Rapid Manufacturing of Metal Parts

As a key technology of rapid prototyping and manufacturing (RP&M), rapid manufacturing of metal parts is a target of RP&M. Introducing selective laser sintering (SLS), an important branch of RP&M, this paper gives a new method oriented on low power SLS system to fabricate metal parts. With this kind of technology, the mixture of metal and polymer powder is sintered first to get green part, then, after debinding and metal infiltration, dense parts are gotten. In the end, influencing factors of this technology are analyzed. At the same time, some applications are given.

Rapid manufacturing of SiC molds with micro-sized holes using abrasive water jet

Silicon carbide (SiC) is highly wear resistant with good mechanical properties, including high temperature strength, excellent chemical resistance, and high thermal conductivity and thermal shock resistance. SiC molds, which can be produced with diverse microstructural features, are now widely used in glass molding owing to their excellent characteristics, and also have potential applicability in IT industries. SiC molds are traditionally fabricated by silicon micromachining or dicing. The fabrication cost of silicon micromachining is very high, however, because several expensive masks are needed. Furthermore, the fabrication time is very long. Meanwhile, it is difficult to make micro-patterned molds with arbitrary shapes using dicing saws. Abrasive water jet (AWJ) is widely applied to cut and drill very brittle, soft and fibrous materials. It offers high energy density, the absence of a heat affected zone(HAZ), high performance, and an environment friendly process. In spite of these advantages, micro-hole drilling via conventional AWJ processing suffers from notable shortcomings. We proposed a new abrasive supplying method of AWJ. The proposed method reduces frosting phenomena, and provides micro-machining of AWJ. The characteristics of a hole machined was investigated by the proposed AWJ process according to the ratio of water and abrasives. With the optimal experimental conditions, 3×3 array SiC molds with the diameter of 700 μm and depth of 900 μm were successfully manufactured.

Research on Application Technology Oriented Rapid Response Manufacturing in the Distributed Network Environment

A new chance of developing traditional manufacturing industry comes forth with the development of network technology. Application technology oriented rapid response manufacturing in the distributed network environments, that is, how to take advantage of the Intranet and Internet, combine the numerous manufacturing resources spread around the region, the country and even the globe is the key to the agile design, manufacturing and the buildup of comprehensively competitive power, at the same time, is also an important research direction in the field of advanced manufacturing technology. Rapid response manufacturing in the distributed network environment is a newly manufactory pattern that can be used to implement the conception of agile design and manufacturing, but there are some new problems coming with it, which will directly influence the enterprise’s ability of rapid response in the distributed network manufacturing pattern and lead to the failure of the league and the lost of the given orders. In this paper, we establish some approaches to solve these problems in product development process. The paper then presents the research on key application technologies and solutions includes: network safety strategy which guarantees data transferring among the leaguer members, production data management based on Web/DOT (Distributed Object Technology) and XML criteria which guarantees data exchange in structure-variance characteristic environments, the network platform which provides the conversion service of different types of CAD files each other. All of these solutions are aim for technology problems existing in the distributed network environments and among the league members. Finally, the paper takes one project, that is, the establishment of the online application service system for Shanghai Advance Manufacturing Technology Research Center as a good instance.

A review of additive manufacturing technology and its application to foundry in China

The application of additive manufacturing technology is one of the main approaches to achieving the rapid casting.Additive manufacturing technology can directly prepare casting molds(cores)with no need of patterns,and quickly cast complex castings.The combination of additive manufacturing and traditional casting technology can break the constraint of traditional casting technology,improve casting flexibility,and ameliorate the working environment.Besides,additive manufacturing promotes the realization of"free casting",greatly simplifying the processing procedures and shortening the manufacturing cycle.This paper summarizes the basic principle of additive manufacturing technology and its development situation domestically and overseas,mainly focusing on the development status of several main additive manufacturing technologies applicable to the foundry field,including three-dimensional printing,selective laser sintering,stereolithography,layered extrusion forming,etc.Finally,the future development trend of additive manufacturing technology in the foundry field is prospected.

