Browsing by Subject "hybrid manufacturing"

Now showing 1 - 19 of 19

3D Printing of Electro Mechanical Systems
(University of Texas at Austin, 2013) Aguilera, Efrain; Ramos, Jorge; Espalin, David; Cedillos, Fernando; Muse, Dan; Wicker, Ryan; MacDonald, Eric
Recent research has focused on the fabrication freedom of 3D printing to not only create conceptual models but final end-use products as well. By democratizing the manufacturing process, products will inevitably be fabricated locally and with unit-level customization. For 3D printed end-use products to be profoundly meaningful, the fabrication technologies will be required to enhance the structures with additional features such as electromechanical content. In the last decade, several research groups have reported embedding electronic components and electrical interconnect into 3D printed structures during process interruptions. However, to date there appears to be an absence of fabricated devices with electromechanical functionality in which moving parts with electronic control have been created within a single Additive Manufacturing (AM) build sequence. Moreover, previously reported 3D printed electronics were limited by the use of conductive inks, which serve as electrical interconnect and are commonly known for inadequate conductivity. This paper describes the fabrication of a high current (>1 amp) electromechanical device through a single hybrid AM build sequence using a uPrint Plus, a relatively low cost 3D. Additionally, a novel integrated process for embedding high performance conductors directly into the thermoplastic FDM substrate is demonstrated. By avoiding low conductivity inks, high power electromechanical applications are enabled such as 3D printed robotics, UAVs and biomedical devices.
Characterization of High-Deposition Polymer Extrusion in Hybrid Manufacturing
(University of Texas at Austin, 2018) Weaver, Jason; Jones, Jason
Hybrid manufacturing processes that include additive and subtractive operations have unlocked many of the design limitations that were not previously available. Additive processes allow increased design flexibility, customization, and complexity. Subtractive processes enable higher production speeds and improved accuracy and surface finish. This paper describes a hybrid system that combines a computer numerically controlled (CNC) milling machine with a high deposition rate polymer extruder to create artifacts using hybrid additive/subtractive processes. Future research plans are described, including possible applications for this system in multimaterial and multi-process manufacturing.
Clamping Concept for 6 Side Hybrid Manufacturing
(2022) Mischliwski, S.; András, D.; Weigold, M.
For most technical applications, the surface quality and tolerances that result directly from additive processes are not suitable. Hybrid manufacturing as a combination of additive and subtractive manufacturing process steps can help solving this issue. In this work, a conceptional adjustable cast clamping process is introduced for a combination of Laser-based Powder-Bed-Fusion (LPBF) and milling. For component clamping during the milling process, the components are cast in place with a low-melting metal alloy, creating form-fit and force-fit connection. To prove the applicability, a rough estimation of occurring milling forces was conducted. In a subsequent series of tests, validation of clamping force was carried out using complex part geometries. A prototype fixture designed for this cast clamping process has been developed and tested. This fixture allows complex non-restricted 6-side machining of parts without moving it relative to the fixture or the need of any additional manual rework on part surfaces.
Development of a Hybrid Manufacturing Process for Precision Metal Parts
(University of Texas at Austin, 2017) Hill, Leon; Sparks, Todd; Liou, Frank
This paper summarizes the research and development of a hybrid manufacturing process to produce fully dense metal parts with CNC-level precision. High performance metals, such as titanium alloys, nickel superalloys, tool steels, stainless steels, etc. can benefit from this process. Coupling the additive and the subtractive processes into a multi-axis workstation, the hybrid process, can produce and repair metal parts with accuracy. The surface quality of the final product is similar to the industrial milling capability. To achieve such a system, issues of the metal deposition process and the automated process planning of the hybrid manufacturing process will be discussed.
A Digitally-Driven Hybrid Manufacturing Process for the Flexible Production of Engineering Ceramic Components
(University of Texas at Austin, 2018) Hinter, J.; Basu, D.; Flynn, D.F.; Harris, R.A.; Kay, R.W.
Ceramic materials are a versatile class of materials with numerous applications across a range of industrial sectors. Predominant methods of manufacturing ceramic components use template-driven methods, which hampers responsiveness and impose significant design constraints. This has driven significant interest towards digitally-driven manufacturing approaches, primarily, additive manufacturing. Additive manufacturing has demonstrated the rapid production of bespoke and highly complex geometries and designs direct from digital data without the need for component specific tooling. Yet, when used in isolation these techniques are restricted by uncontrollable porosity, high shrinkages during firing plus a lack of process-compatible materials. This paper presents the research and development of a new hybrid manufacturing process chain for the agile production of engineering grade ceramics components. The combination of high viscosity ceramic paste extrusion, sacrificial support deposition and subtractive micro-machining has yielded complex monolithic ceramic components with feature sizes of 100µm, part densities of ~99.7%, surface roughness down to ~1µm Ra and 3-point bend strength of 218MPa. Since a wide range of materials can be formulated into visco-elastic pastes they can be readily deposited using this approach.
