Innovative Product Development by Additive Manufacturing 2021

Description

Specifications, potentials and solutions.- Design and optimization.- Simulation, validation and quality assurance.- Process Chain and business models. Preamble—Innovative Product Development by Additive Manufacturing 2021 Contents About the Editors 1 Effect-Engineering by Additive Manufacturing 1 Introduction 2 Potentials of Effect-Engineering 2.1 Application: Design of Particle-Damped Structural Components 2.2 Application: Thermomechanical Systems 2.3 Additive Manufacturing Technologies 3 Conclusion References Design and Optimization 2 Wire-and-Arc-Additive-Manufacturing of a Component with a Pre-defined Hardness Profile 1 Introduction 2 Materials and Methods 3 Process Parameter Estimation 4 Results and Discussion 5 Summary and Outlook References 3 Toward a Design Compendium for Metal Binder Jetting 1 Introduction 2 Metal Binder Jetting 3 Design Compendium 3.1 Existing Design Guidelines 3.2 Approach to Compendium Development 4 Conclusion and Outlook References 4 Development of a Coaxial Laser Wire System for the Additive Manufacturing of Functional Graded Materials using Direct Energy Deposition 1 Introduction 2 State of the Art 2.1 Coaxial Laser Wire Direct Energy Deposition 2.2 Functional Graded Materials by Direct Energy Deposition 2.3 Analysis of the Coaxial Processing Head LZH Coax-Head MKII 2.4 Analysis of a Multiple Diode Processing Head Prototype 3 Development of a Coaxial Multiple Diode Double Wire Laser Processing Head 3.1 Derivation of Requirements 3.2 Prototypical Realisation of the Multiple Diode Coaxial Laser (DiCoLas) Processing Head 4 Conclusion References 5 Joining Technology of Additively Manufactured Components: Design Measures for Optimizing the Strength of Adhesively Bonded Joints 1 Introduction 2 State of the Art 2.1 Industrial Practice: Bonded Frame Structures 2.2 Structural Bonding of AM Components 3 Methodical Approach 4 Optimization of the Adhesive Application 4.1 Classification 4.2 External Feed 5 Tests: Static Strength and Fatigue Behavior 5.1 Material Properties 5.2 Tensile Test 5.3 Fatigue Test 6 FEA-Based Strength Optimization of the Joint 6.1 Model Parameters 6.2 Optimization Results 7 Conclusion 8 Outlook References 6 Restructuring of Product Architecture Towards Additive Manufacturing Through Functional Analysis for High Temperature Applications 1 Introduction 2 State of the Art 2.1 Technical Assessment and AM Value-Added 2.2 Product Architecture and Functional Integration 3 PA-Assisted Method 3.1 Heuristic Transformation Approach 4 Application and Results 4.1 Conventional Product Architecture—2-Stage Main Nozzle 4.2 Heuristic Transformation Approach and AM-Supporting Product Architecture 5 Conclusion and Outlook References 7 Additive Manufacturing of Soft Robots 1 Introduction 2 Silicone 3D Printing 2.1 Technology Description 2.2 Processible Materials 3 Development of Design Guidelines 4 Case Study 4.1 Selection of Design Guidelines 4.2 Application of Design Guidelines 5 Conclusions and Outlook References 8 Design Automation of a Patient-Specific Endoprosthesis with Multi- Objective Optimized Lattice Structures 1 Introduction 2 Related Work 2.1 Computational Design Syntheses of Individualized Products 2.2 Evolutionary Multi-objective Optimization 3 CDS of Patient-Specific Short Shaft Endoprosthesis for Maximum Bone Ingrowth 3.1 Medical Reverse Engineering and Computational Design Syntheses of a Parametric Short Shaft 3.2 Effect-Engineering: Generation of a Lattice Structure for Maximum Bone Ingrowth 4 Summary and Outlook References 9 Design of a Thermo-Hydraulically Optimised Heat Exchanger for Production by Laser Powder Bed Fusion 1 Introduction 2 Conventionally and Additively Manufactured Heat Exchanger 2.1 Conventional Heat Exchangers and Difficulties 2.2 Potentials of Additive Manufactured Heat Exchangers 3 Case Example: Design of a Gas Cooler for LPBF-Printing 3.1 Design Consideration for the Designed Heat Exchanger 3.2 Conceptual Design of the Heat Exchanger 3.3 Construction and Simulation of the Lattice Structure 3.4 Additive Manufacturing 4 Conclusion References 10 Systematic Investigations Concerning Eddy Currents in Additively Manufactured Structures 1 Introduction 2 State of the Art 2.1 Eddy Currents 3 Derivation of Suitable Geometric Structures for Eddy Current Reduction 3.1 Purpose of the Investigation 3.2 Methodical Implementation 3.3 Experimental Investigation 4 Conclusion and Outlook References 11 Electroplating as an Innovative Joining Method for Laser Additive Manufactured Components Made