Localized electrodeposition micro additive manufacturing of pure copper microstructures

The fabrication of pure copper microstructures with submicron resolution has found a host of applications,such as 5G communications and highly sensitive detection.The tiny and complex features of these structures can enhance device performance during high-frequency operation.However,manufacturing pure copper microstructures remain challenging.In this paper,we present localized electrochemical deposition micro additive manufacturing(LECD-μAM).This method combines localized electrochemical deposition(LECD)and closed-loop control of atomic force servo technology,which can effectively print helical springs and hollow tubes.We further demonstrate an overall model based on pulsed microfluidics from a hollow cantilever LECD process and closed-loop control of an atomic force servo.The printing state of the micro-helical springs can be assessed by simultaneously detecting the Z-axis displacement and the deflection of the atomic force probe cantilever.The results showed that it took 361 s to print a helical spring with a wire length of 320.11μm at a deposition rate of 0.887μm s^(-1),which can be changed on the fly by simply tuning the extrusion pressure and the applied voltage.Moreover,the in situ nanoindenter was used to measure the compressive mechanical properties of the helical spring.The shear modulus of the helical spring material was about 60.8 GPa,much higher than that of bulk copper(~44.2 GPa).Additionally,the microscopic morphology and chemical composition of the spring were characterized.These results delineate a new way of fabricating terahertz transmitter components and micro-helical antennas with LECD-μAM technology.

On Application of Metal Additive Manufacturing

Metal additive manufacturing is an important branch of AM, which provides an effective method for the innovative manufacturing of metal parts. Here, flow chart and main techniques of metal additive manufacturing are firstly described according to the used material types. Many application examples of metal additive manufacturing are then listed based on application value. The summary is finally given to point development direction of metal additive manufacturing in the future. Additive manufacturing, which is an effective supplement to traditional methods, will play an important role in intelligent and digital manufacturing.

New development on additive manufacturing technology and its applications

Additive manufacturing technology has been developed in Xi＇ an Jiaotong University for almost 20 years. Up to now~ it is still attracting the attentions of the researchers or manufacturers all over the world. Some in- novative processes and frontier application research are all being conducted here to catch up with the new develop- ment of this technology. In the paper, newly developed processes, such as ultraviolet-light emitting diode （UV- LED） stereolithography, ceramic stereolithography, and direct metal forming, were described. Some results of the frontier application researches, such as indirect fabrication of ceramic casting mould, wind-tunnel-testing models, photonic crystals and metamatcrials, were also briefly reviewed.

The Impact of 3D Printing Technology to the Nigerian Manufacturing GDP

3D printing can spur manufacturing rebirth in Nigeria and the World in general. There are many areas where 3D printing is creating significant change, particularly in designing and prototyping of new products, in the arts, and in visualizing abstract concepts. This is a step change from conventional manufacturing processes to rapid prototyping and layer manufacturing. This report has defined rapid prototyping, rapid manufacturing and the current technologies available to fabricate 3D components. In addition to this, it provides a brief overview of the current contributions of the Edo University Iyamho (EUI) in collaboration with the Federal University of Petroleum Resources, to sustain manufacturing research initiatives towards the development of locally fabricated 3D printer and the possible future Additive Manufacturing in Nigeria. It is anticipated that this work will benefit the Nigerian academic, research institutes, industries, thus, enhance the GDP contribution of the manufacturing sector in Nigeria.

Integration of a Didactic Manufacturing Cell with Different Robot Configurations

The present work makes the exhibition of a manfacturing cell for didactic pulposes, implemented as part of evaluation in the last cycle of mechatronics engineering formation within Technological University of North Aguascalientes. It includes the motivation that led to plnning and subsequent implementation of manufacturing system described, the characteristics of particular processing operations that it was decided to include, methodology to achieve joint work and synchronization of each operation performed, the results of operation obtained and their comparison with initial expectations, as well as the conclusions derived from process, which lead to considering such a project as an ideal model to verify the formation of the future mechatroonics engineers, when faced with applications of their area of exercise, reviewing operating principle of mechanical, electronic, control and computing systems to achieve their synergy in a mechatronic system.

Direct Digital Manufacturing Industry Ascendant

The paper introduces the origin of the word of Direct Digital Manufacturing and other forms of address, and the working principles of Direct Digital Manufacturing technology and major types of the technology, hard- ware and software development, use of materials, applications, market growth and its development prospects. Focused presentations of Direct Digital Manufacturing （additive manufacturing） compared to traditional mechani- cal manufacturing industry in the use of prices, processing speed, reliability and cost advantages and characteris- tics. Particularly the significant challenges and competitiveness of Direct Digital Manufacturing technology in the processing of any complexity created directly the number of objects, internal structure and channel function, as well as the shape of the chassis components and structure of the matching and optimization.