Digitally-Driven Micro Surface Patterning by Hybrid Manufacturing
(University of Texas at Austin, 2018) Smith, Matthew A.A.; Fry, Nicholas R.; Kay, Robert W.; Harris, Russell A.
Aerosol Jet printing is a versatile direct-write method allowing selective deposition and alteration of surface chemistry on a variety of substrates, making it suitable for incorporation in a range of hybrid manufacturing processes. The digitally controlled nature of the presented hybrid manufacturing process enables rapid turnaround of designs, and improvements in flexibility and complexity compared to established methods. The apparatus and instrumentation that has been created at the University of Leeds enables specific processing conditions that result in deposition of features with critical dimensions smaller than 20µm. In this study the analysis of the effect of process variables on deposition geometries is presented. The features were assessed by a combination of optical microscopy and white light interferometry. Using in-process machine vision, topographical compensation, and alignment capability the deposition of material into micropatterned features in poly(dimethylsiloxane) (PDMS) was demonstrated. High-value applications of this technology for surface functionalisation include electronics and bio-engineering.
Electronics Integration in Conformal Substrates Fabricated with Additive Layered Manufacturing
(University of Texas at Austin, 2009-09) Castillo, Sylvia; Muse, Dan; Medina, Frank; MacDonald, Eric; Wicker, Ryan
A three-dimensional (3D) accelerometer sensor system with microprocessor control was fabricated using a previously developed integrated layered manufacturing system that combines conductive ink dispensing with stereolithography (SL). The electronics are integrated into a conformal substrate that is press-fit into a helmet for the purpose of detecting Traumatic Head Injury (THI) when an excessive acceleration to the head is measured. Applications include monitoring the health of soldiers or athletes. Traditional fabrication of electronics is implemented with a 2 dimensional printed circuit board (PCB), which are not well suited for rugged installations in curved locations such as the interior of a helmet. The advantage of layered manufacturing for the integration of electronics is the ability to fabricate in a conformal substrate - conforming to the curved, complex, and often flexible shapes dictated by the human body.
EVALUATING THE COMPRESSIVE STRENGTH OF AM RISERS FOR GREEN SAND METALCASTING
(University of Texas at Austin, 2023) Hasbrouck, C.R.; Melnik, Samantha A.
While many metalcasting foundries have experimented with using additive manufacturing (AM) for patternmaking, the compressive strength of the tapered AM risers for green sand metalcasting has not yet been explored. This study investigates the effects of infill pattern type, infill density, and shell thickness on the compressive strength of a standard 3-inch diameter by 5-inch tall by 3-degree taper cylindrical riser manufactured with PLA using a material extrusion process. The findings for these AM risers include plots and mathematical models of compressive strengths at three different scales of the standard geometry (full, three-quarters, and half), predicted build times and masses using other common infill patterns, potential failure mechanisms during use of AM and conventionally manufactured riser patterns, and considerations on design for both additive manufacturing and green sand metalcasting. It is concluded that AM risers can be incorporated into and perform well as part of conventional green sand metalcasting patterns.
Hybrid Manufacturing with FDM Technology for Enabling Power Electronics Component Fabrication
(University of Texas at Austin, 2018) Coronel, Jose L. Jr; Billah, Kazi Md Masum; Acosta Carrasco, Carlos F.; Barraza, Sol A.; Wicker, Ryan B.; Espalin, David
The introduction of Kapton coated wires within a printed substrate presents the opportunity to design and fabricate power electronics components. Preventing dielectric breakdown of the printed substrate, the ultrasonic embedding approach enables complex geometrical embedding through customized software. This work presents the effective embedding of large diameter (14 AWG) kapton coated litz wire into polycarbonate (PC) substrate. Custom software allowed for generation of embedding toolpaths directly from the CAD model of the designed coupon. Results showed the most successful embedding paths were circular pre-formed cavities. Through characterization of a myriad of printed samples, an approach was developed for embedding large diameter wire. Through the use of the Foundry Multi3D System, the increased complexity of embedded electronic parts can further impulse the implementation of hybrid additive manufacturing in large scale applications.
Integrated Hardfacing of Stellite-6 Using Hybrid Manufacturing Process
(University of Texas at Austin, 2019) Praniewicz, M.; Feldhausen, T.; Kersten, S.; Berez, J.; Jost, E.; Kurfess, T.; Saldana, C.
