|
Preface |
5 |
|
|
Organization |
7 |
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|
Organizing Committee |
7 |
|
|
Members of the Industrial Committee |
7 |
|
|
Members of the Scientific Committee |
7 |
|
|
Contents |
9 |
|
|
Design Tools and Methods |
13 |
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|
Evolution of Design Guidelines for Additive Manufacturing - Highlighting Achievements and Open Issues by Revisiting an Early SLM Aircraft Bracket |
14 |
|
|
1 Introduction |
14 |
|
|
2 Review of Existing Design Guidelines |
16 |
|
|
3 Design Task and Requirements |
17 |
|
|
4 Initial SLM-Design of the Year 2008 |
18 |
|
|
5 Re-designed Bracket of the Year 2017 |
20 |
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|
6 Conclusion |
22 |
|
|
References |
22 |
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|
A Design Method for SLM-Parts Using Internal Structures in an Extended Design Space |
25 |
|
|
Abstract |
25 |
|
|
1 Introduction |
25 |
|
|
2 Design Method |
26 |
|
|
2.1 Design Guidelines for Internal Structures |
26 |
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|
2.2 Simulation Environment |
27 |
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|
3 Adaption of a Demonstrator |
28 |
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|
3.1 Clarification of Requirements |
28 |
|
|
3.2 Definition of Design Space |
28 |
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|
3.3 Potential Analysis and Application |
29 |
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|
3.4 Dimensioning for Stress Reduction |
30 |
|
|
3.5 Manufacturing Oriented Detailing |
31 |
|
|
4 Conclusion |
31 |
|
|
References |
33 |
|
|
Exploring the Impact of Shape Complexity on Build Time for Material Extrusion and Material Jetting |
35 |
|
|
Abstract |
35 |
|
|
1 Introduction |
35 |
|
|
2 Method |
37 |
|
|
2.1 Experiment |
39 |
|
|
3 Results |
40 |
|
|
3.1 Shape and Build Time in Material Extrusion |
40 |
|
|
3.2 Shape and Build Time in Material Jetting |
41 |
|
|
4 Discussion and Conclusion |
42 |
|
|
References |
43 |
|
|
Novel Optimised Structural Aluminium Cross-Sections Towards 3D Printing |
45 |
|
|
Abstract |
45 |
|
|
1 Introduction |
45 |
|
|
2 Manufacturing Processes |
47 |
|
|
3 Topology Optimisation Approach |
49 |
|
|
4 Topology Optimisation of Cross-Sections |
50 |
|
|
5 Finite Element Analysis |
52 |
|
|
6 Concluding Remarks |
56 |
|
|
References |
57 |
|
|
Manufacturing Process Chain |
58 |
|
|
Finite Element Modeling of Ceramic Deposition by LBM(SLM) Additive Manufacturing |
59 |
|
|
1 Introduction |
59 |
|
|
2 Modeling |
60 |
|
|
2.1 Level Set Method |
60 |
|
|
2.2 Governing Equations |
61 |
|
|
2.3 Simulation Configuration |
63 |
|
|
3 Results and Discussion |
63 |
|
|
4 Conclusions |
66 |
|
|
References |
67 |
|
|
Analysis of the Influence of Shielding and Carrier Gases on the DED Powder Deposition Efficiency for a New Deposition Nozzle Design Solution |
69 |
|
|
Abstract |
69 |
|
|
1 Introduction |
69 |
|
|
2 Material and Equipment |
71 |
|
|
3 Experimental Procedure |
73 |
|
|
3.1 Image Analysis Method |
73 |
|
|
4 CFD Modeling |
75 |
|
|
5 Results and Short Discussion |
75 |
|
|
6 Conclusions |
77 |
|
|
Acknowledgements |
78 |
|
|
References |
78 |
|
|
On-Demand Spare Parts for the Marine Industry with Directed Energy Deposition: Propeller Use Case |
80 |
|
|
Abstract |
80 |
|
|
