based validation environments in integrated product development. Based on a case study, relevant process steps, activities and possible barriers in the realisation of an injection-moulded product are identified and analysed. The aim of the method is to support the target-oriented application of Additive Tooling to obtain physical prototypes at an early stage and to shorten validation cycles.
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.
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.
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.
Additive manufacturing offers completely new production technologies thanks to the layered structure and the simultaneous processing of several materials. In order to exploit the potential of this new technology, it is already necessary in product development to consider the components no longer as monolithic blocks, but as a structure of many layers and individual elements (voxels). Therefore, this paper will examine the current state of voxel-based CAD systems and the subsequent 3D multi-material printing of the designed components. Different voxel-based CAD systems are used and analyzed for component design and a sample component is additively manufactured. The results show that simple components can be designed using voxel-based CAD systems. With the application of 3D multi-material printing, different materials and thus functions can be assigned to the designed voxel-based CAD-model.
Dieses Lehrbuch ermöglicht Anfängern 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 vorliegende Auflage enthält nun eine Übersicht der 3D-Druckwerkstoffe und geht auf die aktuellen Weiterentwicklungen von Onshape ein. Die neue vereinfachte Anmeldung sowie die Erstellung einer Explosionsdarstellung werden in zwei neuen Kapiteln demonstriert.
Fusion 360 – kurz und bündig
(2022)
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.
In der vorliegenden Auflage wurde die Konstruktionsmethodik überarbeitet und einige Kapitel wurden ergänzt, beispielweise um das Erstellen von Teams.