Hybrid manufacturing systems provide a platform for integrated additive, subtractive and inspection methods on a single machine setup. The present work explores use of hybrid manufacturing for hardfacing of performance components for improving wear resistance. In this work, Stellite-6 was applied to a 410 stainless steel substrate using a hybrid manufacturing system incorporating multi-axis directed energy deposition and machining. Experimental testing was conducted to determine the effects of hybrid manufacturing parameters on internal porosity, surface porosity and microstructure in the cladded material, as well as on the roughness of the final machined surface. Correlation between porosity measurements made by x-ray tomography and surface inspection is presented and determination of ideal process parameters for hardfacing of components using hybrid manufacturing systems is briefly discussed. A deposition process is presented and implemented on a large industrial component. The component is inspected using dye-penetrant testing and metallographic techniques.
Investigation of Build Strategies for a Hybrid Manufacturing Process Progress on Ti-6Al-4V
(University of Texas at Austin, 2017) Yan, Lei; Hill, Leon; Newkirk, Joseph W.; Liou, Frank
The various processing parameters of a hybrid manufacturing process, including deposition and machining, is being investigated with a Design of Experiment (DoE). The intent was to explore the effect of different build strategies on the final part’s Vickers hardness, tensile test, fatigue life, and microstructure. From this experiment, the processing parameters can be linked to various mechanical properties. This will lead to the ability to create a combination of deposition and machining parameters, which will result in improved mechanical properties.
Level Set Grids for Hybrid Manufacturing
(University of Texas at Austin, 2023) White, Liam; Quaife, Bryan; Borish, Michael; Adkins, Cameron; Roschli, Alex
We propose a novel hybrid model, the Level Set Grid, to facilitate parallel additive and subtractive processes in hybrid manufacturing. The Level Set Grid combines the strengths of explicit and implicit representations, offering precise modeling of evolving geometries and fast and efficient collision detection. This research focuses on integrating Level Set Grids into the additive slicing and subtractive pathing generation processes, laying the groundwork for future advancements in the parallelization of hybrid manufacturing.
Mechanical Properties Evaluation of a Ti-6Al-4V Thin-Wall Structure Produced by a Hybrid Manufacturing Process
(University of Texas at Austin, 2018) Yan, Lei; Cui, Wenyuan; Newkirk, Joseph W.; Liou, Frank; Thomas, Eric E.; Baker, Andrew H.; Castle, James B.
The hybrid manufacturing (HM) process combines the precision of computer numerical control (CNC) and the freeform capability of additive manufacturing to expand the versatility of advanced manufacturing. The intent of this paper is to explore the relationship between HM processing parameters and mechanical properties of the final parts manufactured by one type of HM process that combines laser metal deposition (LMD) and CNC milling. The design of experiment (DOE) is implemented to explore the Ti-6Al-4V thin-wall structure fabrication process with different HM build strategies. Vickers hardness, tensile test, and microstructure analyses are conducted to evaluate the mechanical property variance within the final parts fabricated according to the DOE matrix. Finally, a prediction model of yield strength at 0.2% offset for Ti-6Al-4V parts built through the aforementioned HM process was obtained by an analysis of variance (ANOVA) test, which revealed the significant factors are build height within each LMD process, laser energy input, and the interaction of build height within each LMD process to the preheating condition.
Metallic Components Repair Strategies Using the Hybrid Manufacturing Process
(University of Texas at Austin, 2017) Zhang, Xinchang; Cui, Wenyuan; Li, Wei; Liou, Frank
The hybrid manufacturing process which integrates additive manufacturing with subtractive machining is competitive and promising in component repair. To automate this process, detecting the missing volume and generating the deposition tracks is the key. In this study, strategies for repairing defects on flat and non-flat surfaces were investigated. A cost-effective reverse engineering tool was utilized to reconstruct STL models of damaged objects. Point data of the fracture surface on flat surfaces was obtained to generate the tool path for material building up. For defects on non-flat surfaces, the damaged model was best-fitted with the nominal model. Then both models were sliced and by using area comparison method, the defective domain was detected. Then a series of projection rays were utilized to slice the damaged cross-sections to extract the repair volume. Finally, repair experiments were performed to assess the repair quality through repair automation.
