New possibilities using additive manufacturing with materials that are difficult to process and with complex structures

NASA Astrophysics Data System (ADS)

Olsson, Anders; Hellsing, Maja S.; Rennie, Adrian R.

2017-05-01

Additive manufacturing (or 3D printing) opens the possibility of creating new designs and manufacturing objects with new materials rapidly and economically. Particularly for use with polymers and polymer composites, simple printers can make high quality products, and these can be produced easily in offices, schools and in workshops and laboratories. This technology has opened a route for many to test ideas or to make custom devices. It is possible to easily manufacture complex geometries that would be difficult or even impossible to create with traditional methods. Naturally this technology has attracted attention in many fields that include the production of medical devices and prostheses, mechanical engineering as well as basic sciences. Materials that are highly problematic to machine can be used. We illustrate process developments with an account of the production of printer parts to cope with polymer fillers that are hard and abrasive; new nozzles with ruby inserts designed for such materials are durable and can be used to print boron carbide composites. As with other materials, complex parts can be printed using boron carbide composites with fine structures, such as screw threads and labels to identify materials. General ideas about design for this new era of manufacturing customised parts are presented.

Initiatives to Improve Quality of Additively Manufactured Parts

NASA Technical Reports Server (NTRS)

Waller, Jess; Nichols, Charles

2017-01-01

NASA is providing leadership in an international effort linking government and industry resources to speed adoption of additive manufactured (AM) parts. Participants include government agencies (NASA, USAF, NIST, FAA), industry (commercial aerospace, NDE manufacturers, AM equipment manufacturers), standards organizations and academia. NASA is also partnering with its international space exploration organizations such as ESA and JAXA. NDT is identified as a universal need for all aspects of additive manufacturing.

Rapid manufacturing of metallic Molds for parts in Automobile

NASA Astrophysics Data System (ADS)

Zhang, Renji; Xu, Da; Liu, Yuan; Yan, Xudong; Yan, Yongnian

1998-03-01

The recent research of RPM (Rapid Prototyping Manufacturing) in our lab has been focused on the rapid creation of alloyed cast iron (ACI) molds. There are a lot of machinery parts in an automobile, so a lot of mettallic molds are needed in automobile industry. A new mold manufacturing technology has been proposed. A new large scale RP machine has been set up in our lab now. Then rapid prototypes could be manufactured by means of laminated object manufacturing (LOM) technology. The molds for parts in automobile have been produced by ceramic shell precision casting. An example is a drawing mold for cover parts in automobile. Sufficient precision and surface roughness have been obtained. Itis proved that this is a vew kind of technology. Work supported by the Mational Science Foundation of China.

Anomaly Detection In Additively Manufactured Parts Using Laser Doppler Vibrometery

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hernandez, Carlos A.

Additively manufactured parts are susceptible to non-uniform structure caused by the unique manufacturing process. This can lead to structural weakness or catastrophic failure. Using laser Doppler vibrometry and frequency response analysis, non-contact detection of anomalies in additively manufactured parts may be possible. Preliminary tests show promise for small scale detection, but more future work is necessary.

Visual Inspection Reliability for Precision Manufactured Parts.

PubMed

See, Judi E

2015-12-01

Sandia National Laboratories conducted an experiment for the National Nuclear Security Administration to determine the reliability of visual inspection of precision manufactured parts used in nuclear weapons. Visual inspection has been extensively researched since the early 20th century; however, the reliability of visual inspection for nuclear weapons parts has not been addressed. In addition, the efficacy of using inspector confidence ratings to guide multiple inspections in an effort to improve overall performance accuracy is unknown. Further, the workload associated with inspection has not been documented, and newer measures of stress have not been applied. Eighty-two inspectors in the U.S. Nuclear Security Enterprise inspected 140 parts for eight different defects. Inspectors correctly rejected 85% of defective items and incorrectly rejected 35% of acceptable parts. Use of a phased inspection approach based on inspector confidence ratings was not an effective or efficient technique to improve the overall accuracy of the process. Results did verify that inspection is a workload-intensive task, dominated by mental demand and effort. Hits for Nuclear Security Enterprise inspection were not vastly superior to the industry average of 80%, and they were achieved at the expense of a high scrap rate not typically observed during visual inspection tasks. This study provides the first empirical data to address the reliability of visual inspection for precision manufactured parts used in nuclear weapons. Results enhance current understanding of the process of visual inspection and can be applied to improve reliability for precision manufactured parts. © 2015, Human Factors and Ergonomics Society.

A Complex Shaped Reinforced Thermoplastic Composite Part Made of Commingled Yarns With Integrated Sensor

NASA Astrophysics Data System (ADS)

Risicato, Jean-Vincent; Kelly, Fern; Soulat, Damien; Legrand, Xavier; Trümper, Wolfgang; Cochrane, Cedric; Koncar, Vladan

2015-02-01

This paper focuses on the design and one shot manufacturing process of complex shaped composite parts based on the overbraiding of commingled yarns. The commingled yarns contain thermoplastic fibres used as the matrix and glass fibres as the reinforcement material. This technology reduces the flow path length for the melted thermoplastic and aims to improve the impregnation of materials with high viscosity. The tensile strength behaviour of the material was firstly investigated in order to evaluate the influence of the manufacturing parameters on flat structured braids that have been consolidated on a heating press. A good compatibility between the required geometry and the braiding process was observed. Additionally, piezo-resistive sensor yarns, based on glass yarns coated with PEDOT: PSS, have been successfully integrated within the composite structure. The sensor yarns have been inserted into the braided fabric, before consolidation. The inserted sensors provide the ability to monitor the structural health of the composite part in a real time. The design and manufacture of the complete complex shaped part has then been successfully achieved.

Preliminary Comparison of Properties between Ni-electroplated Stainless Steel Parts Fabricated with Laser Additive Manufacturing and Conventional Machining

NASA Astrophysics Data System (ADS)

Mäkinen, Mika; Jauhiainen, Eeva; Matilainen, Ville-Pekka; Riihimäki, Jaakko; Ritvanen, Jussi; Piili, Heidi; Salminen, Antti

Laser additive manufacturing (LAM) is a fabrication technology, which enables production of complex parts from metallic materials with mechanical properties comparable to those of conventionally machined parts. These LAM parts are manufactured via melting metallic powder layer by layer with laser beam. Aim of this study is to define preliminarily the possibilities of using electroplating to supreme surface properties. Electrodeposited nickel and chromium as well as electroless (autocatalytic) deposited nickel was used to enhance laser additive manufactured and machined parts properties, like corrosion resistance, friction and wearing. All test pieces in this study were manufactured with a modified research AM equipment, equal to commercial EOS M series. The laser system used for tests was IPG 200 W CW fiber laser. The material used in this study for additive manufacturing was commercial stainless steel powder grade named SS316L. This SS316L is not equal to AISI 316L grade, but commercial name of this kind of powder is widely known in additive manufacturing as SS316L. Material used for fabrication of comparison test pieces (i.e. conventionally manufactured) was AISI 316L stainless steel bar. Electroplating was done in matrix cell and electroless was done in plastic sink properties of plated parts were tested within acetic acid salt spray corrosion chamber (AASS, SFS-EN-ISO 9227 standard). Adhesion of coating, friction and wearing properties were tested with Pin-On-Rod machine. Results show that in these preliminary tests, LAM parts and machined parts have certain differences due to manufacturing route and surface conditions. These have an effect on electroplated and electroless parts features on adhesion, corrosion, wearing and friction. However, further and more detailed studies are needed to fully understand these phenomena.

Mask manufacturing of advanced technology designs using multi-beam lithography (part 2)

NASA Astrophysics Data System (ADS)

Green, Michael; Ham, Young; Dillon, Brian; Kasprowicz, Bryan; Hur, Ik Boum; Park, Joong Hee; Choi, Yohan; McMurran, Jeff; Kamberian, Henry; Chalom, Daniel; Klikovits, Jan; Jurkovic, Michal; Hudek, Peter

2016-09-01

As optical lithography is extended into 10nm and below nodes, advanced designs are becoming a key challenge for mask manufacturers. Techniques including advanced optical proximity correction (OPC) and Inverse Lithography Technology (ILT) result in structures that pose a range of issues across the mask manufacturing process. Among the new challenges are continued shrinking sub-resolution assist features (SRAFs), curvilinear SRAFs, and other complex mask geometries that are counter-intuitive relative to the desired wafer pattern. Considerable capability improvements over current mask making methods are necessary to meet the new requirements particularly regarding minimum feature resolution and pattern fidelity. Advanced processes using the IMS Multi-beam Mask Writer (MBMW) are feasible solutions to these coming challenges. In this paper, Part 2 of our study, we further characterize an MBMW process for 10nm and below logic node mask manufacturing including advanced pattern analysis and write time demonstration.

An investigation of hardwood plywood markets. Part 2. Fixture manufacturers

Treesearch

Craig L. Forbes; Larry G. Jahn; Philip A. Araman

2001-01-01

This is the second part of a two-part study investigating markets for hardwood plywood. Part 1 dealt with architectural woodworkers. North American fixture manufacturers were surveyed to better understand the structure and use of wood-based panels in the industry. A questionnaire was mailed to a sample of U.S. and Canadian fixture manufacturers. The sample consisted of...

Synchrotron X-ray CT characterization of titanium parts fabricated by additive manufacturing. Part I. Morphology.

PubMed

Scarlett, Nicola Vivienne Yorke; Tyson, Peter; Fraser, Darren; Mayo, Sheridan; Maksimenko, Anton

2016-07-01

Synchrotron X-ray tomography has been applied to the study of titanium parts fabricated by additive manufacturing (AM). The AM method employed here was the Arcam EBM(®) (electron beam melting) process which uses powdered titanium alloy, Ti64 (Ti alloy with approximately 6%Al and 4%V), as the feed and an electron beam for the sintering/welding. The experiment was conducted on the Imaging and Medical Beamline of the Australian Synchrotron. Samples were chosen to examine the effect of build direction and complexity of design on the surface morphology and final dimensions of the piece.

Additive Manufacturing: Which DLA-Managed Legacy Parts are Potential AM Candidates

DTIC Science & Technology

2016-07-01

R G ADDITIVE MANUFACTURING : WHICH DLA-MANAGED LEGACY PARTS ARE POTENTIAL AM CANDIDATES? REPORT DL501T1 J UL Y 2016...L Y 2 0 1 6 ADDITIVE MANUFACTURING : WHICH DLA-MANAGED LEGACY PARTS ARE POTENTIAL AM CANDIDATES? REPORT DL501T1 Thomas K . Pa rk s...DESIGNATED BY OTHER OFFICIAL DOCUMENTATION. LMI © 2016. ALL RIGHTS RESERVED. iii Additive Manufacturing : Which DLA-Managed Legacy Parts Are

Synchrotron X-ray CT characterization of titanium parts fabricated by additive manufacturing. Part II. Defects.

PubMed

Scarlett, Nicola Vivienne Yorke; Tyson, Peter; Fraser, Darren; Mayo, Sheridan; Maksimenko, Anton

2016-07-01

Synchrotron X-ray tomography (SXRT) has been applied to the study of defects within three-dimensional printed titanium parts. These parts were made using the Arcam EBM(®) (electron beam melting) process which uses powdered titanium alloy, Ti64 (Ti alloy with approximately 6%Al and 4%V) as the feed and an electron beam for the sintering/welding. The experiment was conducted on the Imaging and Medical Beamline of the Australian Synchrotron. The samples represent a selection of complex shapes with a variety of internal morphologies. Inspection via SXRT has revealed a number of defects which may not otherwise have been seen. The location and nature of such defects combined with detailed knowledge of the process conditions can contribute to understanding the interplay between design and manufacturing strategy. This fundamental understanding may subsequently be incorporated into process modelling, prediction of properties and the development of robust methodologies for the production of defect-free parts.

Modeling OPC complexity for design for manufacturability

NASA Astrophysics Data System (ADS)

Gupta, Puneet; Kahng, Andrew B.; Muddu, Swamy; Nakagawa, Sam; Park, Chul-Hong

2005-11-01

Increasing design complexity in sub-90nm designs results in increased mask complexity and cost. Resolution enhancement techniques (RET) such as assist feature addition, phase shifting (attenuated PSM) and aggressive optical proximity correction (OPC) help in preserving feature fidelity in silicon but increase mask complexity and cost. Data volume increase with rise in mask complexity is becoming prohibitive for manufacturing. Mask cost is determined by mask write time and mask inspection time, which are directly related to the complexity of features printed on the mask. Aggressive RET increase complexity by adding assist features and by modifying existing features. Passing design intent to OPC has been identified as a solution for reducing mask complexity and cost in several recent works. The goal of design-aware OPC is to relax OPC tolerances of layout features to minimize mask cost, without sacrificing parametric yield. To convey optimal OPC tolerances for manufacturing, design optimization should drive OPC tolerance optimization using models of mask cost for devices and wires. Design optimization should be aware of impact of OPC correction levels on mask cost and performance of the design. This work introduces mask cost characterization (MCC) that quantifies OPC complexity, measured in terms of fracture count of the mask, for different OPC tolerances. MCC with different OPC tolerances is a critical step in linking design and manufacturing. In this paper, we present a MCC methodology that provides models of fracture count of standard cells and wire patterns for use in design optimization. MCC cannot be performed by designers as they do not have access to foundry OPC recipes and RET tools. To build a fracture count model, we perform OPC and fracturing on a limited set of standard cells and wire configurations with all tolerance combinations. Separately, we identify the characteristics of the layout that impact fracture count. Based on the fracture count (FC) data

Strategic drivers of contract manufacturing: Part I, The theory.

PubMed

Tomlinson, Geoff; Geimer, Harald

2002-12-01

Medical device manufacturers and diagnostics companies have significantly increased their use of contract manufacturers to outsource production of components. This, the first of a two-part article, reviews strategic benefits and best practices in outsourcing.

Fabrication of Flex Joint Utilizing Additively Manufactured Parts

NASA Technical Reports Server (NTRS)

Eddleman, David; Richard, Jim

2015-01-01

The Selective Laser Melting (SLM) manufacturing technique has been utilized in the manufacture of a flex joint typical of those found in rocket engine and main propulsion system ducting. The SLM process allowed for the combination of parts that are typically machined separately and welded together. This resulted in roughly a 65% reduction of the total number of parts, roughly 70% reduction in the total number of welds, and an estimated 60% reduction in the number of machining operations. The majority of the new design was in three SLM pieces. These pieces, as well as a few traditionally fabricated parts, were assembled into a complete unit, which has been pressure tested. The design and planned cryogenic testing of the unit will be presented.

The complexity and cost of vaccine manufacturing - An overview.

PubMed

Plotkin, Stanley; Robinson, James M; Cunningham, Gerard; Iqbal, Robyn; Larsen, Shannon

2017-07-24

As companies, countries, and governments consider investments in vaccine production for routine immunization and outbreak response, understanding the complexity and cost drivers associated with vaccine production will help to inform business decisions. Leading multinational corporations have good understanding of the complex manufacturing processes, high technological and R&D barriers to entry, and the costs associated with vaccine production. However, decision makers in developing countries, donors and investors may not be aware of the factors that continue to limit the number of new manufacturers and have caused attrition and consolidation among existing manufacturers. This paper describes the processes and cost drivers in acquiring and maintaining licensure of childhood vaccines. In addition, when export is the goal, we describe the requirements to supply those vaccines at affordable prices to low-resource markets, including the process of World Health Organization (WHO) prequalification and supporting policy recommendation. By providing a generalized and consolidated view of these requirements we seek to build awareness in the global community of the benefits and costs associated with vaccine manufacturing and the challenges associated with maintaining consistent supply. We show that while vaccine manufacture may prima facie seem an economic growth opportunity, the complexity and high fixed costs of vaccine manufacturing limit potential profit. Further, for most lower and middle income countries a large majority of the equipment, personnel and consumables will need to be imported for years, further limiting benefits to the local economy. Copyright © 2017 The Authors. Published by Elsevier Ltd.. All rights reserved.

Manufacturing interior furniture parts: a new look at an old problem

Treesearch

Edwin L. Lucas; Philip A. Araman

1975-01-01

The yields of interior furniture parts from four manufacturing sequences were compared. In three of the sequences, gang-ripping was the first step; in the fourth, the lumber was crosscut first. Though the grade of lumber used affects the percentage yield of parts, the manufacturing sequence used does not - but it will affect the cost per part. The selection of the best...

In Situ Manufacturing is a Necessary Part of Any Planetary Architecture

NASA Technical Reports Server (NTRS)

Edmunson, Jennifer E.; McLemore, Carole A.

2012-01-01

The key to any sustainable presence in space is the ability to manufacture necessary tools, parts, structures, spares, etc. in situ and on demand. Cost, volume, and up-mass constraints prohibit launching everything needed for long-duration or long-distance missions from Earth, including spare parts and replacement systems. There are many benefits to building items as-needed in situ using computer aided drafting (CAD) models and additive manufacturing technology: (1) Cost, up-mass, and volume savings for launch due to the ability to manufacture specific parts when needed. (2) CAD models can be generated on Earth and transmitted to the station or spacecraft, or they can be designed in situ for any task. Thus, multiple people in many locations can work on a single problem. (3) Items can be produced that will enhance the safety of crew and vehicles (e.g., latches or guards). (4) Items can be produced on-demand in a small amount of time (i.e., hours or days) compared to traditional manufacturing methods and, therefore, would not require the lengthy amount of time needed to machine the part from a solid block of material nor the wait time required if the part had to be launched from Earth. (5) Used and obsolete parts can be recycled into powder or wire feedstock for use in later manufacturing. (6) Ultimately, the ability to produce items as-needed will reduce mission risk, as one will have everything they need to fix a broken system or fashion a new part making it available on a more timely basis.

Complex shaped boron carbides from negative additive manufacturing

DOE PAGES

Lu, Ryan; Chandrasekaran, Swetha; Du Frane, Wyatt L.; ...

2018-03-13

In this paper, complex shaped boron carbide with carbon (B 4C/C) at near-full densities were achieved for the first time using negative additive manufacturing techniques via gelcasting. Negative additive manufacturing involves 3D printing of sacrificial molds used for casting negative copies. B 4C powder distributions and rheology of suspensions were optimized to successfully cast complex shapes. In addition to demonstrating scalability of these complex geometries, hierarchically meso-porous structures were also shown to be possible from this technique. Resorcinol-Formaldehyde (RF) polymer was selected as the gelling agent and can also pyrolyze into a carbon aerogel network to act as the sinteringmore » aid for B 4C. Finally, due to the highly effective distribution of in situ carbon for the B 4C matrix, near-full sintered density of 97–98% of theoretical maximum density was achieved.« less

Complex shaped boron carbides from negative additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lu, Ryan; Chandrasekaran, Swetha; Du Frane, Wyatt L.

In this paper, complex shaped boron carbide with carbon (B 4C/C) at near-full densities were achieved for the first time using negative additive manufacturing techniques via gelcasting. Negative additive manufacturing involves 3D printing of sacrificial molds used for casting negative copies. B 4C powder distributions and rheology of suspensions were optimized to successfully cast complex shapes. In addition to demonstrating scalability of these complex geometries, hierarchically meso-porous structures were also shown to be possible from this technique. Resorcinol-Formaldehyde (RF) polymer was selected as the gelling agent and can also pyrolyze into a carbon aerogel network to act as the sinteringmore » aid for B 4C. Finally, due to the highly effective distribution of in situ carbon for the B 4C matrix, near-full sintered density of 97–98% of theoretical maximum density was achieved.« less

75 FR 37990 - Airworthiness Directives; Ontic Engineering and Manufacturing, Inc. Propeller Governors, Part...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-07-01

... Airworthiness Directives; Ontic Engineering and Manufacturing, Inc. Propeller Governors, Part Numbers C210776... Engineering and Manufacturing, Inc. propeller governors, part numbers (P/Ns) C210776, T210761, D210760, and... this AD from Ontic Engineering and Manufacturing, Inc., 20400 Plummer Sreet, Chatsworth, CA 91311, e...

19 CFR Appendix A to Part 191 - General Manufacturing Drawback Rulings

Code of Federal Regulations, 2014 CFR

2014-04-01

... drawback; and 9. Description of the manufacturing or production process, unless specifically described in...) and 55207(1) (see § 191.9 of this part). D. Process Of Manufacture Or Production The imported... it is first separated in the manufacturing process. 2. Appearing-in method The appearing in basis may...

19 CFR Appendix A to Part 191 - General Manufacturing Drawback Rulings

Code of Federal Regulations, 2013 CFR

2013-04-01

... drawback; and 9. Description of the manufacturing or production process, unless specifically described in...) and 55207(1) (see § 191.9 of this part). D. Process Of Manufacture Or Production The imported... it is first separated in the manufacturing process. 2. Appearing-in method The appearing in basis may...

19 CFR Appendix A to Part 191 - General Manufacturing Drawback Rulings

Code of Federal Regulations, 2011 CFR

2011-04-01

... drawback; and 9. Description of the manufacturing or production process, unless specifically described in...) and 55207(1) (see § 191.9 of this part). D. Process Of Manufacture Or Production The imported... it is first separated in the manufacturing process. 2. Appearing-in method The appearing in basis may...

19 CFR Appendix A to Part 191 - General Manufacturing Drawback Rulings

Code of Federal Regulations, 2012 CFR

2012-04-01

... drawback; and 9. Description of the manufacturing or production process, unless specifically described in...) and 55207(1) (see § 191.9 of this part). D. Process Of Manufacture Or Production The imported... it is first separated in the manufacturing process. 2. Appearing-in method The appearing in basis may...

Potential of direct metal deposition technology for manufacturing thick functionally graded coatings and parts for reactors components

NASA Astrophysics Data System (ADS)

Thivillon, L.; Bertrand, Ph.; Laget, B.; Smurov, I.

2009-03-01

Direct metal deposition (DMD) is an automated 3D deposition process arising from laser cladding technology with co-axial powder injection to refine or refurbish parts. Recently DMD has been extended to manufacture large-size near-net-shape components. When applied for manufacturing new parts (or their refinement), DMD can provide tailored thermal properties, high corrosion resistance, tailored tribology, multifunctional performance and cost savings due to smart material combinations. In repair (refurbishment) operations, DMD can be applied for parts with a wide variety of geometries and sizes. In contrast to the current tool repair techniques such as tungsten inert gas (TIG), metal inert gas (MIG) and plasma welding, laser cladding technology by DMD offers a well-controlled heat-treated zone due to the high energy density of the laser beam. In addition, this technology may be used for preventative maintenance and design changes/up-grading. One of the advantages of DMD is the possibility to build functionally graded coatings (from 1 mm thickness and higher) and 3D multi-material objects (for example, 100 mm-sized monolithic rectangular) in a single-step manufacturing cycle by using up to 4-channel powder feeder. Approved materials are: Fe (including stainless steel), Ni and Co alloys, (Cu,Ni 10%), WC compounds, TiC compounds. The developed coatings/parts are characterized by low porosity (<1%), fine microstructure, and their microhardness is close to the benchmark value of wrought alloys after thermal treatment (Co-based alloy Stellite, Inox 316L, stainless steel 17-4PH). The intended applications concern cooling elements with complex geometry, friction joints under high temperature and load, light-weight mechanical support structures, hermetic joints, tubes with complex geometry, and tailored inside and outside surface properties, etc.

Reduction of Surface Roughness by Means of Laser Processing over Additive Manufacturing Metal Parts.

PubMed

Alfieri, Vittorio; Argenio, Paolo; Caiazzo, Fabrizia; Sergi, Vincenzo

2016-12-31

Optimization of processing parameters and exposure strategies is usually performed in additive manufacturing to set up the process; nevertheless, standards for roughness may not be evenly matched on a single complex part, since surface features depend on the building direction of the part. This paper aims to evaluate post processing treating via laser surface modification by means of scanning optics and beam wobbling to process metal parts resulting from selective laser melting of stainless steel in order to improve surface topography. The results are discussed in terms of roughness, geometry of the fusion zone in the cross-section, microstructural modification, and microhardness so as to assess the effects of laser post processing. The benefits of beam wobbling over linear scanning processing are shown, as heat effects in the base metal are proven to be lower.

Visual inspection reliability for precision manufactured parts

DOE PAGES

See, Judi E.

2015-09-04

Sandia National Laboratories conducted an experiment for the National Nuclear Security Administration to determine the reliability of visual inspection of precision manufactured parts used in nuclear weapons. In addition visual inspection has been extensively researched since the early 20th century; however, the reliability of visual inspection for nuclear weapons parts has not been addressed. In addition, the efficacy of using inspector confidence ratings to guide multiple inspections in an effort to improve overall performance accuracy is unknown. Further, the workload associated with inspection has not been documented, and newer measures of stress have not been applied.

Reduction of Surface Roughness by Means of Laser Processing over Additive Manufacturing Metal Parts

PubMed Central

Alfieri, Vittorio; Argenio, Paolo; Caiazzo, Fabrizia; Sergi, Vincenzo

2016-01-01

Optimization of processing parameters and exposure strategies is usually performed in additive manufacturing to set up the process; nevertheless, standards for roughness may not be evenly matched on a single complex part, since surface features depend on the building direction of the part. This paper aims to evaluate post processing treating via laser surface modification by means of scanning optics and beam wobbling to process metal parts resulting from selective laser melting of stainless steel in order to improve surface topography. The results are discussed in terms of roughness, geometry of the fusion zone in the cross-section, microstructural modification, and microhardness so as to assess the effects of laser post processing. The benefits of beam wobbling over linear scanning processing are shown, as heat effects in the base metal are proven to be lower. PMID:28772380

Process development for green part printing using binder jetting additive manufacturing

NASA Astrophysics Data System (ADS)

Miyanaji, Hadi; Orth, Morgan; Akbar, Junaid Muhammad; Yang, Li

2018-05-01

Originally developed decades ago, the binder jetting additive manufacturing (BJ-AM) process possesses various advantages compared to other additive manufacturing (AM) technologies such as broad material compatibility and technological expandability. However, the adoption of BJ-AM has been limited by the lack of knowledge with the fundamental understanding of the process principles and characteristics, as well as the relatively few systematic design guideline that are available. In this work, the process design considerations for BJ-AM in green part fabrication were discussed in detail in order to provide a comprehensive perspective of the design for additive manufacturing for the process. Various process factors, including binder saturation, in-process drying, powder spreading, powder feedstock characteristics, binder characteristics and post-process curing, could significantly affect the printing quality of the green parts such as geometrical accuracy and part integrity. For powder feedstock with low flowability, even though process parameters could be optimized to partially offset the printing feasibility issue, the qualities of the green parts will be intrinsically limited due to the existence of large internal voids that are inaccessible to the binder. In addition, during the process development, the balanced combination between the saturation level and in-process drying is of critical importance in the quality control of the green parts.

Manufacturing complexity analysis

NASA Technical Reports Server (NTRS)

Delionback, L. M.

1977-01-01

The analysis of the complexity of a typical system is presented. Starting with the subsystems of an example system, the step-by-step procedure for analysis of the complexity of an overall system is given. The learning curves for the various subsystems are determined as well as the concurrent numbers of relevant design parameters. Then trend curves are plotted for the learning curve slopes versus the various design-oriented parameters, e.g. number of parts versus slope of learning curve, or number of fasteners versus slope of learning curve, etc. Representative cuts are taken from each trend curve, and a figure-of-merit analysis is made for each of the subsystems. Based on these values, a characteristic curve is plotted which is indicative of the complexity of the particular subsystem. Each such characteristic curve is based on a universe of trend curve data taken from data points observed for the subsystem in question. Thus, a characteristic curve is developed for each of the subsystems in the overall system.

Smart manufacturing of complex shaped pipe components

NASA Astrophysics Data System (ADS)

Salchak, Y. A.; Kotelnikov, A. A.; Sednev, D. A.; Borikov, V. N.

2018-03-01

Manufacturing industry is constantly improving. Nowadays the most relevant trend is widespread automation and optimization of the production process. This paper represents a novel approach for smart manufacturing of steel pipe valves. The system includes two main parts: mechanical treatment and quality assurance units. Mechanical treatment is performed by application of the milling machine with implementation of computerized numerical control, whilst the quality assurance unit contains three testing modules for different tasks, such as X-ray testing, optical scanning and ultrasound testing modules. The advances of each of them provide reliable results that contain information about any failures of the technological process, any deviations of geometrical parameters of the valves. The system also allows detecting defects on the surface or in the inner structure of the component.

Study on the Quality and Performance of CoCrMo Alloy Parts Manufactured by Selective Laser Melting

NASA Astrophysics Data System (ADS)

Guoqing, Zhang; Yongqiang, Yang; Hui, Lin; Changhui, Song; Zimian, Zhang

2017-05-01

To obtain medical implants with better performance, it is necessary to conduct studies on the quality and other performances of the selective laser melting (SLM) manufacturing parts. Interior defects in CoCrMo parts manufactured by SLM were detected using x-ray radiographic inspection, and the manufactured parts compared with three-dimensional models to assess manufacturing quality. Impact tests were employed to establish the mechanical properties of the manufactured parts. With the aim of studying the mechanism of fracture of the parts, we utilized a metalloscope and SEM to observe the surface and fractal theory was used to analyze the appearance of fractures. The results show that part defects manifested in an increase in transmittance caused by the non-uniform distribution of density, resulting in variation in the residual stresses of the parts. The density of the parts was more uniform following heat treatment. Internal residual stress of the manufactured parts enhanced their impact toughness. There was a ductile-brittle transition temperature between the two annealing temperatures. We determined that the fracture mechanism was brittle fracture. Fractures exhibited significant fractal behavior. The impact energy and fractal dimension were positively correlated, which provided good support for using selective laser melting manufacturing of CoCrMo alloy in medical implants.

Computerized parts list system coordinates engineering releases, parts control, and manufacturing planning

NASA Technical Reports Server (NTRS)

Horton, W.; Kinsey, M.

1967-01-01

Computerized parts list system compiles and summarize all pertinent and available information on complex new systems. The parts list system consists of three computer subroutines - list of parts, parts numerical sequence list, and specifications list.

Design complexity and strength of laterality are correlated in New Caledonian crows' pandanus tool manufacture

PubMed Central

Hunt, Gavin R; Corballis, Michael C; Gray, Russell D

2006-01-01

Population-level laterality is generally considered to reflect functional brain specialization. Consequently, the strength of population-level laterality in manipulatory tasks is predicted to positively correlate with task complexity. This relationship has not been investigated in tool manufacture. Here, we report the correlation between strength of laterality and design complexity in the manufacture of New Caledonian crows' three pandanus tool designs: wide, narrow and stepped designs. We documented indirect evidence of over 5800 tool manufactures on 1232 pandanus trees at 23 sites. We found that the strength of laterality in tool manufacture was correlated with design complexity in three ways: (i) the strongest effect size among the population-level edge biases for each design was for the more complex, stepped design, (ii) the strength of laterality at individual sites was on average greater for the stepped design than it was for the simpler wide and narrow, non-stepped designs, and (iii) there was a positive, but non-significant, trend for a correlation between the strength of laterality and the number of steps on a stepped tool. These three aspects together indicate that greater design complexity generally elicits stronger lateralization of crows' pandanus tool manufacture. PMID:16600891

Design complexity and strength of laterality are correlated in New Caledonian crows' pandanus tool manufacture.

PubMed

Hunt, Gavin R; Corballis, Michael C; Gray, Russell D

2006-05-07

Population-level laterality is generally considered to reflect functional brain specialization. Consequently, the strength of population-level laterality in manipulatory tasks is predicted to positively correlate with task complexity. This relationship has not been investigated in tool manufacture. Here, we report the correlation between strength of laterality and design complexity in the manufacture of New Caledonian crows' three pandanus tool designs: wide, narrow and stepped designs. We documented indirect evidence of over 5,800 tool manufactures on 1,232 pandanus trees at 23 sites. We found that the strength of laterality in tool manufacture was correlated with design complexity in three ways: (i) the strongest effect size among the population-level edge biases for each design was for the more complex, stepped design, (ii) the strength of laterality at individual sites was on average greater for the stepped design than it was for the simpler wide and narrow, non-stepped designs, and (iii) there was a positive, but non-significant, trend for a correlation between the strength of laterality and the number of steps on a stepped tool. These three aspects together indicate that greater design complexity generally elicits stronger lateralization of crows' pandanus tool manufacture.

An In-Depth Review on Direct Additive Manufacturing of Metals

NASA Astrophysics Data System (ADS)

Azam, Farooq I.; Rani, Ahmad Majdi Abdul; Altaf, Khurram; Rao, T. V. V. L. N.; Aimi Zaharin, Haizum

2018-03-01

Additive manufacturing (AM), also known as 3D Printing, is a revolutionary manufacturing technique which has been developing rapidly in the last 30 years. The evolution of this precision manufacturing process from rapid prototyping to ready-to-use parts has significantly alleviated manufacturing constraints and design freedom has been outstandingly widened. AM is a non-conventional manufacturing technique which utilizes a 3D CAD model data to build parts by adding one material layer at a time, rather than removing it and fulfills the demand for manufacturing parts with complex geometric shapes, great dimensional accuracy, and easy to assemble parts. Additive manufacturing of metals has become the area of extensive research, progressing towards the production of final products and replacing conventional manufacturing methods. This paper provides an insight to the available metal additive manufacturing technologies that can be used to produce end user products without using conventional manufacturing methods. The paper also includes the comparison of mechanical and physical properties of parts produced by AM with the parts manufactured using conventional processes.

Rubber pad forming - Efficient approach for the manufacturing of complex structured sheet metal blanks for food industry

NASA Astrophysics Data System (ADS)

Spoelstra, Paul; Djakow, Eugen; Homberg, Werner

2017-10-01

The production of complex organic shapes in sheet metals is gaining more importance in the food industry due to increasing functional and hygienic demands. Hence it is necessary to produce parts with complex geometries promoting cleanability and general sanitation leading to improvement of food safety. In this context, and especially when stainless steel has to be formed into highly complex geometries while maintaining desired surface properties, it is inevitable that alternative manufacturing processes will need to be used which meet these requirements. Rubber pad forming offers high potential when it comes to shaping complex parts with excellent surface quality, with virtually no tool marks and scratches. Especially in cases where only small series are to be produced, rubber pad forming processes offers both technological and economic advantages. Due to the flexible punch, variation in metal thickness can be used with the same forming tool. The investments to set-up Rubber pad forming is low in comparison to conventional sheet metal forming processes. The process facilitates production of shallow sheet metal parts with complex contours and bends. Different bending sequences in a multiple tool set-up can also be conducted. The planned contribution thus describes a brief overview of the rubber pad technology. It shows the prototype rubber pad forming machine which can be used to perform complex part geometries made from stainless steel (1.4301). Based on an analysis of the already existing systems and new machines for rubber pad forming processes, together with their process properties, influencing variables and areas of application, some relevant parts for the food industry are presented.

Selective Laser Melting of Hot Gas Turbine Components: Materials, Design and Manufacturing Aspects

NASA Astrophysics Data System (ADS)

Goutianos, Stergios

2017-07-01

Selective Laser Melting (SLM) allows the design and manufacturing of novel parts and structures with improved performance e.g. by incorporating complex and more efficient cooling schemes in hot gas turbine parts. In contrast to conventional manufacturing of removing material, with SLM parts are built additively to nearly net shape. This allows the fabrication of arbitrary complex geometries that cannot be made by conventional manufacturing techniques. However, despite the powerful capabilities of SLM, a number of issues (e.g. part orientation, support structures, internal stresses), have to be considered in order to manufacture cost-effective and high quality parts at an industrial scale. These issues are discussed in the present work from an engineering point of view with the aim to provide simple quidelines to produce high quality SLM parts.

A cyber physical system approach for composite part: From smart manufacturing to predictive maintenance

NASA Astrophysics Data System (ADS)

Quaranta, Giacomo; Abisset-Chavanne, Emmanuelle; Chinesta, Francisco; Duval, Jean-Louis

2018-05-01

In this work, a Cyber Physical System called Hybrid Twin is proposed for composite parts manufactured from RTM. This allows to introduce in the virtual twin of the parts the defect and the final properties induced by the real manufacturing process and to use on line data collection for predictive maintenance.

Structure Property Studies for Additively Manufactured Parts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Milenski, Helen M; Schmalzer, Andrew Michael; Kelly, Daniel

2015-08-17

Since the invention of modern Additive Manufacturing (AM) processes engineers and designers have worked hard to capitalize on the unique building capabilities that AM allows. By being able to customize the interior fill of parts it is now possible to design components with a controlled density and customized internal structure. The creation of new polymers and polymer composites allow for even greater control over the mechanical properties of AM parts. One of the key reasons to explore AM, is to bring about a new paradigm in part design, where materials can be strategically optimized in a way that conventional subtractivemore » methods cannot achieve. The two processes investigated in my research were the Fused Deposition Modeling (FDM) process and the Direct Ink Write (DIW) process. The objectives of the research were to determine the impact of in-fill density and morphology on the mechanical properties of FDM parts, and to determine if DIW printed samples could be produced where the filament diameter was varied while the overall density remained constant.« less

Additive Manufacturing Infrared Inspection

NASA Technical Reports Server (NTRS)

Gaddy, Darrell

2014-01-01

Additive manufacturing is a rapid prototyping technology that allows parts to be built in a series of thin layers from plastic, ceramics, and metallics. Metallic additive manufacturing is an emerging form of rapid prototyping that allows complex structures to be built using various metallic powders. Significant time and cost savings have also been observed using the metallic additive manufacturing compared with traditional techniques. Development of the metallic additive manufacturing technology has advanced significantly over the last decade, although many of the techniques to inspect parts made from these processes have not advanced significantly or have limitations. Several external geometry inspection techniques exist such as Coordinate Measurement Machines (CMM), Laser Scanners, Structured Light Scanning Systems, or even traditional calipers and gages. All of the aforementioned techniques are limited to external geometry and contours or must use a contact probe to inspect limited internal dimensions. This presentation will document the development of a process for real-time dimensional inspection technique and digital quality record of the additive manufacturing process using Infrared camera imaging and processing techniques.