1 Introduction |
80 |
|
|
2 Setup, Materials and Experiments |
81 |
|
|
3 Process Chain: Design Exploration and Manufacture |
84 |
|
|
4 Post-processing |
89 |
|
|
5 Discussion and Conclusion |
89 |
|
|
Acknowledgment |
90 |
|
|
References |
90 |
|
|
Macroscopic Finite Element Thermal Modelling of Selective Laser Melting for IN718 Real Part Geometries |
92 |
|
|
1 Introduction |
92 |
|
|
2 Modelling Strategy |
93 |
|
|
2.1 G-code Interpreter Module |
94 |
|
|
2.2 Scheme for Energy Input |
94 |
|
|
2.3 Refining and Unrefining the Mesh |
95 |
|
|
3 Application |
96 |
|
|
3.1 Geometrical Parameters |
96 |
|
|
3.2 Thermal Modelling |
97 |
|
|
3.3 Mesh Adaptation |
97 |
|
|
3.4 Model Validation |
98 |
|
|
3.5 Simulation Results |
99 |
|
|
4 Conclusions |
100 |
|
|
5 Outlook |
101 |
|
|
References |
101 |
|
|
Additive Manufacturing of Piezoelectric 3-3 Composite Structures |
103 |
|
|
Abstract |
103 |
|
|
1 Introduction |
103 |
|
|
2 Experimental |
105 |
|
|
2.1 Preparation of Feedstock |
105 |
|
|
2.2 3D Printing of Feedstock |
106 |
|
|
2.3 Debinding and Sintering of 3D Printed Ceramic Structures |
107 |
|
|
2.4 Piezoelectric Composite Fabrication |
107 |
|
|
2.5 Characterization of 3D Printed Ceramic Structures |
108 |
|
|
3 Results and Discussion |
108 |
|
|
3.1 3D-Printing |
109 |
|
|
3.2 Piezoelectric Composites |
110 |
|
|
4 Conclusions |
112 |
|
|
Acknowledgements |
112 |
|
|
References |
112 |
|
|
Additive Manufacturing of Semiconductor Silicon on Silicon Using Direct Laser Melting |
114 |
|
|
Abstract |
114 |
|
|
1 Introduction |
114 |
|
|
2 Experimental |
115 |
|
|
2.1 Direct Laser Melting (DLM) Setup |
115 |
|
|
2.2 Process |
118 |
|
|
2.3 Materials |
119 |
|
|
2.4 Powder Characterization |
119 |
|
|
2.5 Temperature Measurements |
119 |
|
|
2.6 Pillar Characterization |
119 |
|
|
3 Results |
120 |
|
|
3.1 Powder Characterization |
120 |
|
|
3.2 Deposition Experiments |
121 |
|
|
4 Discussion |
124 |
|
|
5 Conclusions |
125 |
|
|
Acknowledgments |
126 |
|
|
References |
126 |
|
|
Additive Manufacturing of Complex Ceramic Architectures |
127 |
|
|
Abstract |
127 |
|
|
1 Introduction |
127 |
|
|
2 Experimental Procedure |
128 |
|
|
3 Applications |
129 |
|
|
4 Automotive Catalytic Supports |
129 |
|
|
5 Heat Exchangers |
130 |
|
|
6 Conclusions |
132 |
|
|
References |
132 |
|
|
Process Chain Integration |
134 |
|
|
An Advanced STEP-NC Platform for Additive Manufacturing |
135 |
|
|
Abstract |
135 |
|
|
1 Introduction |
135 |
|
|
2 Current Situation of Additive Manufacturing Digital Chain and Recent Alternatives |
136 |
|
|
3 New Vision of the Digital Chain with STEP-NC Standard |
137 |
|
|
4 Additive Manufacturing STEP-NC Model Proposition |
138 |
|
|
5 Advanced STEP-NC Platform for Additive Manufacturing Architecture |
139 |
|
|
6 Toward the Integration of Additive Manufacturing in a Multi-process STEP-NC Platform |
141 |
|
|
7 Conclusion |
142 |
|
|
References |
142 |
|
|
Additive Manufacturing on 3D Surfaces |
145 |
|
|
Abstract |
145 |
|
|
1 Introduction |
145 |
|
|
2 The Example of Smart Prosthesis |
146 |
|
|
2.1 Sensors and Communication Solutions |
147 |
|
|
2.2 Development of Key Fabrication Steps |
148 |
|
|
2.3 Fabrication and Testing of Sensors |
149 |
|
|
3 Discussion and Future Developments |
151 |
|
|
References |
152 |
|
|
Integrated Platform for Multi-resolution Additive Manufacturing |
153 |
|
|