Preliminary Study on Hybrid Manufacturing of the Electronic-Mechanical Integrated Systems (EMIS) via the LCD Stereolithography Technology
(University of Texas at Austin, 2019) Fei, Guanghai; Wei, Tiwei; Shi, Qimin; Guo, Yongjian; Oprins, Herman; Yang, Shoufeng
Compared to limited complexity capacity in traditional fabrication and assembly techniques, Additive Manufacturing (AM)-based hybrid fabrication is emerging in electronics industry for fabricating complex structures and simplifying the assembly steps. In this study, the fabrication process of the Electronic-Mechanical Integrated Systems (EMIS) is investigated, in which mechanical parts (gas/liquid chambers) were 3D printed directly on PCB substrate (the carrier of electronic devices). A mixture of resin with silica was used as printing feedstock, to reduce mismatch of thermal expansion coefficient (CTE) between the part and PCB. The silica loading of 60 vol% was appropriate to achieve a compromise between viscosity of the suspension and CTE. Adhesion forces between printed parts and PCBs were measured, showing a significant correlation with the PCB surface roughness. Thermal cycling test indicated that the tailored materials owned excellent CTE compatibility with PCB. Consequently, AM-based hybrid manufacturing is capable of fabricating protective/functional bodies for electronics.
Review of Current Problems and Developments in Large Area Additive Manufacturing (LAAM)
(University of Texas at Austin, 2021) Crisp, Tyler G.; Weaver, Jason M.
Large Area Additive Manufacturing (LAAM), also known as Big Area Additive Manufacturing (BAAM), is a screw extrusion, pellet-fed additive manufacturing technology. The large build area, rapid build speed, and inexpensive pelletized feedstock of LAAM are major advantages over conventional AM methods. LAAM has a large variety of applications in areas including energy, automotive, aerospace, high volume production, and composite molds. However, LAAM is not without its challenges. The largest challenges LAAM faces include mechanical properties, uniformity and precision, and predictability of composite material properties. The goal of this paper is to present current research regarding challenges in LAAM, methods of addressing those challenges, developments, and applications, as well to highlight further research to be done.
Robot-Based Hybrid Manufacturing Process Chain
(University of Texas at Austin, 2019) Baier, Christian; Weigold, Matthias
The combination of additive and subtractive processes using an industrial robot in a hybrid production concept is an innovative approach in manufacturing technology. An improvement in the near net shape geometry production processes is achieved by using a wire-based laser metal deposition process with the added benefit of saving resources. Assisted by qualified CAM tools and an interposed laser line scanning, this process chain enables production of tool and dies, especially for automotive industry and manufacturing of parts made of nickelbased alloys for aerospace industry. This expands the workpiece material application range for robot-based milling. For the robot-machining processes, extended strategies in CAM path planning have been qualified focusing on increased machining-process quality. The system technology and sub-processes have been integrated into a robot-cell, enabling a hybrid part production process in a single workpiece clamping.
Stereo Vision Based Hybrid Manufacturing of Ti-6Al-4V in Component Repair Process
(University of Texas at Austin, 2014) Liu, Renwei; Wang, Zhiyuan; Sparks, Todd; Liou, Frank
Parts or products from high performance metal are very expensive, partly due to the processing complexities during manufacturing. Recent studies have indicated that hybrid processes of additive manufacturing and machining process can be used to repair titanium parts, thus extending the service life. In order to implement these methods automatically, it is necessary to obtain the spatial geometry information of component with defects to generate the tool path. The purpose of this paper is to summarize the research on hybrid manufacturing with stereo vision function which can be applied to the component repair process. Stereo vision is adopted to detect the location and the size of the defect area which is marked by color marker. And then laser displacement sensor is applied to scan the defect area. Therefore, automated alignment, reconstruction of the defect area and tool path planning could be implemented based on the spatial geometry information. Finally, a Ti64 part repair experiment is done to verify the method. This work provides an automatic method for repairing damaged parts by hybrid manufacturing.
Tool Path Generation for Hybrid Additive Manufacturing
(University of Texas at Austin, 2018) Leite, M.; Cunha, J.; Sardinha, M.; Soares, B.; Reis, L.; Ribeiro, A.R.
This paper presents a new approach to tool path generation for a hybrid additive-subtractive manufacturing apparatus. The goal is the development of an integrated hybrid process, based on additive and subtractive manufacturing, to produce complex geometries with continuous fiber reinforced thermoplastics. The authors propose a novel system that can handle two heads: a filament deposition head and a milling head. The system allows for additive, subtractive, additive followed by subtractive and additive and subtractive at each layer. Due to the use of continuous fiber reinforced thermoplastics the tool path trajectories will be different depending on part geometry to accrue mechanical properties. To evaluate the proposed strategies, one example with different features is provided on how to take an .stl file with a final geometry and generate the necessary adjustments to enable the subtractive process.