Additive Manufacturing of Shape Memory Alloys

NASA Astrophysics Data System (ADS)

Van Humbeeck, Jan

2018-04-01

Selective Laser Melting (SLM) is an additive manufacturing production process, also called 3D printing, in which functional, complex parts are produced by selectively melting patterns in consecutive layers of powder with a laser beam. The pattern the laser beam is following is controlled by software that calculates the pattern by slicing a 3D CAD model of the part to be constructed. Apart from SLM, also other additive manufacturing techniques such as EBM (Electron Beam Melting), FDM (Fused Deposition Modelling), WAAM (Wire Arc Additive Manufacturing), LENS (Laser Engineered Net Shaping such as Laser Cladding) and binder jetting allow to construct complete parts layer upon layer. But since more experience of AM of shape memory alloys is collected by SLM, this paper will overview the potentials, limits and problems of producing NiTi parts by SLM.

Rough-Part Sizes Needed from Lumber for Manufacturing Furniture and Kitchen Cabinets

Treesearch

Philip A. Araman

1982-01-01

This report summarizes the results from a recent survey of the rough-part sizes needed from lumber for manufacturing furniture and kitchen cabinets. Twenty furniture and twelve cabinet companies participated in the survey. Lumber thicknesses needed and rough-part qualities desired are presented along with distributions describing the required rough-part dimensions....

75 FR 12148 - Airworthiness Directives; Ontic Engineering and Manufacturing, Inc. Propeller Governors, Part...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-03-15

...-0102; Directorate Identifier 2010-NE-09-AD] RIN 2120-AA64 Airworthiness Directives; Ontic Engineering... Ontic Engineering and Manufacturing, Inc. propeller governors, part numbers (P/Ns) C210776, T210761... Federal holidays. Fax: (202) 493-2251. Contact Ontic Engineering and Manufacturing, Inc., 20400 Plummer...

Feature based Weld-Deposition for Additive Manufacturing of Complex Shapes

NASA Astrophysics Data System (ADS)

Panchagnula, Jayaprakash Sharma; Simhambhatla, Suryakumar

2018-06-01

Fabricating functional metal parts using Additive Manufacturing (AM) is a leading trend. However, realizing overhanging features has been a challenge due to the lack of support mechanism for metals. Powder-bed fusion techniques like, Selective Laser Sintering (SLS) employ easily-breakable-scaffolds made of the same material to realize the overhangs. However, the same approach is not extendible to deposition processes like laser or arc based direct energy deposition processes. Although it is possible to realize small overhangs by exploiting the inherent overhanging capability of the process or by blinding some small features like holes, the same cannot be extended for more complex geometries. The current work presents a novel approach for realizing complex overhanging features without the need of support structures. This is possible by using higher order kinematics and suitably aligning the overhang with the deposition direction. Feature based non-uniform slicing and non-uniform area-filling are some vital concepts required in realizing the same and are briefly discussed here. This method can be used to fabricate and/or repair fully dense and functional components for various engineering applications. Although this approach has been implemented for weld-deposition based system, the same can be extended to any other direct energy deposition processes also.

Manufacturing technology methodology for propulsion system parts

NASA Astrophysics Data System (ADS)

McRae, M. M.

1992-07-01

A development history and a current status evaluation are presented for lost-wax casting of such gas turbine engine components as turbine vanes and blades. The most advanced such systems employ computer-integrated manufacturing methods for high process repeatability, reprogramming versatility, and feedback monitoring. Stereolithography-based plastic model 3D prototyping has also been incorporated for the wax part of the investment casting; it may ultimately be possible to produce the 3D prototype in wax directly, or even to create a ceramic mold directly. Nonintrusive inspections are conducted by X-radiography and neutron radiography.

Nondestructive Testing of Additive Manufactured Metal Parts Used in Aerospace Applications

NASA Technical Reports Server (NTRS)

Waller, Jess M.

2018-01-01

NDE inspectors, QA/QE professionals, and program managers responsible for the out-sourcing, procurement, fabrication, finishing, inspection, and qualification and certification of additively manufactured (AM) parts should attend this course.

A case study on topology optimized design for additive manufacturing

NASA Astrophysics Data System (ADS)

Gebisa, A. W.; Lemu, H. G.

2017-12-01

Topology optimization is an optimization method that employs mathematical tools to optimize material distribution in a part to be designed. Earlier developments of topology optimization considered conventional manufacturing techniques that have limitations in producing complex geometries. This has hindered the topology optimization efforts not to fully be realized. With the emergence of additive manufacturing (AM) technologies, the technology that builds a part layer upon a layer directly from three dimensional (3D) model data of the part, however, producing complex shape geometry is no longer an issue. Realization of topology optimization through AM provides full design freedom for the design engineers. The article focuses on topologically optimized design approach for additive manufacturing with a case study on lightweight design of jet engine bracket. The study result shows that topology optimization is a powerful design technique to reduce the weight of a product while maintaining the design requirements if additive manufacturing is considered.

Development of Spray on Bag for manufacturing of large composites parts: Diffusivity analysis

NASA Astrophysics Data System (ADS)

Dempah, Maxime Joseph

Bagging materials are utilized in many composites manufacturing processes. The selection is mainly driven by cost, temperature requirements, chemical compatibility and tear properties of the bag. The air barrier properties of the bag are assumed to be adequate or in many cases are not considered at all. However, the gas barrier property of a bag is the most critical parameter, as it can negatively affect the quality of the final laminate. The barrier property is a function of the bag material, uniformity, thickness and temperature. Improved barrier properties are needed for large parts, high pressure consolidated components and structures where air stays entrapped on the part surface. The air resistance property of the film is defined as permeability and is investigated in this thesis. A model was developed to evaluate the gas transport through the film and an experimental cell was implemented to characterize various commercial films. Understanding and characterizing the transport phenomena through the film allows optimization of the bagging material for various manufacturing processes. Spray-on-Bag is a scalable alternative bagging method compared to standard films. The approach allows in-situ fabrication of the bag on large and complex geometry structures where optimization of the bag properties can be varied on a local level. An experimental setup was developed and implemented using a six axis robot and an automated spraying system. Experiments were performed on a flat surface and specimens were characterized and compared to conventional films. Air barrier properties were within range of standard film approaches showing the potential to fabricate net shape bagging structures in an automated process.

A Sensory Material Approach for Reducing Variability in Additively Manufactured Metal Parts.

PubMed

Franco, B E; Ma, J; Loveall, B; Tapia, G A; Karayagiz, K; Liu, J; Elwany, A; Arroyave, R; Karaman, I

2017-06-15

Despite the recent growth in interest for metal additive manufacturing (AM) in the biomedical and aerospace industries, variability in the performance, composition, and microstructure of AM parts remains a major impediment to its widespread adoption. The underlying physical mechanisms, which cause variability, as well as the scale and nature of variability are not well understood, and current methods are ineffective at capturing these details. Here, a Nickel-Titanium alloy is used as a sensory material in order to quantitatively, and rather rapidly, observe compositional and/or microstructural variability in selective laser melting manufactured parts; thereby providing a means to evaluate the role of process parameters on the variability. We perform detailed microstructural investigations using transmission electron microscopy at various locations to reveal the origins of microstructural variability in this sensory material. This approach helped reveal how reducing the distance between adjacent laser scans below a critical value greatly reduces both the in-sample and sample-to-sample variability. Microstructural investigations revealed that when the laser scan distance is wide, there is an inhomogeneity in subgrain size, precipitate distribution, and dislocation density in the microstructure, responsible for the observed variability. These results provide an important first step towards understanding the nature of variability in additively manufactured parts.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing Part I: System Analysis, Component Identification, Additive Manufacturing, and Testing of Polymer Composites

NASA Technical Reports Server (NTRS)

Grady, Joseph E.; Haller, William J.; Poinsatte, Philip E.; Halbig, Michael C.; Schnulo, Sydney L.; Singh, Mrityunjay; Weir, Don; Wali, Natalie; Vinup, Michael; Jones, Michael G.;

Utility of Big Area Additive Manufacturing (BAAM) For The Rapid Manufacture of Customized Electric Vehicles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Love, Lonnie J.

This Oak Ridge National Laboratory (ORNL) Manufacturing Development Facility (MDF) technical collaboration project was conducted in two phases as a CRADA with Local Motors Inc. Phase 1 was previously reported as Advanced Manufacturing of Complex Cyber Mechanical Devices through Community Engagement and Micro-manufacturing and demonstrated the integration of components onto a prototype body part for a vehicle. Phase 2 was reported as Utility of Big Area Additive Manufacturing (BAAM) for the Rapid Manufacture of Customized Electric Vehicles and demonstrated the high profile live printing of an all-electric vehicle using ONRL s Big Area Additive Manufacturing (BAAM) technology. This demonstration generatedmore » considerable national attention and successfully demonstrated the capabilities of the BAAM system as developed by ORNL and Cincinnati, Inc. and the feasibility of additive manufacturing of a full scale electric vehicle as envisioned by the CRADA partner Local Motors, Inc.« less

Pellet to Part Manufacturing System for CNCs

DOE Office of Scientific and Technical Information (OSTI.GOV)

Roschli, Alex C.; Love, Lonnie J.; Post, Brian K.

Oak Ridge National Laboratory’s Manufacturing Demonstration Facility worked with Hybrid Manufacturing Technologies to develop a compact prototype composite additive manufacturing head that can effectively extrude injection molding pellets. The head interfaces with conventional CNC machine tools enabling rapid conversion of conventional machine tools to additive manufacturing tools. The intent was to enable wider adoption of Big Area Additive Manufacturing (BAAM) technology and combine BAAM technology with conventional machining systems.

Flexible manufacturing of aircraft engine parts

NASA Astrophysics Data System (ADS)

Hassan, Ossama M.; Jenkins, Douglas M.

1992-06-01

GE Aircraft Engines, a major supplier of jet engines for commercial and military aircraft, has developed a fully integrated manufacturing facility to produce aircraft engine components in flexible manufacturing cells. This paper discusses many aspects of the implementation including process technologies, material handling, software control system architecture, socio-technical systems and lessons learned. Emphasis is placed on the appropriate use of automation in a flexible manufacturing system.

Building a Competitive Edge with Additive Manufacturing

DTIC Science & Technology

2013-02-14

construct ceramic molds for complex metal parts using a 3D printing technique. They estimate the new 6 technique could eliminate all of the...processes. They include 3D printing and Additive Beam Techniques.15 Most Additive Manufacturing techniques are specific to certain classes of materials...9 Example Additive Manufacturing Techniques16 3D Printing Additive Beam Stereolithography (SLA) Direct Metal Laser Sintering (DMLS

Cleaning and Cleanliness Measurement of Additive Manufactured Parts

NASA Technical Reports Server (NTRS)

Welker, Roger W.; Mitchell, Mark A.

2015-01-01

The successful acquisition and utilization of piece parts and assemblies for contamination sensitive applications requires application of cleanliness acceptance criteria. Contamination can be classified using many different schemes. One common scheme is classification as organic, ionic and particulate contaminants. These may be present in and on the surface of solid components and assemblies or may be dispersed in various gaseous or liquid media. This discussion will focus on insoluble particle contamination on the surface of piece parts and assemblies. Cleanliness of parts can be controlled using two strategies, referred to as gross cleanliness and precision cleanliness. Under a gross cleanliness strategy acceptance is based on visual cleanliness. This approach introduces a number of concerns that render it unsuitable for controlling cleanliness of high technology products. Under the precision cleanliness strategy, subjective, visual assessment of cleanliness is replaced by objective measurement of cleanliness. When a precision cleanliness strategy is adopted there naturally arises the question: How clean is clean enough? The six commonly used methods for establishing objective cleanliness acceptance limits will be discussed. Special emphasis shall focus on the use of multiple extraction, a technique that has been demonstrated for additively manufactured parts.

Hardening parts by chrome plating in manufacture and repair

NASA Astrophysics Data System (ADS)

Astanin, V. K.; Pukhov, E. V.; Stekolnikov, Y. A.; Emtsev, V. V.; Golikova, O. A.

2018-03-01

In the engineering industry, galvanic coatings are widely used to prolong the service life of the machines, which contribute to the increase in the strength of the parts and their resistance to environmental influences, temperature and pressure drops, wear and fretting corrosion. Galvanic coatings have been widely applied in engineering, including agriculture, aircraft building, mining, construction, and electronics. The article focuses on the manufacturing methods of new agricultural machinery parts and the repair techniques of worn parts by chrome plating. The main attention is paid to the unstable methods of chromium deposition (in pulsed and reversing modes) in low-concentration electrolytes, which makes it possible to increase the reliability and durability of the hardened parts operation by changing the conditions of electrocrystallization, that is, directed formation of the structure and texture, thickness, roughness and microhardness of chromium plating. The practical recommendations are given on the current and temperature regimes of chromium deposition and composition of baths used for the restoration and hardening of the machine parts. Moreover, the basic methods of machining allowances removal are analysed.

Applications of Metal Additive Manufacturing in Veterinary Orthopedic Surgery

NASA Astrophysics Data System (ADS)

Harrysson, Ola L. A.; Marcellin-Little, Denis J.; Horn, Timothy J.

2015-03-01

Veterinary medicine has undergone a rapid increase in specialization over the last three decades. Veterinarians now routinely perform joint replacement, neurosurgery, limb-sparing surgery, interventional radiology, radiation therapy, and other complex medical procedures. Many procedures involve advanced imaging and surgical planning. Evidence-based medicine has also become part of the modus operandi of veterinary clinicians. Modeling and additive manufacturing can provide individualized or customized therapeutic solutions to support the management of companion animals with complex medical problems. The use of metal additive manufacturing is increasing in veterinary orthopedic surgery. This review describes and discusses current and potential applications of metal additive manufacturing in veterinary orthopedic surgery.

Mask manufacturing of advanced technology designs using multi-beam lithography (Part 1)

NASA Astrophysics Data System (ADS)

Green, Michael; Ham, Young; Dillon, Brian; Kasprowicz, Bryan; Hur, Ik Boum; Park, Joong Hee; Choi, Yohan; McMurran, Jeff; Kamberian, Henry; Chalom, Daniel; Klikovits, Jan; Jurkovic, Michal; Hudek, Peter

2016-10-01

As optical lithography is extended into 10nm and below nodes, advanced designs are becoming a key challenge for mask manufacturers. Techniques including advanced Optical Proximity Correction (OPC) and Inverse Lithography Technology (ILT) result in structures that pose a range of issues across the mask manufacturing process. Among the new challenges are continued shrinking Sub-Resolution Assist Features (SRAFs), curvilinear SRAFs, and other complex mask geometries that are counter-intuitive relative to the desired wafer pattern. Considerable capability improvements over current mask making methods are necessary to meet the new requirements particularly regarding minimum feature resolution and pattern fidelity. Advanced processes using the IMS Multi-beam Mask Writer (MBMW) are feasible solutions to these coming challenges. In this paper, we study one such process, characterizing mask manufacturing capability of 10nm and below structures with particular focus on minimum resolution and pattern fidelity.

A new large-scale manufacturing platform for complex biopharmaceuticals.

PubMed

Vogel, Jens H; Nguyen, Huong; Giovannini, Roberto; Ignowski, Jolene; Garger, Steve; Salgotra, Anil; Tom, Jennifer

2012-12-01

Complex biopharmaceuticals, such as recombinant blood coagulation factors, are addressing critical medical needs and represent a growing multibillion-dollar market. For commercial manufacturing of such, sometimes inherently unstable, molecules it is important to minimize product residence time in non-ideal milieu in order to obtain acceptable yields and consistently high product quality. Continuous perfusion cell culture allows minimization of residence time in the bioreactor, but also brings unique challenges in product recovery, which requires innovative solutions. In order to maximize yield, process efficiency, facility and equipment utilization, we have developed, scaled-up and successfully implemented a new integrated manufacturing platform in commercial scale. This platform consists of a (semi-)continuous cell separation process based on a disposable flow path and integrated with the upstream perfusion operation, followed by membrane chromatography on large-scale adsorber capsules in rapid cycling mode. Implementation of the platform at commercial scale for a new product candidate led to a yield improvement of 40% compared to the conventional process technology, while product quality has been shown to be more consistently high. Over 1,000,000 L of cell culture harvest have been processed with 100% success rate to date, demonstrating the robustness of the new platform process in GMP manufacturing. While membrane chromatography is well established for polishing in flow-through mode, this is its first commercial-scale application for bind/elute chromatography in the biopharmaceutical industry and demonstrates its potential in particular for manufacturing of potent, low-dose biopharmaceuticals. Copyright © 2012 Wiley Periodicals, Inc.

Computational Process Modeling for Additive Manufacturing (OSU)

NASA Technical Reports Server (NTRS)

Bagg, Stacey; Zhang, Wei

2015-01-01

Powder-Bed Additive Manufacturing (AM) through Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) is being used by NASA and the Aerospace industry to "print" parts that traditionally are very complex, high cost, or long schedule lead items. The process spreads a thin layer of metal powder over a build platform, then melts the powder in a series of welds in a desired shape. The next layer of powder is applied, and the process is repeated until layer-by-layer, a very complex part can be built. This reduces cost and schedule by eliminating very complex tooling and processes traditionally used in aerospace component manufacturing. To use the process to print end-use items, NASA seeks to understand SLM material well enough to develop a method of qualifying parts for space flight operation. Traditionally, a new material process takes many years and high investment to generate statistical databases and experiential knowledge, but computational modeling can truncate the schedule and cost -many experiments can be run quickly in a model, which would take years and a high material cost to run empirically. This project seeks to optimize material build parameters with reduced time and cost through modeling.

Japan's technology and manufacturing infrastructure

NASA Astrophysics Data System (ADS)

Boulton, William R.; Meieran, Eugene S.; Tummala, Rao R.

1995-02-01

The JTEC panel found that, after four decades of development in electronics and manufacturing technologies, Japanese electronics companies are leaders in the development, support, and management of complex, low-cost packaging and assembly technologies used in the production of a broad range of consumer electronics products. The electronics industry's suppliers provide basic materials and equipment required for electronic packaging applications. Panelists concluded that some Japanese firms could be leading U.S. competitors by as much as a decade in these areas. Japan's technology and manufacturing infrastructure is an integral part of its microelectronics industry's success.

Japan's technology and manufacturing infrastructure

NASA Technical Reports Server (NTRS)

Boulton, William R.; Meieran, Eugene S.; Tummala, Rao R.

1995-01-01

The JTEC panel found that, after four decades of development in electronics and manufacturing technologies, Japanese electronics companies are leaders in the development, support, and management of complex, low-cost packaging and assembly technologies used in the production of a broad range of consumer electronics products. The electronics industry's suppliers provide basic materials and equipment required for electronic packaging applications. Panelists concluded that some Japanese firms could be leading U.S. competitors by as much as a decade in these areas. Japan's technology and manufacturing infrastructure is an integral part of its microelectronics industry's success.

Monitoring system for the quality assessment in additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carl, Volker, E-mail: carl@t-zfp.de

Additive Manufacturing (AM) refers to a process by which a set of digital data -representing a certain complex 3dim design - is used to grow the respective 3dim real structure equal to the corresponding design. For the powder-based EOS manufacturing process a variety of plastic and metal materials can be used. Thereby, AM is in many aspects a very powerful tool as it can help to overcome particular limitations in conventional manufacturing. AM enables more freedom of design, complex, hollow and/or lightweight structures as well as product individualisation and functional integration. As such it is a promising approach with respectmore » to the future design and manufacturing of complex 3dim structures. On the other hand, it certainly calls for new methods and standards in view of quality assessment. In particular, when utilizing AM for the design of complex parts used in aviation and aerospace technologies, appropriate monitoring systems are mandatory. In this respect, recently, sustainable progress has been accomplished by joining the common efforts and concerns of a manufacturer Additive Manufacturing systems and respective materials (EOS), along with those of an operator of such systems (MTU Aero Engines) and experienced application engineers (Carl Metrology), using decent know how in the field of optical and infrared methods regarding non-destructive-examination (NDE). The newly developed technology is best described by a high-resolution layer by layer inspection technique, which allows for a 3D tomography-analysis of the complex part at any time during the manufacturing process. Thereby, inspection costs are kept rather low by using smart image-processing methods as well as CMOS sensors instead of infrared detectors. Moreover, results from conventional physical metallurgy may easily be correlated with the predictive results of the monitoring system which not only allows for improvements of the AM monitoring system, but finally leads to an optimisation of the

Monitoring system for the quality assessment in additive manufacturing

NASA Astrophysics Data System (ADS)

Carl, Volker

2015-03-01

Additive Manufacturing (AM) refers to a process by which a set of digital data -representing a certain complex 3dim design - is used to grow the respective 3dim real structure equal to the corresponding design. For the powder-based EOS manufacturing process a variety of plastic and metal materials can be used. Thereby, AM is in many aspects a very powerful tool as it can help to overcome particular limitations in conventional manufacturing. AM enables more freedom of design, complex, hollow and/or lightweight structures as well as product individualisation and functional integration. As such it is a promising approach with respect to the future design and manufacturing of complex 3dim structures. On the other hand, it certainly calls for new methods and standards in view of quality assessment. In particular, when utilizing AM for the design of complex parts used in aviation and aerospace technologies, appropriate monitoring systems are mandatory. In this respect, recently, sustainable progress has been accomplished by joining the common efforts and concerns of a manufacturer Additive Manufacturing systems and respective materials (EOS), along with those of an operator of such systems (MTU Aero Engines) and experienced application engineers (Carl Metrology), using decent know how in the field of optical and infrared methods regarding non-destructive-examination (NDE). The newly developed technology is best described by a high-resolution layer by layer inspection technique, which allows for a 3D tomography-analysis of the complex part at any time during the manufacturing process. Thereby, inspection costs are kept rather low by using smart image-processing methods as well as CMOS sensors instead of infrared detectors. Moreover, results from conventional physical metallurgy may easily be correlated with the predictive results of the monitoring system which not only allows for improvements of the AM monitoring system, but finally leads to an optimisation of the quality

Experimental comparison of photogrammetry for additive manufactured parts with and without laser speckle projection

NASA Astrophysics Data System (ADS)

Sims-Waterhouse, D.; Bointon, P.; Piano, S.; Leach, R. K.

2017-06-01

In this paper we show that, by using a photogrammetry system with and without laser speckle, a large range of additive manufacturing (AM) parts with different geometries, materials and post-processing textures can be measured to high accuracy. AM test artefacts have been produced in three materials: polymer powder bed fusion (nylon-12), metal powder bed fusion (Ti-6Al-4V) and polymer material extrusion (ABS plastic). Each test artefact was then measured with the photogrammetry system in both normal and laser speckle projection modes and the resulting point clouds compared with the artefact CAD model. The results show that laser speckle projection can result in a reduction of the point cloud standard deviation from the CAD data of up to 101 μm. A complex relationship with surface texture, artefact geometry and the laser speckle projection is also observed and discussed.

Replicative manufacturing of complex lighting optics by non-isothermal glass molding

NASA Astrophysics Data System (ADS)

Kreilkamp, Holger; Vu, Anh Tuan; Dambon, Olaf; Klocke, Fritz

2016-09-01

The advantages of LED lighting, especially its energy efficiency and the long service life have led to a wide distribution of LED technology in the world. However, in order to make fully use of the great potential that LED lighting offers, complex optics are required to distribute the emitted light from the LED efficiently. Nowadays, many applications use polymer optics which can be manufactured at low costs. However, due to ever increasing luminous power, polymer optics reach their technological limits. Due to its outstanding properties, especially its temperature resistance, resistance against UV radiation and its long term stability, glass is the alternative material of choice for the use in LED optics. This research is introducing a new replicative glass manufacturing approach, namely non-isothermal glass molding (NGM) which is able to manufacture complex lighting optics in high volumes at competitive prices. The integration of FEM simulation at the early stage of the process development is presented and helps to guarantee a fast development cycle. A coupled thermo-mechanical model is used to define the geometry of the glass preform as well as to define the mold surface geometry. Furthermore, simulation is used to predict main process outcomes, especially in terms of resulting form accuracy of the molded optics. Experiments conducted on a commercially available molding machine are presented to validate the developed simulation model. Finally, the influence of distinct parameters on important process outcomes like form accuracy, surface roughness, birefringence, etc. is discussed.

Sustainability Characterization for Additive Manufacturing

PubMed Central

Mani, Mahesh; Lyons, Kevin W; Gupta, SK

2014-01-01

Additive manufacturing (AM) has the potential to create geometrically complex parts that require a high degree of customization, using less material and producing less waste. Recent studies have shown that AM can be an economically viable option for use by the industry, yet there are some inherent challenges associated with AM for wider acceptance. The lack of standards in AM impedes its use for parts production since industries primarily depend on established standards in processes and material selection to ensure the consistency and quality. Inability to compare AM performance against traditional manufacturing methods can be a barrier for implementing AM processes. AM process sustainability has become a driver due to growing environmental concerns for manufacturing. This has reinforced the importance to understand and characterize AM processes for sustainability. Process characterization for sustainability will help close the gaps for comparing AM performance to traditional manufacturing methods. Based on a literature review, this paper first examines the potential environmental impacts of AM. A methodology for sustainability characterization of AM is then proposed to serve as a resource for the community to benchmark AM processes for sustainability. Next, research perspectives are discussed along with relevant standardization efforts. PMID:26601038

Sustainability Characterization for Additive Manufacturing.

PubMed

Mani, Mahesh; Lyons, Kevin W; Gupta, S K

2014-01-01

Additive manufacturing (AM) has the potential to create geometrically complex parts that require a high degree of customization, using less material and producing less waste. Recent studies have shown that AM can be an economically viable option for use by the industry, yet there are some inherent challenges associated with AM for wider acceptance. The lack of standards in AM impedes its use for parts production since industries primarily depend on established standards in processes and material selection to ensure the consistency and quality. Inability to compare AM performance against traditional manufacturing methods can be a barrier for implementing AM processes. AM process sustainability has become a driver due to growing environmental concerns for manufacturing. This has reinforced the importance to understand and characterize AM processes for sustainability. Process characterization for sustainability will help close the gaps for comparing AM performance to traditional manufacturing methods. Based on a literature review, this paper first examines the potential environmental impacts of AM. A methodology for sustainability characterization of AM is then proposed to serve as a resource for the community to benchmark AM processes for sustainability. Next, research perspectives are discussed along with relevant standardization efforts.

APPROACHES TO GEOMETRIC DATA ANALYSIS ON BIG AREA ADDITIVELY MANUFACTURED (BAAM) PARTS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dreifus, Gregory D; Ally, Nadya R; Post, Brian K

The promise of additive manufacturing is that a user can design and print complex geometries that are very difficult, if not impossible, to machine. The capabilities of 3D printing are restricted by a number of factors, including properties of the build material, time constraints, and geometric design restrictions. In this paper, a thorough accounting and study of the geometric restrictions that exist in the current iteration of additive manufacturing (AM) fused deposition modeling (FDM) technologies are discussed. Offline and online methodologies for collecting data sets for qualitative analysis of large scale AM, in particular Oak Ridge National Laboratory s (ORNL)more » big area additive manufacturing (BAAM) system, are summarized. In doing so, a survey of tools for designers and software developers is provided. In particular, strategies in which geometric data can be used as training sets for smarter AM technologies in the future are explained as well.« less

Are Agile and Lean Manufacturing Systems Employing Sustainability, Complexity and Organizational Learning?

ERIC Educational Resources Information Center

Flumerfelt, Shannon; Siriban-Manalang, Anna Bella; Kahlen, Franz-Josef

2012-01-01

Purpose: This paper aims to peruse theories and practices of agile and lean manufacturing systems to determine whether they employ sustainability, complexity and organizational learning. Design/methodology/approach: The critical review of the comparative operational similarities and difference of the two systems was conducted while the new views…

Strength and Formability Improvement of Al-Cu-Mn Aluminum Alloy Complex Parts by Thermomechanical Treatment with Sheet Hydroforming

NASA Astrophysics Data System (ADS)

Chen, Yi-Zhe; Liu, Wei; Yuan, Shi-Jian

2015-05-01

Normally, the strength and formability of aluminum alloys can be increased largely by severe plastic deformation and heat treatment. However, many plastic deformation processes are more suitable for making raw material, not for formed parts. In this article, an experimental study of the thermomechanical treatment by using the sheet hydroforming process was developed to improve both mechanical strength and formability for aluminum alloys in forming complex parts. The limiting drawing ratio, thickness, and strain distribution of complex parts formed by sheet hydroforming were investigated to study the formability and sheet-deformation behavior. Based on the optimal formed parts, the tensile strength, microhardness, grain structure, and strengthening precipitates were analyzed to identify the strengthening effect of thermomechanical treatment. The results show that in the solution state, the limiting drawing ratio of cylindrical parts could be increased for 10.9% compared with traditional deep drawing process. The peak values of tensile stress and microhardness of formed parts are 18.0% and 12.5% higher than that in T6 state. This investigation shows that the thermomechanical treatment by sheet hydroforming is a potential method for the products manufacturing of aluminum alloy with high strength and good formability.

40 CFR 63.5787 - What if I also manufacture fiberglass boats or boat parts?

Code of Federal Regulations, 2012 CFR

2012-07-01

... boats or boat parts? 63.5787 Section 63.5787 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY... Composites Production What This Subpart Covers § 63.5787 What if I also manufacture fiberglass boats or boat parts? (a) If your source meets the applicability criteria in § 63.5785, and is not subject to the Boat...

40 CFR 63.5787 - What if I also manufacture fiberglass boats or boat parts?

Code of Federal Regulations, 2011 CFR

2011-07-01

... boats or boat parts? 63.5787 Section 63.5787 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY... Production What This Subpart Covers § 63.5787 What if I also manufacture fiberglass boats or boat parts? (a) If your source meets the applicability criteria in § 63.5785, and is not subject to the Boat...

40 CFR 63.5787 - What if I also manufacture fiberglass boats or boat parts?

Code of Federal Regulations, 2013 CFR

2013-07-01

... boats or boat parts? 63.5787 Section 63.5787 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY... Composites Production What This Subpart Covers § 63.5787 What if I also manufacture fiberglass boats or boat parts? (a) If your source meets the applicability criteria in § 63.5785, and is not subject to the Boat...

40 CFR 63.5787 - What if I also manufacture fiberglass boats or boat parts?

Code of Federal Regulations, 2014 CFR

2014-07-01

... boats or boat parts? 63.5787 Section 63.5787 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY... Composites Production What This Subpart Covers § 63.5787 What if I also manufacture fiberglass boats or boat parts? (a) If your source meets the applicability criteria in § 63.5785, and is not subject to the Boat...

Complex Network Analysis for Characterizing Global Value Chains in Equipment Manufacturing

PubMed Central

Meng, Bo; Cheng, Lihong

2017-01-01

The rise of global value chains (GVCs) characterized by the so-called “outsourcing”, “fragmentation production”, and “trade in tasks” has been considered one of the most important phenomena for the 21st century trade. GVCs also can play a decisive role in trade policy making. However, due to the increasing complexity and sophistication of international production networks, especially in the equipment manufacturing industry, conventional trade statistics and the corresponding trade indicators may give us a distorted picture of trade. This paper applies various network analysis tools to the new GVC accounting system proposed by Koopman et al. (2014) and Wang et al. (2013) in which gross exports can be decomposed into value-added terms through various routes along GVCs. This helps to divide the equipment manufacturing-related GVCs into some sub-networks with clear visualization. The empirical results of this paper significantly improve our understanding of the topology of equipment manufacturing-related GVCs as well as the interdependency of countries in these GVCs that is generally invisible from the traditional trade statistics. PMID:28081201

Complex Network Analysis for Characterizing Global Value Chains in Equipment Manufacturing.

PubMed

Xiao, Hao; Sun, Tianyang; Meng, Bo; Cheng, Lihong

2017-01-01

The rise of global value chains (GVCs) characterized by the so-called "outsourcing", "fragmentation production", and "trade in tasks" has been considered one of the most important phenomena for the 21st century trade. GVCs also can play a decisive role in trade policy making. However, due to the increasing complexity and sophistication of international production networks, especially in the equipment manufacturing industry, conventional trade statistics and the corresponding trade indicators may give us a distorted picture of trade. This paper applies various network analysis tools to the new GVC accounting system proposed by Koopman et al. (2014) and Wang et al. (2013) in which gross exports can be decomposed into value-added terms through various routes along GVCs. This helps to divide the equipment manufacturing-related GVCs into some sub-networks with clear visualization. The empirical results of this paper significantly improve our understanding of the topology of equipment manufacturing-related GVCs as well as the interdependency of countries in these GVCs that is generally invisible from the traditional trade statistics.

Cement manufacture and the environment - Part I: Chemistry and technology

USGS Publications Warehouse

Van Oss, H. G.; Padovani, A.C.

2002-01-01

Hydraulic (chiefly portland) cement is the binding agent in concrete and mortar and thus a key component of a country's construction sector. Concrete is arguably the most abundant of all manufactured solid materials. Portland cement is made primarily from finely ground clinker, which itself is composed dominantly of hydraulically active calcium silicate minerals formed through high-temperature burning of limestone and other materials in a kiln. This process requires approximately 1.7 tons of raw materials perton of clinker produced and yields about 1 ton of carbon dioxide (CO2) emissions, of which calcination of limestone and the combustion of fuels each contribute about half. The overall level of CO2 output makes the cement industry one of the top two manufacturing industry sources of greenhouse gases; however, in many countries, the cement industry's contribution is a small fraction of that from fossil fuel combustion by power plants and motor vehicles. The nature of clinker and the enormous heat requirements of its manufacture allow the cement industry to consume a wide variety of waste raw materials and fuels, thus providing the opportunity to apply key concepts of industrial ecology, most notably the closing of loops through the use of by-products of other industries (industrial symbiosis). In this article, the chemistry and technology of cement manufacture are summarized. In a forthcoming companion article (part II), some of the environmental challenges and opportunities facing the cement industry are described. Because of the size and scope of the U.S. cement industry, the analysis relies primarily on data and practices from the United States.

Part height control of laser metal additive manufacturing process

NASA Astrophysics Data System (ADS)

Pan, Yu-Herng

Laser Metal Deposition (LMD) has been used to not only make but also repair damaged parts in a layer-by-layer fashion. Parts made in this manner may produce less waste than those made through conventional machining processes. However, a common issue of LMD involves controlling the deposition's layer thickness. Accuracy is important, and as it increases, both the time required to produce the part and the material wasted during the material removal process (e.g., milling, lathe) decrease. The deposition rate is affected by multiple parameters, such as the powder feed rate, laser input power, axis feed rate, material type, and part design, the values of each of which may change during the LMD process. Using a mathematical model to build a generic equation that predicts the deposition's layer thickness is difficult due to these complex parameters. In this thesis, we propose a simple method that utilizes a single device. This device uses a pyrometer to monitor the current build height, thereby allowing the layer thickness to be controlled during the LMD process. This method also helps the LMD system to build parts even with complex parameters and to increase material efficiency.

New surface smoothing technologies for manufacturing of complex shaped glass components

NASA Astrophysics Data System (ADS)

Henkel, Sebastian; Schwager, Anne-Marie; Bliedtner, Jens; Götze, Kerstin; Rädlein, Edda; Schulze, Christian; Gerhardt, Martin; Fuhr, Michael

2017-10-01

The production of complex glass components with 2.5D or 3D-structures involves great effort and the need for advanced CNC-technology. Especially the final surface treatment, for generation of transparent surfaces, represents a timeconsuming and costly process. The ultrasonic-assisted grinding procedure is used to generate arbitrary shaped components and freeform-surfaces. The special kinematic principle, containing a high-frequency tool oscillation, enables efficient manufacturing processes. Surfaces produced in this way allow for application of novel smoothing methods, providing considerable advantages compared to classic polishing. It is shown, that manufacturing of transparent glass surfaces with low roughness down to Rq = 10 nm is possible, using an ultra-fine grinding process. By adding a CO2-laser polishing process, roughness can be reduced even further with a very short polishing time.

Additive Manufacturing for Affordable Rocket Engines

NASA Technical Reports Server (NTRS)

West, Brian; Robertson, Elizabeth; Osborne, Robin; Calvert, Marty

2016-01-01

Additive manufacturing (also known as 3D printing) technology has the potential to drastically reduce costs and lead times associated with the development of complex liquid rocket engine systems. NASA is using 3D printing to manufacture rocket engine components including augmented spark igniters, injectors, turbopumps, and valves. NASA is advancing the process to certify these components for flight. Success Story: MSFC has been developing rocket 3D-printing technology using the Selective Laser Melting (SLM) process. Over the last several years, NASA has built and tested several injectors and combustion chambers. Recently, MSFC has 3D printed an augmented spark igniter for potential use the RS-25 engines that will be used on the Space Launch System. The new design is expected to reduce the cost of the igniter by a factor of four. MSFC has also 3D printed and tested a liquid hydrogen turbopump for potential use on an Upper Stage Engine. Additive manufacturing of the turbopump resulted in a 45% part count reduction. To understanding how the 3D printed parts perform and to certify them for flight, MSFC built a breadboard liquid rocket engine using additive manufactured components including injectors, turbomachinery, and valves. The liquid rocket engine was tested seven times in 2016 using liquid oxygen and liquid hydrogen. In addition to exposing the hardware to harsh environments, engineers learned to design for the new manufacturing technique, taking advantage of its capabilities and gaining awareness of its limitations. Benefit: The 3D-printing technology promises reduced cost and schedule for rocket engines. Cost is a function of complexity, and the most complicated features provide the largest opportunities for cost reductions. This is especially true where brazes or welds can be eliminated. The drastic reduction in part count achievable with 3D printing creates a waterfall effect that reduces the number of processes and drawings, decreases the amount of touch

Additive Manufacturing (3D Printing) Aircraft Parts and Tooling at the Maintenance Group Level

DTIC Science & Technology

The purpose of this research was to evaluate the effectiveness of additive manufacturing (AM) or 3D printing for the Air Force aircraft maintenance...case study of the 552d MXGs 3D printing operation explores their use of a Fused Deposition Modeling (FDM) thermoplastic material to manufacture parts...by applying the case study’s analysis toward a proof of concept, producing a C-130J Aft Cargo Door Rub Strip for 3D printing . The study concluded by

Process combinations for the manufacturing of metal-plastic hybrid parts

NASA Astrophysics Data System (ADS)

Drossel, W.-G.; Lies, C.; Albert, A.; Haase, R.; Müller, R.; Scholz, P.