1 Introduction |
153 |
|
|
2 Materials and Methods |
154 |
|
|
2.1 Laser Direct-Writing Through Multimode Optical Fibers |
154 |
|
|
2.2 Compact Drop-on-Demand System |
155 |
|
|
3 Results and Discussion |
156 |
|
|
3.1 Laser Direct-Writing Through Multimode Optical Fibers |
156 |
|
|
3.2 Compact Drop-on-Demand System |
156 |
|
|
3.3 Possible Industrial Applications of the System |
158 |
|
|
4 Conclusion |
158 |
|
|
References |
159 |
|
|
Enhanced Toolpath Generation for Direct Metal Deposition by Using Distinctive CAD Data |
160 |
|
|
1 Introduction |
160 |
|
|
2 Concept of Distinctive CAD Data |
161 |
|
|
3 Toolpath Strategies |
162 |
|
|
4 Implementation of the CAM Algorithm |
164 |
|
|
5 Experimental Validation |
166 |
|
|
6 Conclusion |
168 |
|
|
References |
169 |
|
|
Performance Simulation and Verification of Vat Photopolymerization Based, Additively Manufactured Injection Molding Inserts with Micro-Features |
170 |
|
|
1 Introduction |
170 |
|
|
2 Materials and Methods |
171 |
|
|
2.1 Design of Test Part |
171 |
|
|
2.2 Tooling |
171 |
|
|
2.3 Simulation |
171 |
|
|
2.4 Injection Molding and Thermal Imaging |
171 |
|
|
2.5 Metrological Assessment |
172 |
|
|
3 Results |
172 |
|
|
3.1 Comparison of Thermal Simulations and Temperature Measurements |
172 |
|
|
3.2 Temperature Development |
173 |
|
|
3.3 Insert Life Time |
173 |
|
|
3.4 Inserts Before and After Injection Molding |
175 |
|
|
4 Conclusions |
175 |
|
|
References |
176 |
|
|
Additive Repair Design Approach: Case Study of Transverse Loading of Aluminum Beams |
177 |
|
|
Abstract |
177 |
|
|
1 Introduction |
177 |
|
|
2 Developed Method for Conceptual Design of Additive Repair |
178 |
|
|
3 Beam Under Transverse Load |
179 |
|
|
4 Case Study: Simply Supported Beam Under Static Transverse Load |
180 |
|
|
4.1 Numerical Analysis |
180 |
|
|
4.2 Experimental Analysis |
181 |
|
|
5 Results and Discussion |
182 |
|
|
6 Conclusions |
184 |
|
|
References |
185 |
|
|
Quality Assurance |
186 |
|
|
Controlled Porosity Structures in Aluminum and Titanium Alloys by Selective Laser Melting |
187 |
|
|
Abstract |
187 |
|
|
1 Introduction |
187 |
|
|
2 SLM Process |
189 |
|
|
2.1 SLM Scanning Strategy |
189 |
|
|
3 Materials and Methods |
190 |
|
|
3.1 Experimental Equipment and Material |
190 |
|
|
3.2 Building of Porous Structures by SLM |
190 |
|
|
4 Results and Discussion |
191 |
|
|
4.1 Non-stochastic Porous Structures |
191 |
|
|
4.2 Foams |
193 |
|
|
5 Conclusion |
194 |
|
|
References |
194 |
|
|
Development and Optimization of an Innovative Double Chamber Nozzle for Highly Efficient DMD |
197 |
|
|
Abstract |
197 |
|
|
1 Introduction |
197 |
|
|
2 Experimental Campaign |
198 |
|
|
2.1 Evaluated Geometries and Experimental Apparatus |
198 |
|
|
2.2 Experimental Procedure |
199 |
|
|
3 Simulations and Numerical Analysis |
201 |
|
|
4 Results and Discussion |
202 |
|
|
4.1 Image Elaboration Methodology |
202 |
|
|
4.2 Experimental Results |
203 |
|
|
5 Conclusions |
204 |
|
|
Acknowledgements |
204 |
|
|
References |
204 |
|
|
In Situ and Real-Time Monitoring of Powder-Bed AM by Combining Acoustic Emission and Artificial Intelligence |
206 |
|
|
Abstract |
206 |
|
|
1 Introduction |
206 |
|
|
2 Experimental Setup, Material and Acoustic Datasets |
208 |
|
|
3 Data Processing |
209 |
|
|
3.1 Wavelet Spectrograms |
209 |
|
|
3.2 Introduction to Wavelet Spectrograms |
210 |