Rapid Sample Product Trial Manufacture Technique for Developing Water Meter New Products

This paper advances the viewpoints and methods of the rapid sample product trial manufacture technique for developing water meter new products by CAD and simulation, computer virtual assembling and optimizing, rapid machining process and measurement etc. as the design and sample product trial manufacture process of water meter new products are long in product development period, and low in product development efficiency in the present time.

Rapid manufacture of Ni-based superalloy components by three-dimensional printing

The challenge to rapid manufacturing high performance metal components is how to consolidate the uncompressed powder preforms to full or near full density without shape distortion. A new approach developed by ProMetal was proposed, in which a bimodal powder, typically a coarse prealloyed powder blended with a fine metal powder was used to build green preforms by three-dimensional printing and then sintered at a temperature above the solidus temperature of the coarse prealloyed powder and below the melting temperature of the fine powder particles or the solidus temperature if the fine powder is a prealloyed powder as well. This approach was successfully applied to sinter Ni-based superalloy 718 preforms, which were built through three dimensional printing into near full density.

EFFECT OF TIME AND ENVIRONMENT ON THE DIMENSION PRECISION AND MASS OF LOM PROTOTYPES

The effect of time and environment on the dimension precision and mass of LOM prototypes was experimentally investigated.It is to identify the stability of the dimension of LOM prototypes after forming.The results show that the dimension and the mass tendency to grow,which is mainly caused by elastic recovery and moisture absorption and is characterized principally by the growth of Z dimension.Self restraint can be a significant factor to influence Z growth of LOM prototypes.

Rapid Prototyping and Manufacturing Technology:Principle, Representative Technics, Applications, and Development Trends

The rapid prototyping and manufacturing technology (RPM), is an integration of many different disciplines. It is based on an advanced dispersed-accumulated forming principle and originated from 1980s. It generates an entity by first forming a series of layers according to the dispersed section information of the digital model, and then piling the formed layers sequentially together. It is capable of forming parts with complicated structures and non-homogeneous materials. Traditional RPM techniques are mainly used as prototypes in product invention process, such as stereolithography, three-dimensional printing, laminated object manufacturing, and fused deposition modeling. Later, with the progress of material and enabling technology, many new RPM techniques emerged out and have been already applied in the fields such as rapid tooling/moulding, direct formed usable part, nano-/micro-RPM, and biomanufacturing. This high flexible digital manufacturing method has a likely ability to become an almighty forming technology.

Rapid Prototyping and Manufacturing Technology and Its Integration with CIMS

Recent developments of rapid prototyping and manufaturing (RP&M)technology are discussed. To facilitate application of RP&M technology as an enabling technology in product development and manufacturing, our center has done a series of pojects covering RP theory (modern shaping science), new RP processes and equipment,rapid tooling technology and rapid product development systems. With the STEP protocol and product modeling technology, RP&M technology can be integrated into CIMS to form a new subsystem, the free form manufacturing subsystem. The subsystem architecture is investigated in this paper.

Research on Nanofabrication Technology of Micro-/Nano-Stereo Rapid Prototyping of PCVD

At present, the most common micro/nano-scale fabri ca tion processes include the plane silicon process based on IC technology, stereo silicon process, LIGA, quasi-LIGA based on near ultra violet deep lithography, MEMS, energy beam etching and micro/nano-machining, etc. A common problem for t hese processes is the difficulty to fabricate arbitrary form for 3-dimensional micro/nano-parts, devices or mechanisms. To develop advanced MEMS manufacturin g technology, and to achieve fabrication of true 3-dimensional parts, devices or mechanisms, this paper proposes a nanofabrication technology for rapid proto typing of 3-dimensional parts, using plasma chemical vapor deposition (PCVD). This process can be describes as follows: A laser beam is produced by a low power, quasi molecule laser. It enters the vac uum chamber through a window, and is focused on with the substrate surface. A ga s in the chamber is ionized by the laser beam to produce PCVD on the substrate s urface, and forms a particle of the size of Ф100 nm (its thickness is about 100 nm). When the laser beam moves along X-axis, many particles form a line. Then the laser beam moves one step in Y-axis to form a new line. A plane is complete d by many lines. Then the substrate moves in Z-axis to form new plane. Eventu ally, many planes form a 3-dimensional component. Using available CAD/CAM softw are with this process, rapid prototyping of complex components can be achieved. A nanometer precision linear motor, such as that described in Chinese national p atent (patent No. ZL 98 2 16753.9), can be used to obtain the nanometer precisio n movements in the process. The process does not require mask, can be used for v arious rapid prototyping materials, to obtain high fabrication precision (its sc ale precision is 15 nm), and larger ratio of height to width of micro/nano-stru cture. It can find widespread applications in the fabrication of micro-mechani sm, trimming IC, and fabricating minilens, etc.