2016-03-01

The usage of innovative lightweight materials and processing technologies gains importance in manifold industrial scopes. Especially for moving parts and mobility products the weight is decisively. The aerospace and automotive industries use light and high-strength materials to reduce weight and energy consumption and thereby improve the performance of their products. Composites with reinforced plastics are of particular importance. They offer a low density in combination with high specific stiffness and strength. A pure material substitution through reinforced plastics is still not economical. The approach of using hybrid metal-plastic structures with the principle of “using the right material at the right place” is a promising solution for the economical realization of lightweight structures with a high achievement potential. The article shows four innovative manufacturing possibilities for the realization of metal-plastic-hybrid parts.

Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

NASA Astrophysics Data System (ADS)

MacDonald, D.; Fernández, R.; Delloro, F.; Jodoin, B.

2017-04-01

Titanium parts are ideally suited for aerospace applications due to their unique combination of high specific strength and excellent corrosion resistance. However, titanium as bulk material is expensive and challenging/costly to machine. Production of complex titanium parts through additive manufacturing looks promising, but there are still many barriers to overcome before reaching mainstream commercialization. The cold gas dynamic spraying process offers the potential for additive manufacturing of large titanium parts due to its reduced reactive environment, its simplicity to operate, and the high deposition rates it offers. A few challenges are to be addressed before the additive manufacturing potential of titanium by cold gas dynamic spraying can be reached. In particular, it is known that titanium is easy to deposit by cold gas dynamic spraying, but the deposits produced are usually porous when nitrogen is used as the carrier gas. In this work, a method to manufacture low-porosity titanium components at high deposition efficiencies is revealed. The components are produced by combining low-pressure cold spray using nitrogen as the carrier gas with low-cost titanium powder produced using the Armstrong process. The microstructure and mechanical properties of additive manufactured titanium components are investigated.

Digitalization in roll forming manufacturing

NASA Astrophysics Data System (ADS)

Sedlmaier, A.; Dietl, T.; Ferreira, P.

2017-09-01

Roll formed profiles are used in automotive chassis production as building blocks for the body-in-white. The ability to produce profiles with discontinuous cross sections, both in width and in depth, allows weight savings in the final automotive chassis through the use of load optimized cross sections. This has been the target of the 3D Roll Forming process. A machine concept is presented where a new forming concept for roll formed parts in combination with advanced robotics allowing freely positioned roll forming tooling in 3D space enables the production of complex shapes by roll forming. This is a step forward into the digitalization of roll forming manufacturing by making the process flexible and capable of rapid prototyping and production of small series of parts. Moreover, data collection in a large scale through the control system and integrated sensors lead to an increased understanding of the process and provide the basis to develop self-optimizing roll forming machines, increasing the productivity, quality and predictability of the roll-forming process. The first parts successfully manufactured with this new forming concept are presented.

Modeling of additive manufacturing processes for metals: Challenges and opportunities

DOE PAGES

Francois, Marianne M.; Sun, Amy; King, Wayne E.; ...

2017-01-09

Here, with the technology being developed to manufacture metallic parts using increasingly advanced additive manufacturing processes, a new era has opened up for designing novel structural materials, from designing shapes and complex geometries to controlling the microstructure (alloy composition and morphology). The material properties used within specific structural components are also designable in order to meet specific performance requirements that are not imaginable with traditional metal forming and machining (subtractive) techniques.

The Future of Pharmaceutical Manufacturing Sciences.

PubMed

Rantanen, Jukka; Khinast, Johannes

2015-11-01

The entire pharmaceutical sector is in an urgent need of both innovative technological solutions and fundamental scientific work, enabling the production of highly engineered drug products. Commercial-scale manufacturing of complex drug delivery systems (DDSs) using the existing technologies is challenging. This review covers important elements of manufacturing sciences, beginning with risk management strategies and design of experiments (DoE) techniques. Experimental techniques should, where possible, be supported by computational approaches. With that regard, state-of-art mechanistic process modeling techniques are described in detail. Implementation of materials science tools paves the way to molecular-based processing of future DDSs. A snapshot of some of the existing tools is presented. Additionally, general engineering principles are discussed covering process measurement and process control solutions. Last part of the review addresses future manufacturing solutions, covering continuous processing and, specifically, hot-melt processing and printing-based technologies. Finally, challenges related to implementing these technologies as a part of future health care systems are discussed. © 2015 The Authors. Journal of Pharmaceutical Sciences published by Wiley Periodicals, Inc. and the American Pharmacists Association.

Solving the Big Data (BD) Problem in Advanced Manufacturing (Subcategory for work done at Georgia Tech. Study Process and Design Factors for Additive Manufacturing Improvement)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Clark, Brett W.; Diaz, Kimberly A.; Ochiobi, Chinaza Darlene

2015-09-01

3D printing originally known as additive manufacturing is a process of making 3 dimensional solid objects from a CAD file. This ground breaking technology is widely used for industrial and biomedical purposes such as building objects, tools, body parts and cosmetics. An important benefit of 3D printing is the cost reduction and manufacturing flexibility; complex parts are built at the fraction of the price. However, layer by layer printing of complex shapes adds error due to the surface roughness. Any such error results in poor quality products with inaccurate dimensions. The main purpose of this research is to measure themore » amount of printing errors for parts with different geometric shapes and to analyze them for finding optimal printing settings to minimize the error. We use a Design of Experiments framework, and focus on studying parts with cone and ellipsoid shapes. We found that the orientation and the shape of geometric shapes have significant effect on the printing error. From our analysis, we also determined the optimal orientation that gives the least printing error.« less

Influence of Plastic Deformation on Martensitic Transformation During Hot Stamping of Complex Structure Auto Parts

NASA Astrophysics Data System (ADS)

Shen, Yuhan; Song, Yanli; Hua, Lin; Lu, Jue

2017-04-01

The ultra-high strength steel auto parts manufactured by hot stamping are widely applied for weight reduction and safety improvement. During the hot stamping process, hot forming and quenching are performed in one step wherein plastic deformation and phase transformation simultaneously take place and affect each other. Thereinto, the influence of deformation on martensitic transformation is of great importance. In the present paper, the influence of plastic deformation on martensitic transformation during hot stamping of complex structure auto parts was investigated. For this purpose, a B-pillar reinforced panel in B1500HS steel was manufactured by hot stamping, and the process was simulated by finite element software based on a thermo-mechanical-metallurgical coupled model. Considering various deformation degrees, the microstructures and mechanical properties at four typical locations of the hot stamped B-pillar reinforced panel were detected. The results show that the martensitic content and the microhardness increase with the increase in the deformation amount. There are two reasons causing this phenomenon: (1) the increase in mechanical driving force and (2) the increased probability of the martensitic nucleation at crystal defects. The x-ray diffraction analysis indicates the carbon enrichment in retained austenite which results from the carbon diffusion during the low-carbon martensite formation. Furthermore, the carbon content decreases with the increase in the deformation amount, because the deformation of austenite suppresses the carbon diffusion.

Solid-State Additive Manufacturing for Heat Exchangers

NASA Astrophysics Data System (ADS)

Norfolk, Mark; Johnson, Hilary

2015-03-01

Energy densities in devices are increasing across many industries including power generation, high power electronics, manufacturing, and automotive. Increasingly, there is a need for very high efficiency thermal management devices that can pull heat out of a small area at higher and higher rates. Metal additive manufacturing (AM) technologies have the promise of creating parts with complex internal geometries required for integral thermal management. However, this goal has not been met due to constraints in fusion-based metal 3D printers. This work presents a new strategy for metal AM of heat exchangers using an ultrasonic sheet lamination approach.

In-Situ Printing of Conductive Polylactic Acid (cPLA) Strain Sensors Embedded into Additively Manufactured Parts using Fused Deposition Modeling

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ouellette, Brittany Joy

Additive Manufacturing (AM) technology has been around for decades, but until recently, machines have been expensive, relatively large, and not available to most institutions. Increased technological advances in 3D printing and awareness throughout industry, universities, and even hobbyists has increased demand to substitute AM parts in place of traditionally manufactured (subtractive) designs; however, there is a large variability of part quality and mechanical behavior due to the inherent printing process, which must be understood before AM parts are used for load bearing and structural design.

Structure and properties of parts produced by electron-beam additive manufacturing

NASA Astrophysics Data System (ADS)

Klimenov, Vasilii; Klopotov, Anatolii; Fedorov, Vasilii; Abzaev, Yurii; Batranin, Andrey; Kurgan, Kirill; Kairalapov, Daniyar

2017-12-01

The paper deals with the study of structure, microstructure, composition and microhardness of a tube processed by electron-beam additive manufacturing using optical and scanning electron microscopy. The structure and macrodefects of a tube made of Grade2 titanium alloy is studied using the X-ray computed tomography. The principles of layer-by-layer assembly and boundaries after powder sintering are set out in this paper. It is found that the titanium alloy has two phases. Future work will involve methods to improve properties of created parts.

Considerations on the construction of a Powder Bed Fusion platform for Additive Manufacturing

NASA Astrophysics Data System (ADS)

Andersen, Sebastian Aagaard; Nielsen, Karl-Emil; Pedersen, David Bue; Nielsen, Jakob Skov

As the demand for moulds and other tools becomes increasingly specific and complex, an additive manufacturing approach to production is making its way to the industry through laser based consolidation of metal powder particles by a method known as powder bed fusion. This paper concerns a variety of design choices facilitating the development of an experimental powder bed fusion machine tool, capable of manufacturing metal parts with strength matching that of conventional manufactured parts and a complexity surpassing that of subtractive processes. To understand the different mechanisms acting within such an experimental machine tool, a fully open and customizable rig is constructed. Emphasizing modularity in the rig, allows alternation of lasers, scanner systems, optical elements, powder deposition, layer height, temperature, atmosphere, and powder type. Through a custom-made software platform, control of the process is achieved, which extends into a graphical user interface, easing adjustment of process parameters and the job file generation.

Additive Manufacturing Processes: Selective Laser Melting, Electron Beam Melting and Binder Jetting—Selection Guidelines

PubMed Central

Konda Gokuldoss, Prashanth; Kolla, Sri; Eckert, Jürgen

2017-01-01

Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is gaining increasing attention due to its ability to produce parts with added functionality and increased complexities in geometrical design, on top of the fact that it is theoretically possible to produce any shape without limitations. However, most of the research on additive manufacturing techniques are focused on the development of materials/process parameters/products design with different additive manufacturing processes such as selective laser melting, electron beam melting, or binder jetting. However, we do not have any guidelines that discuss the selection of the most suitable additive manufacturing process, depending on the material to be processed, the complexity of the parts to be produced, or the design considerations. Considering the very fact that no reports deal with this process selection, the present manuscript aims to discuss the different selection criteria that are to be considered, in order to select the best AM process (binder jetting/selective laser melting/electron beam melting) for fabricating a specific component with a defined set of material properties. PMID:28773031

Additive Manufacturing Processes: Selective Laser Melting, Electron Beam Melting and Binder Jetting-Selection Guidelines.

PubMed

Gokuldoss, Prashanth Konda; Kolla, Sri; Eckert, Jürgen

2017-06-19

Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is gaining increasing attention due to its ability to produce parts with added functionality and increased complexities in geometrical design, on top of the fact that it is theoretically possible to produce any shape without limitations. However, most of the research on additive manufacturing techniques are focused on the development of materials/process parameters/products design with different additive manufacturing processes such as selective laser melting, electron beam melting, or binder jetting. However, we do not have any guidelines that discuss the selection of the most suitable additive manufacturing process, depending on the material to be processed, the complexity of the parts to be produced, or the design considerations. Considering the very fact that no reports deal with this process selection, the present manuscript aims to discuss the different selection criteria that are to be considered, in order to select the best AM process (binder jetting/selective laser melting/electron beam melting) for fabricating a specific component with a defined set of material properties.

One-step volumetric additive manufacturing of complex polymer structures

DOE PAGES

Shusteff, Maxim; Browar, Allison E. M.; Kelly, Brett E.; ...

2017-12-01

Two limitations of additive manufacturing methods that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality). Both limitations are overcome in the work reported here, introducing a new volumetric additive fabrication paradigm that produces photopolymer structures with complex non-periodic 3D geometries on a timescale of seconds. We implement this approach using holographic patterning of light fields, demonstrate the fabrication of a variety of structures, and study the properties of the light patterns and photosensitive resins required for this fabrication approach. The results indicate that lowabsorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10-100more » mW) may be successfully used to build full structures in ~1-10 s.« less

One-step volumetric additive manufacturing of complex polymer structures

DOE Office of Scientific and Technical Information (OSTI.GOV)

Shusteff, Maxim; Browar, Allison E. M.; Kelly, Brett E.

Two limitations of additive manufacturing methods that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality). Both limitations are overcome in the work reported here, introducing a new volumetric additive fabrication paradigm that produces photopolymer structures with complex non-periodic 3D geometries on a timescale of seconds. We implement this approach using holographic patterning of light fields, demonstrate the fabrication of a variety of structures, and study the properties of the light patterns and photosensitive resins required for this fabrication approach. The results indicate that lowabsorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10-100more » mW) may be successfully used to build full structures in ~1-10 s.« less

One-step volumetric additive manufacturing of complex polymer structures

PubMed Central

Shusteff, Maxim; Browar, Allison E. M.; Kelly, Brett E.; Henriksson, Johannes; Weisgraber, Todd H.; Panas, Robert M.; Fang, Nicholas X.; Spadaccini, Christopher M.

2017-01-01

Two limitations of additive manufacturing methods that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality). Both limitations are overcome in the work reported here, introducing a new volumetric additive fabrication paradigm that produces photopolymer structures with complex nonperiodic three-dimensional geometries on a time scale of seconds. We implement this approach using holographic patterning of light fields, demonstrate the fabrication of a variety of structures, and study the properties of the light patterns and photosensitive resins required for this fabrication approach. The results indicate that low-absorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10 to 100 mW), may be successfully used to build full structures in ~1 to 10 s. PMID:29230437

One-step volumetric additive manufacturing of complex polymer structures.

PubMed

Shusteff, Maxim; Browar, Allison E M; Kelly, Brett E; Henriksson, Johannes; Weisgraber, Todd H; Panas, Robert M; Fang, Nicholas X; Spadaccini, Christopher M

2017-12-01

Two limitations of additive manufacturing methods that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality). Both limitations are overcome in the work reported here, introducing a new volumetric additive fabrication paradigm that produces photopolymer structures with complex nonperiodic three-dimensional geometries on a time scale of seconds. We implement this approach using holographic patterning of light fields, demonstrate the fabrication of a variety of structures, and study the properties of the light patterns and photosensitive resins required for this fabrication approach. The results indicate that low-absorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10 to 100 mW), may be successfully used to build full structures in ~1 to 10 s.

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing of Ceramic Composites. Part III; Additive Manufacturing and Characterization of Ceramic Composites

NASA Technical Reports Server (NTRS)

Halbig, Michael C.; Grady, Joseph E.; Singh, Mrityunjay; Ramsey, Jack; Patterson, Clark; Santelle, Tom

2015-01-01

This publication is the third part of a three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce ceramic matrix composite materials and aircraft engine components by the binder jet process. Different SiC powders with median sizes ranging from 9.3 to 53.0 microns were investigated solely and in powder blends in order to maximize powder packing. Various infiltration approaches were investigated to include polycarbosilane (SMP-10), phenolic, and liquid silicon. Single infiltrations of SMP-10 and phenolic only slightly filled in the interior. When the SMP-10 was loaded with sub-micron sized SiC powders, the infiltrant gave a much better result of filling in the interior. Silicon carbide fibers were added to the powder bed to make ceramic matrix composite materials. Microscopy showed that the fibers were well distributed with no preferred orientation on the horizontal plane and fibers in the vertical plane were at angles as much as 45deg. Secondary infiltration steps were necessary to further densify the material. Two to three extra infiltration steps of SMP-10 increased the density by 0.20 to 0.55 g/cc. However, the highest densities achieved were 2.10 to 2.15 g/cc. Mechanical tests consisting of 4 point bend tests were conducted. Samples from the two CMC panels had higher strengths and strains to failure than the samples from the two nonfiber reinforced panels. The highest strengths were from Set N with 65 vol% fiber loading which had an average strength of 66 MPa. Analysis of the fracture surfaces did not reveal pullout of the reinforcing fibers. Blunt fiber failure suggested that there was not composite behavior. The binder jet additive manufacturing method was used to also demonstrate the fabrication of turbine engine vane components of two different designs and sizes. The

Feedstock powder processing research needs for additive manufacturing development

DOE PAGES

Anderson, Iver E.; White, Emma M. H.; Dehoff, Ryan

2018-02-01

Additive manufacturing (AM) promises to redesign traditional manufacturing by enabling the ultimate in agility for rapid component design changes in commercial products and for fabricating complex integrated parts. Here, by significantly increasing quality and yield of metallic alloy powders, the pace for design, development, and deployment of the most promising AM approaches can be greatly accelerated, resulting in rapid commercialization of these advanced manufacturing methods. By successful completion of a critical suite of processing research tasks that are intended to greatly enhance gas atomized powder quality and the precision and efficiency of powder production, researchers can help promote continued rapidmore » growth of AM. Finally, other powder-based or spray-based advanced manufacturing methods could also benefit from these research outcomes, promoting the next wave of sustainable manufacturing technologies for conventional and advanced materials.« less

Feedstock powder processing research needs for additive manufacturing development

DOE Office of Scientific and Technical Information (OSTI.GOV)

Anderson, Iver E.; White, Emma M. H.; Dehoff, Ryan

Additive manufacturing (AM) promises to redesign traditional manufacturing by enabling the ultimate in agility for rapid component design changes in commercial products and for fabricating complex integrated parts. Here, by significantly increasing quality and yield of metallic alloy powders, the pace for design, development, and deployment of the most promising AM approaches can be greatly accelerated, resulting in rapid commercialization of these advanced manufacturing methods. By successful completion of a critical suite of processing research tasks that are intended to greatly enhance gas atomized powder quality and the precision and efficiency of powder production, researchers can help promote continued rapidmore » growth of AM. Finally, other powder-based or spray-based advanced manufacturing methods could also benefit from these research outcomes, promoting the next wave of sustainable manufacturing technologies for conventional and advanced materials.« less

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing, Part II: Additive Manufacturing and Characterization of Polymer Composites

NASA Technical Reports Server (NTRS)

Chuang, Kathy C.; Grady, Joseph E.; Arnold, Steven M.; Draper, Robert D.; Shin, Eugene; Patterson, Clark; Santelle, Tom; Lao, Chao; Rhein, Morgan; Mehl, Jeremy

2015-01-01

This publication is the second part of the three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides-Ultem 9085 and experimental Ultem 1000 mixed with 10% chopped carbon fiber. A property comparison between FDM-printed and injection molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25 to 31%. Coupons of Ultem 9085, experimental Ultem 1000 composites and XH6050 resin were tested at room temperature and 400F to evaluate their corresponding mechanical properties. A preliminary modeling was also initiated to predict the mechanical properties of FDM-printed Ultem 9085 coupons in relation to varied raster angles and void contents, using the GRC-developed MAC/GMC program.

The Future of Pharmaceutical Manufacturing Sciences

PubMed Central

2015-01-01

The entire pharmaceutical sector is in an urgent need of both innovative technological solutions and fundamental scientific work, enabling the production of highly engineered drug products. Commercial‐scale manufacturing of complex drug delivery systems (DDSs) using the existing technologies is challenging. This review covers important elements of manufacturing sciences, beginning with risk management strategies and design of experiments (DoE) techniques. Experimental techniques should, where possible, be supported by computational approaches. With that regard, state‐of‐art mechanistic process modeling techniques are described in detail. Implementation of materials science tools paves the way to molecular‐based processing of future DDSs. A snapshot of some of the existing tools is presented. Additionally, general engineering principles are discussed covering process measurement and process control solutions. Last part of the review addresses future manufacturing solutions, covering continuous processing and, specifically, hot‐melt processing and printing‐based technologies. Finally, challenges related to implementing these technologies as a part of future health care systems are discussed. © 2015 The Authors. Journal of Pharmaceutical Sciences published by Wiley Periodicals, Inc. and the American Pharmacists Association J Pharm Sci 104:3612–3638, 2015 PMID:26280993

Manufacturing plastic injection optical molds

NASA Astrophysics Data System (ADS)

Bourque, David

2008-08-01

ABCO Tool & Die, Inc. is a mold manufacturer specializing in the manufacturing of plastic injection molds for molded optical parts. The purpose of this presentation is to explain the concepts and procedures required to build a mold that produces precision optical parts. Optical molds can produce a variety of molded parts ranging from safety eyewear to sophisticated military lens parts, which must meet precise optical specifications. The manufacturing of these molds begins with the design engineering of precision optical components. The mold design and the related optical inserts are determined based upon the specific optical criteria and optical surface geometry. The mold manufacturing techniques will be based upon the optical surface geometry requirements and specific details. Manufacturing processes used will be specific to prescribed geometrical surface requirements of the molded part. The combined efforts result in a robust optical mold which can produce molded parts that meet the most precise optical specifications.

A Bootstrap Approach to Martian Manufacturing

NASA Technical Reports Server (NTRS)

Dorais, Gregory A.

2004-01-01

In-Situ Resource Utilization (ISRU) is an essential element of any affordable strategy for a sustained human presence on Mars. Ideally, Martian habitats would be extremely massive to allow plenty of room to comfortably live and work, as well as to protect the occupants from the environment. Moreover, transportation and power generation systems would also require significant mass if affordable. For our approach to ISRU, we use the industrialization of the U.S. as a metaphor. The 19th century started with small blacksmith shops and ended with massive steel mills primarily accomplished by blacksmiths increasing their production capacity and product size to create larger shops, which produced small mills, which produced the large steel mills that industrialized the country. Most of the mass of a steel mill is comprised of steel in simple shapes, which are produced and repaired with few pieces of equipment also mostly made of steel in basic shapes. Due to this simplicity, we expect that the 19th century manufacturing growth can be repeated on Mars in the 21st century using robots as the primary labor force. We suggest a "bootstrap" approach to manufacturing on Mars that uses a "seed" manufacturing system that uses regolith to create major structural components and spare parts. The regolith would be melted, foamed, and sintered as needed to fabricate parts using casting and solid freeform fabrication techniques. Complex components, such as electronics, would be brought from Earth and integrated as needed. These parts would be assembled to create additional manufacturing systems, which can be both more capable and higher capacity. These subsequent manufacturing systems could refine vast amounts of raw materials to create large components, as well as assemble equipment, habitats, pressure vessels, cranes, pipelines, railways, trains, power generation stations, and other facilities needed to economically maintain a sustained human presence on Mars.

10 CFR 2.501 - Notice of hearing on application under subpart F of 10 CFR part 52 for a license to manufacture...

Code of Federal Regulations, 2011 CFR

2011-01-01

... part 52 for a license to manufacture nuclear power reactors. 2.501 Section 2.501 Energy NUCLEAR... Procedures Applicable to Proceedings for the Issuance of Licenses To Manufacture Nuclear Power Reactors To Be... power reactors. (a) In the case of an application under subpart F of part 52 of this chapter for a...

10 CFR 2.501 - Notice of hearing on application under subpart F of 10 CFR part 52 for a license to manufacture...

Code of Federal Regulations, 2010 CFR

2010-01-01

... part 52 for a license to manufacture nuclear power reactors. 2.501 Section 2.501 Energy NUCLEAR... Procedures Applicable to Proceedings for the Issuance of Licenses To Manufacture Nuclear Power Reactors To Be... power reactors. (a) In the case of an application under subpart F of part 52 of this chapter for a...

Design and optimization of the micro-engine turbine rotor manufacturing using the rapid prototyping technology

NASA Astrophysics Data System (ADS)

Vdovin, R. A.; Smelov, V. G.

2017-02-01

This work describes the experience in manufacturing the turbine rotor for the micro-engine. It demonstrates the design principles for the complex investment casting process combining the use of the ProCast software and the rapid prototyping techniques. At the virtual modelling stage, in addition to optimized process parameters, the casting structure was improved to obtain the defect-free section. The real production stage allowed demonstrating the performance and fitness of rapid prototyping techniques for the manufacture of geometrically-complex engine-building parts.

Integrated flexible manufacturing program for manufacturing automation and rapid prototyping

NASA Technical Reports Server (NTRS)

Brooks, S. L.; Brown, C. W.; King, M. S.; Simons, W. R.; Zimmerman, J. J.

1993-01-01

The Kansas City Division of Allied Signal Inc., as part of the Integrated Flexible Manufacturing Program (IFMP), is developing an integrated manufacturing environment. Several systems are being developed to produce standards and automation tools for specific activities within the manufacturing environment. The Advanced Manufacturing Development System (AMDS) is concentrating on information standards (STEP) and product data transfer; the Expert Cut Planner system (XCUT) is concentrating on machining operation process planning standards and automation capabilities; the Advanced Numerical Control system (ANC) is concentrating on NC data preparation standards and NC data generation tools; the Inspection Planning and Programming Expert system (IPPEX) is concentrating on inspection process planning, coordinate measuring machine (CMM) inspection standards and CMM part program generation tools; and the Intelligent Scheduling and Planning System (ISAPS) is concentrating on planning and scheduling tools for a flexible manufacturing system environment. All of these projects are working together to address information exchange, standardization, and information sharing to support rapid prototyping in a Flexible Manufacturing System (FMS) environment.

Effect of IN718 Recycled Powder Reuse on Properties of Parts Manufactured by Means of Selective Laser Melting

NASA Astrophysics Data System (ADS)

Ardila, L. C.; Garciandia, F.; González-Díaz, J. B.; Álvarez, P.; Echeverria, A.; Petite, M. M.; Deffley, R.; Ochoa, J.

Powder quality control is essential to obtain parts with suitable mechanical properties in Selective Laser Melting manufacturing technique. One of the most important advantages of suchtechnique is that it allows an efficient use of the material, due to the possibility to recycle and reuse un-melted powder. Nevertheless, powder material properties may change due to repeated recycling, affecting this way the mechanicalbehavior of parts. In this paper the effect of powder reuse on its quality and on the mechanical properties of the resulting melted parts is studied via self-developed recycling methodology. The material considered for investigation was IN718, a nickel superalloy widely used in industry. After recycling powder up to 14 times, no significant changes were observed in powder and test parts properties. The results obtained in this work will help to validate powder recycling methodology for its use in current industrial Selective Laser Melting manufacturing.

Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control.

PubMed

Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

2014-01-01

Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented.

Characterization of Metal Powders Used for Additive Manufacturing.

PubMed

Slotwinski, J A; Garboczi, E J; Stutzman, P E; Ferraris, C F; Watson, S S; Peltz, M A

2014-01-01

Additive manufacturing (AM) techniques can produce complex, high-value metal parts, with potential applications as critical parts, such as those found in aerospace components. The production of AM parts with consistent and predictable properties requires input materials (e.g., metal powders) with known and repeatable characteristics, which in turn requires standardized measurement methods for powder properties. First, based on our previous work, we assess the applicability of current standardized methods for powder characterization for metal AM powders. Then we present the results of systematic studies carried out on two different powder materials used for additive manufacturing: stainless steel and cobalt-chrome. The characterization of these powders is important in NIST efforts to develop appropriate measurements and standards for additive materials and to document the property of powders used in a NIST-led additive manufacturing material round robin. An extensive array of characterization techniques was applied to these two powders, in both virgin and recycled states. The physical techniques included laser diffraction particle size analysis, X-ray computed tomography for size and shape analysis, and optical and scanning electron microscopy. Techniques sensitive to structure and chemistry, including X-ray diffraction, energy dispersive analytical X-ray analysis using the X-rays generated during scanning electron microscopy, and X-Ray photoelectron spectroscopy were also employed. The results of these analyses show how virgin powder changes after being exposed to and recycled from one or more Direct Metal Laser Sintering (DMLS) additive manufacturing build cycles. In addition, these findings can give insight into the actual additive manufacturing process.

Characterization of Metal Powders Used for Additive Manufacturing

PubMed Central

Slotwinski, JA; Garboczi, EJ; Stutzman, PE; Ferraris, CF; Watson, SS; Peltz, MA

2014-01-01

Additive manufacturing (AM) techniques1 can produce complex, high-value metal parts, with potential applications as critical parts, such as those found in aerospace components. The production of AM parts with consistent and predictable properties requires input materials (e.g., metal powders) with known and repeatable characteristics, which in turn requires standardized measurement methods for powder properties. First, based on our previous work, we assess the applicability of current standardized methods for powder characterization for metal AM powders. Then we present the results of systematic studies carried out on two different powder materials used for additive manufacturing: stainless steel and cobalt-chrome. The characterization of these powders is important in NIST efforts to develop appropriate measurements and standards for additive materials and to document the property of powders used in a NIST-led additive manufacturing material round robin. An extensive array of characterization techniques was applied to these two powders, in both virgin and recycled states. The physical techniques included laser diffraction particle size analysis, X-ray computed tomography for size and shape analysis, and optical and scanning electron microscopy. Techniques sensitive to structure and chemistry, including X-ray diffraction, energy dispersive analytical X-ray analysis using the X-rays generated during scanning electron microscopy, and X-Ray photoelectron spectroscopy were also employed. The results of these analyses show how virgin powder changes after being exposed to and recycled from one or more Direct Metal Laser Sintering (DMLS) additive manufacturing build cycles. In addition, these findings can give insight into the actual additive manufacturing process. PMID:26601040

Determination of Process Parameters for High-Density, Ti-6Al-4V Parts Using Additive Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kamath, C.

In our earlier work, we described an approach for determining the process parameters that re- sult in high-density parts manufactured using the additive-manufacturing process of selective laser melting (SLM). Our approach, which combines simple simulations and experiments, was demon- strated using 316L stainless steel. We have also used the approach successfully for several other materials. This short note summarizes the results of our work in determining process parameters for Ti-6Al-4V using a Concept Laser M2 system.

Design and development of a layer-based additive manufacturing process for the realization of metal parts of designed mesostructure

NASA Astrophysics Data System (ADS)

Williams, Christopher Bryant

Low-density cellular materials, metallic bodies with gaseous voids, are a unique class of materials that are characterized by their high strength, low mass, good energy absorption characteristics, and good thermal and acoustic insulation properties. In an effort to take advantage of this entire suite of positive mechanical traits, designers are tailoring the cellular mesostructure for multiple design objectives. Unfortunately, existing cellular material manufacturing technologies limit the design space as they are limited to certain part mesostructure, material type, and macrostructure. The opportunity that exists to improve the design of existing products, and the ability to reap the benefits of cellular materials in new applications is the driving force behind this research. As such, the primary research goal of this work is to design, embody, and analyze a manufacturing process that provides a designer the ability to specify the material type, material composition, void morphology, and mesostructure topology for any conceivable part geometry. The accomplishment of this goal is achieved in three phases of research: (1) Design---Following a systematic design process and a rigorous selection exercise, a layer-based additive manufacturing process is designed that is capable of meeting the unique requirements of fabricating cellular material geometry. Specifically, metal parts of designed mesostructure are fabricated via three-dimensional printing of metal oxide ceramic powder followed by post-processing in a reducing atmosphere. (2) Embodiment ---The primary research hypothesis is verified through the use of the designed manufacturing process chain to successfully realize metal parts of designed mesostructure. (3) Modeling & Evaluation ---The designed manufacturing process is modeled in this final research phase so as to increase understanding of experimental results and to establish a foundation for future analytical modeling research. In addition to an analysis of

Additive Manufacturing of Multifunctional Components Using High Density Carbon Nanotube Yarn Filaments

NASA Technical Reports Server (NTRS)

Gardner, John M.; Sauti, Godfrey; Kim, Jae-Woo; Cano, Roberto J.; Wincheski, Russell A.; Stelter, Christopher J.; Grimsley, Brian W.; Working, Dennis C.; Siochi, Emilie J.

2016-01-01

Additive manufacturing allows for design freedom and part complexity not currently attainable using traditional manufacturing technologies. Fused Filament Fabrication (FFF), for example, can yield novel component geometries and functionalities because the method provides a high level of control over material placement and processing conditions. This is achievable by extrusion of a preprocessed filament feedstock material along a predetermined path. However if fabrication of a multifunctional part relies only on conventional filament materials, it will require a different material for each unique functionality printed into the part. Carbon nanotubes (CNTs) are an attractive material for many applications due to their high specific strength as well as good electrical and thermal conductivity. The presence of this set of properties in a single material presents an opportunity to use one material to achieve multifunctionality in an additively manufactured part. This paper describes a recently developed method for processing continuous CNT yarn filaments into three-dimensional articles, and summarizes the mechanical, electrical, and sensing performance of the components fabricated in this way.

Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control

PubMed Central

Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

2014-01-01

Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part’s porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented. PMID:26601041

“Additive Manufacturing: Building the Pathway Towards Process and Material Qualification”

DOE PAGES

Carpenter, John S.; Beese, Allison M.; Bourell, David L.; ...

2016-06-14

The potential benefits of metal additive manufacturing, as compared with more traditional, subtractive-only approaches, has created excitement within design circles seeking to take advantage of the ability to build and repair complex shapes, to integrate or consolidate multiple parts and minimize joining concerns, and to locally tailor material properties to increase functionality. Tempering the excitement of designers, however, has been concerns with the material deposited by the process. It is not enough for a part to ‘look’ right from a geometric perspective. Rather, the metallurgical aspects associated with the material being deposited must ‘look’ and ‘behave’ correctly along with themore » aforementioned geometric accuracy. Finally, without elucidation of the connections between processing, microstructure, properties, and performance from a materials science perspective, metal additive manufacturing will not realize its potential to change the manufacturing world for property and performance-critical engineering applications.« less

Exploring Manufacturing Occupations. Instructor's Guide. The Manufacturing Cluster.

ERIC Educational Resources Information Center

Fairleigh Dickinson Univ., Rutherford, NJ.

The major focus of this guide and its accompanying student manual (CE 010 397) is to help the student understand the manufacturing enterprise. (The guide and student manual are part of a manufacturing cluster series which addresses itself to career awareness, orientation, exploration, and preparation.) Seven sections are included. An overview of…

Evaluation of Additive Manufacturing for Composite Part Molds

DOE Office of Scientific and Technical Information (OSTI.GOV)

Duty, Chad E.; Springfield, Robert M.

2015-02-01

The ORNL Manufacturing Demonstration Facility (MDF) collaborated with Tru-Design to test the quality and durability of molds used for making fiber reinforced composites using additive manufacturing. The partners developed surface treatment techniques including epoxy coatings and machining to improve the quality of the surface finish. Test samples made using the printed and surface finished molds demonstrated life spans suitable for one-of-a-kind and low-volume applications, meeting the project objective.

19 CFR Appendix A to Part 191 - General Manufacturing Drawback Rulings

Code of Federal Regulations, 2010 CFR

2010-04-01

... manufacture or production. B. These general manufacturing drawback rulings supersede general “contracts... manufacturing drawback rulings which have been designed to simplify drawback procedures. Any person who can... drawback; and 9. Description of the manufacturing or production process, unless specifically described in...

Highly Manufacturable Deep (Sub-Millimeter) Etching Enabled High Aspect Ratio Complex Geometry Lego-Like Silicon Electronics.

PubMed

Ghoneim, Mohamed Tarek; Hussain, Muhammad Mustafa

2017-04-01

A highly manufacturable deep reactive ion etching based process involving a hybrid soft/hard mask process technology shows high aspect ratio complex geometry Lego-like silicon electronics formation enabling free-form (physically flexible, stretchable, and reconfigurable) electronic systems. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Design for Additive Bio-Manufacturing: From Patient-Specific Medical Devices to Rationally Designed Meta-Biomaterials.

PubMed

Zadpoor, Amir A

2017-07-25

Recent advances in additive manufacturing (AM) techniques in terms of accuracy, reliability, the range of processable materials, and commercial availability have made them promising candidates for production of functional parts including those used in the biomedical industry. The complexity-for-free feature offered by AM means that very complex designs become feasible to manufacture, while batch-size-indifference enables fabrication of fully patient-specific medical devices. Design for AM (DfAM) approaches aim to fully utilize those features for development of medical devices with substantially enhanced performance and biomaterials with unprecedented combinations of favorable properties that originate from complex geometrical designs at the micro-scale. This paper reviews the most important approaches in DfAM particularly those applicable to additive bio-manufacturing including image-based design pipelines, parametric and non-parametric designs, metamaterials, rational and computationally enabled design, topology optimization, and bio-inspired design. Areas with limited research have been identified and suggestions have been made for future research. The paper concludes with a brief discussion on the practical aspects of DfAM and the potential of combining AM with subtractive and formative manufacturing processes in so-called hybrid manufacturing processes.

Design for Additive Bio-Manufacturing: From Patient-Specific Medical Devices to Rationally Designed Meta-Biomaterials

PubMed Central

Zadpoor, Amir A.

2017-01-01

Recent advances in additive manufacturing (AM) techniques in terms of accuracy, reliability, the range of processable materials, and commercial availability have made them promising candidates for production of functional parts including those used in the biomedical industry. The complexity-for-free feature offered by AM means that very complex designs become feasible to manufacture, while batch-size-indifference enables fabrication of fully patient-specific medical devices. Design for AM (DfAM) approaches aim to fully utilize those features for development of medical devices with substantially enhanced performance and biomaterials with unprecedented combinations of favorable properties that originate from complex geometrical designs at the micro-scale. This paper reviews the most important approaches in DfAM particularly those applicable to additive bio-manufacturing including image-based design pipelines, parametric and non-parametric designs, metamaterials, rational and computationally enabled design, topology optimization, and bio-inspired design. Areas with limited research have been identified and suggestions have been made for future research. The paper concludes with a brief discussion on the practical aspects of DfAM and the potential of combining AM with subtractive and formative manufacturing processes in so-called hybrid manufacturing processes. PMID:28757572

Finite element simulation and experimental verification of ultrasonic non-destructive inspection of defects in additively manufactured materials

NASA Astrophysics Data System (ADS)

Taheri, H.; Koester, L.; Bigelow, T.; Bond, L. J.