|
|
4 Results and Discussion |
211 |
|
|
4.1 Dynamical Range |
211 |
|
|
4.2 Classification Results |
211 |
|
|
5 Conclusions |
212 |
|
|
References |
213 |
|
|
Quality Related Effects of the Preheating Temperature on Laser Melted High Carbon Content Steels |
216 |
|
|
Abstract |
216 |
|
|
1 Introduction |
216 |
|
|
2 Methods and Experiments |
217 |
|
|
2.1 Powder |
217 |
|
|
2.2 Laser Melting |
218 |
|
|
2.3 Porosity |
218 |
|
|
2.4 Temperature Gradient Induced Residual Stresses |
219 |
|
|
3 Results and Discussion |
220 |
|
|
3.1 Process Parameters |
220 |
|
|
3.2 Effect of Baseplate Temperature on Residual Stresses |
222 |
|
|
4 Conclusions |
224 |
|
|
Acknowledgements |
224 |
|
|
References |
225 |
|
|
Business Cases |
226 |
|
|
Additive Manufacturing in Automotive Spare Parts Supply Chains – A Conceptual Scenario Analysis of Possible Effects |
227 |
|
|
Abstract |
227 |
|
|
1 Introduction |
227 |
|
|
2 Literature Review |
228 |
|
|
2.1 Automotive Aftermarket |
228 |
|
|
2.2 Additive Manufacturing |
229 |
|
|
2.3 Current State of Research on AM in the Automotive Spare Parts Industry |
230 |
|
|
3 Results |
230 |
|
|
3.1 Centralized AM Implementation |
230 |
|
|
3.2 Hybrid AM Implementation |
232 |
|
|
3.3 Decentralized AM Implementation |
234 |
|
|
3.4 Outsourcing of AM |
236 |
|
|
4 Discussion and Conclusion |
238 |
|
|
References |
239 |
|
|
Selection of High-Variety Components for Selective Laser Sintering: An Industrial Case Study |
242 |
|
|
1 Introduction |
242 |
|
|
2 Methods |
243 |
|
|
2.1 Operating Costs for Conventional Production |
246 |
|
|
2.2 Operating Costs for SLS Production |
247 |
|
|
2.3 Observed Optimisation Scenarios |
249 |
|
|
2.4 Definition of Aggregated Lot-Size |
250 |
|
|
3 Results and Discussion |
250 |
|
|
4 Conclusions |
253 |
|
|
References |
254 |
|
|
Process Setup for Manufacturing of a Pump Impeller by Selective Laser Melting |
256 |
|
|
Abstract |
256 |
|
|
1 Introduction |
256 |
|
|
2 Impeller Geometry |
258 |
|
|
3 Optimization of Build Direction |
258 |
|
|
4 Support Design Iteration 1 |
260 |
|
|
5 Support Design Iteration 2 |
262 |
|
|
6 Prototype Design and Manufacturing |
265 |
|
|
7 Conclusion and Outlook |
266 |
|
|
Acknowledgment |
266 |
|
|
References |
267 |
|
|
Hybrid Integration |
268 |
|
|
Abstract |
268 |
|
|
1 Introduction |
268 |
|
|
2 Sun Sensor Fabrication, Characterization and Validation |
269 |
|
|
2.1 Quad Cell Approach |
269 |
|
|
2.2 Printed Components Fabrication and Characterization |
270 |
|
|
2.3 Sun Sensor Layout and Fabrication |
272 |
|
|
2.4 Sun Sensor Validation |
274 |
|
|
3 Conclusions |
275 |
|
|
Acknowledgments |
276 |
|
|
References |
276 |
|
|
Temperature Monitoring of an SLM Part with Embedded Sensor |
277 |
|
|
Abstract |
277 |
|
|
1 Motivation |
277 |
|
|
2 State of the Art |
278 |
|
|
2.1 Focus of the Present Study |
279 |
|
|
3 Materials and Methods |
279 |
|
|
3.1 SLM Setup and Material |
279 |
|
|
3.2 Temperature Sensors |
280 |
|
|
3.3 Embedding Concepts |
280 |
|
|
3.3.1 Cavity Design |
280 |
|
|
3.3.2 Positioning and Fixation of Temperature Sensors |
281 |
|
|
3.3.3 Continuation of SLM Process |
282 |
|
|
4 Results and Discussion |
282 |
|
|
4.1 Sensing Capability |
282 |
|
|
4.1.1 Sensor Survival Conditions |
282 |
|
|
4.1.2 Response Time |
282 |
|
|
5 Conclusions and Outlook |
286 |
|
|
Acknowledgements |
287 |
|
|
References |
287 |