A comparison of the ballistic behaviour of conventionally sintered and additively manufactured alumina

Production of ceramic armour solutions on-demand/in-theatre would have significant logistical and military advantages.However,even assuming that such technologies could be successfully deployed in the field,such near net-shape manufacturing technology is relatively immature compared to conventional sintering of ceramics.In this study,the ballistic performance of a series of additively manufactured(AM)/rapidly-prototyped(RP)alumina tiles of 97.2%of the density of Sintox FATM were investigated using both forward-and reverse-ballistic experiments.These experiments,undertaken with compressed gasguns,employed the depth-of-penetration technique and flash X-ray as primary diagnostics to interrogate both efficiency of penetration and projectile-target interaction,respectively.The RP alumina was found to exhibit useful ballistic properties,successfully defeating steel-cored(AP)7.62×39 mm BXN rounds at velocities of up-to c.a.850 m/s,while exhibiting comparable failure modes to conventionally sintered armour-grade Sintox FATM.However,where a<1%by vol.Cu dopant was introduced into the RP material failure modes changed dramatically with performance dropping below that of conventionally sintered alumina.Overall,the results from both sets of experiments were complimentary and clearly indicated the potential of such RP materials to play an active role in provision of real-world body armour solutions provided quality control of the RP material can be maintained.

Principle and Feasibility of Electric or Magnetic Field Deflection-Projection Based Rapid Prototyping Technique

Rapid prototype manufacturing(RPM) is a new advanced manufacturing technology, which is based on the philosophy of materials increasing of lay by lay forming. Zero adventure rapid design/manufacturing can be realized with rapid prototypes of 3D CAD of products. Rapid prototyping has been an effective tool of R&D of new products. A novel rapid prototyping and manufacturing (RP&M) technique is brought forward. The principle of the process is to form layered sections and to make the prototype or part layer by layer by deflection projection of electric charged powder granules passing through electric or magnetic field and by controllable line and field scan of the powder granule beam. The feasibility issue of the process is theoretically and experimentally investigated.It shows that deflection projection of electric charged powder granules beam passing through electric field can be significant and feasible to the rapid prototyping technique.

Hybrid Additive Manufacturing of Forming Tools

Additive manufacturing(AM)is widely used in the automotive industry and has been expanded to include aerospace,marine,and rail.High flexibility and the possibility of manufacturing complex parts in AM motivate the integration of additive manu-facturing with classical forming technologies,which can improve tooling concepts and reduce costs.This study presents three applications of this integration.First,the possibility of successful utilization of selective laser melting for manufacturing extrusion tools with complex cooling channels and paths for thermocouples is reported,leading to significantly reduced inner die temperatures during the extrusion process.Second,sheet lamination is integrated with laser metal deposition(LMD)to manufacture deep-drawing dies.Promising results are achieved in reducing the stair step effect,which is the main challenge in sheet lamination,by LMD and following post-processing such as milling,ball burnishing,and laser polishing.The new manufacturing route shows that LMD can economically and efficiently reduce the stair step effect and omit the hardening step from the conventional manufacturing process route.Finally,LMD is used to manufacture a hot stamping punch with improved surface roughness by ball burnishing and near-surface complex cooling channels.The experimental results show that the manufactured punch has lower temperatures during hot stamping compared with the conventionally manufactured punch.This study shows the successful integration of AM processes with classical forming processes.

Rapid Tooling-Rapid Abrading Process Integratedwith Rapid Prototyping

The paper is to outline a new process for manufacturing rapid graphite electrode. It detailsthe steps in Providing integration with Rapid Prototyping (RP) into rapid electrode abrading Process.The key to this combination is the successful model or patted creating using the RP technology.Significantly reduced lead-time, shortened learns curve, lowered revision changes cost and eliminatedor reduced mold polishing are the consequent results. high quality Electrical Discharge Machining(EDM) electrodes are sometimes difficult to be manufactured rapidly and are very time-consumingby conventional methods, even using Computer Numerical Control (CNC) machines. Abradingprovides a simple way to create etuemely detailed and complex electrode to make molds in toolingmaking industries. Integration with the rapid development of the Rapid Prototyping & Manufacturing(RP&M) technology, the rapid electrode abrading process has been regarded as one of the majorbreakthrough in tooling making technology.