2018-04-01

Industrial applications of additively manufactured components are increasing quickly. Adequate quality control of the parts is necessary in ensuring safety when using these materials. Base material properties, surface conditions, as well as location and size of defects are some of the main targets for nondestructive evaluation of additively manufactured parts, and the problem of adequate characterization is compounded given the challenges of complex part geometry. Numerical modeling can allow the interplay of the various factors to be studied, which can lead to improved measurement design. This paper presents a finite element simulation verified by experimental results of ultrasonic waves scattering from flat bottom holes (FBH) in additive manufacturing materials. A focused beam immersion ultrasound transducer was used for both the modeling and simulations in the additive manufactured samples. The samples were SS17 4 PH steel samples made by laser sintering in a powder bed.

One-step manufacturing of innovative flat-knitted 3D net-shape preforms for composite applications

NASA Astrophysics Data System (ADS)

Bollengier, Quentin; Wieczorek, Florian; Hellmann, Sven; Trümper, Wolfgang; Cherif, Chokri

2017-10-01

Mostly due to the cost-intensive manually performed processing operations, the production of complex-shaped fibre reinforced plastic composites (FRPC) is currently very expensive and therefore either restricted to sectors with high added value or for small batch applications (e.g. in the aerospace or automotive industry). Previous works suggest that the successful integration of conventional textile manufacturing processes in the FRPC-process chain is the key to a cost-efficient manufacturing of complex three-dimensional (3D) FRPC-components with stress-oriented fibre arrangement. Therefore, this work focuses on the development of the multilayer weft knitting technology for the one-step manufacturing of complex 3D net-shaped preforms for high performance FRPC applications. In order to highlight the advantages of net-shaped multilayer weft knitted fabrics for the production of complex FRPC parts, seamless preforms such as 3D skin-stringer structures and tubular fabrics with load oriented fibre arrangement are realised. In this paper, the development of the textile bindings and performed technical modifications on flat knitting machines are presented. The results show that the multilayer weft knitting technology meets perfectly the requirements for a fully automated and reproducible manufacturing of complex 3D textile preforms with stress-oriented fibre arrangement.

Metal Additive Manufacturing: A Review

NASA Astrophysics Data System (ADS)

Frazier, William E.

2014-06-01

This paper reviews the state-of-the-art of an important, rapidly emerging, manufacturing technology that is alternatively called additive manufacturing (AM), direct digital manufacturing, free form fabrication, or 3D printing, etc. A broad contextual overview of metallic AM is provided. AM has the potential to revolutionize the global parts manufacturing and logistics landscape. It enables distributed manufacturing and the productions of parts-on-demand while offering the potential to reduce cost, energy consumption, and carbon footprint. This paper explores the material science, processes, and business consideration associated with achieving these performance gains. It is concluded that a paradigm shift is required in order to fully exploit AM potential.

Environmental Cracking and Irradiation Resistant Stainless Steels by Additive Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rebak, Raul B.; Lou, Xiaoyuan

Metal additive manufacturing (AM), or metal 3D printing is an emergent advanced manufacturing method that can create near net shape geometries directly from computer models. This technology can provide the capability to rapidly fabricate complex parts that may be required to enhance the integrity of reactor internals components. Such opportunities may be observed during a plant refueling outage and AM parts can be rapidly custom designed, manufactured and deployed within the outage interval. Additive manufacturing of stainless steel (SS) components can add business benefits on fast delivery on repair hardware, installation tooling, new design prototypes tests, etc. For the nuclearmore » industry, the supply chain is always an issue for reactor service. AM can provide through-life supply chain (40-60 years) for high-value low-volume components. In the meantime, the capability of generating complex geometries and functional gradient materials will improve the performance, reduce the overall component cost, plant asset management cost and increase the plant reliability by the improvement in materials performance in nuclear environments. While extensive work has been conducted regarding additively manufacturing of austenitic SS parts, most efforts focused only on basic attributes such as porosity, residual stress, basic tensile properties, along with components yield and process monitoring. Little work has been done to define and evaluate the material requirements for nuclear applications. Technical gaps exist, which limit this technology adoption in the nuclear industry, which includes high manufacturing cost, unknown risks, limited nuclear related data, lack of specification and qualification methods, and no prior business experience. The main objective of this program was to generate research data to address all these technical gaps and establish a commercial practice to use AM technology in the nuclear power industry. The detailed objectives are listed as follows

An artificial vision solution for reusing discarded parts resulted after a manufacturing process

NASA Astrophysics Data System (ADS)

Cohal, V.; Cohal, A.

2016-08-01

The profit of a factory can be improved by reusing the discarded components produced. This paper is based on the case of a manufacturing process where rectangular metallic sheets of different sizes are produced. Using an artificial vision system, the shapes and the sizes of the produced parts can be determined. Those sheets which do not respect the requirements imposed are labeled as discarded. Instead of throwing these parts, a decision algorithm can analyze if another metallic sheet with smaller dimensions can be obtained from these. Two methods of decision are presented in this paper, considering the restriction that the sides of the new sheet has to be parallel with the axis of the coordinate system. The coordinates of each new part obtained from a discarded sheet are computed in order to be delivered to a milling machine. Details about implementing these algorithms (image processing and decision respectively) in the MATLAB environment using Image Processing Toolbox are given.

Development Algorithm of the Technological Process of Manufacturing Gas Turbine Parts by Selective Laser Melting

NASA Astrophysics Data System (ADS)

Sotov, A. V.; Agapovichev, A. V.; Smelov, V. G.; Kyarimov, R. R.

2018-01-01

The technology of the selective laser melting (SLM) allows making products from powders of aluminum, titanium, heat-resistant alloys and stainless steels. Today the use of SLM technology develops at manufacture of the functional parts. This in turn requires development of a methodology projection of technological processes (TP) for manufacturing parts including databases of standard TP. Use of a technique will allow to exclude influence of technologist’s qualification on made products quality, and also to reduce labor input and energy consumption by development of TP due to use of the databases of standard TP integrated into a methodology. As approbation of the developed methodology the research of influence of the modes of a laser emission on a roughness of a surface of synthesized material was presented. It is established that the best values of a roughness of exemplars in the longitudinal and transversal directions make 1.98 μm and 3.59 μm respectively. These values of a roughness were received at specific density of energy 6.25 J/mm2 that corresponds to power and the speed of scanning of 200 W and 400 mm/s, respectively, and a hatch distance of 0.08 mm.

Highly oriented carbon fiber–polymer composites via additive manufacturing

DOE PAGES

Tekinalp, Halil L.; Kunc, Vlastimil; Velez-Garcia, Gregorio M.; ...

2014-10-16

Additive manufacturing, diverging from traditional manufacturing techniques, such as casting and machining materials, can handle complex shapes with great design flexibility without the typical waste. Although this technique has been mainly used for rapid prototyping, interest is growing in using this method to directly manufacture actual parts of complex shape. To use 3D-printing additive manufacturing in wide spread applications, the technique and the feedstock materials require improvements to meet the mechanical requirements of load-bearing components. Thus, we investigated the short fiber (0.2 mm to 0.4 mm) reinforced acrylonitrile-butadiene-styrene composites as a feedstock for 3D-printing in terms of their processibility, microstructuremore » and mechanical performance; and also provided comparison with traditional compression molded composites. The tensile strength and modulus of 3D-printed samples increased ~115% and ~700%, respectively. 3D-printer yielded samples with very high fiber orientation in printing direction (up to 91.5 %), whereas, compression molding process yielded samples with significantly less fiber orientation. Microstructure-mechanical property relationships revealed that although the relatively high porosity is observed in the 3D-printed composites as compared to those produced by the conventional compression molding technique, they both exhibited comparable tensile strength and modulus. Furthermore, this phenomena is explained based on the changes in fiber orientation, dispersion and void formation.« less

Next-generation biomedical implants using additive manufacturing of complex, cellular and functional mesh arrays.

PubMed

Murr, L E; Gaytan, S M; Medina, F; Lopez, H; Martinez, E; Machado, B I; Hernandez, D H; Martinez, L; Lopez, M I; Wicker, R B; Bracke, J

2010-04-28

In this paper, we examine prospects for the manufacture of patient-specific biomedical implants replacing hard tissues (bone), particularly knee and hip stems and large bone (femoral) intramedullary rods, using additive manufacturing (AM) by electron beam melting (EBM). Of particular interest is the fabrication of complex functional (biocompatible) mesh arrays. Mesh elements or unit cells can be divided into different regions in order to use different cell designs in different areas of the component to produce various or continually varying (functionally graded) mesh densities. Numerous design elements have been used to fabricate prototypes by AM using EBM of Ti-6Al-4V powders, where the densities have been compared with the elastic (Young) moduli determined by resonant frequency and damping analysis. Density optimization at the bone-implant interface can allow for bone ingrowth and cementless implant components. Computerized tomography (CT) scans of metal (aluminium alloy) foam have also allowed for the building of Ti-6Al-4V foams by embedding the digital-layered scans in computer-aided design or software models for EBM. Variations in mesh complexity and especially strut (or truss) dimensions alter the cooling and solidification rate, which alters the alpha-phase (hexagonal close-packed) microstructure by creating mixtures of alpha/alpha' (martensite) observed by optical and electron metallography. Microindentation hardness measurements are characteristic of these microstructures and microstructure mixtures (alpha/alpha') and sizes.

Rapid production of hollow SS316 profiles by extrusion based additive manufacturing

NASA Astrophysics Data System (ADS)

Rane, Kedarnath; Cataldo, Salvatore; Parenti, Paolo; Sbaglia, Luca; Mussi, Valerio; Annoni, Massimiliano; Giberti, Hermes; Strano, Matteo

2018-05-01

Complex shaped stainless steel tubes are often required for special purpose biomedical equipment. Nevertheless, traditional manufacturing technologies, such as extrusion, lack the ability to compete in a market of customized complex components because of associated expenses towards tooling and extrusion presses. To rapid manufacture few of such components with low cost and high precision, a new Extrusion based Additive Manufacturing (EAM) process, is proposed in this paper, and as an example, short stainless steel 316L complex shaped and sectioned tubes were prepared by EAM. Several sample parts were produced using this process; the dimensional stability, surface roughness and chemical composition of sintered samples were investigated to prove process competence. The results indicate that feedstock with a 316L particle content of 92.5 wt. % can be prepared with a sigma blade mixing, whose rheological behavior is fit for EAM. The green samples have sufficient strength to handle them for subsequent treatments. The sintered samples considerably shrunk to designed dimensions and have a homogeneous microstructure to impart mechanical strength. Whereas, maintaining comparable dimensional accuracy and chemical composition which are required for biomedical equipment still need iterations, a kinematic correction and modification in debinding cycle was proposed.

40 CFR 60.4247 - What parts of the mobile source provisions apply to me if I am a manufacturer of stationary SI...

Code of Federal Regulations, 2010 CFR

2010-07-01

... 40 Protection of Environment 6 2010-07-01 2010-07-01 false What parts of the mobile source provisions apply to me if I am a manufacturer of stationary SI internal combustion engines or a manufacturer of equipment containing such engines? 60.4247 Section 60.4247 Protection of Environment ENVIRONMENTAL...

Additive Manufacturing Infrared Inspection

NASA Technical Reports Server (NTRS)

Gaddy, Darrell; Nettles, Mindy

2015-01-01

The Additive Manufacturing Infrared Inspection Task started the development of a real-time dimensional inspection technique and digital quality record for the additive manufacturing process using infrared camera imaging and processing techniques. This project will benefit additive manufacturing by providing real-time inspection of internal geometry that is not currently possible and reduce the time and cost of additive manufactured parts with automated real-time dimensional inspections which deletes post-production inspections.

Workshop Report on Additive Manufacturing for Large-Scale Metal Components - Development and Deployment of Metal Big-Area-Additive-Manufacturing (Large-Scale Metals AM) System

DOE Office of Scientific and Technical Information (OSTI.GOV)

Babu, Sudarsanam Suresh; Love, Lonnie J.; Peter, William H.

Additive manufacturing (AM) is considered an emerging technology that is expected to transform the way industry can make low-volume, high value complex structures. This disruptive technology promises to replace legacy manufacturing methods for the fabrication of existing components in addition to bringing new innovation for new components with increased functional and mechanical properties. This report outlines the outcome of a workshop on large-scale metal additive manufacturing held at Oak Ridge National Laboratory (ORNL) on March 11, 2016. The charter for the workshop was outlined by the Department of Energy (DOE) Advanced Manufacturing Office program manager. The status and impact ofmore » the Big Area Additive Manufacturing (BAAM) for polymer matrix composites was presented as the background motivation for the workshop. Following, the extension of underlying technology to low-cost metals was proposed with the following goals: (i) High deposition rates (approaching 100 lbs/h); (ii) Low cost (<$10/lbs) for steel, iron, aluminum, nickel, as well as, higher cost titanium, (iii) large components (major axis greater than 6 ft) and (iv) compliance of property requirements. The above concept was discussed in depth by representatives from different industrial sectors including welding, metal fabrication machinery, energy, construction, aerospace and heavy manufacturing. In addition, DOE’s newly launched High Performance Computing for Manufacturing (HPC4MFG) program was reviewed. This program will apply thermo-mechanical models to elucidate deeper understanding of the interactions between design, process, and materials during additive manufacturing. Following these presentations, all the attendees took part in a brainstorming session where everyone identified the top 10 challenges in large-scale metal AM from their own perspective. The feedback was analyzed and grouped in different categories including, (i) CAD to PART software, (ii) selection of energy source, (iii

Designing using manufacturing features

NASA Astrophysics Data System (ADS)

Szecsi, T.; Hoque, A. S. M.

2012-04-01

This paper presents a design system that enables the composition of a part using manufacturing features. Features are selected from feature libraries. Upon insertion, the system ensures that the feature does not contradict the design-for-manufacture rules. This helps eliminating costly manufacturing problems. The system is developed as an extension to a commercial CAD/CAM system Pro/Engineer.

Microstructural Development and Technical Challenges in Laser Additive Manufacturing: Case Study with a 316L Industrial Part

NASA Astrophysics Data System (ADS)

Marya, Manuel; Singh, Virendra; Marya, Surendar; Hascoet, Jean Yves

2015-08-01

Additive manufacturing (AM) brings disruptive changes to the ways parts, and products are designed, fabricated, tested, qualified, inspected, marketed, and sold. These changes introduce novel technical challenges and concerns arising from the maturity and diversity of today's AM processes, feedstock materials, and process parameter interactions. AM bears a resemblance with laser and electron beam welding in the so-called conduction mode, which involves a multitude of dynamic physical events between the projected feedstock and a moving heat source that eventually influence AM part properties. For this paper, an air vent was selected for its thin-walled, hollow, and variable cross section, and limited size. The studied air vents, randomly selected from a qualification batch, were fabricated out of 316L stainless steel using a 4 kW fiber laser powder-fed AM system, referred to as construction laser additive direct (CLAD). These were systematically characterized by microhardness indentation, visual examination, optical and scanning electron microscopy, and electron-back-scattering diffraction in order to determine AM part suitability for service and also broadly discuss metallurgical phenomena. The paper then briefly expands the discussion to include additional engineering alloys and further analyze relationships between AM process parameters and AM part properties, consistently utilizing past experience with the same powder-fed CLAD 3D printer, the well-established science and technology of welding and joining, and recent publications on additive manufacturing.

Preliminary Investigation of Keyhole Phenomena during Single Layer Fabrication in Laser Additive Manufacturing of Stainless Steel

NASA Astrophysics Data System (ADS)

Matilainen, Ville-Pekka; Piili, Heidi; Salminen, Antti; Nyrhilä, Olli

Laser additive manufacturing (LAM) is a fabrication technology that enables production of complex parts from metallic materials with mechanical properties comparable to conventionally manufactured parts. In the LAM process, parts are manufactured by melting metallic powder layer-by-layer with a laser beam. This manufacturing technology is nowadays called powder bed fusion (PBF) according to the ASTM F2792-12a standard. This strategy involves several different independent and dependent thermal cycles, all of which have an influence on the final properties of the manufactured part. The quality of PBF parts depends strongly on the characteristics of each single laser-melted track and each single layer. This study consequently concentrates on investigating the effects of process parameters such as laser power on single track and layer formation and laser-material interaction phenomena occurring during the PBF process. Experimental tests were done with two different machines: a modified research machine based on an EOS EOSINT M-series system and an EOS EOSINT M280 system. The material used was EOS stainless steel 17-4 PH. Process monitoring was done with an active illuminated high speed camera system. After microscopy analysis, it was concluded that a keyhole can form during laser additive manufacturing of stainless steel. It was noted that heat input has an important effect on the likelihood of keyhole formation. The threshold intensity value for keyhole formation of 106 W/cm2 was exceeded in all manufactured single tracks. Laser interaction time was found to have an effect on penetration depth and keyhole formation, since the penetration depth increased with increased laser interaction time. It was also concluded that active illuminated high speed camera systems are suitable for monitoring of the manufacturing process and facilitate process control.

Using Innovative Techniques for Manufacturing Rocket Engine Hardware

NASA Technical Reports Server (NTRS)

Betts, Erin M.; Reynolds, David C.; Eddleman, David E.; Hardin, Andy

2011-01-01

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As we enter into a new space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt new and innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using the Workhorse Gas Generator (WHGG) test setup at MSFC?s East Test Area test stand 116, the duct was subject to extreme J-2X gas generator environments and endured a total of 538 seconds of hot-fire time. The duct survived the testing and was inspected after the test. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

Out of bounds additive manufacturing

DOE PAGES

Holshouser, Chris; Newell, Clint; Palas, Sid; ...

2013-03-01

Lockheed Martin and Oak Ridge National Laboratory are working on an additive manufacturing system capable of manufacturing components measured not in terms of inches or feet, but multiple yards in all dimensions with the potential to manufacture parts that are completely unbounded in size.

Manufacturing Error Effects on Mechanical Properties and Dynamic Characteristics of Rotor Parts under High Acceleration

NASA Astrophysics Data System (ADS)

Jia, Mei-Hui; Wang, Cheng-Lin; Ren, Bin

2017-07-01

Stress, strain and vibration characteristics of rotor parts should be changed significantly under high acceleration, manufacturing error is one of the most important reason. However, current research on this problem has not been carried out. A rotor with an acceleration of 150,000 g is considered as the objective, the effects of manufacturing errors on rotor mechanical properties and dynamic characteristics are executed by the selection of the key affecting factors. Through the force balance equation of the rotor infinitesimal unit establishment, a theoretical model of stress calculation based on slice method is proposed and established, a formula for the rotor stress at any point derives. A finite element model (FEM) of rotor with holes is established with manufacturing errors. The changes of the stresses and strains of a rotor in parallelism and symmetry errors are analyzed, which verify the validity of the theoretical model. The pre-stressing modal analysis is performed based on the aforementioned static analysis. The key dynamic characteristics are analyzed. The results demonstrated that, as the parallelism and symmetry errors increase, the equivalent stresses and strains of the rotor slowly increase linearly, the highest growth rate does not exceed 4%, the maximum change rate of natural frequency is 0.1%. The rotor vibration mode is not significantly affected. The FEM construction method of the rotor with manufacturing errors can be utilized for the quantitative research on rotor characteristics, which will assist in the active control of rotor component reliability under high acceleration.

Modeling, Simulation, Additive Manufacturing, and Experimental Evaluation of Solid and Porous NiTi

NASA Astrophysics Data System (ADS)

Taheri Andani, Mohsen

In recent years, shape memory alloys (SMAs) have entered a wide range of engineering applications in fields such as aerospace and medical applications. Nickel-titanium (NiTi) is the most commonly used SMAs due to its excellent functional characteristics (shape memory effect and superelasticity behavior). These properties are based on a solid-solid phase transformation between martensite and austenite. Beside these two characteristics, low stiffness, biocompatibility and corrosion properties of NiTi make it an attractive candidate for biomedical applications (e.g., bone plates, bone screws, and vascular stents). It is well know that manufacturing and processing of NiTi is very challenging. The functional properties of NiTi are significantly affected by the impurity level and due to the high titanium content, NiTi are highly reactive. Therefore, high temperature processed parts through methods such as melting and casting which result in increased impurity levels have inadequate structural and functional properties. Furthermore, high ductility and elasticity of NiTi, adhesion, work hardening and spring back effects make machining quite challenging. These unfavorable effects for machining cause significant tool wear along with decreasing the quality of work piece. Recently, additive manufacturing (AM) has gained significant attention for manufacturing NiTi. Since AM can create a part directly from CAD data, it is predicted that AM can overcome most of the manufacturing difficulties. This technique provides the possibility of fabricating highly complex parts, which cannot be processed by any other methods. Curved holes, designed porosity, and lattice like structures are some examples of mentioned complex parts. This work investigates manufacturing superelastic NiTi by selective laser melting (SLM) technique (using PXM by Phenix/3D Systems). An extended experimental study is conducted on the effect of subsequent heat treatments with different aging conditions on phase

An Assessment of Nondestructive Evaluation Capability for Complex Additive Manufacturing Aerospace Components

NASA Technical Reports Server (NTRS)

Walker, James; Beshears, Ron; Lambert, Dennis; Tilson, William

2016-01-01

The primary focus of this work is to investigate some of the fundamental relationships between processing, mechanical testing, materials characterization, and NDE for additively manufactured (AM) components using the powder bed fusion direct melt laser sintered process. The goal is to understand the criticality of defects unique to the AM process and then how conventional nondestructive evaluation methods as well as some of the more non-traditional methods such as computed tomography, are effected by the AM material. Specific defects including cracking, porosity and partially/unfused powder will be addressed. Besides line-of-site NDE, as appropriate these inspection capabilities will be put into the context of complex AM geometries where hidden features obscure, or inhibit traditional NDE methods.

Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carpenter, John S.; Beese, Allison M.; Bourell, David L.

Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

DOE PAGES

Carpenter, John S.; Beese, Allison M.; Bourell, David L.; ...

2015-06-26

Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

Practical aspects of modern interferometry for optical manufacturing quality control: Part 2

NASA Astrophysics Data System (ADS)

Smythe, Robert

2012-07-01

Modern phase shifting interferometers enable the manufacture of optical systems that drive the global economy. Semiconductor chips, solid-state cameras, cell phone cameras, infrared imaging systems, space based satellite imaging and DVD and Blu-Ray disks are all enabled by phase shifting interferometers. Theoretical treatments of data analysis and instrument design advance the technology but often are not helpful towards the practical use of interferometers. An understanding of the parameters that drive system performance is critical to produce useful results. Any interferometer will produce a data map and results; this paper, in three parts, reviews some of the key issues to minimize error sources in that data and provide a valid measurement.

Practical aspects of modern interferometry for optical manufacturing quality control, Part 3

NASA Astrophysics Data System (ADS)

Smythe, Robert A.

2012-09-01

Modern phase shifting interferometers enable the manufacture of optical systems that drive the global economy. Semiconductor chips, solid-state cameras, cell phone cameras, infrared imaging systems, space-based satellite imaging, and DVD and Blu-Ray disks are all enabled by phase-shifting interferometers. Theoretical treatments of data analysis and instrument design advance the technology but often are not helpful toward the practical use of interferometers. An understanding of the parameters that drive the system performance is critical to produce useful results. Any interferometer will produce a data map and results; this paper, in three parts, reviews some of the key issues to minimize error sources in that data and provide a valid measurement.

Using Innovative Technologies for Manufacturing and Evaluating Rocket Engine Hardware

NASA Technical Reports Server (NTRS)

Betts, Erin M.; Hardin, Andy

2011-01-01

Many of the manufacturing and evaluation techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As we enter into a new space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt new and innovative techniques for manufacturing and evaluating hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, manufacturing techniques such as Direct Metal Laser Sintering (DMLS) and white light scanning are being adopted and evaluated for their use on J-2X, with hopes of employing both technologies on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powdered metal manufacturing process in order to produce complex part geometries. The white light technique is a non-invasive method that can be used to inspect for geometric feature alignment. Both the DMLS manufacturing method and the white light scanning technique have proven to be viable options for manufacturing and evaluating rocket engine hardware, and further development and use of these techniques is recommended.

Fixtureless nonrigid part inspection using depth cameras

NASA Astrophysics Data System (ADS)

Xiong, Hanwei; Xu, Jun; Xu, Chenxi; Pan, Ming

2016-10-01

In automobile industry, flexible thin shell parts are used to cover car body. Such parts could have a different shape in a free state than the design model due to dimensional variation, gravity loads and residual strains. Special inspection fixtures are generally indispensable for geometric inspection. Recently, some researchers have proposed fixtureless nonridged inspect methods using intrinsic geometry or virtual spring-mass system, based on some assumptions about deformation between Free State shape and nominal CAD shape. In this paper, we propose a new fixtureless method to inspect flexible parts with a depth camera, which is efficient and low computational complexity. Unlike traditional method, we gather two point cloud set of the manufactured part in two different states, and make correspondences between them and one of them to the CAD model. The manufacturing defects can be derived from the correspondences. Finite element method (FEM) disappears in our method. Experimental evaluation of the proposed method is presented.

Microgravity Manufacturing Via Fused Deposition

NASA Technical Reports Server (NTRS)

Cooper, K. G.; Griffin, M. R.

2003-01-01

Manufacturing polymer hardware during space flight is currently outside the state of the art. A process called fused deposition modeling (FDM) can make this approach a reality by producing net-shaped components of polymer materials directly from a CAE model. FDM is a rapid prototyping process developed by Stratasys, Inc.. which deposits a fine line of semi-molten polymer onto a substrate while moving via computer control to form the cross-sectional shape of the part it is building. The build platen is then lowered and the process is repeated, building a component directly layer by layer. This method enables direct net-shaped production of polymer components directly from a computer file. The layered manufacturing process allows for the manufacture of complex shapes and internal cavities otherwise impossible to machine. This task demonstrated the benefits of the FDM technique to quickly and inexpensively produce replacement components or repair broken hardware in a Space Shuttle or Space Station environment. The intent of the task was to develop and fabricate an FDM system that was lightweight, compact, and required minimum power consumption to fabricate ABS plastic hardware in microgravity. The final product of the shortened task turned out to be a ground-based breadboard device, demonstrating miniaturization capability of the system.

Continuous filament composite parts and articles of manufacture thereof

DOEpatents

Weisberg, Andrew H.

2016-06-28

An article of manufacture according to one embodiment includes a plurality of plies in a stacked configuration, where each ply includes a plurality of tape winds having edges. A distance between the edges of adjacent tape winds in the same ply is about constant along a length of the wind. Each tape wind comprises elongated fibers and a matrix, axes of the fibers being oriented about parallel to a longitudinal axis of the tape wind. Additional systems, methods and articles of manufacture are also presented.

Manufacturing Aids

NASA Astrophysics Data System (ADS)

1983-01-01

Contractor's work for Lewis Research Center on "thermal barrier" coatings designed to improve aircraft engine efficiency resulted in two related but separate spinoffs. The Materials and Manufacturing Technology Center of TRW, Inc. invented a robotic system for applying the coating, and in the course of that research found it necessary to develop a new, extremely accurate type of optical gage that offers multiple improvements in controlling the quality of certain manufactured parts.

Post-processing of 3D-printed parts using femtosecond and picosecond laser radiation

NASA Astrophysics Data System (ADS)

Mingareev, Ilya; Gehlich, Nils; Bonhoff, Tobias; Meiners, Wilhelm; Kelbassa, Ingomar; Biermann, Tim; Richardson, Martin C.

2014-03-01

Additive manufacturing, also known as 3D-printing, is a near-net shape manufacturing approach, delivering part geometry that can be considerably affected by various process conditions, heat-induced distortions, solidified melt droplets, partially fused powders, and surface modifications induced by the manufacturing tool motion and processing strategy. High-repetition rate femtosecond and picosecond laser radiation was utilized to improve surface quality of metal parts manufactured by laser additive techniques. Different laser scanning approaches were utilized to increase the ablation efficiency and to reduce the surface roughness while preserving the initial part geometry. We studied post-processing of 3D-shaped parts made of Nickel- and Titanium-base alloys by utilizing Selective Laser Melting (SLM) and Laser Metal Deposition (LMD) as additive manufacturing techniques. Process parameters such as the pulse energy, the number of layers and their spatial separation were varied. Surface processing in several layers was necessary to remove the excessive material, such as individual powder particles, and to reduce the average surface roughness from asdeposited 22-45 μm to a few microns. Due to the ultrafast laser-processing regime and the small heat-affected zone induced in materials, this novel integrated manufacturing approach can be used to post-process parts made of thermally and mechanically sensitive materials, and to attain complex designed shapes with micrometer precision.

Using Innovative Technologies for Manufacturing Rocket Engine Hardware

NASA Technical Reports Server (NTRS)

Betts, E. M.; Eddleman, D. E.; Reynolds, D. C.; Hardin, N. A.

2011-01-01

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As the United States enters into the next space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, rapid manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on NASA s Space Launch System (SLS) upper stage engine, J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator (GG) discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using a workhorse gas generator (WHGG) test fixture at MSFC's East Test Area, the duct was subjected to extreme J-2X hot gas environments during 7 tests for a total of 537 seconds of hot-fire time. The duct underwent extensive post-test evaluation and showed no signs of degradation. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

Local density measurement of additive manufactured copper parts by instrumented indentation

NASA Astrophysics Data System (ADS)

Santo, Loredana; Quadrini, Fabrizio; Bellisario, Denise; Tedde, Giovanni Matteo; Zarcone, Mariano; Di Domenico, Gildo; D'Angelo, Pierpaolo; Corona, Diego

2018-05-01

Instrumented flat indentation has been used to evaluate local density of additive manufactured (AM) copper samples with different relative density. Indentations were made by using tungsten carbide (WC) flat pins with 1 mm diameter. Pure copper powders were used in a selective laser melting (SLM) machine to produce samples to test. By changing process parameters, samples density was changed from the relative density of 63% to 71%. Indentation tests were performed on the xy surface of the AM samples. In order to make a correlation between indentation test results and sample density, the indentation pressure at fixed displacement was selected. Results show that instrumented indentation is a valid technique to measure density distribution along the geometry of an SLM part. In fact, a linear trend between indentation pressure and sample density was found for the selected density range.

Electronics manufacturing and assembly in Japan

NASA Technical Reports Server (NTRS)

Kukowski, John A.; Boulton, William R.

1995-01-01

In the consumer electronics industry, precision processing technology is the basis for enhancing product functions and for minimizing components and end products. Throughout Japan, manufacturing technology is seen as critical to the production and assembly of advanced products. While its population has increased less than 30 percent over twenty-five years, Japan's gross national product has increase thirtyfold; this growth has resulted in large part from rapid replacement of manual operations with innovative, high-speed, large-scale, continuously running, complex machines that process a growing number of miniaturized components. The JTEC panel found that introduction of next-generation electronics products in Japan goes hand-in-hand with introduction of new and improved production equipment. In the panel's judgment, Japan's advanced process technologies and equipment development and its highly automated factories are crucial elements of its domination of the consumer electronics marketplace - and Japan's expertise in manufacturing consumer electronics products gives it potentially unapproachable process expertise in all electronics markets.

Acquisition of equipment for composite manufacturing laboratory.

DOT National Transportation Integrated Search

2009-12-01

An interdisciplinary team of faculty was formed to upgrade the Composite Manufacturing and Testing Facilities at Missouri S&T. The Metering Unit is useful to manufacture composite pultruded parts using two part polyurethane resin system. Prior to the...

Improvements in Operational Readiness by Distributing Manufacturing Capability in the Supply Chain through Additive Manufacturing

DTIC Science & Technology

2017-12-01

inefficiencies of a more complex system. Additional time may also be due to the longer distances traveled . The fulfillment time for a requisition to...Approved OMB No. 0704-0188 Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time ...advanced manufacturing methods with additive manufacturing. This work decomposes the additive manufacturing processes into 11 primary functions. The time

Solar Photovoltaic Manufacturing Cost Analysis | Energy Analysis | NREL

Science.gov Websites

Solar Photovoltaic Manufacturing Cost Analysis Solar Photovoltaic Manufacturing Cost Analysis NREL's photovoltaic (PV) manufacturing cost analysis-part of our broader effort supporting manufacturing manufacturing sector, and is that growth sustainable? NREL's manufacturing cost analysis studies show that: U.S

2001 Industry Studies: Advanced Manufacturing

DTIC Science & Technology

2001-05-28

oriented, 19 and manufacturers are employing the Internet and associated information technologies to better integrate supply chains and form extended...ways to compete in world markets . As part of this ongoing transformation, the broad implementation of advanced manufacturing technologies , processes...competitive advantages and better performance in world markets . Importantly, advanced manufacturing involves the innovative integration of new technology

Additive Manufacturing of Functional Elements on Sheet Metal

NASA Astrophysics Data System (ADS)

Schaub, Adam; Ahuja, Bhrigu; Butzhammer, Lorenz; Osterziel, Johannes; Schmidt, Michael; Merklein, Marion

Laser Beam Melting (LBM) process with its advantages of high design flexibility and free form manufacturing methodology is often applied limitedly due to its low productivity and unsuitability for mass production compared to conventional manufacturing processes. In order to overcome these limitations, a hybrid manufacturing methodology is developed combining the additive manufacturing process of laser beam melting with sheet forming processes. With an interest towards aerospace and medical industry, the material in focus is Ti-6Al-4V. Although Ti-6Al-4V is a commercially established material and its application for LBM process has been extensively investigated, the combination of LBM of Ti-6Al-4V with sheet metal still needs to be researched. Process dynamics such as high temperature gradients and thermally induced stresses lead to complex stress states at the interaction zone between the sheet and LBM structure. Within the presented paper mechanical characterization of hybrid parts will be performed by shear testing. The association of shear strength with process parameters is further investigated by analyzing the internal structure of the hybrid geometry at varying energy inputs during the LBM process. In order to compare the hybrid manufacturing methodology with conventional fabrication, the conventional methodologies subtractive machining and state of the art Laser Beam Melting is evaluated within this work. These processes will be analyzed for their mechanical characteristics and productivity by determining the build time and raw material consumption for each case. The paper is concluded by presenting the characteristics of the hybrid manufacturing methodology compared to alternative manufacturing technologies.

Simulations of the heat exchange in thermoplastic injection molds manufactured by additive techniques

NASA Astrophysics Data System (ADS)

Daldoul, Wafa; Toulorge, Thomas; Vincent, Michel

2017-10-01

The cost and quality of complex parts manufactured by thermoplastic injection is traditionally limited by design constraints on the cooling system of the mold. A possible solution is to create the mold by additive manufacturing, which makes it possible to freely design the cooling channels. Such molds normally contain hollow parts (alveoli) in order to decrease their cost. However, the complex geometry of the cooling channels and the alveoli makes it difficult to predict the performance of the cooling system. This work aims to compute the heat exchanges between the polymer, the mold and the cooling channels with complex geometries. An Immersed Volume approach is taken, where the different parts of the domain (i.e. the polymer, the cooling channels, the alveoli and the mold) are represented by level-sets and the thermo-mechanical properties of the materials vary smoothly at the interface between the parts. The energy and momentum equations are solved by a stabilized Finite Element method. In order to accurately resolve the large variations of material properties and the steep temperature gradients at interfaces, state-of-the art anisotropic mesh refinement techniques are employed. The filling stage of the process is neglected. In a first step, only the heat equation is solved, so that the packing stage is also disregarded. In a second step, thermo-mechanical effects occurring in the polymer during the packing stage are taken into account, which results in the injection of an additional amount of polymer that significantly influences the temperature evolution. The method is validated on the simple geometry of a center-gated disk and compared with experimental measurements. The agreement is very good. Simulations are performed on an industrial case which illustrates the ability of the method to deal with complex geometries.

BAAM Additive Manufacturing of Magnetically Levitated Wind Turbine

DOE Office of Scientific and Technical Information (OSTI.GOV)

Richardson, Bradley S.; Noakes, Mark W.; Roschli, Alex C.

ORNL worked with Hover Energy LLC (Hover) on the design of Big Area Additive Manufacturing (BAAM) extrusion components. The objective of this technical collaboration was to identify and evaluate fabrication of components using alternative additive manufacturing techniques. Multiple candidate parts were identified. A design modification to fabricate diverters using additive manufacturing (AM) was performed and the part was analyzed based on anticipated wind loading. Scaled versions of two parts were printed using the BAAM for wind tunnel testing.

Energy 101: Clean Energy Manufacturing

ScienceCinema

None

2018-01-16

Most of us have a basic understanding of manufacturing. It's how we convert raw materials, components, and parts into finished goods that meet our essential needs and make our lives easier. But what about clean energy manufacturing? Clean energy and advanced manufacturing have the potential to rejuvenate the U.S. manufacturing industry and open pathways to increased American competitiveness. Watch this video to learn more about this exciting movement and to see some of these innovations in action.

49 CFR Appendix C to Part 180 - Eddy Current Examination With Visual Inspection for DOT 3AL Cylinders Manufactured of Aluminum...

Code of Federal Regulations, 2013 CFR

2013-10-01

... for DOT 3AL Cylinders Manufactured of Aluminum Alloy 6351-T6 C Appendix C to Part 180 Transportation... Pt. 180, App. C Appendix C to Part 180—Eddy Current Examination With Visual Inspection for DOT 3AL... with CGA pamphlet C-6.1 (IBR; see § 171.7 of this subchapter). 3. Eddy Current Equipment. A reference...

Improving the strength of additively manufactured objects via modified interior structure

NASA Astrophysics Data System (ADS)

Al, Can Mert; Yaman, Ulas

2017-10-01

Additive manufacturing (AM), in other words 3D printing, is becoming more common because of its crucial advantages such as geometric complexity, functional interior structures, etc. over traditional manufacturing methods. Especially, Fused Filament Fabrication (FFF) 3D printing technology is frequently used because of the fact that desktop variants of these types of printers are highly appropriate for different fields and are improving rapidly. In spite of the fact that there are significant advantages of AM, the strength of the parts fabricated with AM is still a major problem especially when plastic materials, such as Acrylonitrile butadiene styrene (ABS), Polylactic acid (PLA), Nylon, etc., are utilized. In this study, an alternative method is proposed in which the strength of AM fabricated parts is improved employing direct slicing approach. Traditional Computer Aided Manufacturing (CAM) software of 3D printers takes only the geometry as an input in triangular mesh form (stereolithography, STL file) generated by Computer Aided Design software. This file format includes data only about the outer boundaries of the geometry. Interior of the artifacts are manufactured with homogeneous infill patterns, such as diagonal, honeycomb, linear, etc. according to the paths generated in CAM software. The developed method within this study provides a way to fabricate parts with heterogeneous infill patterns by utilizing the stress field data obtained from a Finite Element Analysis software, such as ABAQUS. According to the performed tensile tests, the strength of the test specimen is improved by about 45% compared to the conventional way of 3D printing.