|
|
Unique Customer Benefits |
289 |
|
|
Integration of Fiber-Reinforced Polymers in a Life Cycle Assessment of Injection Molding Process Chains with Additive Manufacturing |
290 |
|
|
1 Introduction |
290 |
|
|
2 Methods |
291 |
|
|
3 Results |
293 |
|
|
4 Conclusion |
297 |
|
|
References |
297 |
|
|
Advantages in Additive Manufacturing for a Medium Format Metrology Camera |
299 |
|
|
Abstract |
299 |
|
|
1 Introduction |
299 |
|
|
2 Requirements for Metric Cameras and Development of the ALPA 12 Metric |
301 |
|
|
3 The ALPA 12 FPS Add|Metric: Technical Basis and Metrical Enhancement |
303 |
|
|
4 Design Process |
304 |
|
|
5 Cost Aspect |
307 |
|
|
6 Evaluation of the ALPA 12 FPS Add|Metric |
307 |
|
|
7 Summary |
309 |
|
|
References |
309 |
|
|
Patient Specific Implants from a 3D Printer – An Innovative Manufacturing Process for Custom PEEK Implants in Cranio-Maxillofacial Surgery |
311 |
|
|
Abstract |
311 |
|
|
1 Introduction |
312 |
|
|
2 Materials and Printing Process |
313 |
|
|
2.1 3D Printer |
313 |
|
|
2.2 PEEK Filament |
313 |
|
|
2.3 Printing Process |
313 |
|
|
3 Preliminary Results |
314 |
|
|
4 Discussion |
316 |
|
|
5 Conclusion |
317 |
|
|
References |
317 |
|
|
Teaching and Training |
319 |
|
|
Work-Process Orientated and Competence Based Professional Training for Skilled Workers in Laser Additive Manufacturing |
320 |
|
|
Abstract |
320 |
|
|
1 Introduction |
320 |
|
|
2 State of the Art in Professional Training for Additive Manufacturing |
321 |
|
|
3 Identification of Competencies for Additive Manufacturing |
322 |
|
|
4 Development of Work Process Orientated Professional Training |
324 |
|
|
5 Summary and Outlook |
327 |
|
|
Acknowledgments |
328 |
|
|
References |
328 |
|
|
Why Education and Training in the Field of Additive Manufacturing is a Necessity |
330 |
|
|
Abstract |
330 |
|
|
1 Introduction |
330 |
|
|
2 Bachelor Degree |
332 |
|
|
2.1 Educational Model - Semester Accompanying Project Work |
333 |
|
|
3 Training in Continuing Education for Professionals |
335 |
|
|
4 Summary and Outlook |
336 |
|
|
References |
336 |
|
|
The Experience Transfer Model for New Technologies - Application on Design for Additive Manufacturing |
338 |
|
|
Abstract |
338 |
|
|
1 Introduction |
338 |
|
|
2 Need for Experience Transfer in Design for AM |
339 |
|
|
3 Theory and Concept of the General Experience Transfer Model for New Technology |
340 |
|
|
4 Experience Transfer Model for the Application of Design of Additive Manufacturing |
341 |
|
|
5 Validation of the ETM with a Swiss SME |
344 |
|
|
6 Conclusion |
346 |
|
|
Acknowledgments |
346 |
|
|
References |
346 |
|
|
Decision-Making in Additive Manufacturing – Survey on AM Experience and Expertise of Designers |
348 |
|
|
Abstract |
348 |
|
|
1 Introduction |
348 |
|
|
2 Methods |
349 |
|
|
3 Results |
350 |
|
|
3.1 Participants of the Survey |
350 |
|
|
3.2 Basic AM Knowledge of Designers |
351 |
|
|
3.3 Detailed Knowledge of AM Technologies and Design Rules |
352 |
|
|
3.4 AM Experience of Designers |
353 |
|
|
3.5 Attitude of Designers Towards AM Technologies for Final Parts |
355 |
|
|
4 Discussion |
357 |
|
|
4.1 AM Knowing of Designers |
357 |
|
|
4.2 AM Experience of Designers |
358 |
|
|
4.3 Attitude of Designers Towards AM Technologies for Final Parts |
358 |
|
|
5 Conclusion and Outlook |
359 |
|
|
References |
360 |
|
|
Author Index |
362 |
|