of AlSi10Mg 1 Introduction 2 State of the Art 2.1 Design for Additive Manufacturing 2.2 Joining of Additive Manufactured Parts 2.3 Research Gap 3 Experimental Setup 3.1 Joining by Electroplating 3.2 Sample Design and Results of Joining 3.3 Tensile Test and Discussion of Results 4 Conclusion and Outlook References Simulation, Validation and Quality Assurance 12 Additive Manufacturing of a Laser Heat Sink: Multiphysical Simulation for Thermal Material Requirement Derivation 1 Introduction 2 Laser System with Additively Manufactured Optomechanics 2.1 Overall System 2.2 Crystal Heat Sink 2.3 Laser Medium 3 Additive Process Chain Feedback Loop 4 Theoretical Simulation Approach 4.1 Optic Simulation 4.2 Thermal Simulation 4.3 Solid Mechanic Simulation 4.4 Model Validation 5 Simulation Results 5.1 Temperature Study 5.2 Mechanical Stress Study 6 Discussion 6.1 Interpretation of Simulation Results 6.2 Potential for Simulation Model Improvement 6.3 Simulation Model Improvements to the State of the Art 7 Conclusion and Outlook 7.1 Conclusion 7.2 Outlook References 13 Investigation of Powder Bed Topography by Fringe Projection for Determining the Recoating Process and Powder Bed Quality 1 Introduction 2 Powder Bed Quality Assessment by 3D Topography Measurement 3 Methodology 4 Experimental and Empirical Validation 5 Discussion of Results and Conclusion 6 Future Work References 14 Normalization Matrix for Sustainability Assessments Considering the Laser Powder Bed Fusion Process 1 Introduction 2 Research Background 2.1 Life Cycle Assessment 2.2 Life Cycle Inventory Assessment 2.3 Normalization Methods 3 Method 3.1 External Normalization 3.2 Internal Normalization 4 Case Study: Laser Powder Bed Fusion, Investment Casting and Milling 4.1 External Normalization Step 4.2 Internal Normalization Step 4.3 Results 5 Conclusion and Outlook References Specifications, Potentials and Solution Finding 15 Additive Manufacturing of 3D Multilayer Devices 1 Introduction 2 Multilayer Printing (MLP) Approach 2.1 Process Chain 2.2 Printing of Coatings 2.3 Laser Sintering 2.4 Laser Ablation 2.5 Laser Cleaning 3 Practical Demonstration 3.1 Printed Double Layer 3.2 3D Multilayer Device (MLD) Component 3.3 Vertical Interconnect Accesses (VIA) 4 Product Design 5 Conclusion References 16 Automated Identification of Geometric Structures with Potential for Functional Integration 1 Introduction and Motivation 2 State of the Art 2.1 Approaches of Part Identification for Additive Manufacturing 2.2 Identification of Use-Cases for Functional Integration 3 Need for Research 4 Methodical Approach and Materials 4.1 Advanced Filter Structure for Preselection of Suitable Assemblies 4.2 Part Classification According to Degrees of Freedom 4.3 Separation of Elements in Product Structure 4.4 Modularity of Product Structure to Find Static Groups 5 Results 5.1 Validation and Discussion 6 Summary and Outlook References 17 Microfluidic Flow Rate Control Device: From Concept to Product Through Additive Manufacturing 1 Introduction 2 Conceptual Design and Manufacturing 2.1 Fluidic System 2.2 Electronics and Control System 3 Integration, Testing, and Optimization 3.1 Initial Setup 3.2 First Prototype 3.3 Prototype Optimization 4 Final Product 5 Conclusions References 18 Experimental Investigation of Additive Manufacturing of Fused Silica Fibers for the Production of Structural Components in the Laser Glass Deposition Process 1 Introduction 2 Methods 3 Results 4 Conclusion References 19 Multi-Functional Parts—Increase Functionality of Semi-Finished Parts by Additive Manufacturing 1 Introduction 1.1 Relevance of Multi-functional Parts—Material Extrusion on Semi-Finished Parts 1.2 Hybrid Design Approach 2 Problem and Objectives 3 State of Knowledge 3.1 Hybrid Structures by 3D-Printing 3.2 Principles of Joining with 3D-Printing 4 Material and Methods 4.1 Test Object for Contact Zone Experiment 4.2 Substrate-Surface-Structure Test Object 4.3 Preparation of PMMA Substrates 4.4 Measurement of Bonding Strength 4.5 Assessment of Initial-Layer Structure After Failure 4.6 Measurement of Lap-Shear Strength 5 Results and Discussion 5.1 Influence of Contact Zone Structure onto Bonding Strength 5.2 Influence of Substrate Surface Structure onto Bonding Strength 6 Conclusion References 20 Customer Benefit Oriented Approach on the Application of Additive Manufacturing Potentials Based on Product Property Trade-Off’s 1 Introduction 2 Design for Additive Manufacturing: Current View 3 Customer Benefit Oriented Application of AM Potentials 4 Validation Workshops 5 Conclusion and Outlook References