Bio-reinforced composite development for additive manufacturing: Nanocellulose-PLA

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tekinalp, Halil L.; Lu, Yuan; Kunc, Vlastimil

Additive manufacturing (AM) is transitioning from being only a prototyping method towards becoming a manufacturing technique for the quick production of parts with complex geometries. For the complete realization of this transition, the mechanical properties of the printed parts have to meet the requirements of actual load-bearing structural components. Integration of a reinforcing second phase into a polymer is a viable approach for the improvement of resins mechanical performance. Addition of carbon fibers into acrylonitrile-butadiene-styrene (ABS) has already been shown to improve its mechanical properties compared to the neat ABS resin (both additively manufactured), and led to the manufacture ofmore » world s first 3D-printed car. However, both ABS resin and carbon fibers are petroleum-based products, and there is a continuous search for alternative, bio-sourced, renewable materials as a feedstock for manufacturing. Towards this direction, we have investigated the potential of cellulose nanofibril-reinforced polylactic acid (PLA) resin systems as an alternative. CNF-PLA composite systems with up to 40 wt% CNF loadings were prepared via compression molding technique and tested. Significant improvements in both tensile strength (80%) and elastic modulus (128%) were observed. Filaments prepared from the same compositions were also successfully 3D-printed into tensile testing specimens with up to 30% CNF concentrations, and showed similar improvements in mechanical performance. Although CNFs were not individually dispersed in PLA matrix, they were observed to be well blended with the polymer based on SEM micrographs. In summary, preparation and 3D-printing of a 100% bio-based feedstock material with the mechanical properties comparable to the carbon fiber-ABS system was successfully demonstrated that it can open up new window of opportunities in the additive manufacturing industry. Acknowledgement Research sponsored by the U.S. Department of Energy, Office of

The use of Tecnomatix software to simulate the manufacturing flows in an industrial enterprise producing hydrostatic components

NASA Astrophysics Data System (ADS)

Petrila, S.; Brabie, G.; Chirita, B.

2016-08-01

The analysis performed on manufacturing flows within industrial enterprises producing hydrostatic components twos made on a number of factors that influence smooth running of production such: distance between pieces, waiting time from one surgery to another; time achievement of setups on CNC machines; tool changing in case of a large number of operators and manufacturing complexity of large files [2]. To optimize the manufacturing flow it was used the software Tecnomatix. This software represents a complete portfolio of manufacturing solutions digital manufactured by Siemens. It provides innovation by linking all production methods of a product from process design, process simulation, validation and ending the manufacturing process. Among its many capabilities to create a wide range of simulations, the program offers various demonstrations regarding the behavior manufacturing cycles. This program allows the simulation and optimization of production systems and processes in several areas such as: car suppliers, production of industrial equipment; electronics manufacturing, design and production of aerospace and defense parts.

Analytical Modelling and Optimization of the Temperature-Dependent Dynamic Mechanical Properties of Fused Deposition Fabricated Parts Made of PC-ABS

PubMed Central

Mohamed, Omar Ahmed; Masood, Syed Hasan; Bhowmik, Jahar Lal

2016-01-01

Fused deposition modeling (FDM) additive manufacturing has been intensively used for many industrial applications due to its attractive advantages over traditional manufacturing processes. The process parameters used in FDM have significant influence on the part quality and its properties. This process produces the plastic part through complex mechanisms and it involves complex relationships between the manufacturing conditions and the quality of the processed part. In the present study, the influence of multi-level manufacturing parameters on the temperature-dependent dynamic mechanical properties of FDM processed parts was investigated using IV-optimality response surface methodology (RSM) and multilayer feed-forward neural networks (MFNNs). The process parameters considered for optimization and investigation are slice thickness, raster to raster air gap, deposition angle, part print direction, bead width, and number of perimeters. Storage compliance and loss compliance were considered as response variables. The effect of each process parameter was investigated using developed regression models and multiple regression analysis. The surface characteristics are studied using scanning electron microscope (SEM). Furthermore, performance of optimum conditions was determined and validated by conducting confirmation experiment. The comparison between the experimental values and the predicted values by IV-Optimal RSM and MFNN was conducted for each experimental run and results indicate that the MFNN provides better predictions than IV-Optimal RSM. PMID:28774019

Analytical Modelling and Optimization of the Temperature-Dependent Dynamic Mechanical Properties of Fused Deposition Fabricated Parts Made of PC-ABS.

PubMed

Mohamed, Omar Ahmed; Masood, Syed Hasan; Bhowmik, Jahar Lal

2016-11-04

Fused deposition modeling (FDM) additive manufacturing has been intensively used for many industrial applications due to its attractive advantages over traditional manufacturing processes. The process parameters used in FDM have significant influence on the part quality and its properties. This process produces the plastic part through complex mechanisms and it involves complex relationships between the manufacturing conditions and the quality of the processed part. In the present study, the influence of multi-level manufacturing parameters on the temperature-dependent dynamic mechanical properties of FDM processed parts was investigated using IV-optimality response surface methodology (RSM) and multilayer feed-forward neural networks (MFNNs). The process parameters considered for optimization and investigation are slice thickness, raster to raster air gap, deposition angle, part print direction, bead width, and number of perimeters. Storage compliance and loss compliance were considered as response variables. The effect of each process parameter was investigated using developed regression models and multiple regression analysis. The surface characteristics are studied using scanning electron microscope (SEM). Furthermore, performance of optimum conditions was determined and validated by conducting confirmation experiment. The comparison between the experimental values and the predicted values by IV-Optimal RSM and MFNN was conducted for each experimental run and results indicate that the MFNN provides better predictions than IV-Optimal RSM.

Greening up Auto Part Manufacturing: A Collaboration between Academia and Industry

ERIC Educational Resources Information Center

Kneas, Kristi A.; Armstrong, Drew L.; Brank, Alice R.; Johnson, Amanda L.; Kissinger, Chelsea A.; Mabe, Adam R.; Sezer, Ozge; Fontinell, Mike

2009-01-01

Historically, manufacture of automotive electronic components and screen-printing of automotive instrument clusters at DENSO Manufacturing Tennessee, Inc. required washing of equipment such as screens, stencils, and jigs with sizable quantities of volatile organic compounds and hazardous air pollutants. Collaborative efforts between the Maryville…

Manufacturing and fabrication, part 3. [extraterrestrial resources

NASA Technical Reports Server (NTRS)

Sastri, Sankar; Duke, Michael B.; Haskin, Larry A.

1992-01-01

The accessibility of material and energy off the Earth and the leverage that these nonterrestrial resources can exert on the space transportation system are important influences on the long-term goal of exploring the solar system. Research on separation of lunar materials and manufacturing of useful products from them is in its infancy. A few possible processes and products are described in this report. Specific attention is given to oxygen, metal, and silicate products.

Influence of Resin Composition on the Defect Formation in Alumina Manufactured by Stereolithography

PubMed Central

Johansson, Emil; Lidström, Oscar; Johansson, Jan; Lyckfeldt, Ola; Adolfsson, Erik

2017-01-01

Stereolithography (SL) is a technique allowing additive manufacturing of complex ceramic parts by selective photopolymerization of a photocurable suspension containing photocurable monomer, photoinitiator, and a ceramic powder. The manufactured three-dimensional object is cleaned and converted into a dense ceramic part by thermal debinding of the polymer network and subsequent sintering. The debinding is the most critical and time-consuming step, and often the source of cracks. In this study, photocurable alumina suspensions have been developed, and the influence of resin composition on defect formation has been investigated. The suspensions were characterized in terms of rheology and curing behaviour, and cross-sections of sintered specimens manufactured by SL were evaluated by SEM. It was found that the addition of a non-reactive component to the photocurable resin reduced polymerization shrinkage and altered the thermal decomposition of the polymer matrix, which led to a reduction in both delamination and intra-laminar cracks. Using a non-reactive component that decomposed rather than evaporated led to less residual porosity. PMID:28772496

WASTE MINIMIZATION ASSESSMENT FOR A MANUFACTURER OF ALUMINUM AND STEEL PARTS

EPA Science Inventory

The U.S.Environmental Protection Agency (EPA) has funded a pilot project to assist small and medium-sized manufacturers who want to minimize their generation of waste but who lack the expertise to do so. In an effort to assist these manufacturers, Waste Minimization Assessment Ce...

27 CFR 53.181 - Further manufacture included.

Code of Federal Regulations, 2010 CFR

2010-04-01

... 27 Alcohol, Tobacco Products and Firearms 2 2010-04-01 2010-04-01 false Further manufacture... Further manufacture included. (a) In general. The payment of tax imposed by chapter 32 of the Code on the... of any use in further manufacture, or sale as part of a second manufactured article, described in...

On-line application of near-infrared spectroscopy for monitoring water levels in parts per million in a manufacturing-scale distillation process.

PubMed

Lambertus, Gordon; Shi, Zhenqi; Forbes, Robert; Kramer, Timothy T; Doherty, Steven; Hermiller, James; Scully, Norma; Wong, Sze Wing; LaPack, Mark

2014-01-01

An on-line analytical method based on transmission near-infrared spectroscopy (NIRS) for the quantitative determination of water concentrations (in parts per million) was developed and applied to the manufacture of a pharmaceutical intermediate. Calibration models for water analysis, built at the development site and applied at the manufacturing site, were successfully demonstrated during six manufacturing runs at a 250-gallon scale. The water measurements will be used as a forward-processing control point following distillation of a toluene product solution prior to use in a Grignard reaction. The most significant impact of using this NIRS-based process analytical technology (PAT) to replace off-line measurements is the significant reduction in the risk of operator exposure through the elimination of sampling of a severely lachrymatory and mutagenic compound. The work described in this report illustrates the development effort from proof-of-concept phase to manufacturing implementation.

The Clean Energy Manufacturing Initiative: Dissolving Silos

DOE Office of Scientific and Technical Information (OSTI.GOV)

Danielson, David; Orr, Lynn; Sarkar, Reuben

2016-06-15

DOE’s work is closely tied to manufacturing because manufacturing is an important part of technology innovation and commercialization. Find out how DOE – through the Clean Energy Manufacturing Initiative – is helping America lead the clean energy revolution.

Simulation Based Optimization of Complex Monolithic Composite Structures Using Cellular Core Technology

NASA Astrophysics Data System (ADS)

Hickmott, Curtis W.

Cellular core tooling is a new technology which has the capability to manufacture complex integrated monolithic composite structures. This novel tooling method utilizes thermoplastic cellular cores as inner tooling. The semi-rigid nature of the cellular cores makes them convenient for lay-up, and under autoclave temperature and pressure they soften and expand providing uniform compaction on all surfaces including internal features such as ribs and spar tubes. This process has the capability of developing fully optimized aerospace structures by reducing or eliminating assembly using fasteners or bonded joints. The technology is studied in the context of evaluating its capabilities, advantages, and limitations in developing high quality structures. The complex nature of these parts has led to development of a model using the Finite Element Analysis (FEA) software Abaqus and the plug-in COMPRO Common Component Architecture (CCA) provided by Convergent Manufacturing Technologies. This model utilizes a "virtual autoclave" technique to simulate temperature profiles, resin flow paths, and ultimately deformation from residual stress. A model has been developed simulating the temperature profile during curing of composite parts made with the cellular core technology. While modeling of composites has been performed in the past, this project will look to take this existing knowledge and apply it to this new manufacturing method capable of building more complex parts and develop a model designed specifically for building large, complex components with a high degree of accuracy. The model development has been carried out in conjunction with experimental validation. A double box beam structure was chosen for analysis to determine the effects of the technology on internal ribs and joints. Double box beams were manufactured and sectioned into T-joints for characterization. Mechanical behavior of T-joints was performed using the T-joint pull-off test and compared to traditional

Advanced Material Strategies for Next-Generation Additive Manufacturing

PubMed Central

Chang, Jinke; He, Jiankang; Zhou, Wenxing; Lei, Qi; Li, Xiao; Li, Dichen

2018-01-01

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing. PMID:29361754

Advanced Material Strategies for Next-Generation Additive Manufacturing.

PubMed

Chang, Jinke; He, Jiankang; Mao, Mao; Zhou, Wenxing; Lei, Qi; Li, Xiao; Li, Dichen; Chua, Chee-Kai; Zhao, Xin

2018-01-22

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing.

The scope of additive manufacturing in cryogenics, component design, and applications

NASA Astrophysics Data System (ADS)

Stautner, W.; Vanapalli, S.; Weiss, K.-P.; Chen, R.; Amm, K.; Budesheim, E.; Ricci, J.

2017-12-01

Additive manufacturing techniques using composites or metals are rapidly gaining momentum in cryogenic applications. Small or large, complex structural components are now no longer limited to mere design studies but can now move into the production stream thanks to new machines on the market that allow for light-weight, cost optimized designs with short turnaround times. The potential for cost reductions from bulk materials machined to tight tolerances has become obvious. Furthermore, additive manufacturing opens doors and design space for cryogenic components that to date did not exist or were not possible in the past, using bulk materials along with elaborate and expensive machining processes, e.g. micromachining. The cryogenic engineer now faces the challenge to design toward those new additive manufacturing capabilities. Additionally, re-thinking designs toward cost optimization and fast implementation also requires detailed knowledge of mechanical and thermal properties at cryogenic temperatures. In the following we compile the information available to date and show a possible roadmap for additive manufacturing applications of parts and components typically used in cryogenic engineering designs.

Additive Manufacturing Design Considerations for Liquid Engine Components

NASA Technical Reports Server (NTRS)

Whitten, Dave; Hissam, Andy; Baker, Kevin; Rice, Darron

2014-01-01

The Marshall Space Flight Center's Propulsion Systems Department has gained significant experience in the last year designing, building, and testing liquid engine components using additive manufacturing. The department has developed valve, duct, turbo-machinery, and combustion device components using this technology. Many valuable lessons were learned during this process. These lessons will be the focus of this presentation. We will present criteria for selecting part candidates for additive manufacturing. Some part characteristics are 'tailor made' for this process. Selecting the right parts for the process is the first step to maximizing productivity gains. We will also present specific lessons we learned about feature geometry that can and cannot be produced using additive manufacturing machines. Most liquid engine components were made using a two-step process. The base part was made using additive manufacturing and then traditional machining processes were used to produce the final part. The presentation will describe design accommodations needed to make the base part and lessons we learned about which features could be built directly and which require the final machine process. Tolerance capabilities, surface finish, and material thickness allowances will also be covered. Additive Manufacturing can produce internal passages that cannot be made using traditional approaches. It can also eliminate a significant amount of manpower by reducing part count and leveraging model-based design and analysis techniques. Information will be shared about performance enhancements and design efficiencies we experienced for certain categories of engine parts.

Methodology for designing and manufacturing complex biologically inspired soft robotic fluidic actuators: prosthetic hand case study.

PubMed

Thompson-Bean, E; Das, R; McDaid, A

2016-10-31

We present a novel methodology for the design and manufacture of complex biologically inspired soft robotic fluidic actuators. The methodology is applied to the design and manufacture of a prosthetic for the hand. Real human hands are scanned to produce a 3D model of a finger, and pneumatic networks are implemented within it to produce a biomimetic bending motion. The finger is then partitioned into material sections, and a genetic algorithm based optimization, using finite element analysis, is employed to discover the optimal material for each section. This is based on two biomimetic performance criteria. Two sets of optimizations using two material sets are performed. Promising optimized material arrangements are fabricated using two techniques to validate the optimization routine, and the fabricated and simulated results are compared. We find that the optimization is successful in producing biomimetic soft robotic fingers and that fabrication of the fingers is possible. Limitations and paths for development are discussed. This methodology can be applied for other fluidic soft robotic devices.

Creative strategies of businesses with the holistic eigensolution in manufacturing industries

NASA Astrophysics Data System (ADS)

Zeichen, Gerfried; Huray, Paul G.

1998-10-01

It is a mission of this contribution to recognize and synthesize all the efforts in industry and in management science to strengthen our techniques and tools for successfully solving increasingly complex leadership problems in manufacturing industries. With the high standard of the work sharing method--the so called Taylorism principle--for cost efficient and mass production, invented at the beginning of the 20th century and the opening of the world market for global sales of goods and services a gigantic progress in living standards was reached. But at the beginning of the 21st century we are needing new ideas and methods for the guidance of overcoming increasing complexity. The holistic eigensolution presents a new operational framework for viewing and controlling the behavior of businesses. In contrast to the traditional process for viewing complex business systems through the intricate analysis of every part of that system, the authors have employed a technique used by physicists to understand the characteristic of `eigen' behaviors of complex physical systems. This method of systems analysis is achieved by observing interactions between the parts in a whole. This kind of analysis has a rigorous mathematical foundation in the physical world and it can be employed to understand most natural phenomena. Within a holistic framework, the observer is challenged to view the system form just the right perspective so that characteristic eigenmodes reveal themselves. The conclusion of the article describes why exactly the intelligent manufacturing science--especially in a broader sense--has the responsibility and chance to develop the holistic eigensolution framework as a Taylorism II-principle for the 21st century.

The Clean Energy Manufacturing Initiative: Dissolving Silos

ScienceCinema

Danielson, David; Orr, Lynn; Sarkar, Reuben; Zayas, Jose; Johnson, Mark

2018-01-16

DOE’s work is closely tied to manufacturing because manufacturing is an important part of technology innovation and commercialization. Find out how DOE – through the Clean Energy Manufacturing Initiative – is helping America lead the clean energy revolution.

National Institutes of Health-Sponsored Clinical Islet Transplantation Consortium Phase 3 Trial: Manufacture of a Complex Cellular Product at Eight Processing Facilities.

PubMed

Ricordi, Camillo; Goldstein, Julia S; Balamurugan, A N; Szot, Gregory L; Kin, Tatsuya; Liu, Chengyang; Czarniecki, Christine W; Barbaro, Barbara; Bridges, Nancy D; Cano, Jose; Clarke, William R; Eggerman, Thomas L; Hunsicker, Lawrence G; Kaufman, Dixon B; Khan, Aisha; Lafontant, David-Erick; Linetsky, Elina; Luo, Xunrong; Markmann, James F; Naji, Ali; Korsgren, Olle; Oberholzer, Jose; Turgeon, Nicole A; Brandhorst, Daniel; Chen, Xiaojuan; Friberg, Andrew S; Lei, Ji; Wang, Ling-Jia; Wilhelm, Joshua J; Willits, Jamie; Zhang, Xiaomin; Hering, Bernhard J; Posselt, Andrew M; Stock, Peter G; Shapiro, A M James; Chen, Xiaojuan

2016-11-01

Eight manufacturing facilities participating in the National Institutes of Health-sponsored Clinical Islet Transplantation (CIT) Consortium jointly developed and implemented a harmonized process for the manufacture of allogeneic purified human pancreatic islet (PHPI) product evaluated in a phase 3 trial in subjects with type 1 diabetes. Manufacturing was controlled by a common master production batch record, standard operating procedures that included acceptance criteria for deceased donor organ pancreata and critical raw materials, PHPI product specifications, certificate of analysis, and test methods. The process was compliant with Current Good Manufacturing Practices and Current Good Tissue Practices. This report describes the manufacturing process for 75 PHPI clinical lots and summarizes the results, including lot release. The results demonstrate the feasibility of implementing a harmonized process at multiple facilities for the manufacture of a complex cellular product. The quality systems and regulatory and operational strategies developed by the CIT Consortium yielded product lots that met the prespecified characteristics of safety, purity, potency, and identity and were successfully transplanted into 48 subjects. No adverse events attributable to the product and no cases of primary nonfunction were observed. © 2016 by the American Diabetes Association.

National Institutes of Health–Sponsored Clinical Islet Transplantation Consortium Phase 3 Trial: Manufacture of a Complex Cellular Product at Eight Processing Facilities

PubMed Central

Balamurugan, A.N.; Szot, Gregory L.; Kin, Tatsuya; Liu, Chengyang; Czarniecki, Christine W.; Barbaro, Barbara; Bridges, Nancy D.; Cano, Jose; Clarke, William R.; Eggerman, Thomas L.; Hunsicker, Lawrence G.; Kaufman, Dixon B.; Khan, Aisha; Lafontant, David-Erick; Linetsky, Elina; Luo, Xunrong; Markmann, James F.; Naji, Ali; Korsgren, Olle; Oberholzer, Jose; Turgeon, Nicole A.; Brandhorst, Daniel; Chen, Xiaojuan; Friberg, Andrew S.; Lei, Ji; Wang, Ling-jia; Wilhelm, Joshua J.; Willits, Jamie; Zhang, Xiaomin; Hering, Bernhard J.; Posselt, Andrew M.; Stock, Peter G.; Shapiro, A.M. James

2016-01-01

Eight manufacturing facilities participating in the National Institutes of Health–sponsored Clinical Islet Transplantation (CIT) Consortium jointly developed and implemented a harmonized process for the manufacture of allogeneic purified human pancreatic islet (PHPI) product evaluated in a phase 3 trial in subjects with type 1 diabetes. Manufacturing was controlled by a common master production batch record, standard operating procedures that included acceptance criteria for deceased donor organ pancreata and critical raw materials, PHPI product specifications, certificate of analysis, and test methods. The process was compliant with Current Good Manufacturing Practices and Current Good Tissue Practices. This report describes the manufacturing process for 75 PHPI clinical lots and summarizes the results, including lot release. The results demonstrate the feasibility of implementing a harmonized process at multiple facilities for the manufacture of a complex cellular product. The quality systems and regulatory and operational strategies developed by the CIT Consortium yielded product lots that met the prespecified characteristics of safety, purity, potency, and identity and were successfully transplanted into 48 subjects. No adverse events attributable to the product and no cases of primary nonfunction were observed. PMID:27465220

Additive Manufacture of Plasma Diagnostic Components Final Report Phase II

DOE Office of Scientific and Technical Information (OSTI.GOV)

Woodruff, Simon; Romero-Talamas, Carlos; You, Setthivoine

There is now a well-established set of plasma diagnostics (see e.g. [3]), but these remain some of the mostexpensive assemblies in fusion systems since for every system they have to be custom built, and time fordiagnostic development can pace the project. Additive manufacturing (AM) has the potential to decreaseproduction cost and significantly lower design time of fusion diagnostic subsystems, which would realizesignificant cost reduction for standard diagnostics. In some cases, these basic components can be additivelymanufactured for less than 1/100th costs of conventional manufacturing.In our DOE Phase II SBIR, we examined the impact that AM can have on plasma diagnosticmore » cost bytaking 15 separate diagnostics through an engineering design using Conventional Manufacturing (CM) tech-niques, then optimizing the design to exploit the benefits of AM. The impact of AM techniques on cost isfound to be in several areas. First, the cost of materials falls because AM parts can be manufactured withlittle to no waste, and engineered to use less material than CM. Next, the cost of fabrication falls for AMparts relative to CM since the fabrication time can be computed exactly, and often no post-processing isrequired for the part to be functional. We find that AM techniques are well suited for plasma diagnosticssince typical diagnostic complexity comes at no additional cost. Cooling channels, for example, can be builtin to plasma-facing components at no extra cost. Fabrication costs associated with assembly are lower forAM parts because many components can be combined and printed as monoliths, thereby mitigating the needfor alignment or calibration. Finally, the cost of engineering is impacted by exploiting AM design tools thatallow standard components to be customized through web-interfaces. Furthermore, we find that conceptdesign costs can be impacted by scripting interfaces for online engineering design tools.« less

Resolving Inadequacies of the Navy Industrial Fund Cost Accounting System to Enable Its Use in the RAMP SMP (Rapid Acquisition of Manufactured Parts Small Manufactured Parts) Facility

DTIC Science & Technology

1988-12-01

maintenance, depreciation , rent, utilities, insurance, and taxes. 6 Historically, manufacturing activities have been labor intensive and man-paced...developed and produced which renders older equipment obsolete sooner. As a result, equipment must be replaced more frequently and depreciation is charged...McIlhattan, 1987). As previously mentioned, automated manufacturing activities incur greater amounts of depreciation expenses more rapidly than a

78 FR 18234 - Service of Process on Manufacturers; Manufacturers Importing Electronic Products Into the United...

Federal Register 2010, 2011, 2012, 2013, 2014

2013-03-26

... DEPARTMENT OF HEALTH AND HUMAN SERVICES Food and Drug Administration 21 CFR Part 1005 [Docket No. FDA-2007-N-0091; (formerly 2007N-0104)] Service of Process on Manufacturers; Manufacturers Importing Electronic Products Into the United States; Agent Designation; Change of Address AGENCY: Food and Drug...

Simulating The Technological Movements Of The Equipment Used For Manufacturing Prosthetic Devices Using 3D Models

NASA Astrophysics Data System (ADS)

Chicea, Anca-Lucia

2015-09-01

The paper presents the process of building geometric and kinematic models of a technological equipment used in the process of manufacturing devices. First, the process of building the model for a six axes industrial robot is presented. In the second part of the paper, the process of building the model for a five-axis CNC milling machining center is also shown. Both models can be used for accurate cutting processes simulation of complex parts, such as prosthetic devices.

Manufacturing information system

NASA Astrophysics Data System (ADS)

Allen, D. K.; Smith, P. R.; Smart, M. J.

1983-12-01

The size and cost of manufacturing equipment has made it extremely difficult to perform realistic modeling and simulation of the manufacturing process in university research laboratories. Likewise the size and cost factors, coupled with many uncontrolled variables of the production situation has even made it difficult to perform adequate manufacturing research in the industrial setting. Only the largest companies can afford manufacturing research laboratories; research results are often held proprietary and seldom find their way into the university classroom to aid in education and training of new manufacturing engineers. It is the purpose for this research to continue the development of miniature prototype equipment suitable for use in an integrated CAD/CAM Laboratory. The equipment being developed is capable of actually performing production operations (e.g. drilling, milling, turning, punching, etc.) on metallic and non-metallic workpieces. The integrated CAD/CAM Mini-Lab is integrating high resolution, computer graphics, parametric design, parametric N/C parts programmings, CNC machine control, automated storage and retrieval, with robotics materials handling. The availability of miniature CAD/CAM laboratory equipment will provide the basis for intensive laboratory research on manufacturing information systems.

OPERATOR BURDEN IN METAL ADDITIVE MANUFACTURING

DOE Office of Scientific and Technical Information (OSTI.GOV)

Elliott, Amy M; Love, Lonnie J

2016-01-01

Additive manufacturing (AM) is an emerging manufacturing process that creates usable machine parts via layer-by-layer joining of a stock material. With this layer-wise approach, high-performance geometries can be created which are impossible with traditional manufacturing methods. Metal AM technology has the potential to significantly reduce the manufacturing burden of developing custom hardware; however, a major consideration in choosing a metal AM system is the required amount of operator involvement (i.e., operator burden) in the manufacturing process. The operator burden not only determines the amount of operator training and specialization required but also the usability of the system in a facility.more » As operators of several metal AM processes, the Manufacturing Demonstration Facility (MDF) at Oak Ridge National Labs is uniquely poised to provide insight into requirements for operator involvement in each of the three major metal AM processes. The paper covers an overview of each of the three metal AM technologies, focusing on the burden on the operator to complete the build cycle, process the part for final use, and reset the AM equipment for future builds.« less

Modular Manufacturing Simulator: Users Manual

NASA Technical Reports Server (NTRS)

1997-01-01

The Modular Manufacturing Simulator (MMS) has been developed for the beginning user of computer simulations. Consequently, the MMS cannot model complex systems that require branching and convergence logic. Once a user becomes more proficient in computer simulation and wants to add more complexity, the user is encouraged to use one of the many available commercial simulation systems. The (MMS) is based on the SSE5 that was developed in the early 1990's by the University of Alabama in Huntsville (UAH). A recent survey by MSFC indicated that the simulator has been a major contributor to the economic impact of the MSFC technology transfer program. Many manufacturers have requested additional features for the SSE5. Consequently, the following features have been added to the MMS that are not available in the SSE5: runs under Windows, print option for both input parameters and output statistics, operator can be fixed at a station or assigned to a group of stations, operator movement based on time limit, part limit, or work-in-process (WIP) limit at next station. The movement options for a moveable operators are: go to station with largest WIP, rabbit chase where operator moves in circular sequence between stations, and push/pull where operator moves back and forth between stations. This user's manual contains the necessary information for installing the MMS on a PC, a description of the various MMS commands, and the solutions to a number of sample problems using the MMS. Also included in the beginning of this report is a brief discussion of technology transfer.

Current use and potential of additive manufacturing for optical applications

NASA Astrophysics Data System (ADS)

Brunelle, Matthew; Ferralli, Ian; Whitsitt, Rebecca; Medicus, Kate

2017-10-01

Additive manufacturing, or 3D printing, has become widely used in recent years for the creation of both prototype and end-use parts. Because the parts are created in a layer-by-layer manner, the flexibility of additive manufacturing is unparalleled and has opened the design space to enable features like undercuts and internal channels which cannot exist on traditional, subtractively manufactured parts. This flexibility can also be leveraged for optical applications. This paper outlines some of the current uses of 3D printing in the optical manufacturing process at Optimax. Several materials and additive technologies are utilized, including polymer printing through fused deposition modeling, which creates parts by depositing a softened thermoplastic filament in a layerwise fashion. Stereolithography, which uses light to cure layers of a photopolymer resin, will also be discussed. These technologies are used to manufacture functional prototypes, fixtures, sealed housings, and other components. Additionally, metal printing through selective laser melting, which uses a laser to melt metal powder layers into a dense solid, will be discussed due to the potential to manufacture thermally stable opticalmechanical assembly frameworks and functional optics. Examples of several additively manufactured optical components will be shown.

Ramp Technology and Intelligent Processing in Small Manufacturing

NASA Technical Reports Server (NTRS)

Rentz, Richard E.

1992-01-01

To address the issues of excessive inventories and increasing procurement lead times, the Navy is actively pursuing flexible computer integrated manufacturing (FCIM) technologies, integrated by communication networks to respond rapidly to its requirements for parts. The Rapid Acquisition of Manufactured Parts (RAMP) program, initiated in 1986, is an integral part of this effort. The RAMP program's goal is to reduce the current average production lead times experienced by the Navy's inventory control points by a factor of 90 percent. The manufacturing engineering component of the RAMP architecture utilizes an intelligent processing technology built around a knowledge-based shell provided by ICAD, Inc. Rules and data bases in the software simulate an expert manufacturing planner's knowledge of shop processes and equipment. This expert system can use Product Data Exchange using STEP (PDES) data to determine what features the required part has, what material is required to manufacture it, what machines and tools are needed, and how the part should be held (fixtured) for machining, among other factors. The program's rule base then indicates, for example, how to make each feature, in what order to make it, and to which machines on the shop floor the part should be routed for processing. This information becomes part of the shop work order. The process planning function under RAMP greatly reduces the time and effort required to complete a process plan. Since the PDES file that drives the intelligent processing is 100 percent complete and accurate to start with, the potential for costly errors is greatly diminished.

Ramp technology and intelligent processing in small manufacturing

NASA Astrophysics Data System (ADS)

Rentz, Richard E.

1992-04-01

To address the issues of excessive inventories and increasing procurement lead times, the Navy is actively pursuing flexible computer integrated manufacturing (FCIM) technologies, integrated by communication networks to respond rapidly to its requirements for parts. The Rapid Acquisition of Manufactured Parts (RAMP) program, initiated in 1986, is an integral part of this effort. The RAMP program's goal is to reduce the current average production lead times experienced by the Navy's inventory control points by a factor of 90 percent. The manufacturing engineering component of the RAMP architecture utilizes an intelligent processing technology built around a knowledge-based shell provided by ICAD, Inc. Rules and data bases in the software simulate an expert manufacturing planner's knowledge of shop processes and equipment. This expert system can use Product Data Exchange using STEP (PDES) data to determine what features the required part has, what material is required to manufacture it, what machines and tools are needed, and how the part should be held (fixtured) for machining, among other factors. The program's rule base then indicates, for example, how to make each feature, in what order to make it, and to which machines on the shop floor the part should be routed for processing. This information becomes part of the shop work order. The process planning function under RAMP greatly reduces the time and effort required to complete a process plan. Since the PDES file that drives the intelligent processing is 100 percent complete and accurate to start with, the potential for costly errors is greatly diminished.

Characterizing synthetic gypsum for wallboard manufacture

DOE Office of Scientific and Technical Information (OSTI.GOV)

Henkels, P.J.; Gynor, J.C.

1996-12-31

United States Gypsum Company (USGC) has developed specifications and guidelines covering the chemical and physical aspects of synthetic gypsum to help predict end use acceptability in wallboard manufacture. These guidelines are based in part on past experiences with natural and synthetic gypsum. Similarly, most wallboard manufacturers in North America have developed their own guidelines based in part on its unique history and particular experiences with synthetic gypsum. While there are similarities between manufacturers` guidelines, differences do exist. This paper discusses the importance of selected parameters contained in the FGD gypsum guidelines. In most cases, the parameters are equally relevant tomore » other synthetic gypsums and the naturally occurring gypsum mineral as well.« less

Microstructural Analysis of Ti-6Al-4V Components Made by Electron Beam Additive Manufacturing

NASA Astrophysics Data System (ADS)

Coleman, Rashadd L.

Electron Beam Additive Manufacturing (EBAM) is a relatively new additive manufacturing (AM) technology that uses a high-energy electron beam to melt and fuse powders to build full-density parts in a layer by layer fashion. EBAM can fabricate metallic components, particularly, of complex shapes, in an efficient and cost-effective manner compared to conventional manufacturing means. EBAM is an enabling technology for rapid manufacturing (RM) of metallic components, and thus, can efficiently integrate the design and manufacturing of aerospace components. However, EBAM for aerospace-related applications remain limited because the effect of the EBAM process on part characteristics is not fully understood. In this study, various techniques including microhardness, optical microscopy (OM), X-ray diffraction (XRD), Scanning Electron Microscopy (SEM), and electron backscatter diffraction (EBSD) were used to characterize Ti-6Al-4V components processed using EBAM. The results were compared to Ti-6Al-4V components processed using conventional techniques. In this study it is shown that EBAM built Ti-64 components have increased hardness, elastic modulus, and yield strength compared to wrought Ti-6Al-4V. Further, it is also shown in this study that the horizontal build EBAM Ti-6Al-4V has increased hardness, elastic modulus, and yield strength compared to vertical build EBAM due to a preferential growth of the beta phase.

Sustainability issues in laser-based additive manufacturing

NASA Astrophysics Data System (ADS)

Sreenivasan, R.; Goel, A.; Bourell, D. L.

Sustainability is a consideration of resource utilization without depletion or adverse environmental impact. In manufacturing, important sustainability issues include energy consumption, waste generation, water usage and the environmental impact of the manufactured part in service. This paper deals with three aspects of sustainability as it applies to additive manufacturing. First is a review of the research needs for energy and sustainability as applied to additive manufacturing based on the 2009 Roadmap for Additive Manufacturing Workshop. The second part is an energy assessment for selective laser sintering (SLS) of polymers. Using polyamide powder in a 3D Systems Vanguard HiQ Sinterstation, energy loss during a build was measured due to the chamber heaters, the roller mechanism, the piston elevators and the laser. This accounted for 95% of the total energy consumption. An overall energy assessment was accomplished using eco-indicators. The last topic is electrochemical deposition of porous SLS non-polymeric preforms. The goal is to reduce energy consumption in SLS of non-polymeric materials. The approach was to mix a transient binder with the material, to create an SLS green part, to convert the binder, and then to remove the open, connected porosity and to densify the part by chemical deposition at room temperature within the pore network. The model system was silicon carbide powder mixed with a phenolic transient binder coupled with electrolytic deposition of nickel. Deposition was facilitated by inserting a conductive graphite cathode in the part center to draw the positive nickel ions through the interconnected porous network and to deposit them on the pore walls. The Roadmap for Additive Manufacturing Workshop was sponsored by the National Science Foundation under Grant CMMI-0906212 and by the Office of Naval Research under Grant N00014-09-1-0558. The electrolytic deposition research was sponsored by the National Science Foundation, Grant CMMI-0926316.

Cesic: manufacturing study for next generation telescopes

NASA Astrophysics Data System (ADS)

Kroedel, M.; Lichtscheindl, J.; Mair, Hp.

2005-08-01

Under ESO - European Southern Observatory - contract ECM has performed a feasibility study for the manufacturing of Cesic primary and secondary mirror segments for the OWL-Telescope. The main issues of this study were to demonstrate the feasibility of the serial production (~ 2550 segments) of Cesic mirror segments under a certain schedule and cost optimisation aspect for the segments. Part of this study was also a pre-design of a manufacturing facility for this big amount of mirror segments. This study is limited only up to the manufacturing of a polishable surface, the feasibility of the polishing capability is not part of this study.

Using microwave Doppler radar in automated manufacturing applications

NASA Astrophysics Data System (ADS)

Smith, Gregory C.

