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Additive manufacturing, complex geometries - Coggle Diagram

- - - - Easy to print
- - - - Applications
        
        prostheses
        
        biomedical approach
        
        jewellery
        
        prototyping
        
        scale down size
        
        mold positive
        
        piezoelectric materials
      - advantages
        
        complex geometries
        
        Generative Design
        
        Topological Optimization
        
        very fine details
        
        textures
        
        very small dimensions
        
        Tolerances of 0.01mm
        
        complex shapes
        
        customization
      - characteristics
        
        resin
        
        porosity
        
        storage
        
        flow control for cooling
        
        Curing
        
        inbetween layers
        
        post-printing
        
        Degree of Polymerization
        
        Design
        
        link: How to Design for SLA (stereolitography)
        
        Tolerances depend on:
        
        Material
        
        Screen Resolution
        
        Wall thickness
        
        unsupported: 0.6mm min
        
        Supported: 0.4mm min
        
        Overhang angle
        
        19º max
        
        Embossing
        
        0.1mm tall to be visible
        
        Engraving
        
        0.4mm wide and deep to be visible
      - disadvantages
        
        fragile (resin)
        
        depending on the quantity to be produced can be expensive (time)
        
        Radiation sensitive
        
        low fatigue performance
        
        Bubbles in resin ?
        
        plenty of warping (compared to FFF)
  - - - watchmaking in situ
      - nautical repair on yard
    - - geometrical advantage on performance
      - features
        
        internal cavities
        
        difficult fittings
  - - - Ships/Vessels
      - Classic Vehicles
        
        Powertrain conversion
        
        Different motivation, in practice same parts, w/ emphasis on brackets for the powertrain fitting on the chassis
        
        Better fitting on oeiras contest
        
        Increase of reliability
        
        EasyStop
        
        Repairs
        
        Problem/motivation
        
        High impact on asset value
        
        small defects - high impact
        
        low fidelity parts - high impact
        
        no repairment on adequate time
        
        leads to further damage on other components
        
        accelerated decrease of asset value
        
        High repair cost
        
        Out of production spares
        
        little to no supply + substantial demand
        
        long arrival time
        
        specialized labour
        
        Specification of parts tightens with age of the vehicle
        
        Solution: App of AM
        
        Why:
        
        Customization
        
        Difficult geometries can be reverse engineered and easily produced
        
        Optimization
        
        Increase durability
        
        Costs
        
        Low supply and fast deterioration of assets increase pressure from demand
        
        1 more item...
        
        Applicable parts
        
        Engine
        
        C rankshaft
        
        Pistons
        
        Rods
        
        Spindles/axles
        
        Steering
        
        Racks
        
        Brackets
        
        Ornamental parts / non structural function parts
        
        handles
        
        ornaments
        
        Interior parts
        
        References
        
        Extending the Life of Classic Cars, the Additive Manufacturing Way
        
        How a classic car
        enthusiast solved the
        spare parts dilemma
        
        HV3D ~Works
        
        Porsche Classic supplies classic parts from a 3D printer
        
        THE IMPACT OF ADDITIVE
        MANUFACTURING TECHNOLOGIES
        ON INDUSTRIAL SPARE PARTS
        STRATEGIES
        
        websites Thingiverse and Kazzata are to be named representatively. In fact,
        Thingiverse offers a series of spare parts for classic cars – for example ‘cold air intakes’ for a Porsche 948.12
        
        CADs
        
        Cam Trigger housing for 924 / 931 Porsche
        
        Ferrari F-40 Tribute Generative design Organic Chassis / frame
- - - - the clamping system
      - the surface "table"
    - - the system must be versatile to every height
        
        height 6mm
        
        height 3mm
        
        height 10mm
  - - - minimum thickness, width, length and height of the parts
      - Optimized and maximized Infill
      - Reduce Walls, Area and Volume
        
        Only normal loads applied - unidirectional resistance
      - Balanced weight ? (cog?)
    - - Max 2 parts
        
        Top
        
        no lateral walls
        
        Bottom + Ruler (to reduce momentum)
    - - Constrain it
        
        Beam cavity of marginal length (25mmx25mm) + 0.1mm on contact parts
      - Hold its marginal length
      - Adapt to different specimens
        
        Minimal constraints between different parts
    - - Maintain clamp position
        
        Clamp cavity on contact part of diam = 22.70mm + tolerance of 0.5mm
      - Withstand clamping pressure (to constrain beam)
      - Maximize contact area w/ beam
        
        Top part w/ cavity of 25x25mm + 0.1mm
    - - Measure tip displacement (2 axis)
        
        Embedded Markings - extrusion w/ 0.2mm precision (thin wall enabled)
      - Resistant to handling
        
        Resistant in the connection with the holder - reinforcement
        
        Flexural strength
        
        decrease width and lower infill density - side walls?