Since the beginning of the Industrial Revolution, manufacturers worldwide have used automation to improve productivity, gain market share, and meet growing or changing consumer demand for manufactured products. To stimulate further industrial productivity, manufacturers need more advanced automation technologies: "smart" part handling systems, automated assembly machines, CNC machine tools, and industrial robots that use new sensor technologies, advanced control systems, and intelligent decision-making algorithms to "see," "hear," "feel," and "think" at the levels needed to handle complex manufacturing tasks without human intervention. The investigator's dissertation offers three methods that could help make "smart" CNC machine tools and industrial robots possible: (1) A method for detecting acoustic emission using a microwave Doppler radar detector, (2) A method for detecting tool wear on a CNC lathe using a Doppler radar detector, and (3) An online non-contact method for detecting industrial robot position errors using a microwave Doppler radar motion detector. The dissertation studies indicate that microwave Doppler radar could be quite useful in automated manufacturing applications. In particular, the methods developed may help solve two difficult problems that hinder further progress in automating manufacturing processes: (1) Automating metal-cutting operations on CNC machine tools by providing a reliable non-contact method for detecting tool wear, and (2) Fully automating robotic manufacturing tasks by providing a reliable low-cost non-contact method for detecting on-line position errors. In addition, the studies offer a general non-contact method for detecting acoustic emission that may be useful in many other manufacturing and non-manufacturing areas, as well (e.g., monitoring and nondestructively testing structures, materials, manufacturing processes, and devices). By advancing the state of the art in manufacturing automation, the studies may help

77 FR 48992 - Tobacco Product Manufacturing Facility Visits

Federal Register 2010, 2011, 2012, 2013, 2014

2012-08-15

... manufacturing operations--from the receipt of raw materials to the distribution of finished products, and Learn... Manufacturing facilities for materials used for further processing in finished tobacco products (including, but..., parts, accessories, and Manufacturers of materials used for further processing in finished tobacco...

Environmentally sound manufacturing

NASA Technical Reports Server (NTRS)

Caddy, Larry A.; Bowman, Ross; Richards, Rex A.

1994-01-01

The NASA/Thiokol/industry team has developed and started implementation of an environmentally sound manufacturing plan for the continued production of solid rocket motors. They have worked with other industry representatives and the U.S. Environmental Protection Agency to prepare a comprehensive plan to eliminate all ozone depleting chemicals from manufacturing processes and to reduce the use of other hazardous materials used to produce the space shuttle reusable solid rocket motors. The team used a classical approach for problem solving combined with a creative synthesis of new approaches to attack this problem. As our ability to gather data on the state of the Earth's environmental health increases, environmentally sound manufacturing must become an integral part of the business decision making process.

Navy Additive Manufacturing: Adding Parts, Subtracting Steps

DTIC Science & Technology

2015-06-01

complex weapon systems within designed specifications requires extensive routine and preventative maintenance as well as expeditious repairs when...failures occur. These repairs are sometimes complex and often unpredictable in both peace and wartime environments. To keep these weapon systems...basis. The solution is not a simple one, but rather one of high complexity that cannot just be adopted from a big-box store such as Walmart, Target

Summary of NDE of Additive Manufacturing Efforts in NASA

NASA Technical Reports Server (NTRS)

Waller, Jess; Saulsberry, Regor; Parker, Bradford; Hodges, Kenneth; Burke, Eric; Taminger, Karen

2014-01-01

(1) General Rationale for Additive Manufacturing (AM): (a) Operate under a 'design-to-constraint' paradigm, make parts too complicated to fabricate otherwise, (b) Reduce weight by 20 percent with monolithic parts, (c) Reduce waste (green manufacturing), (e) Eliminate reliance on Original Equipment Manufacturers for critical spares, and (f) Extend life of in-service parts by innovative repair methods; (2) NASA OSMA NDE of AM State-of-the-Discipline Report; (3) Overview of NASA AM Efforts at Various Centers: (a) Analytical Tools, (b) Ground-Based Fabrication (c) Space-Based Fabrication; and (d) Center Activity Summaries; (4) Overview of NASA NDE data to date on AM parts; and (5) Gap Analysis/Recommendations for NDE of AM.

Biocompatibility of Advanced Manufactured Titanium Implants-A Review.

PubMed

Sidambe, Alfred T

2014-12-19

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy.

Biocompatibility of Advanced Manufactured Titanium Implants—A Review

PubMed Central

Sidambe, Alfred T.

2014-01-01

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy. PMID:28788296

Manufacturing DTaP-based combination vaccines: industrial challenges around essential public health tools.

PubMed

Vidor, Emmanuel; Soubeyrand, Benoit

2016-12-01

The manufacture of DTP-backboned combination vaccines is complex, and vaccine quality is evaluated by both batch composition and conformance of manufacturing history. Since their first availability, both the manufacturing regulations for DTP combination vaccines and their demand have evolved significantly. This has resulted in a constant need to modify manufacturing and quality control processes. Areas covered: Regulations that govern the manufacture of complex vaccines can be inconsistent between countries and need to be aligned with the regulatory requirements that apply in all countries of distribution. Changes in product mix and quantities can lead to uncertainty in vaccine supply maintenance. These problems are discussed in the context of the importance of these products as essential public health tools. Expert commentary: Increasing demand for complex vaccines globally has led to problems in supply due to intrinsically complex manufacturing and regulatory procedures. Vaccine manufacturers are fully engaged in the resolution of these challenges, but currently changes in demand need ideally to be anticipated approximately 3 years in advance due to long production cycle times.

Integrated Computer-Aided Manufacturing (ICAM) Architecture. Part 3. Volume 7. MFG01 Glossary.

DTIC Science & Technology

1983-09-01

lat oe C % 000 Sj C4 le ’ 4, 4,4 2:4 tj t*K l- X: 44 0’~ k IW- C4 % 40 Go r 00 c ~ IL P v C c -. . v IL zl - 4 1 S . v I .I a w I 1 v c u > c- -FT U 4...CC c .C C aI o , 0 A Z . 6--c 0 cCrV 46 a .0 b. 1 c 1 . Ga, v 0 M 0 44 c c c f-V - 4 0 aLS C C - . l-l - 2 - 0 S- C (~ b , J O’~ 0 .4. hSV b... ~ b...RD-R144 426 INTEGRATED COMPUTER-AIDED MANUFACTURING (ICAM)_ 1 /3 ARCHITECTURE PART 3 VOLUME.. (U) SOFTECH INC WALTHAM MRR HEINE ET RL. SEP 83 RFWRL-TR

Costs, Benefits, and Adoption of Additive Manufacturing: A Supply Chain Perspective.

PubMed

Thomas, Douglas

2016-07-01

There are three primary aspects to the economics of additive manufacturing: measuring the value of goods produced, measuring the costs and benefits of using the technology, and estimating the adoption and diffusion of the technology. This paper provides an updated estimate of the value of goods produced. It then reviews the literature on additive manufacturing costs and identifies those instances in the literature where this technology is cost effective. The paper then goes on to propose an approach for examining and understanding the societal costs and benefits of this technology both from a monetary viewpoint and a resource consumption viewpoint. The final section discusses the trends in the adoption of additive manufacturing. Globally, there is an estimated $667 million in value added produced using additive manufacturing, which equates to 0.01 % of total global manufacturing value added. US value added is estimated as $241 million. Current research on additive manufacturing costs reveals that it is cost effective for manufacturing small batches with continued centralized production; however, with increased automation distributed production may become cost effective. Due to the complexities of measuring additive manufacturing costs and data limitations, current studies are limited in their scope. Many of the current studies examine the production of single parts and those that examine assemblies tend not to examine supply chain effects such as inventory and transportation costs along with decreased risk to supply disruption. The additive manufacturing system and the material costs constitute a significant portion of an additive manufactured product; however, these costs are declining over time. The current trends in costs and benefits have resulted in this technology representing 0.02 % of the relevant manufacturing industries in the US; however, as the costs of additive manufacturing systems decrease, this technology may become widely adopted and change the

Additive Manufacturing of SiC Based Ceramics and Ceramic Matrix Composites

NASA Technical Reports Server (NTRS)

Halbig, Michael Charles; Singh, Mrityunjay

2015-01-01

Silicon carbide (SiC) ceramics and SiC fiber reinforcedSiC ceramic matrix composites (SiCSiC CMCs) offer high payoff as replacements for metals in turbine engine applications due to their lighter weight, higher temperature capability, and lower cooling requirements. Additive manufacturing approaches can offer game changing technologies for the quick and low cost fabrication of parts with much greater design freedom and geometric complexity. Four approaches for developing these materials are presented. The first two utilize low cost 3D printers. The first uses pre-ceramic pastes developed as feed materials which are converted to SiC after firing. The second uses wood containing filament to print a carbonaceous preform which is infiltrated with a pre-ceramic polymer and converted to SiC. The other two approaches pursue the AM of CMCs. The first is binder jet SiC powder processing in collaboration with rp+m (Rapid Prototyping+Manufacturing). Processing optimization was pursued through SiC powder blending, infiltration with and without SiC nano powder loading, and integration of nanofibers into the powder bed. The second approach was laminated object manufacturing (LOM) in which fiber prepregs and laminates are cut to shape by a laser and stacked to form the desired part. Scanning electron microscopy was conducted on materials from all approaches with select approaches also characterized with XRD, TGA, and bend testing.

A Framework for Preliminary Design of Aircraft Structures Based on Process Information. Part 1

NASA Technical Reports Server (NTRS)

Rais-Rohani, Masoud

1998-01-01

This report discusses the general framework and development of a computational tool for preliminary design of aircraft structures based on process information. The described methodology is suitable for multidisciplinary design optimization (MDO) activities associated with integrated product and process development (IPPD). The framework consists of three parts: (1) product and process definitions; (2) engineering synthesis, and (3) optimization. The product and process definitions are part of input information provided by the design team. The backbone of the system is its ability to analyze a given structural design for performance as well as manufacturability and cost assessment. The system uses a database on material systems and manufacturing processes. Based on the identified set of design variables and an objective function, the system is capable of performing optimization subject to manufacturability, cost, and performance constraints. The accuracy of the manufacturability measures and cost models discussed here depend largely on the available data on specific methods of manufacture and assembly and associated labor requirements. As such, our focus in this research has been on the methodology itself and not so much on its accurate implementation in an industrial setting. A three-tier approach is presented for an IPPD-MDO based design of aircraft structures. The variable-complexity cost estimation methodology and an approach for integrating manufacturing cost assessment into design process are also discussed. This report is presented in two parts. In the first part, the design methodology is presented, and the computational design tool is described. In the second part, a prototype model of the preliminary design Tool for Aircraft Structures based on Process Information (TASPI) is described. Part two also contains an example problem that applies the methodology described here for evaluation of six different design concepts for a wing spar.

14 CFR 21.43 - Location of manufacturing facilities.

Code of Federal Regulations, 2010 CFR

2010-01-01

... 14 Aeronautics and Space 1 2010-01-01 2010-01-01 false Location of manufacturing facilities. 21.43... CERTIFICATION PROCEDURES FOR PRODUCTS AND PARTS Type Certificates § 21.43 Location of manufacturing facilities... location of the manufacturer's facilities places no undue burden on the FAA in administering applicable...

NASA Game Changing Development Program Manufacturing Innovation Project

NASA Technical Reports Server (NTRS)

Tolbert, Carol; Vickers, John

2011-01-01

This presentation examines the new NASA Manufacturing Innovation Project. The project is a part of the Game Changing Development Program which is one element of the Space Technology Programs Managed by Office of the Chief Technologist. The project includes innovative technologies in model-based manufacturing, digital additive manufacturing, and other next generation manufacturing tools. The project is also coupled with the larger federal initiatives in this area including the National Digital Engineering and Manufacturing Initiative and the Advanced Manufacturing Partnership. In addition to NASA, other interagency partners include the Department of Defense, Department of Commerce, NIST, Department of Energy, and the National Science Foundation. The development of game-changing manufacturing technologies are critical for NASA s mission of exploration, strengthening America s manufacturing competitiveness, and are highly related to current challenges in defense manufacturing activities. There is strong consensus across industry, academia, and government that the future competitiveness of U.S. industry will be determined, in large part, by a technologically advanced manufacturing sector. This presentation highlights the prospectus of next generation manufacturing technologies to the challenges faced NASA and by the Department of Defense. The project focuses on maturing innovative/high payoff model-based manufacturing technologies that may lead to entirely new approaches for a broad array of future NASA missions and solutions to significant national needs. Digital manufacturing and computer-integrated manufacturing "virtually" guarantee advantages in quality, speed, and cost and offer many long-term benefits across the entire product lifecycle. This paper addresses key enablers and emerging strategies in areas such as: Current government initiatives, Model-based manufacturing, and Additive manufacturing.

Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

NASA Technical Reports Server (NTRS)

O'Neal, Derek

2016-01-01

A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. The near-net shape DMLS parts have been delivered and final machining is underway. Fabrication of the traditionally manufactured hardware is also proceeding. Testing in liquid oxygen is planned for Q2 of FY2017. This topic explores the design of the turbopump along with fabrication and material testing of the DMLS hardware.

76 FR 77149 - Authority To Manufacture and Distribute Postage Evidencing Systems

Federal Register 2010, 2011, 2012, 2013, 2014

2011-12-12

... POSTAL SERVICE 39 CFR Part 501 Authority To Manufacture and Distribute Postage Evidencing Systems AGENCY: Postal Service\\TM\\. ACTION: Final rule. SUMMARY: This rule clarifies the responsibility of the... reasons stated, 39 CFR part 501 is amended as follows: PART 501--AUTHORIZATION TO MANUFACTURE AND...

21st Century Manufacturing Supervisors and Their Historical Roots

ERIC Educational Resources Information Center

Hotek, Douglas R.

2003-01-01

This article provides a perspective of the past and present roles of the manufacturing supervisor with a specific focus on new skills requirements. Within the structure of manufacturing management, the supervisor plays a key role in implementing today's complex automated manufacturing technologies. The supervisor is at the bottom of the management…

Vertical movement of iron-cyanide complexes in soils of a former Manufactured Gas Plant site

NASA Astrophysics Data System (ADS)

Sut, Magdalena; Repmann, Frank; Raab, Thomas

2015-04-01

In Germany, soil and groundwater at more than a thousand sites are contaminated with iron-cyanide complexes. These contaminations originate from the gas purification process that was conducted in Manufactured Gas Plants (MGP). The phenomenon of iron-cyanide complexes mobility in soil, according to the literature, is mainly governed by the dissolution and precipitation of ferric ferrocyanide, which is only slightly soluble (< 1 mg L-1) under acidic conditions. This study suggests vertical transport of a colloidal ferric ferrocyanide, in the excess of iron and circum-neutral pH conditions, as an alternative process that influences the retardation of the pollutant movement through the soil profile. Preliminary in situ investigations of the two boreholes implied transport of ferric ferricyanide from the initial deposition in the wastes layer towards the sandy loam material (secondary accumulation), which possibly retarded the mobility of cyanide (CN). The acidic character of the wastes and the accumulation of the blue patches suggested the potential filter function of a sandy loam material due to colloidal transport of the ferric ferricyanide. Series of batch and column experiments, using sandy loam soil, revealed reduction of CN concentration due to mechanical filtration of precipitated solid iron-cyanide complexes and due to the formation of potassium manganese iron-cyanide (K2Mn[Fe(CN)6]).

26 CFR 48.6416(b)(3)-2 - Further manufacture included.

Code of Federal Regulations, 2010 CFR

2010-04-01

... 26 Internal Revenue 16 2010-04-01 2010-04-01 true Further manufacture included. 48.6416(b)(3)-2... of Special Application to Retailers and Manufacturers Taxes § 48.6416(b)(3)-2 Further manufacture... overpayment by reason of any use in further manufacture, or sale as part of a second manufactured article...

Virtual Planning of a Complex Three-Part Bimaxillary Osteotomy

PubMed Central

Anghinoni, Marilena Laura

2017-01-01

In maxillofacial surgery, every patient presents special problems requiring careful evaluation. Conventional methods to study the deformities are still reliable, but the advent of tridimensional (3D) imaging, especially computed tomography (CT) scan and laser scanning of casts, created the opportunity to better understanding the skeletal support and the soft tissue structures. Nowadays, virtual technologies are increasingly employed in maxillofacial surgery and demonstrated precision and reliability. However, in complex surgical procedures, these new technologies are still controversial. Especially in the less frequent cases of three-part maxillary surgery, the experience is limited, and scientific literature cannot give a clear support. This paper presents the case of a young patient affected by a complex long face dentofacial deformity treated by a bimaxillary surgery with three-part segmentation of the maxilla. The operator performed the surgical study completely with a virtual workflow. Pre- and postoperative CT scan and optical scanning of plaster models were collected and compared. Every postoperatory maxillary piece was superimposed with the presurgical one, and the differences were examined in a color-coded map. Only mild differences were found near the osteotomy lines, when the bony surface and the teeth demonstrated an excellent coincidence. PMID:29318057

Cincinnati Big Area Additive Manufacturing (BAAM)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Duty, Chad E.; Love, Lonnie J.

Oak Ridge National Laboratory (ORNL) worked with Cincinnati Incorporated (CI) to demonstrate Big Area Additive Manufacturing which increases the speed of the additive manufacturing (AM) process by over 1000X, increases the size of parts by over 10X and shows a cost reduction of over 100X. ORNL worked with CI to transition the Big Area Additive Manufacturing (BAAM) technology from a proof-of-principle (TRL 2-3) demonstration to a prototype product stage (TRL 7-8).

Additive manufacturing of optical components

NASA Astrophysics Data System (ADS)

Heinrich, Andreas; Rank, Manuel; Maillard, Philippe; Suckow, Anne; Bauckhage, Yannick; Rößler, Patrick; Lang, Johannes; Shariff, Fatin; Pekrul, Sven

2016-08-01

The development of additive manufacturing methods has enlarged rapidly in recent years. Thereby, the work mainly focuses on the realization of mechanical components, but the additive manufacturing technology offers a high potential in the field of optics as well. Owing to new design possibilities, completely new solutions are possible. This article briefly reviews and compares the most important additive manufacturing methods for polymer optics. Additionally, it points out the characteristics of additive manufactured polymer optics. Thereby, surface quality is of crucial importance. In order to improve it, appropriate post-processing steps are necessary (e.g. robot polishing or coating), which will be discussed. An essential part of this paper deals with various additive manufactured optical components and their use, especially in optical systems for shape metrology (e.g. borehole sensor, tilt sensor, freeform surface sensor, fisheye lens). The examples should demonstrate the potentials and limitations of optical components produced by additive manufacturing.

Enhancing Surface Finish of Additively Manufactured Titanium and Cobalt Chrome Elements Using Laser Based Finishing

NASA Astrophysics Data System (ADS)

Gora, Wojciech S.; Tian, Yingtao; Cabo, Aldara Pan; Ardron, Marcus; Maier, Robert R. J.; Prangnell, Philip; Weston, Nicholas J.; Hand, Duncan P.

Additive manufacturing (AM) offers the possibility of creating a complex free form object as a single element, which is not possible using traditional mechanical machining. Unfortunately the typically rough surface finish of additively manufactured parts is unsuitable for many applications. As a result AM parts must be post-processed; typically mechanically machined and/or and polished using either chemical or mechanical techniques (both of which have their limitations). Laser based polishing is based on remelting of a very thin surface layer and it offers potential as a highly repeatable, higher speed process capable of selective area polishing, and without any waste problems (no abrasives or liquids). In this paper an in-depth investigation of CW laser polishing of titanium and cobalt chrome AM elements is presented. The impact of different scanning strategies, laser parameters and initial surface condition on the achieved surface finish is evaluated.

ADVANCED MANUFACTURING TEAM

NASA Image and Video Library

2016-03-17

KEN COOPER, TEAM LEAD OF MSFC’S ADVANCED MANUFACTURING TEAM, WITH NICKEL ALLOY 718 PARTS FABRICATED USING THE M1 SELECTIVE LASER MELTING SYSTEM. THE M1 MACHINE IS DEDICATED TO BUILDING QUALIFICATION SAMPLES AND HARDWARE DEMONSTRATORS FOR THE RS25 ENGINE PROJECT.

Industrial based volume manufacturing of lightweight aluminium alloy panel components with high-strength and complex-shape for car body and chassis structures

NASA Astrophysics Data System (ADS)

Anyasodor, Gerald; Koroschetz, Christian

2017-09-01

To achieve the high volume manufacture of lightweight passenger cars at economic cost as required in the automotive industry, low density materials and new process route will be needed. While high strength aluminium alloy grades: AA7075 and AA6082 may provide the alternative material solution, hot stamping process used for high-strength and ultrahigh strength steels such as boron steel 22mnb5 can enable the volume manufacture of panel components with high-strength and complex-shape for car body and chassis structures. These aluminium alloy grades can be used to manufacture panel components with possible yield strengths ≥ 500 MPa. Due to the differences in material behaviors, hot stamping process of 22mnb5 cannot be directly applied to high strength aluminium alloy grades. Despite recorded successes in laboratories, researches and niche hot forming processes of high strength aluminium alloy grades, not much have been achieved for adequate and efficient volume manufacturing system applicable in the automotive industry. Due to lack of such system and based on expert knowledge in hot stamping production-line, AP&T presents in this paper a hot stamping processing route for high strength aluminium alloys been suitable for production-line development and volume manufacturing.

Evaluation of a local exhaust system used in the manufacture of small parts made of reinforced plastic.

PubMed

Lazure, L P

2000-09-01

Fiber-reinforced plastics are used to manufacture a large variety of products, particularly for the transportation sector. Hand lay-up molding and projection molding are the main methods of manufacture. The users of these processes are exposed to appreciable emissions of styrene; in Quebec, more than 3000 workers work in this industry. A statistical analysis of styrene concentrations measured over a five-year period by the Institut de recherche en santé et en sécurité du travail (IRSST, Occupational Health and Safety Research Institute) reveals that for all of the main manufacturing sectors involved, between 40 percent and 78 percent of the results exceed the exposure standard of 50 ppm. This study evaluated the effectiveness of a ventilated table in controlling worker exposure to styrene and acetone in a shop that manufactures fiber-reinforced plastics parts. The evaluated local extraction system consists of a ventilated table with a surface area of 1.2 m x 1.2 m. During molding, the styrene emissions are exhausted through the ventilated table as well as through the slots in a lateral hood. Replacement air, introduced vertically through a supply air shower located above the worker, limits the diffusion of contaminants toward the worker's breathing zone. The reduction in worker exposure to styrene and acetone during hand lay-up molding was measured in the breathing zone for two sizes of molds. The results show that exhaust ventilation reduced the styrene concentrations by 91 percent and that the introduction of replacement air increased the efficiency of the ventilated table to 96 percent. The evaluation performed indicates that the ventilated table adequately controls worker exposure to styrene and acetone during the molding of small components.

15 CFR Supplement No. 2 to Part 783 - Manufacturing Activities

Code of Federal Regulations, 2010 CFR

2010-01-01

... dissipates decay heat during handling, transportation and storage. (12) The manufacture of reactor control... or greater than the equivalent of 0.5 meters of concrete, with a density of 3.2 g/cm3 or greater...

15 CFR Supplement No. 2 to Part 783 - Manufacturing Activities

Code of Federal Regulations, 2011 CFR

2011-01-01

... dissipates decay heat during handling, transportation and storage. (12) The manufacture of reactor control... or greater than the equivalent of 0.5 meters of concrete, with a density of 3.2 g/cm3 or greater...

15 CFR Supplement No. 2 to Part 783 - Manufacturing Activities

Code of Federal Regulations, 2014 CFR

2014-01-01

... dissipates decay heat during handling, transportation and storage. (12) The manufacture of reactor control... or greater than the equivalent of 0.5 meters of concrete, with a density of 3.2 g/cm3 or greater...

15 CFR Supplement No. 2 to Part 783 - Manufacturing Activities

Code of Federal Regulations, 2013 CFR

2013-01-01

... dissipates decay heat during handling, transportation and storage. (12) The manufacture of reactor control... or greater than the equivalent of 0.5 meters of concrete, with a density of 3.2 g/cm3 or greater...

15 CFR Supplement No. 2 to Part 783 - Manufacturing Activities

Code of Federal Regulations, 2012 CFR

2012-01-01

... dissipates decay heat during handling, transportation and storage. (12) The manufacture of reactor control... or greater than the equivalent of 0.5 meters of concrete, with a density of 3.2 g/cm3 or greater...

Microlabels For Auto Parts

NASA Technical Reports Server (NTRS)

Ash, John P.

1993-01-01

Proposed method of unique labeling and identification of automotive parts greatly simplifies recall campaigns and reduces effort and expense associated. Compressed symbols fully characterize each part by type and manufacturing history. Manufacturers notify only those owners whose cars need repairs or modifications. Similar compressed symbology developed for possible use on spacecraft.

14 CFR 21.143 - Quality control data requirements; prime manufacturer.

Code of Federal Regulations, 2010 CFR

2010-01-01

..., purchased items, and parts and assemblies produced by manufacturers' suppliers including methods used to... special manufacturing processes involved, the means used to control the processes, the final test... procedure for recording review board decisions and disposing of rejected parts; (5) An outline of a system...

Long-term health experience of jet engine manufacturing workers: VIII. glioblastoma incidence in relation to workplace experiences with parts and processes.

PubMed

Marsh, Gary M; Youk, Ada O; Buchanich, Jeanine M; Downing, Sarah; Kennedy, Kathleen J; Esmen, Nurtan A; Hancock, Roger P; Lacey, Steven E; Pierce, Jennifer S; Fleissner, Mary Lou

2013-06-01

To determine whether glioblastoma (GB) incidence rates among jet engine manufacturing workers were associated with workplace experiences with specific parts produced and processes performed. Subjects were 210,784 workers employed between 1952 and 2001. We conducted nested case-control and cohort incidence studies with focus on 277 GB cases. We estimated time experienced with 16 part families, 4 process categories, and 32 concurrent part-process combinations with 20 or more GB cases. In both the cohort and case-control studies, none of the part families, process categories, or both considered was associated with increased GB risk. If not due to chance alone, the not statistically significantly elevated GB rates in the North Haven plant may reflect external occupational factors or nonoccupational factors unmeasured in the current evaluation.

Additive manufacturing of tools for lapping glass

NASA Astrophysics Data System (ADS)

Williams, Wesley B.

2013-09-01

Additive manufacturing technologies have the ability to directly produce parts with complex geometries without the need for secondary processes, tooling or fixtures. This ability was used to produce concave lapping tools with a VFlash 3D printer from 3D Systems. The lapping tools were first designed in Creo Parametric with a defined constant radius and radial groove pattern. The models were converted to stereolithography files which the VFlash used in building the parts, layer by layer, from a UV curable resin. The tools were rotated at 60 rpm and used with 120 grit and 220 grit silicon carbide lapping paste to lap 0.750" diameter fused silica workpieces. The samples developed a matte appearance on the lapped surface that started as a ring at the edge of the workpiece and expanded to the center. This indicated that as material was removed, the workpiece radius was beginning to match the tool radius. The workpieces were then cleaned and lapped on a second tool (with equivalent geometry) using a 3000 grit corundum aluminum oxide lapping paste, until a near specular surface was achieved. By using lapping tools that have been additively manufactured, fused silica workpieces can be lapped to approach a specified convex geometry. This approach may enable more rapid lapping of near net shape workpieces that minimize the material removal required by subsequent polishing. This research may also enable development of new lapping tool geometry and groove patterns for improved loose abrasive finishing.

Process monitoring of additive manufacturing by using optical tomography

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zenzinger, Guenter, E-mail: guenter.zenzinger@mtu.de, E-mail: alexander.ladewig@mtu.de; Bamberg, Joachim, E-mail: guenter.zenzinger@mtu.de, E-mail: alexander.ladewig@mtu.de; Ladewig, Alexander, E-mail: guenter.zenzinger@mtu.de, E-mail: alexander.ladewig@mtu.de

2015-03-31

Parts fabricated by means of additive manufacturing are usually of complex shape and owing to the fabrication procedure by using selective laser melting (SLM), potential defects and inaccuracies are often very small in lateral size. Therefore, an adequate quality inspection of such parts is rather challenging, while non-destructive-techniques (NDT) are difficult to realize, but considerable efforts are necessary in order to ensure the quality of SLM-parts especially used for aerospace components. Thus, MTU Aero Engines is currently focusing on the development of an Online Process Control system which monitors and documents the complete welding process during the SLM fabrication procedure.more » A high-resolution camera system is used to obtain images, from which tomographic data for a 3dim analysis of SLM-parts are processed. From the analysis, structural irregularities and structural disorder resulting from any possible erroneous melting process become visible and may be allocated anywhere within the 3dim structure. Results of our optical tomography (OT) method as obtained on real defects are presented.« less

Composite fuselage crown panel manufacturing technology

NASA Technical Reports Server (NTRS)

Willden, Kurtis; Metschan, S.; Grant, C.; Brown, T.

1992-01-01

Commercial fuselage structures contain significant challenges in attempting to save manufacturing costs with advanced composite technology. Assembly issues, materials costs, and fabrication of elements with complex geometry are each expected to drive the cost of composite fuselage structure. Key technologies, such as large crown panel fabrication, were pursued for low cost. An intricate bond panel design and manufacturing concept were selected based on the efforts of the Design Build Team. The manufacturing processes selected for the intricate bond design include multiple large panel fabrication with Advanced Tow Placement (ATP) process, innovative cure tooling concepts, resin transfer molding of long fuselage frames, and use of low cost materials forms. The process optimization for final design/manufacturing configuration included factory simulations and hardware demonstrations. These efforts and other optimization tasks were instrumental in reducing costs by 18 pct. and weight by 45 pct. relative to an aluminum baseline. The qualitative and quantitative results of the manufacturing demonstrations were used to assess manufacturing risks and technology readiness.

77 FR 41336 - Authorization to Manufacture and Distribute Postage Evidencing Systems; Discontinued Indicia

Federal Register 2010, 2011, 2012, 2013, 2014

2012-07-13

... POSTAL SERVICE 39 CFR Part 501 Authorization to Manufacture and Distribute Postage Evidencing... Service proposes to amend the rules concerning the manufacture and distribution of postage evidencing... MANUFACTURE AND DISTRIBUTE POSTAGE EVIDENCING SYSTEMS 1. The authority citation for 39 CFR part 501 continues...

Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs

NASA Technical Reports Server (NTRS)

Pettit, R. G.; Wang, J. J.; Toh, C.

2000-01-01

The continual need to reduce airframe cost and the emergence of high speed machining and other manufacturing technologies has brought about a renewed interest in large-scale integral structures for aircraft applications. Applications have been inhibited, however, because of the need to demonstrate damage tolerance, and by cost and manufacturing risks associated with the size and complexity of the parts. The Integral Airframe Structures (IAS) Program identified a feasible integrally stiffened fuselage concept and evaluated performance and manufacturing cost compared to conventional designs. An integral skin/stiffener concept was produced both by plate hog-out and near-net extrusion. Alloys evaluated included 7050-T7451 plate, 7050-T74511 extrusion, 6013-T6511 extrusion, and 7475-T7351 plate. Mechanical properties, structural details, and joint performance were evaluated as well as repair, static compression, and two-bay crack residual strength panels. Crack turning behavior was characterized through panel tests and improved methods for predicting crack turning were developed. Manufacturing cost was evaluated using COSTRAN. A hybrid design, made from high-speed machined extruded frames that are mechanically fastened to high-speed machined plate skin/stringer panels, was identified as the most cost-effective manufacturing solution. Recurring labor and material costs of the hybrid design are up to 61 percent less than the current technology baseline.

27 CFR 53.114 - Use in further manufacture.

Code of Federal Regulations, 2010 CFR

2010-04-01

... 27 Alcohol, Tobacco Products and Firearms 2 2010-04-01 2010-04-01 false Use in further manufacture... further manufacture. For purposes of section 4218 and § 53.111, an article is used as material in the manufacture or production of, or as a component part of, another article, if it is incorporated in, or is a...

Incremental electrohydraulic forming - A new approach for the manufacture of structured multifunctional sheet metal blanks

NASA Astrophysics Data System (ADS)

Djakow, Eugen; Springer, Robert; Homberg, Werner; Piper, Mark; Tran, Julian; Zibart, Alexander; Kenig, Eugeny

2017-10-01

Electrohydraulic Forming (EHF) processes permit the production of complex, sharp-edged geometries even when high-strength materials are used. Unfortunately, the forming zone is often limited as compared to other sheet metal forming processes. The use of a special industrial-robot-based tool setup and an incremental process strategy could provide a promising solution for this problem. This paper describes such an innovative approach using an electrohydraulic incremental forming machine, which can be employed to manufacture the large multifunctional and complex part geometries in steel, aluminium, magnesium and reinforced plastic that are employed in lightweight constructions or heating elements.

ENVIRONMENTAL RESEARCH BRIEF: WASTE MINIMIZATION FOR A MANUFACTURER OF ALUMINUM AND STEEL PARTS

EPA Science Inventory

The U.S. Environmental Protection Agency (EPA) has funded a pilot project to assist small and medium-size manufacturers who want to minimize their generation of waste but who lack the expertise to do so. n an effort to assist these manufacturers Waste Minimization Assessment Cent...

Post Processing Methods used to Improve Surface Finish of Products which are Manufactured by Additive Manufacturing Technologies: A Review

NASA Astrophysics Data System (ADS)

Kumbhar, N. N.; Mulay, A. V.

2016-08-01

The Additive Manufacturing (AM) processes open the possibility to go directly from Computer-Aided Design (CAD) to a physical prototype. These prototypes are used as test models before it is finalized as well as sometimes as a final product. Additive Manufacturing has many advantages over the traditional process used to develop a product such as allowing early customer involvement in product development, complex shape generation and also save time as well as money. Additive manufacturing also possess some special challenges that are usually worth overcoming such as Poor Surface quality, Physical Properties and use of specific raw material for manufacturing. To improve the surface quality several attempts had been made by controlling various process parameters of Additive manufacturing and also applying different post processing techniques on components manufactured by Additive manufacturing. The main objective of this work is to document an extensive literature review in the general area of post processing techniques which are used in Additive manufacturing.

Additive Manufacturing of Fuel Injectors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sadek Tadros, Dr. Alber Alphonse; Ritter, Dr. George W.; Drews, Charles Donald

Additive manufacturing (AM), also known as 3D-printing, has been shifting from a novelty prototyping paradigm to a legitimate manufacturing tool capable of creating components for highly complex engineered products. An emerging AM technology for producing metal parts is the laser powder bed fusion (L-PBF) process; however, industry manufacturing specifications and component design practices for L-PBF have not yet been established. Solar Turbines Incorporated (Solar), an industrial gas turbine manufacturer, has been evaluating AM technology for development and production applications with the desire to enable accelerated product development cycle times, overall turbine efficiency improvements, and supply chain flexibility relative to conventionalmore » manufacturing processes (casting, brazing, welding). Accordingly, Solar teamed with EWI on a joint two-and-a-half-year project with the goal of developing a production L-PBF AM process capable of consistently producing high-nickel alloy material suitable for high temperature gas turbine engine fuel injector components. The project plan tasks were designed to understand the interaction of the process variables and their combined impact on the resultant AM material quality. The composition of the high-nickel alloy powders selected for this program met the conventional cast Hastelloy X compositional limits and were commercially available in different particle size distributions (PSD) from two suppliers. Solar produced all the test articles and both EWI and Solar shared responsibility for analyzing them. The effects of powder metal input stock, laser parameters, heat treatments, and post-finishing methods were evaluated. This process knowledge was then used to generate tensile, fatigue, and creep material properties data curves suitable for component design activities. The key process controls for ensuring consistent material properties were documented in AM powder and process specifications. The basic components of the

Personal manufacturing systems

NASA Astrophysics Data System (ADS)

Bailey, P.

1992-04-01

Personal Manufacturing Systems are the missing link in the automation of the design-to- manufacture process. A PMS will act as a CAD peripheral, closing the loop around the designer enabling him to directly produce models, short production runs or soft tooling with as little fuss as he might otherwise plot a drawing. Whereas conventional 5-axis CNC machines are based on orthogonal axes and simple incremental movements, the PMS is based on a geodetic structure and complex co-ordinated 'spline' movements. The software employs a novel 3D pixel technique for give itself 'spatial awareness' and an expert system to determine the optimum machining conditions. A completely automatic machining strategy can then be determined.

Pharmaceutical Additive Manufacturing: a Novel Tool for Complex and Personalized Drug Delivery Systems.

PubMed

Zhang, Jiaxiang; Vo, Anh Q; Feng, Xin; Bandari, Suresh; Repka, Michael A

2018-06-25

Inter-individual variability is always an issue when treating patients of different races, genders, ages, pharmacogenetics, and pharmacokinetic characteristics. However, the development of novel dosage forms is limited by the huge investments required for production line modifications and dosages diversity. Additive manufacturing (AM) or 3D printing can be a novel alternative solution for the development of controlled release dosages because it can produce personalized or unique dosage forms and more complex drug-release profiles. The primary objective of this manuscript is to review the 3D printing processes that have been used in the pharmaceutical area, including their general aspects, materials, and the operation of each AM technique. Advantages and shortcomings of the technologies are discussed with respect to practice and practical applications. Thus, this review will provide an overview and discussion on advanced pharmaceutical AM technologies, which can be used to produce unique controlled drug delivery systems and personalized dosages for the future of personalized medicine.

Technology demonstration of starshade manufacturing for NASA's Exoplanet mission program

NASA Astrophysics Data System (ADS)

Kasdin, N. J.; Lisman, D.; Shaklan, S.; Thomson, M.; Cady, E.; Martin, S.; Marchen, L.; Vanderbei, R. J.; Macintosh, B.; Rudd, R. E.; Savransky, D.; Mikula, J.; Lynch, D.

2012-09-01

It is likely that the coming decade will see the development of a large visible light telescope with enabling technology for imaging exosolar Earthlike planets in the habitable zone of nearby stars. One such technology utilizes an external occulter, a satellite flying far from the telescope and employing a large screen, or starshade, to suppress the incoming starlight suffciently for detecting and characterizing exoplanets. This trades the added complexity of building the precisely shaped starshade and flying it in formation against simplifications in the telescope since extremely precise wavefront control is no longer necessary. In this paper we present the results of our project to design, manufacture, and measure a prototype occulter petal as part of NASA's first Technology Development for Exoplanet Missions program. We describe the mechanical design of the starshade and petal, the precision manufacturing tolerances, and the metrology approach. We demonstrate that the prototype petal meets the requirements and is consistent with a full-size occulter achieving better than 10-10 contrast.

Retrieval of complex χ(2) parts for quantitative analysis of sum-frequency generation intensity spectra

PubMed Central

Hofmann, Matthias J.; Koelsch, Patrick

2015-01-01

Vibrational sum-frequency generation (SFG) spectroscopy has become an established technique for in situ surface analysis. While spectral recording procedures and hardware have been optimized, unique data analysis routines have yet to be established. The SFG intensity is related to probing geometries and properties of the system under investigation such as the absolute square of the second-order susceptibility χ(2)2. A conventional SFG intensity measurement does not grant access to the complex parts of χ(2) unless further assumptions have been made. It is therefore difficult, sometimes impossible, to establish a unique fitting solution for SFG intensity spectra. Recently, interferometric phase-sensitive SFG or heterodyne detection methods have been introduced to measure real and imaginary parts of χ(2) experimentally. Here, we demonstrate that iterative phase-matching between complex spectra retrieved from maximum entropy method analysis and fitting of intensity SFG spectra (iMEMfit) leads to a unique solution for the complex parts of χ(2) and enables quantitative analysis of SFG intensity spectra. A comparison between complex parts retrieved by iMEMfit applied to intensity spectra and phase sensitive experimental data shows excellent agreement between the two methods. PMID:26450297

Retardation of iron-cyanide complexes in the soil of a former manufactured gas plant site.

PubMed

Sut, Magdalena; Repmann, Frank; Raab, Thomas

2015-01-01

The soil in the vicinities of former Manufactured Gas Plant (MGP) sites is commonly contaminated with iron-cyanide complexes (ferric ferrocyanide). The phenomenon of cyanide mobility in soil, according to the literature, is mainly governed by the dissolution and precipitation of ferric ferrocyanide, which is only slightly soluble (<1 mg L(-1)) under acidic conditions. In this paper, retention properties of the sandy loam soil and the potential vertical movement of the solid iron-cyanide complexes, co-existing with the dissolution, sorption and precipitation reactions were investigated. Preliminary research conducted on a former MGP site implied colloidal transport of ferric ferricyanide from the initial deposition in the wastes layer towards the sandy loam material (secondary accumulation), which possibly retarded the mobility of cyanide (CN). A series of batch and column experiments were applied in order to investigate the retardation of iron-cyanide complexes by the sandy loam soil. Batch experiments revealed that in circumneutral pH conditions sandy loam material decreases the potassium ferro- and ferricyanide concentration. In column experiments a minor reduction in CN concentration was observed prior to addition of iron sulfide (FeS) layer, which induced the formation of the Prussian blue colloids in circumneutral pH conditions. Precipitated solid iron-cyanide complexes were mechanically filtered by the coherent structure of the investigated soil. Additionally, the reduction of the CN concentration of the percolation solutions by the sandy loam soil was presumably induced due to the formation of potassium manganese iron-cyanide (K2Mn[Fe(CN)6]).

Costs, Benefits, and Adoption of Additive Manufacturing: A Supply Chain Perspective

PubMed Central

Thomas, Douglas

2017-01-01

There are three primary aspects to the economics of additive manufacturing: measuring the value of goods produced, measuring the costs and benefits of using the technology, and estimating the adoption and diffusion of the technology. This paper provides an updated estimate of the value of goods produced. It then reviews the literature on additive manufacturing costs and identifies those instances in the literature where this technology is cost effective. The paper then goes on to propose an approach for examining and understanding the societal costs and benefits of this technology both from a monetary viewpoint and a resource consumption viewpoint. The final section discusses the trends in the adoption of additive manufacturing. Globally, there is an estimated $667 million in value added produced using additive manufacturing, which equates to 0.01 % of total global manufacturing value added. US value added is estimated as $241 million. Current research on additive manufacturing costs reveals that it is cost effective for manufacturing small batches with continued centralized production; however, with increased automation distributed production may become cost effective. Due to the complexities of measuring additive manufacturing costs and data limitations, current studies are limited in their scope. Many of the current studies examine the production of single parts and those that examine assemblies tend not to examine supply chain effects such as inventory and transportation costs along with decreased risk to supply disruption. The additive manufacturing system and the material costs constitute a significant portion of an additive manufactured product; however, these costs are declining over time. The current trends in costs and benefits have resulted in this technology representing 0.02 % of the relevant manufacturing industries in the US; however, as the costs of additive manufacturing systems decrease, this technology may become widely adopted and change the

Complexation of buffer constituents with neutral complexation agents: part I. Impact on common buffer properties.

PubMed

Riesová, Martina; Svobodová, Jana; Tošner, Zdeněk; Beneš, Martin; Tesařová, Eva; Gaš, Bohuslav

2013-09-17

The complexation of buffer constituents with the complexation agent present in the solution can very significantly influence the buffer properties, such as pH, ionic strength, or conductivity. These parameters are often crucial for selection of the separation conditions in capillary electrophoresis or high-pressure liquid chromatography (HPLC) and can significantly affect results of separation, particularly for capillary electrophoresis as shown in Part II of this paper series (Beneš, M.; Riesová, M.; Svobodová, J.; Tesařová, E.; Dubský, P.; Gaš, B. Anal. Chem. 2013, DOI: 10.1021/ac401381d). In this paper, the impact of complexation of buffer constituents with a neutral complexation agent is demonstrated theoretically as well as experimentally for the model buffer system composed of benzoic acid/LiOH or common buffers (e.g., CHES/LiOH, TAPS/LiOH, Tricine/LiOH, MOPS/LiOH, MES/LiOH, and acetic acid/LiOH). Cyclodextrins as common chiral selectors were used as model complexation agents. We were not only able to demonstrate substantial changes of pH but also to predict the general complexation characteristics of selected compounds. Because of the zwitterion character of the common buffer constituents, their charged forms complex stronger with cyclodextrins than the neutral ones do. This was fully proven by NMR measurements. Additionally complexation constants of both forms of selected compounds were determined by NMR and affinity capillary electrophoresis with a very good agreement of obtained values. These data were advantageously used for the theoretical descriptions of variations in pH, depending on the composition and concentration of the buffer. Theoretical predictions were shown to be a useful tool for deriving some general rules and laws for complexing systems.

CT-assisted agile manufacturing

NASA Astrophysics Data System (ADS)

Stanley, James H.; Yancey, Robert N.

1996-11-01

The next century will witness at least two great revolutions in the way goods are produced. First, workers will use the medium of virtual reality in all aspects of marketing, research, development, prototyping, manufacturing, sales and service. Second, market forces will drive manufacturing towards small-lot production and just-in-time delivery. Already, we can discern the merging of these megatrends into what some are calling agile manufacturing. Under this new paradigm, parts and processes will be designed and engineered within the mind of a computer, tooled and manufactured by the offspring of today's rapid prototyping equipment, and evaluated for performance and reliability by advanced nondestructive evaluation (NDE) techniques and sophisticated computational models. Computed tomography (CT) is the premier example of an NDE method suitable for future agile manufacturing activities. It is the only modality that provides convenient access to the full suite of engineering data that users will need to avail themselves of computer- aided design, computer-aided manufacturing, and computer- aided engineering capabilities, as well as newly emerging reverse engineering, rapid prototyping and solid freeform fabrication technologies. As such, CT is assured a central, utilitarian role in future industrial operations. An overview of this exciting future for industrial CT is presented.

FMS: The New Wave of Manufacturing Technology.

ERIC Educational Resources Information Center

Industrial Education, 1986

1986-01-01

Flexible manufacturing systems (FMS) are described as a marriage of all of the latest technologies--robotics, numerical control, CAD/CAM (computer-assisted design/computer-assisted manufacturing), etc.--into a cost-efficient, optimized production process yielding the greatest flexibility in making various parts. A typical curriculum to teach FMS…

Modeling and deadlock avoidance of automated manufacturing systems with multiple automated guided vehicles.

PubMed

Wu, Naiqi; Zhou, MengChu

2005-12-01

An automated manufacturing system (AMS) contains a number of versatile machines (or workstations), buffers, an automated material handling system (MHS), and is computer-controlled. An effective and flexible alternative for implementing MHS is to use automated guided vehicle (AGV) system. The deadlock issue in AMS is very important in its operation and has extensively been studied. The deadlock problems were separately treated for parts in production and transportation and many techniques were developed for each problem. However, such treatment does not take the advantage of the flexibility offered by multiple AGVs. In general, it is intractable to obtain maximally permissive control policy for either problem. Instead, this paper investigates these two problems in an integrated way. First we model an AGV system and part processing processes by resource-oriented Petri nets, respectively. Then the two models are integrated by using macro transitions. Based on the combined model, a novel control policy for deadlock avoidance is proposed. It is shown to be maximally permissive with computational complexity of O (n2) where n is the number of machines in AMS if the complexity for controlling the part transportation by AGVs is not considered. Thus, the complexity of deadlock avoidance for the whole system is bounded by the complexity in controlling the AGV system. An illustrative example shows its application and power.

A Process Management System for Networked Manufacturing

NASA Astrophysics Data System (ADS)

Liu, Tingting; Wang, Huifen; Liu, Linyan

With the development of computer, communication and network, networked manufacturing has become one of the main manufacturing paradigms in the 21st century. Under the networked manufacturing environment, there exist a large number of cooperative tasks susceptible to alterations, conflicts caused by resources and problems of cost and quality. This increases the complexity of administration. Process management is a technology used to design, enact, control, and analyze networked manufacturing processes. It supports efficient execution, effective management, conflict resolution, cost containment and quality control. In this paper we propose an integrated process management system for networked manufacturing. Requirements of process management are analyzed and architecture of the system is presented. And a process model considering process cost and quality is developed. Finally a case study is provided to explain how the system runs efficiently.

Exploring a Multiphysics Resolution Approach for Additive Manufacturing

NASA Astrophysics Data System (ADS)

Estupinan Donoso, Alvaro Antonio; Peters, Bernhard

2018-06-01

Metal additive manufacturing (AM) is a fast-evolving technology aiming to efficiently produce complex parts while saving resources. Worldwide, active research is being performed to solve the existing challenges of this growing technique. Constant computational advances have enabled multiscale and multiphysics numerical tools that complement the traditional physical experimentation. In this contribution, an advanced discrete-continuous concept is proposed to address the physical phenomena involved during laser powder bed fusion. The concept treats powder as discrete by the extended discrete element method, which predicts the thermodynamic state and phase change for each particle. The fluid surrounding is solved with multiphase computational fluid dynamics techniques to determine momentum, heat, gas and liquid transfer. Thus, results track the positions and thermochemical history of individual particles in conjunction with the prevailing fluid phases' temperature and composition. It is believed that this methodology can be employed to complement experimental research by analysis of the comprehensive results, which can be extracted from it to enable AM processes optimization for parts qualification.

Utilization of curve offsets in additive manufacturing

NASA Astrophysics Data System (ADS)

Haseltalab, Vahid; Yaman, Ulas; Dolen, Melik

2018-05-01

Curve offsets are utilized in different fields of engineering and science. Additive manufacturing, which lately becomes an explicit requirement in manufacturing industry, utilizes curve offsets widely. One of the necessities of offsetting is for scaling which is required if there is shrinkage after the fabrication or if the surface quality of the resulting part is unacceptable. Therefore, some post-processing is indispensable. But the major application of curve offsets in additive manufacturing processes is for generating head trajectories. In a point-wise AM process, a correct tool-path in each layer can reduce lots of costs and increase the surface quality of the fabricated parts. In this study, different curve offset generation algorithms are analyzed to show their capabilities and disadvantages through some test cases and improvements on their drawbacks are suggested.

Composite fuselage crown panel manufacturing technology

NASA Technical Reports Server (NTRS)

Willden, Kurtis; Metschan, S.; Grant, C.; Brown, T.

1992-01-01

Commercial fuselage structures contain significant challenges in attempting to save manufacturing costs with advanced composite technology. Assembly issues, material costs, and fabrication of elements with complex geometry are each expected to drive the cost of composite fuselage structures. Boeing's efforts under the NASA ACT program have pursued key technologies for low-cost, large crown panel fabrication. An intricate bond panel design and manufacturing concepts were selected based on the efforts of the Design Build Team (DBT). The manufacturing processes selected for the intricate bond design include multiple large panel fabrication with the Advanced Tow Placement (ATP) process, innovative cure tooling concepts, resin transfer molding of long fuselage frames, and utilization of low-cost material forms. The process optimization for final design/manufacturing configuration included factory simulations and hardware demonstrations. These efforts and other optimization tasks were instrumental in reducing cost by 18 percent and weight by 45 percent relative to an aluminum baseline. The qualitative and quantitative results of the manufacturing demonstrations were used to assess manufacturing risks and technology readiness.

Integration of Machining and Inspection in Aerospace Manufacturing

NASA Astrophysics Data System (ADS)

Simpson, Bart; Dicken, Peter J.

2011-12-01

The main challenge for aerospace manufacturers today is to develop the ability to produce high-quality products on a consistent basis as quickly as possible and at the lowest-possible cost. At the same time, rising material prices are making the cost of scrap higher than ever so making it more important to minimise waste. Proper inspection and quality control methods are no longer a luxury; they are an essential part of every manufacturing operation that wants to grow and be successful. However, simply bolting on some quality control procedures to the existing manufacturing processes is not enough. Inspection must be fully-integrated with manufacturing for the investment to really produce significant improvements. The traditional relationship between manufacturing and inspection is that machining is completed first on the company's machine tools and the components are then transferred to dedicated inspection equipment to be approved or rejected. However, as machining techniques become more sophisticated, and as components become larger and more complex, there are a growing number of cases where closer integration is required to give the highest productivity and the biggest reductions in wastage. Instead of a simple linear progression from CAD to CAM to machining to inspection, a more complicated series of steps is needed, with extra data needed to fill any gaps in the information available at the various stages. These new processes can be grouped under the heading of "adaptive machining". The programming of most machining operations is based around knowing three things: the position of the workpiece on the machine, the starting shape of the material to be machined, and the final shape that needs to be achieved at the end of the operation. Adaptive machining techniques allow successful machining when at least one of those elements is unknown, by using in-process measurement to close the information gaps in the process chain. It also allows any errors to be spotted

Just-in-time Design and Additive Manufacture of Patient-specific Medical Implants

NASA Astrophysics Data System (ADS)

Shidid, Darpan; Leary, Martin; Choong, Peter; Brandt, Milan

Recent advances in medical imaging and manufacturing science have enabled the design and production of complex, patient-specific orthopaedic implants. Additive Manufacture (AM) generates three-dimensional structures layer by layer, and is not subject to the constraints associated with traditional manufacturing methods. AM provides significant opportunities for the design of novel geometries and complex lattice structures with enhanced functional performance. However, the design and manufacture of patient-specific AM implant structures requires unique expertise in handling various optimization platforms. Furthermore, the design process for complex structures is computationally intensive. The primary aim of this research is to enable the just-in-time customisation of AM prosthesis; whereby AM implant design and manufacture be completed within the time constraints of a single surgical procedure, while minimising prosthesis mass and optimising the lattice structure to match the stiffness of the surrounding bone tissue. In this research, a design approach using raw CT scan data is applied to the AM manufacture of femoral prosthesis. Using the proposed just-in-time concept, the mass of the prosthesis was rapidly designed and manufactured while satisfying the associated structural requirements. Compressive testing of lattice structures manufactured using proposed method shows that the load carrying capacity of the resected composite bone can be recovered by up to 85% and the compressive stiffness of the AM prosthesis is statistically indistinguishable from the stiffness of the initial bone.

Impact of chemical polishing on surface roughness and dimensional quality of electron beam melting process (EBM) parts

NASA Astrophysics Data System (ADS)

Dolimont, Adrien; Rivière-Lorphèvre, Edouard; Ducobu, François; Backaert, Stéphane

2018-05-01

Additive manufacturing is growing faster and faster. This leads us to study the functionalization of the parts that are produced by these processes. Electron Beam melting (EBM) is one of these technologies. It is a powder based additive manufacturing (AM) method. With this process, it is possible to manufacture high-density metal parts with complex topology. One of the big problems with these technologies is the surface finish. To improve the quality of the surface, some finishing operations are needed. In this study, the focus is set on chemical polishing. The goal is to determine how the chemical etching impacts the dimensional accuracy and the surface roughness of EBM parts. To this end, an experimental campaign was carried out on the most widely used material in EBM, Ti6Al4V. Different exposure times were tested. The impact of these times on surface quality was evaluated. To help predicting the excess thickness to be provided, the dimensional impact of chemical polishing on EBM parts was estimated. 15 parts were measured before and after chemical machining. The improvement of surface quality was also evaluated after each treatment.

Investigation of dimensional variation in parts manufactured by fused deposition modeling using Gauge Repeatability and Reproducibility

NASA Astrophysics Data System (ADS)

Mohamed, Omar Ahmed; Hasan Masood, Syed; Lal Bhowmik, Jahar

2018-02-01

In the additive manufacturing (AM) market, the question is raised by industry and AM users on how reproducible and repeatable the fused deposition modeling (FDM) process is in providing good dimensional accuracy. This paper aims to investigate and evaluate the repeatability and reproducibility of the FDM process through a systematic approach to answer this frequently asked question. A case study based on the statistical gage repeatability and reproducibility (gage R&R) technique is proposed to investigate the dimensional variations in the printed parts of the FDM process. After running the simulation and analysis of the data, the FDM process capability is evaluated, which would help the industry for better understanding the performance of FDM technology.

Neural Network Classifiers to Grade Parts Based on Surface Defects with Spatial Dependencies

Treesearch

Daniel L. Schmoldt

1995-01-01

In many manufacturing situations, production parts must be assigned a qualitative grade, rather than only accepted or rejected. When this is done, spatial relationships between defect areas can be a critical factor in making grade assignments. In the case of grading hardwood lumber, for instance, there exists a highly complex set of grading rules which incorporate...

VIEW OF PRECISION EQUIPMENT USED IN STAINLESS COMPONENT MANUFACTURING. THE ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

VIEW OF PRECISION EQUIPMENT USED IN STAINLESS COMPONENT MANUFACTURING. THE FACILITY WAS DESCRIBED AS THE MOST MODERN NON-NUCLEAR MANUFACTURING BUILDING IN THE U.S. DEPARTMENT OF ENERGY COMPLEX, WITH MANY PRECISION INSTRUMENTS. (9/21/83) - Rocky Flats Plant, Stainless Steel & Non-Nuclear Components Manufacturing, Southeast corner of intersection of Cottonwood & Third Avenues, Golden, Jefferson County, CO

Manufacturing of ionic polymer-metal composites (IPMCs) that can actuate into complex curves

NASA Astrophysics Data System (ADS)

Stoimenov, Boyko L.; Rossiter, Jonathan M.; Mukai, Toshiharu

2007-04-01

Ionic polymer-metal composites (IPMC) are soft actuators with potential applications in the fields of medicine and biologically inspired robotics. Typically, an IPMC bends with approximately constant curvature when voltage is applied to it. More complex shapes were achieved in the past by pre-shaping the actuator or by segmentation and separate actuation of each segment. There are many applications for which fully independent control of each segment of the IPMC is not required and the use of external wiring is objectionable. In this paper we propose two key elements needed to create an IPMC, which can actuate into a complex curve. The first is a connection between adjacent segments, which enables opposite curvature. This can be achieved by reversing the polarity applied on each side of the IPMC, for example by a through-hole connection. The second key element is a variable curvature segment. The segment is designed to bend with any fraction of its full bending ability under given electrical input by changing the overlap of opposite charge electrodes. We demonstrated the usefulness of these key elements in two devices. One is a bi-stable buckled IPMC beam, also used as a building block in a linear actuator device. The other one is an IPMC, actuating into an S-shaped curve with gradually increasing curvature near the ends. The proposed method of manufacturing holds promise for a wide range of new applications of IPMCs, including applications in which IPMCs are used for sensing.

Simulation Environment Synchronizing Real Equipment for Manufacturing Cell

NASA Astrophysics Data System (ADS)

Inukai, Toshihiro; Hibino, Hironori; Fukuda, Yoshiro

Recently, manufacturing industries face various problems such as shorter product life cycle, more diversified customer needs. In this situation, it is very important to reduce lead-time of manufacturing system constructions. At the manufacturing system implementation stage, it is important to make and evaluate facility control programs for a manufacturing cell, such as ladder programs for programmable logical controllers (PLCs) rapidly. However, before the manufacturing systems are implemented, methods to evaluate the facility control programs for the equipment while mixing and synchronizing real equipment and virtual factory models on the computers have not been developed. This difficulty is caused by the complexity of the manufacturing system composed of a great variety of equipment, and stopped precise and rapid support of a manufacturing engineering process. In this paper, a manufacturing engineering environment (MEE) to support manufacturing engineering processes using simulation technologies is proposed. MEE consists of a manufacturing cell simulation environment (MCSE) and a distributed simulation environment (DSE). MCSE, which consists of a manufacturing cell simulator and a soft-wiring system, is emphatically proposed in detail. MCSE realizes making and evaluating facility control programs by using virtual factory models on computers before manufacturing systems are implemented.

Analysis of Additive Manufacturing for Sustainment of Naval Aviation Systems

DTIC Science & Technology

2017-09-01

selection methodology to query the aviation spare-parts inventory for identification of additive manufacturing candidates. The methodology organizes...a component selection methodology to query the aviation spare-parts inventory for identification of additive manufacturing candidates. The... methodology organizes the resultant data using a top-down approach that aligns technical feasibility with programmatic objectives. Finally, a discrete event

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA Technical Reports Server (NTRS)

Babai, Majid; Phillips, Steven; Griffin, Brian

2003-01-01

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA.s Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aide in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing

Additive Manufacturing: Ensuring Quality for Spacecraft Applications

NASA Technical Reports Server (NTRS)

Swanson, Theodore; Stephenson, Timothy

2014-01-01

Reliable manufacturing requires that material properties and fabrication processes be well defined in order to insure that the manufactured parts meet specified requirements. While this issue is now relatively straightforward for traditional processes such as subtractive manufacturing and injection molding, this capability is still evolving for AM products. Hence, one of the principal challenges within AM is in qualifying and verifying source material properties and process control. This issue is particularly critical for applications in harsh environments and demanding applications, such as spacecraft.

Programming and machining of complex parts based on CATIA solid modeling

NASA Astrophysics Data System (ADS)

Zhu, Xiurong

2017-09-01

The complex parts of the use of CATIA solid modeling programming and simulation processing design, elaborated in the field of CNC machining, programming and the importance of processing technology. In parts of the design process, first make a deep analysis on the principle, and then the size of the design, the size of each chain, connected to each other. After the use of backstepping and a variety of methods to calculate the final size of the parts. In the selection of parts materials, careful study, repeated testing, the final choice of 6061 aluminum alloy. According to the actual situation of the processing site, it is necessary to make a comprehensive consideration of various factors in the machining process. The simulation process should be based on the actual processing, not only pay attention to shape. It can be used as reference for machining.

19 CFR 191.8 - Specific manufacturing drawback ruling.

Code of Federal Regulations, 2014 CFR

2014-04-01

... favor of the parent corporation. (b) Sample application. Sample formats for applications for specific manufacturing drawback rulings are contained in appendix B to this part. (c) Content of application. The application of each manufacturer or producer shall include the following information as applicable: (1) Name...

19 CFR 191.8 - Specific manufacturing drawback ruling.

Code of Federal Regulations, 2011 CFR

2011-04-01

... favor of the parent corporation. (b) Sample application. Sample formats for applications for specific manufacturing drawback rulings are contained in appendix B to this part. (c) Content of application. The application of each manufacturer or producer shall include the following information as applicable: (1) Name...

19 CFR 191.8 - Specific manufacturing drawback ruling.

Code of Federal Regulations, 2013 CFR

2013-04-01

... favor of the parent corporation. (b) Sample application. Sample formats for applications for specific manufacturing drawback rulings are contained in appendix B to this part. (c) Content of application. The application of each manufacturer or producer shall include the following information as applicable: (1) Name...

19 CFR 191.8 - Specific manufacturing drawback ruling.

Code of Federal Regulations, 2012 CFR

2012-04-01

... favor of the parent corporation. (b) Sample application. Sample formats for applications for specific manufacturing drawback rulings are contained in appendix B to this part. (c) Content of application. The application of each manufacturer or producer shall include the following information as applicable: (1) Name...

Bio-Manufacturing to market pilot project

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dressen, Tiffaney

The Bio-Manufacturing to Market pilot project was a part of the AMJIAC, the Advanced Manufacturing Jobs and Innovation Accelerator Challenge grant. This internship program set out to further define and enhance the talent pipeline from the University and local Community Colleges to startup culture in East Bay Area, provide undergraduate STEM students with opportunities outside academia, and provide startup companies with much needed talent. Over the 4 year period of performance, the Bio-Manufacturing to Market internship program sponsored 75 undergraduate STEM students who were able to spend anywhere from one to six semesters working with local Bay Area startup companiesmore » and DOE sponsored facilities/programs in the biotech, bio-manufacturing, and biomedical device fields.« less

Fully printed and integrated electrolyzer cells with additive manufacturing for high-efficiency water splitting

DOE PAGES

Yang, Gaoqiang; Mo, Jingke; Kang, Zhenye; ...

2018-02-20

Using additive manufacturing (AM) technology, a fundamental material and structure innovation was proposed to significantly increase the energy efficiency, and to reduce the weight, volume and component quantity of proton exchange membrane electrolyzer cells (PEMECs). Four conventional parts (liquid/gas diffusion layer, bipolar plate, gasket, and current distributor) in a PEMEC were integrated into one multifunctional AM plate without committing to tools or molds for the first time. In addition, since the interfacial contact resistances between those parts were eliminated, the comprehensive in-situ characterizations of AM cells showed that an excellent energy efficiency of up to 86.48% was achieved at 2more » A/cm2 and 80 degrees C, and the hydrogen generation rate was increased by 61.81% compared to the conventional cell. More importantly, the highly complex inner structures of the AM integrated multifunctional plates also exhibit the potential to break limitations of conventional manufacture methods for hydrogen generation and to open a door for the development of other energy conversion devices, including fuel cells, solar cells and batteries.« less

Fully printed and integrated electrolyzer cells with additive manufacturing for high-efficiency water splitting

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yang, Gaoqiang; Mo, Jingke; Kang, Zhenye

Using additive manufacturing (AM) technology, a fundamental material and structure innovation was proposed to significantly increase the energy efficiency, and to reduce the weight, volume and component quantity of proton exchange membrane electrolyzer cells (PEMECs). Four conventional parts (liquid/gas diffusion layer, bipolar plate, gasket, and current distributor) in a PEMEC were integrated into one multifunctional AM plate without committing to tools or molds for the first time. In addition, since the interfacial contact resistances between those parts were eliminated, the comprehensive in-situ characterizations of AM cells showed that an excellent energy efficiency of up to 86.48% was achieved at 2more » A/cm2 and 80 degrees C, and the hydrogen generation rate was increased by 61.81% compared to the conventional cell. More importantly, the highly complex inner structures of the AM integrated multifunctional plates also exhibit the potential to break limitations of conventional manufacture methods for hydrogen generation and to open a door for the development of other energy conversion devices, including fuel cells, solar cells and batteries.« less

Report From BPTCS Project Team On Evaluation Of Additive Manufacturing For Pressure Retaining Equipment

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rawls, G.

ASME is evaluating the use of additive manufacturing (AM) for the construction of pressure equipment. The information in this report assesses available AM technologies for direct metal fabrication of pressure equipment. Background information is included in the report to provide context for those not experienced in AM technology. Only commercially available technologies for direct metal fabrication are addressed in the report because these AM methods are the only viable approaches for the construction of pressure equipment. Metal AM technologies can produce near-net shape parts by using multiple layers of material from a three dimensional (3D) design model of the geometry.more » Additive manufacturing of metal components was developed from polymer based rapid prototyping or 3D printing. At the current maturity level, AM application for pressure equipment has the potential to reduce delivery times and costs for complex shapes. AM will also lead to a reduction in the use of high cost materials, since parts can be created with corrosion resistant layers of high alloy material and structural layers of lower cost materials.« less

Electron beam additive manufacturing with wire - Analysis of the process

NASA Astrophysics Data System (ADS)

Weglowski, Marek St.; Błacha, Sylwester; Pilarczyk, Jan; Dutkiewicz, Jan; Rogal, Łukasz

2018-05-01

The electron beam additive manufacturing process with wire is a part of global trend to find fast and efficient methods for producing complex shapes elements from costly metal alloys such as stainless steels, nickel alloys, titanium alloys etc. whose production by other conventional technologies is unprofitable or technically impossible. Demand for additive manufacturing is linked to the development of new technologies in the automotive, aerospace and machinery industries. The aim of the presented work was to carried out research on electron beam additive manufacturing with a wire as a deposited (filler) material. The scope of the work was to investigate the influence of selected technological parameters such as: wire feed rate, beam current, travelling speed, acceleration voltage on stability of the deposition process and geometric dimensions of the padding welds. The research revealed that, at low beam currents, the deposition process is unstable. The padding weld reinforcement is non-uniform. Irregularity of the width, height and straightness of the padding welds can be observed. At too high acceleration voltage and beam current, burn-through of plate and excess penetration weld can be revealed. The achieved results and gained knowledge allowed to produce, based on EBAM with wire process, whole structure from stainless steel.

Fabrication of Thermoelectric Devices Using Additive-Subtractive Manufacturing Techniques: Application to Waste-Heat Energy Harvesting

NASA Astrophysics Data System (ADS)

Tewolde, Mahder

Thermoelectric generators (TEGs) are solid-state devices that convert heat directly into electricity. They are well suited for waste-heat energy harvesting applications as opposed to primary energy generation. Commercially available thermoelectric modules are flat, inflexible and have limited sizes available. State-of-art manufacturing of TEG devices relies on assembling prefabricated parts with soldering, epoxy bonding, and mechanical clamping. Furthermore, efforts to incorporate them onto curved surfaces such as exhaust pipes, pump housings, steam lines, mixing containers, reaction chambers, etc. require custom-built heat exchangers. This is costly and labor-intensive, in addition to presenting challenges in terms of space, thermal coupling, added weight and long-term reliability. Additive manufacturing technologies are beginning to address many of these issues by reducing part count in complex designs and the elimination of sub-assembly requirements. This work investigates the feasibility of utilizing such novel manufacturing routes for improving the manufacturing process of thermoelectric devices. Much of the research in thermoelectricity is primarily focused on improving thermoelectric material properties by developing of novel materials or finding ways to improve existing ones. Secondary to material development is improving the manufacturing process of TEGs to provide significant cost benefits. To improve the device fabrication process, this work explores additive manufacturing technologies to provide an integrated and scalable approach for TE device manufacturing directly onto engineering component surfaces. Additive manufacturing techniques like thermal spray and ink-dispenser printing are developed with the aim of improving the manufacturing process of TEGs. Subtractive manufacturing techniques like laser micromachining are also studied in detail. This includes the laser processing parameters for cutting the thermal spray materials efficiently by

40 CFR 63.5787 - What if I also manufacture fiberglass boats or boat parts?

Code of Federal Regulations, 2010 CFR

2010-07-01

... CATEGORIES National Emissions Standards for Hazardous Air Pollutants: Reinforced Plastic Composites... the reinforced plastic composites you manufacture are used in manufacturing your boats, you are not... applicability criteria in § 63.5785, and produce reinforced plastic composites that are not used in fiberglass...

Research of the Quality of Quarry Dumpers Engine Crankshafts Sliding Bearings of Various Manufacturers

NASA Astrophysics Data System (ADS)

Korotkov, Alexander; Korotkova, Lidiya; Vidin, Denis

2017-11-01

Sliding bearings are an important part of many large and critical components. They are widely used in power equipment, high-capacity pumps, compressors, electric motors and internal combustion engines (ICE). As a rule, sliding bearings include an antifriction bushing, part of the shaft surface (bearing journal), and a layer of oil between them. These are complex and critical parts in which there may occur dangerous defects, and which directly affect the durability, accuracy and reliability of the entire unit. To ensure high reliability of the equipment with sliding bearings applied in complex equipment, it is necessary to provide the quality control and sufficient level of monitoring of the technical condition, as well as diagnosis of emerging defects. This paper presents a comparative analysis of the internal combustion engines sliding bearings quality of various manufacturing companies. It gives operational properties of bearings depending on the compositional composition. The results of chemical analysis of the base, the cover and intermediate layers of the ICE liners are presented here. We have also made recommendations to increase the operational performance of sliding bearings.

Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

NASA Technical Reports Server (NTRS)

O’Neal, T. Derek

2016-01-01

A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. This paper discusses the impacts of the DMLS fabrication technique on the design of the turbopump and lessons learned during DMLS hardware fabrication and material testing.

Advanced manufacturing rules check (MRC) for fully automated assessment of complex reticle designs

NASA Astrophysics Data System (ADS)

Gladhill, R.; Aguilar, D.; Buck, P. D.; Dawkins, D.; Nolke, S.; Riddick, J.; Straub, J. A.

2005-11-01

Advanced electronic design automation (EDA) tools, with their simulation, modeling, design rule checking, and optical proximity correction capabilities, have facilitated the improvement of first pass wafer yields. While the data produced by these tools may have been processed for optimal wafer manufacturing, it is possible for the same data to be far from ideal for photomask manufacturing, particularly at lithography and inspection stages, resulting in production delays and increased costs. The same EDA tools used to produce the data can be used to detect potential problems for photomask manufacturing in the data. A production implementation of automated photomask manufacturing rule checking (MRC) is presented and discussed for various photomask lithography and inspection lines. This paper will focus on identifying data which may cause production delays at the mask inspection stage. It will be shown how photomask MRC can be used to discover data related problems prior to inspection, separating jobs which are likely to have problems at inspection from those which are not. Photomask MRC can also be used to identify geometries requiring adjustment of inspection parameters for optimal inspection, and to assist with any special handling or change of routing requirements. With this foreknowledge, steps can be taken to avoid production delays that increase manufacturing costs. Finally, the data flow implemented for MRC can be used as a platform for other photomask data preparation tasks.

Process Control and Development for Ultrasonic Additive Manufacturing with Embedded Fibers

NASA Astrophysics Data System (ADS)

Hehr, Adam J.

Ultrasonic additive manufacturing (UAM) is a recent additive manufacturing technology which combines ultrasonic metal welding, CNC machining, and mechanized foil layering to create large gapless near net-shape metallic parts. The process has been attracting much attention lately due to its low formation temperature, the capability to join dissimilar metals, and the ability to create complex design features not possible with traditional subtractive processes alone. These process attributes enable light-weighting of structures and components in an unprecedented way. However, UAM is currently limited to niche areas due to the lack of quality tracking and inadequate scientific understanding of the process. As a result, this thesis work is focused on improving both component quality tracking and process understanding through the use of average electrical power input to the welder. Additionally, the understanding and application space of embedding fibers into metals using UAM is investigated, with particular focus on NiTi shape memory alloy fibers.

Analytic network process model for sustainable lean and green manufacturing performance indicator

NASA Astrophysics Data System (ADS)

Aminuddin, Adam Shariff Adli; Nawawi, Mohd Kamal Mohd; Mohamed, Nik Mohd Zuki Nik

2014-09-01

Sustainable manufacturing is regarded as the most complex manufacturing paradigm to date as it holds the widest scope of requirements. In addition, its three major pillars of economic, environment and society though distinct, have some overlapping among each of its elements. Even though the concept of sustainability is not new, the development of the performance indicator still needs a lot of improvement due to its multifaceted nature, which requires integrated approach to solve the problem. This paper proposed the best combination of criteria en route a robust sustainable manufacturing performance indicator formation via Analytic Network Process (ANP). The integrated lean, green and sustainable ANP model can be used to comprehend the complex decision system of the sustainability assessment. The finding shows that green manufacturing is more sustainable than lean manufacturing. It also illustrates that procurement practice is the most important criteria in the sustainable manufacturing performance indicator.

Automated Rapid Prototyping of 3D Ceramic Parts

NASA Technical Reports Server (NTRS)

McMillin, Scott G.; Griffin, Eugene A.; Griffin, Curtis W.; Coles, Peter W. H.; Engle, James D.

2005-01-01

An automated system of manufacturing equipment produces three-dimensional (3D) ceramic parts specified by computational models of the parts. The system implements an advanced, automated version of a generic rapid-prototyping process in which the fabrication of an object having a possibly complex 3D shape includes stacking of thin sheets, the outlines of which closely approximate the horizontal cross sections of the object at their respective heights. In this process, the thin sheets are made of a ceramic precursor material, and the stack is subsequently heated to transform it into a unitary ceramic object. In addition to the computer used to generate the computational model of the part to be fabricated, the equipment used in this process includes: 1) A commercially available laminated-object-manufacturing machine that was originally designed for building woodlike 3D objects from paper and was modified to accept sheets of ceramic precursor material, and 2) A machine designed specifically to feed single sheets of ceramic precursor material to the laminated-object-manufacturing machine. Like other rapid-prototyping processes that utilize stacking of thin sheets, this process begins with generation of the computational model of the part to be fabricated, followed by computational sectioning of the part into layers of predetermined thickness that collectively define the shape of the part. Information about each layer is transmitted to rapid-prototyping equipment, where the part is built layer by layer. What distinguishes this process from other rapid-prototyping processes that utilize stacking of thin sheets are the details of the machines and the actions that they perform. In this process, flexible sheets of ceramic precursor material (called "green" ceramic sheets) suitable for lamination are produced by tape casting. The binder used in the tape casting is specially formulated to enable lamination of layers with little or no applied heat or pressure. The tape is cut

78 FR 4038 - Critical Parts for Airplane Propellers

Federal Register 2010, 2011, 2012, 2013, 2014

2013-01-18

... requiring a system of processes to identify and manage these parts throughout their service life. This rule... engineering process, a manufacturing process, and a service management process for propeller critical parts... engineering process, to how the part is manufactured and to how the part is maintained in service. Engineering...

Additive Manufacturing of Molds for Fabrication of Insulated Concrete Block

DOE Office of Scientific and Technical Information (OSTI.GOV)

Love, Lonnie J.; Lloyd, Peter D.

ORNL worked with concrete block manufacturer, NRG Insulated Block, to demonstrate additive manufacturing of a multi-component block mold for its line of insulated blocks. Solid models of the mold parts were constructed from existing two-dimensional drawings and the parts were fabricated on a Stratasys Fortus 900 using ULTEM 9085. Block mold parts were delivered to NRG and installed on one of their fabrication lines. While form and fit were acceptable, the molds failed to function during NRG’s testing.

21 CFR 123.5 - Current good manufacturing practice.

Code of Federal Regulations, 2010 CFR

2010-04-01

... 21 Food and Drugs 2 2010-04-01 2010-04-01 false Current good manufacturing practice. 123.5 Section...) FOOD FOR HUMAN CONSUMPTION FISH AND FISHERY PRODUCTS General Provisions § 123.5 Current good manufacturing practice. (a) Part 110 of this chapter applies in determining whether the facilities, methods...

Complexity theory, time series analysis and Tsallis q-entropy principle part one: theoretical aspects

NASA Astrophysics Data System (ADS)

Pavlos, George P.

2017-12-01

In this study, we present the highlights of complexity theory (Part I) and significant experimental verifications (Part II) and we try to give a synoptic description of complexity theory both at the microscopic and at the macroscopic level of the physical reality. Also, we propose that the self-organization observed macroscopically is a phenomenon that reveals the strong unifying character of the complex dynamics which includes thermodynamical and dynamical characteristics in all levels of the physical reality. From this point of view, macroscopical deterministic and stochastic processes are closely related to the microscopical chaos and self-organization. The scientific work of scientists such as Wilson, Nicolis, Prigogine, Hooft, Nottale, El Naschie, Castro, Tsallis, Chang and others is used for the development of a unified physical comprehension of complex dynamics from the microscopic to the macroscopic level. Finally, we provide a comprehensive description of the novel concepts included in the complexity theory from microscopic to macroscopic level. Some of the modern concepts that can be used for a unified description of complex systems and for the understanding of modern complexity theory, as it is manifested at the macroscopic and the microscopic level, are the fractal geometry and fractal space-time, scale invariance and scale relativity, phase transition and self-organization, path integral amplitudes, renormalization group theory, stochastic and chaotic quantization and E-infinite theory, etc.

Microstructure and Corrosion Resistance of Laser Additively Manufactured 316L Stainless Steel

NASA Astrophysics Data System (ADS)

Trelewicz, Jason R.; Halada, Gary P.; Donaldson, Olivia K.; Manogharan, Guha

2016-03-01

Additive manufacturing (AM) of metal alloys to produce complex part designs via powder bed fusion methods such as laser melting promises to be a transformative technology for advanced materials processing. However, effective implementation of AM processes requires a clear understanding of the processing-structure-properties-performance relationships in fabricated components. In this study, we report on the formation of micro and nanoscale structures in 316L stainless steel samples printed by laser AM and their implications for general corrosion resistance. A variety of techniques including x-ray diffraction, optical, scanning and transmission electron microscopy, x-ray fluorescence, and energy dispersive x-ray spectroscopy were employed to characterize the microstructure and chemistry of the laser additively manufactured 316L stainless steel, which are compared with wrought 316L coupons via electrochemical polarization. Apparent segregation of Mo has been found to contribute to a loss of passivity and an increased anodic current density. While porosity will also likely impact the environmental performance (e.g., facilitating crevice corrosion) of AM alloys, this work demonstrates the critical influence of microstructure and heterogeneous solute distributions on the corrosion resistance of laser additively manufactured 316L stainless steel.

Surface inspection system for carriage parts

NASA Astrophysics Data System (ADS)

Denkena, Berend; Acker, Wolfram

2006-04-01

Quality standards are very high in carriage manufacturing, due to the fact, that the visual quality impression is highly relevant for the purchase decision for the customer. In carriage parts even very small dents can be visible on the varnished and polished surface by observing reflections. The industrial demands are to detect these form errors on the unvarnished part. In order to meet the requirements, a stripe projection system for automatic recognition of waviness and form errors is introduced1. It bases on a modified stripe projection method using a high resolution line scan camera. Particular emphasis is put on achieving a short measuring time and a high resolution in depth, aiming at a reliable automatic recognition of dents and waviness of 10 μm on large curved surfaces of approximately 1 m width. The resulting point cloud needs to be filtered in order to detect dents. Therefore a spatial filtering technique is used. This works well on smoothly curved surfaces, if frequency parameters are well defined. On more complex parts like mudguards the method is restricted by the fact that frequencies near the define dent frequencies occur within the surface as well. To allow analysis of complex parts, the system is currently extended by including 3D CAD models into the process of inspection. For smoothly curved surfaces, the measuring speed of the prototype is mainly limited by the amount of light produced by the stripe projector. For complex surfaces the measuring speed is limited by the time consuming matching process. Currently, the development focuses on the improvement of the measuring speed.

76 FR 74749 - Critical Parts for Airplane Propellers

Federal Register 2010, 2011, 2012, 2013, 2014

2011-12-01

... manufacturer, and establish engineering, manufacture, and maintenance processes for those parts. The intended... a specific definition for a propeller critical part, or-- [rtarr9] Require type certificate holders..., however, has regulations that identify a specific definition for propeller critical part, and regulations...

Hardwood pallet cant quality and pallet part yields

Treesearch

Hal L. Mitchell; Marshall White; Philip Araman; Peter Hamner

2005-01-01

Raw materials are the largest cost component in pallet manufacturing. The primary raw material used to produce pallet parts are pallet cants. Therefore, pallet cant quality directly impacts pallet part processing and material costs. By knowing the quality of the cants being processed, pallet manufacturers can predict these costs and improve manufacturing efficiency....

Additive manufacturing: Toward holistic design

DOE PAGES

Jared, Bradley H.; Aguilo, Miguel A.; Beghini, Lauren L.; ...

2017-03-18

Here, additive manufacturing offers unprecedented opportunities to design complex structures optimized for performance envelopes inaccessible under conventional manufacturing constraints. Additive processes also promote realization of engineered materials with microstructures and properties that are impossible via traditional synthesis techniques. Enthused by these capabilities, optimization design tools have experienced a recent revival. The current capabilities of additive processes and optimization tools are summarized briefly, while an emerging opportunity is discussed to achieve a holistic design paradigm whereby computational tools are integrated with stochastic process and material awareness to enable the concurrent optimization of design topologies, material constructs and fabrication processes.

19 CFR Appendix B to Part 191 - Sample Formats for Applications for Specific Manufacturing Drawback Rulings

Code of Federal Regulations, 2010 CFR

2010-04-01

... (see § 191.8(a)).) LOCATION OF FACTORY (Give the address of the factory(s) where the process of... article described under the PROCESS OF MANUFACTURE OR PRODUCTION section below and each article listed... manufacture or production by giving a thorough description of the manufacturing process. This description...

21 CFR 129.1 - Current good manufacturing practice.

Code of Federal Regulations, 2010 CFR

2010-04-01

... 21 Food and Drugs 2 2010-04-01 2010-04-01 false Current good manufacturing practice. 129.1 Section... Current good manufacturing practice. The applicable criteria in part 110 of this chapter, as well as the..., methods, practices, and controls used in the processing, bottling, holding, and shipping of bottled...

Quality cell therapy manufacturing by design.

PubMed

Lipsitz, Yonatan Y; Timmins, Nicholas E; Zandstra, Peter W

2016-04-01

Transplantation of live cells as therapeutic agents is poised to offer new treatment options for a wide range of acute and chronic diseases. However, the biological complexity of cells has hampered the translation of laboratory-scale experiments into industrial processes for reliable, cost-effective manufacturing of cell-based therapies. We argue here that a solution to this challenge is to design cell manufacturing processes according to quality-by-design (QbD) principles. QbD integrates scientific knowledge and risk analysis into manufacturing process development and is already being adopted by the biopharmaceutical industry. Many opportunities to incorporate QbD into cell therapy manufacturing exist, although further technology development is required for full implementation. Linking measurable molecular and cellular characteristics of a cell population to final product quality through QbD is a crucial step in realizing the potential for cell therapies to transform healthcare.

Laser cladding: repairing and manufacturing metal parts and tools

NASA Astrophysics Data System (ADS)

Sexton, Leo

2003-03-01

Laser cladding is presently used to repair high volume aerospace, automotive, marine, rail or general engineering components where excessive wear has occurred. It can also be used if a one-off high value component is either required or has been accidentally over-machined. The ultimate application of laser cladding is to build components up from nothing, using a laser cladding system and a 3D CAD drawing of the component. It is thus emerging that laser cladding can be classified as a special case of Rapid Prototyping (RP). Up to this point in time RP was seen, and is still seen, as in intermediately step between the design stage of a component and a finished working product. This can now be extended so that laser cladding makes RP a one-stop shop and the finished component is made from tool-steel or some alloy-base material. The marriage of laser cladding with RP is an interesting one and offers an alternative to traditional tool builders, re-manufacturers and injection mould design/repair industries. The aim of this paper is to discuss the emergence of this new technology, along with the transference of the process out of the laboratory and into the industrial workplace and show it is finding its rightful place in the manufacturing/repair sector. It will be shown that it can be used as a cost cutting, strategic material saver and consequently a green technology.

Towards Knowledge Management for Smart Manufacturing.

PubMed

Feng, Shaw C; Bernstein, William Z; Hedberg, Thomas; Feeney, Allison Barnard

2017-09-01

The need for capturing knowledge in the digital form in design, process planning, production, and inspection has increasingly become an issue in manufacturing industries as the variety and complexity of product lifecycle applications increase. Both knowledge and data need to be well managed for quality assurance, lifecycle-impact assessment, and design improvement. Some technical barriers exist today that inhibit industry from fully utilizing design, planning, processing, and inspection knowledge. The primary barrier is a lack of a well-accepted mechanism that enables users to integrate data and knowledge. This paper prescribes knowledge management to address a lack of mechanisms for integrating, sharing, and updating domain-specific knowledge in smart manufacturing. Aspects of the knowledge constructs include conceptual design, detailed design, process planning, material property, production, and inspection. The main contribution of this paper is to provide a methodology on what knowledge manufacturing organizations access, update, and archive in the context of smart manufacturing. The case study in this paper provides some example knowledge objects to enable smart manufacturing.

Potential of Continuous Manufacturing for Liposomal Drug Products.

PubMed

Worsham, Robert D; Thomas, Vaughan; Farid, Suzanne S

2018-05-21

Over the last several years, continuous manufacturing of pharmaceuticals has evolved from bulk APIs and solid oral dosages into the more complex realm of biologics. The development of continuous downstream processing techniques has allowed biologics manufacturing to realize the benefits (e.g. improved economics, more consistent quality) that come with continuous processing. If relevant processing techniques and principles are selected, the opportunity arises to develop continuous manufacturing designs for additional pharmaceutical products including liposomal drug formulations. Liposome manufacturing has some inherent aspects that make it favorable for a continuous process. Other aspects such as formulation refinement, materials of construction, and aseptic processing need development, but present an achievable challenge. This paper reviews the current state of continuous manufacturing technology applicable to liposomal drug product manufacturing and an assessment of the challenges and potential of this application. This article is protected by copyright. All rights reserved.

Crossword Puzzle Makes It Fun: Introduce Green Manufacturing in Wood Technology Courses

ERIC Educational Resources Information Center

Iley, John L.; Hague, Doug

2012-01-01

Sustainable, or "green," manufacturing and its practices are becoming more and more a part of today's industry, including wood product manufacturing. This article provides introductory information on green manufacturing in wood technology and a crossword puzzle based on green manufacturing terms. The authors use the puzzle at the college level to…

Materials Testing and Cost Modeling for Composite Parts Through Additive Manufacturing

DTIC Science & Technology

2016-04-30

FDM include plastic jet printing (PJP), fused filament modeling ( FFM ), and fused filament fabrication (FFF). FFF was coined by the RepRap project to...additive manufacturing processes? • Fused deposition modeling (FDM) trademarked by Stratasys • Fused filament modeling ( FFM ) and fused filament

Friction Spinning—New Innovative Tool Systems For The Production of Complex Functionally Graded Workpieces

NASA Astrophysics Data System (ADS)

Homberg, Werner; Hornjak, Daniel

2011-05-01

Friction spinning is a new innovative and promising incremental forming technology implying high potential regarding the manufacturing of complex functionally graded workpieces and enhancing existing forming limits of conventional metal spinning processes. The friction spinning process is based on the integration of thermo-mechanical friction subprocesses in this incremental forming process. By choosing the appropriate process parameters, e.g. axial feed rate or relative motion, the contact conditions between tool and workpiece can be influenced in a defined way and, thus, a required temperature profile can be obtained. Friction spinning allows the extension of forming limits compared to conventional metal spinning in order to produce multifunctional components with locally varying properties and the manufacturing of e.g. complex hollow parts made of tubes, profiles, or sheet metals. In this way, it meets the demands regarding efficiency and the manufacturing of functionally graded lightweight components. There is e.g. the possibility of locally increasing the wall thickness in joining zones and, as a consequence, achieving higher quality of the joint at decreased expense. These products are not or only hardly producible by conventional processes so far. In order to benefit from the advantages and potentials of this new innovative process new tooling systems and concepts are indispensable which fulfill the special requirements of this thermo-mechanical process concerning thermal and tribological loads and which allow simultaneous and defined forming and friction operations. An important goal of the corresponding research work at the Chair of Forming and Machining Technology at the University of Paderborn is the development of tool systems that allow the manufacturing of such complex parts by simple uniaxial or sequential biaxial linear tool paths. In the paper, promising tool systems and geometries as well as results of theoretical and experimental research work (e

Additive Manufacturing: Unlocking the Evolution of Energy Materials

PubMed Central

Zhakeyev, Adilet; Wang, Panfeng; Shu, Wenmiao; Wang, Huizhi

2017-01-01

Abstract The global energy infrastructure is undergoing a drastic transformation towards renewable energy, posing huge challenges on the energy materials research, development and manufacturing. Additive manufacturing has shown its promise to change the way how future energy system can be designed and delivered. It offers capability in manufacturing complex 3D structures, with near‐complete design freedom and high sustainability due to minimal use of materials and toxic chemicals. Recent literatures have reported that additive manufacturing could unlock the evolution of energy materials and chemistries with unprecedented performance in the way that could never be achieved by conventional manufacturing techniques. This comprehensive review will fill the gap in communicating on recent breakthroughs in additive manufacturing for energy material and device applications. It will underpin the discoveries on what 3D functional energy structures can be created without design constraints, which bespoke energy materials could be additively manufactured with customised solutions, and how the additively manufactured devices could be integrated into energy systems. This review will also highlight emerging and important applications in energy additive manufacturing, including fuel cells, batteries, hydrogen, solar cell as well as carbon capture and storage. PMID:29051861

Additive Manufacturing: Unlocking the Evolution of Energy Materials.

PubMed

Zhakeyev, Adilet; Wang, Panfeng; Zhang, Li; Shu, Wenmiao; Wang, Huizhi; Xuan, Jin

2017-10-01

The global energy infrastructure is undergoing a drastic transformation towards renewable energy, posing huge challenges on the energy materials research, development and manufacturing. Additive manufacturing has shown its promise to change the way how future energy system can be designed and delivered. It offers capability in manufacturing complex 3D structures, with near-complete design freedom and high sustainability due to minimal use of materials and toxic chemicals. Recent literatures have reported that additive manufacturing could unlock the evolution of energy materials and chemistries with unprecedented performance in the way that could never be achieved by conventional manufacturing techniques. This comprehensive review will fill the gap in communicating on recent breakthroughs in additive manufacturing for energy material and device applications. It will underpin the discoveries on what 3D functional energy structures can be created without design constraints, which bespoke energy materials could be additively manufactured with customised solutions, and how the additively manufactured devices could be integrated into energy systems. This review will also highlight emerging and important applications in energy additive manufacturing, including fuel cells, batteries, hydrogen, solar cell as well as carbon capture and storage.

Precision manufacturing for clinical-quality regenerative medicines.

PubMed

Williams, David J; Thomas, Robert J; Hourd, Paul C; Chandra, Amit; Ratcliffe, Elizabeth; Liu, Yang; Rayment, Erin A; Archer, J Richard

2012-08-28

Innovations in engineering applied to healthcare make a significant difference to people's lives. Market growth is guaranteed by demographics. Regulation and requirements for good manufacturing practice-extreme levels of repeatability and reliability-demand high-precision process and measurement solutions. Emerging technologies using living biological materials add complexity. This paper presents some results of work demonstrating the precision automated manufacture of living materials, particularly the expansion of populations of human stem cells for therapeutic use as regenerative medicines. The paper also describes quality engineering techniques for precision process design and improvement, and identifies the requirements for manufacturing technology and measurement systems evolution for such therapies.

Manufacturing of biodrugs: need for harmonization in regulatory standards.

PubMed

Sahoo, Niharika; Choudhury, Koel; Manchikanti, Padmavati

2009-01-01

Biodrugs (biologics) are much more complex than chemically synthesized drugs because of their structural heterogeneity and interactions within a given biologic system. The manufacturing process in the biodrug industry varies with each type of molecule and is far more elaborate and stringent due to the use of living organisms and complex substrates. Product purity and altered structural characteristics leading to potential immunogenicity have often been of concern when establishing quality and safety in the use of biodrugs. Regulatory compliance in manufacturing and commercialization of biodrugs involves quality control, quality assurance, and batch documentation. Many factors such as host cell development, cell bank establishment, cell culture, protein production, purification, analysis, formulation, storage, and handling are critical for ensuring the purity, activity, and safety of the finished product. Good Manufacturing Practice (GMP) for biodrugs has been developed in certain regions such as the EU, US, and Japan. Due to differences in manufacturing methods and systems, product-specific GMP guidelines are evolving. In general, there are variations in GMP guidelines between countries, which lead to difficulty for the manufacturers in conforming to different standards, thus entailing delays in the commercialization of biodrugs. There is a need to develop a unified regulatory guideline for biodrug manufacturing across various countries, which would be helpful in the marketing of products and trade. This review deals with the comparative framework and analysis of GMP regulation of biodrugs.

A Multi-Agent Approach to the Simulation of Robotized Manufacturing Systems

NASA Astrophysics Data System (ADS)

Foit, K.; Gwiazda, A.; Banaś, W.

2016-08-01

The recent years of eventful industry development, brought many competing products, addressed to the same market segment. The shortening of a development cycle became a necessity if the company would like to be competitive. Because of switching to the Intelligent Manufacturing model the industry search for new scheduling algorithms, while the traditional ones do not meet the current requirements. The agent-based approach has been considered by many researchers as an important way of evolution of modern manufacturing systems. Due to the properties of the multi-agent systems, this methodology is very helpful during creation of the model of production system, allowing depicting both processing and informational part. The complexity of such approach makes the analysis impossible without the computer assistance. Computer simulation still uses a mathematical model to recreate a real situation, but nowadays the 2D or 3D virtual environments or even virtual reality have been used for realistic illustration of the considered systems. This paper will focus on robotized manufacturing system and will present the one of possible approaches to the simulation of such systems. The selection of multi-agent approach is motivated by the flexibility of this solution that offers the modularity, robustness and autonomy.

Circularly-symmetric complex normal ratio distribution for scalar transmissibility functions. Part I: Fundamentals

NASA Astrophysics Data System (ADS)

Yan, Wang-Ji; Ren, Wei-Xin

2016-12-01

Recent advances in signal processing and structural dynamics have spurred the adoption of transmissibility functions in academia and industry alike. Due to the inherent randomness of measurement and variability of environmental conditions, uncertainty impacts its applications. This study is focused on statistical inference for raw scalar transmissibility functions modeled as complex ratio random variables. The goal is achieved through companion papers. This paper (Part I) is dedicated to dealing with a formal mathematical proof. New theorems on multivariate circularly-symmetric complex normal ratio distribution are proved on the basis of principle of probabilistic transformation of continuous random vectors. The closed-form distributional formulas for multivariate ratios of correlated circularly-symmetric complex normal random variables are analytically derived. Afterwards, several properties are deduced as corollaries and lemmas to the new theorems. Monte Carlo simulation (MCS) is utilized to verify the accuracy of some representative cases. This work lays the mathematical groundwork to find probabilistic models for raw scalar transmissibility functions, which are to be expounded in detail in Part II of this study.

Homogenisation of the strain distribution in stretch formed parts to improve part properties

NASA Astrophysics Data System (ADS)

Schmitz, Roman; Winkelmann, Mike; Bailly, David; Hirt, Gerhard

2018-05-01

Inhomogeneous strain and sheet thickness distributions can be observed in complex sheet metal parts manufactured by stretch forming. In literature, this problem is solved by flexible clampings adapted to the part geometry. In this paper, an approach, which does not rely on extensive tooling, is presented. The strain distribution in the sheet is influenced by means of hole patterns. Holes are introduced into the sheet area between clamping and part next to areas where high strains are expected. When deforming the sheet, high strains are shifted out of the part area. In a local area around the holes, high strains concentrate perpendicular to the drawing direction. Thus, high strains in the part area are reduced and the strain distribution is homogenised. To verify this approach, an FE-model of a stretch forming process of a conical part is implemented in LS-Dyna. The model is validated by corresponding experiments. In the first step, the positioning of the holes is applied manually based on the numerically determined strain distribution and experience. In order to automate the positioning of the holes, an optimisation method is applied in a second step. The presented approach implemented in LS-OPT uses the response surface method to identify the positioning and radius of the holes homogenising the strain in a defined area of the sheet. Due to nonlinear increase of computational complexity with increasing number of holes, the maximum number of holes is set to three. With both, the manual and the automated method, hole patterns were found which allow for a relative reduction of maximum strains and for a homogenisation of the strain distribution. Comparing the manual and automated positioning of holes, the pattern determined by automated optimisation shows better results in terms of homogenising the strain distribution.

3D printing for health & wealth: Fabrication of custom-made medical devices through additive manufacturing

NASA Astrophysics Data System (ADS)

Colpani, Alessandro; Fiorentino, Antonio; Ceretti, Elisabetta

2018-05-01

Additive Manufacturing (AM) differs from traditional manufacturing technologies by its ability to handle complex shapes with great design flexibility. These features make the technique suitable to fabricate customized components, particularly answering specific custom needs. Although AM mainly referred to prototyping, nowadays the interest in direct manufacturing of actual parts is growing. This article shows the application of AM within the project 3DP-4H&W (3D Printing for Health & Wealth) which involves engineers and physicians for developing pediatric custom-made medical devices to enhance the fulfilling of the patients specific needs. In the project, two types of devices made of a two-component biocompatible silicone are considered. The first application (dental field) consists in a device for cleft lip and palate. The second one (audiological field) consists in an acoustic prosthesis. The geometries of the devices are based on the anatomy of the patient that is obtained through a 3D body scan process. For both devices, two different approaches were planned, namely direct AM and indirect Rapid Tooling (RT). In particular, direct AM consists in the FDM processing of silicone, while RT consists in molds FDM fabrication followed by silicone casting. This paper presents the results of the RT method that is articulated in different phases: the acquisition of the geometry to be realized, the design of the molds taking into account the casting feasibility (as casting channel, vents, part extraction), the realization of molds produced through AM, molds surface chemical finishing, pouring and curing of the silicone. The fabricated devices were evaluated by the physicians team that confirmed the effectiveness of the proposed procedure in fabricating the desired devices. Moreover, the procedure can be used as a general method to extend the range of applications to any custom-made device for anatomic districts, especially where complex shapes are present (as tracheal or

Development of hybrid lifecycle cost estimating tool (HLCET) for manufacturing influenced design tradeoff

NASA Astrophysics Data System (ADS)

Sirirojvisuth, Apinut

concept, the additional manufacturing knowledge can be used to identify a more accurate lifecycle cost and facilitate higher fidelity tradeoffs during conceptual and preliminary design. Advanced Composite Cost Estimating Model (ACCEM) is employed as a process-based cost component to replace the original TCM result of the composite part production cost. The reason for the replacement is that TCM estimates production costs from part weights as a result of subtractive manufacturing of metallic origin such as casting, forging, and machining processes. A complexity factor can sometimes be adjusted to reflect different types of metal and machine settings. The TCM assumption, however, gives erroneous results when applied to additive processes like those of composite manufacturing. Another innovative aspect of this research is the introduction of a work measurement technique called Maynard Operation Sequence Technique (MOST) to be used, similarly to Activity-Based Costing (ABC) approach, to estimate manufacturing time of a part by virtue of breaking down the operations occurred during its production. ABC allows a realistic determination of cost incurred in each activity, as opposed to using a traditional method of time estimation by analogy or using response surface equations from historical process data. The MOST concept provides a tailored study of an individual process typically required for a new, innovative design. Nevertheless, the MOST idea has some challenges, one of which is its requirement to build a new process from ground up. The process development requires a Subject Matter Expertise (SME) in manufacturing method of the particular design. The SME must have also a comprehensive understanding of the MOST system so that the correct parameters are chosen. In practice, these knowledge requirements may demand people from outside of the design discipline and a priori training of MOST. To relieve the constraint, this study includes an entirely new sub-system architecture

In-situ acoustic signature monitoring in additive manufacturing processes

NASA Astrophysics Data System (ADS)

Koester, Lucas W.; Taheri, Hossein; Bigelow, Timothy A.; Bond, Leonard J.; Faierson, Eric J.

2018-04-01

Additive manufacturing is a rapidly maturing process for the production of complex metallic, ceramic, polymeric, and composite components. The processes used are numerous, and with the complex geometries involved this can make quality control and standardization of the process and inspection difficult. Acoustic emission measurements have been used previously to monitor a number of processes including machining and welding. The authors have identified acoustic signature measurement as a potential means of monitoring metal additive manufacturing processes using process noise characteristics and those discrete acoustic emission events characteristic of defect growth, including cracks and delamination. Results of acoustic monitoring for a metal additive manufacturing process (directed energy deposition) are reported. The work investigated correlations between acoustic emissions and process noise with variations in machine state and deposition parameters, and provided proof of concept data that such correlations do exist.

Airborne Wind Shear Detection and Warning Systems: Third Combined Manufacturers' and Technologists' Conference, part 2

NASA Technical Reports Server (NTRS)

Vicroy, Dan D. (Compiler); Bowles, Roland L. (Compiler); Schlickenmaier, Herbert (Compiler)

1991-01-01

The Third Combined Manufacturers' and Technologists' Conference was held in Hampton, Va., on October 16-18, 1990. The purpose of the meeting was to transfer significant on-going results of the NASA/FAA joint Airborne Wind Shear Program to the technical industry and to pose problems of current concern to the combined group. It also provided a forum for manufacturers to review forward-look technology concepts and for technologists to gain an understanding of the problems encountered by the manufacturers during the development of airborne equipment and the FAA certification requirements.

NASA's In-Space Manufacturing Project: Materials and Manufacturing Process Development Update

NASA Technical Reports Server (NTRS)

Prater, Tracie; Bean, Quincy; Werkheiser, Niki; Ledbetter, Frank

2017-01-01

The mission of NASA's In-Space Manufacturing (ISM) project is to identify, design, and implement on-demand, sustainable manufacturing solutions for fabrication, maintenance and repair during exploration missions. ISM has undertaken a phased strategy of incrementally increasing manufacturing capabilities to achieve this goal. The ISM project began with the development of the first 3D printer for the International Space Station. To date, the printer has completed two phases of flight operations. Results from phase I specimens indicated some differences in material properties between ground-processed and ISS-processed specimens, but results of follow-on analyses of these parts and a ground-based study with an equivalent printer strongly indicate that this variability is likely attributable to differences in manufacturing process settings between the ground and flight prints rather than microgravity effects on the fused deposition modeling (FDM) process. Analysis of phase II specimens from the 3D Printing in Zero G tech demo, which shed further light on the sources of material variability, will be presented. The ISM project has also developed a materials characterization plan for the Additive Manufacturing Facility, the follow-on commercial multimaterial 3D printing facility developed for ISS by Made in Space. This work will yield a suite of characteristic property values that can inform use of AMF by space system designers. Other project activities include development of an integrated 3D printer and recycler, known as the Refabricator, by Tethers Unlimited, which will be operational on ISS in 2018. The project also recently issued a broad area announcement for a multimaterial fabrication laboratory, which may include in-space manufacturing capabilities for metals, electronics, and polymeric materials, to be deployed on ISS in the 2022 timeframe.

A Modular Aerospike Engine Design Using Additive Manufacturing

NASA Technical Reports Server (NTRS)

Peugeot, John; Garcia, Chance; Burkhardt, Wendel

2014-01-01

A modular aerospike engine concept has been developed with the objective of demonstrating the viability of the aerospike design using additive manufacturing techniques. The aerospike system is a self-compensating design that allows for optimal performance over the entire flight regime and allows for the lowest possible mass vehicle designs. At low altitudes, improvements in Isp can be traded against chamber pressure, staging, and payload. In upper stage applications, expansion ratio and engine envelope can be traded against nozzle efficiency. These features provide flexibility to the System Designer optimizing a complete vehicle stage. The aerospike concept is a good example of a component that has demonstrated improved performance capability, but traditionally has manufacturing requirements that are too expensive and complex to use in a production vehicle. In recent years, additive manufacturing has emerged as a potential method for improving the speed and cost of building geometrically complex components in rocket engines. It offers a reduction in tooling overhead and significant improvements in the integration of the designer and manufacturing method. In addition, the modularity of the engine design provides the ability to perform full scale testing on the combustion devices outside of the full engine configuration. The proposed design uses a hydrocarbon based gas-generator cycle, with plans to take advantage of existing powerhead hardware while focusing DDT&E resources on manufacturing and sub-system testing of the combustion devices. The major risks for the modular aerospike concept lie in the performance of the propellant feed system, the structural integrity of the additive manufactured components, and the aerodynamic efficiency of the exhaust flow.

Ultrasonic scanning for pallet part grading

Treesearch

Mohammed F. Kabir; Daniel L. Schmoldt; Mark E. Schafer; Philip A. Araman

2000-01-01

Sorting and grading of wooden pallet parts are key factors for pallet manufacturing quality and pallet durability. The feasibility of ultrasonic scanning for defect detection in pallet manufacturing is examined in this report. Scanning was conducted by two pressure-contact rolling transducers in a pitch-catch arrangement. Pallet part deckboards were fed through the...

Structural Color for Additive Manufacturing: 3D-Printed Photonic Crystals from Block Copolymers.

PubMed

Boyle, Bret M; French, Tracy A; Pearson, Ryan M; McCarthy, Blaine G; Miyake, Garret M

2017-03-28

The incorporation of structural color into 3D printed parts is reported, presenting an alternative to the need for pigments or dyes for colored parts produced through additive manufacturing. Thermoplastic build materials composed of dendritic block copolymers were designed, synthesized, and used to additively manufacture plastic parts exhibiting structural color. The reflection properties of the photonic crystals arise from the periodic nanostructure formed through block copolymer self-assembly during polymer processing. The wavelength of reflected light could be tuned across the visible spectrum by synthetically controlling the block copolymer molecular weight and manufacture parts that reflected violet, green, or orange light with the capacity to serve as selective optical filters and light guides.

21 CFR 114.5 - Current good manufacturing practice.

Code of Federal Regulations, 2010 CFR

2010-04-01

... 21 Food and Drugs 2 2010-04-01 2010-04-01 false Current good manufacturing practice. 114.5 Section...) FOOD FOR HUMAN CONSUMPTION ACIDIFIED FOODS General Provisions § 114.5 Current good manufacturing practice. The criteria in §§ 114.10, 114.80, 114.83, 114.89, and 114.100, as well as the criteria in part...

Additive Manufacturing: From Rapid Prototyping to Flight

NASA Technical Reports Server (NTRS)

Prater, Tracie

2015-01-01

Additive manufacturing (AM) offers tremendous promise for the rocket propulsion community. Foundational work must be performed to ensure the safe performance of AM parts. Government, industry, and academia must collaborate in the characterization, design, modeling, and process control to accelerate the certification of AM parts for human-rated flight.

The Economics of Big Area Addtiive Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Post, Brian; Lloyd, Peter D; Lindahl, John

Case studies on the economics of Additive Manufacturing (AM) suggest that processing time is the dominant cost in manufacturing. Most additive processes have similar performance metrics: small part sizes, low production rates and expensive feedstocks. Big Area Additive Manufacturing is based on transitioning polymer extrusion technology from a wire to a pellet feedstock. Utilizing pellets significantly increases deposition speed and lowers material cost by utilizing low cost injection molding feedstock. The use of carbon fiber reinforced polymers eliminates the need for a heated chamber, significantly reducing machine power requirements and size constraints. We hypothesize that the increase in productivity coupledmore » with decrease in feedstock and energy costs will enable AM to become more competitive with conventional manufacturing processes for many applications. As a test case, we compare the cost of using traditional fused deposition modeling (FDM) with BAAM for additively manufacturing composite tooling.« less

Manufacturing Methods and Technology Project Summary Reports

DTIC Science & Technology

1985-06-01

Computer -Aided Design (CAD)/ Computer -Aided Manufacturing (CAM) Process for the Production of Cold Forged Gears Project 483 6121 - Robotic Welding and...Caliber Projectile Bodies Project 682 8370 - Automatic Inspection and 1-I1 Process Control of Weapons Parts Manufacturing METALS Project 181 7285 - Cast...designed for use on each project. Experience suggested that a general purpose computer interface might be designed that could be used on any project

Nucleation and growth of chimney pores during electron-beam additive manufacturing

DOE PAGES

Cordero, Zachary C.; Dinwiddie, Ralph B.; Immel, David; ...

2016-12-05

The nucleation and growth of chimney pores during powder-bed, electron-beam additive manufacturing is investigated using in-situ infrared thermography as well as microcomputed tomography of as-printed parts. The pores are found to nucleate at dimples on the part s surface, clearly demonstrating how process parameters can affect surface roughness, which can in turn affect the internal defect structure in an additive manufactured part. Based on the results of this study, several strategies for suppressing the formation of chimney pores are discussed.

Mechanical Prototyping and Manufacturing Internship

NASA Technical Reports Server (NTRS)

Grenfell, Peter

2016-01-01

The internship was located at the Johnson Space Center (JSC) Innovation Design Center (IDC), which is a facility where the JSC workforce can meet and conduct hands-on innovative design, fabrication, evaluation, and testing of ideas and concepts relevant to NASA's mission. The tasks of the internship included mechanical prototyping design and manufacturing projects in service of research and development as well as assisting the users of the IDC in completing their manufacturing projects. The first project was to manufacture hatch mechanisms for a team in the Systems Engineering and Project Advancement Program (SETMAP) hexacopter competition. These mechanisms were intended to improve the performance of the servomotors and offer an access point that would also seal to prevent cross-contamination. I also assisted other teams as they were constructing and modifying their hexacopters. The success of this competition demonstrated a proof of concept for aerial reconnaissance and sample return to be potentially used in future NASA missions. I also worked with Dr. Kumar Krishen to prototype an improved thermos and a novel, portable solar array. Computer-aided design (CAD) software was used to model the parts for both of these projects. Then, 3D printing as well as conventional techniques were used to produce the parts. These prototypes were then subjected to trials to determine the success of the designs. The solar array is intended to work in a cluster that is easy to set up and take down and doesn't require powered servomechanisms. It could be used terrestrially in areas not serviced by power grids. Both projects improve planetary exploration capabilities to future astronauts. Other projects included manufacturing custom rail brackets for EG-2, assisting engineers working on underwater instrument and tool cases for the NEEMO project, and helping to create mock-up parts for Space Center Houston. The use of the IDC enabled efficient completion of these projects at

Numerical and Experimental Study of Ti6Al4V Components Manufactured Using Powder Bed Fusion Additive Manufacturing

NASA Astrophysics Data System (ADS)

Zielinski, Jonas; Mindt, Hans-Wilfried; Düchting, Jan; Schleifenbaum, Johannes Henrich; Megahed, Mustafa

2017-12-01

Powder bed fusion additive manufacturing of titanium alloys is an interesting manufacturing route for many applications requiring high material strength combined with geometric complexity. Managing powder bed fusion challenges, including porosity, surface finish, distortions and residual stresses of as-built material, is the key to bringing the advantages of this process to production main stream. This paper discusses the application of experimental and numerical analysis towards optimizing the manufacturing process of a demonstration component. Powder characterization including assessment of the reusability, assessment of material consolidation and process window optimization is pursued prior to applying the identified optima to study the distortion and residual stresses of the demonstrator. Comparisons of numerical predictions with measurements show good correlations along the complete numerical chain.

Poly(ether ester) Ionomers as Water-Soluble Polymers for Material Extrusion Additive Manufacturing Processes.

PubMed

Pekkanen, Allison M; Zawaski, Callie; Stevenson, André T; Dickerman, Ross; Whittington, Abby R; Williams, Christopher B; Long, Timothy E

2017-04-12

Water-soluble polymers as sacrificial supports for additive manufacturing (AM) facilitate complex features in printed objects. Few water-soluble polymers beyond poly(vinyl alcohol) enable material extrusion AM. In this work, charged poly(ether ester)s with tailored rheological and mechanical properties serve as novel materials for extrusion-based AM at low temperatures. Melt transesterification of poly(ethylene glycol) (PEG, 8k) and dimethyl 5-sulfoisophthalate afforded poly(ether ester)s of sufficient molecular weight to impart mechanical integrity. Quantitative ion exchange provided a library of poly(ether ester)s with varying counterions, including both monovalent and divalent cations. Dynamic mechanical and tensile analysis revealed an insignificant difference in mechanical properties for these polymers below the melting temperature, suggesting an insignificant change in final part properties. Rheological analysis, however, revealed the advantageous effect of divalent countercations (Ca 2+ , Mg 2+ , and Zn 2+ ) in the melt state and exhibited an increase in viscosity of two orders of magnitude. Furthermore, time-temperature superposition identified an elevation in modulus, melt viscosity, and flow activation energy, suggesting intramolecular interactions between polymer chains and a higher apparent molecular weight. In particular, extrusion of poly(PEG 8k -co-CaSIP) revealed vast opportunities for extrusion AM of well-defined parts. The unique melt rheological properties highlighted these poly(ether ester) ionomers as ideal candidates for low-temperature material extrusion additive manufacturing of water-soluble parts.

Airborne Wind Shear Detection and Warning Systems. Second Combined Manufacturers' and Technologists' Conference, part 1

NASA Technical Reports Server (NTRS)

Spady, Amos A., Jr. (Compiler); Bowles, Roland L. (Compiler); Schlickenmaier, Herbert (Compiler)

1990-01-01

The Second Combined Manufacturers' and Technologists' Conference hosted jointly by NASA Langley (LaRC) and the Federal Aviation Administration (FAA) was held in Williamsburg, Virginia, on October 18 to 20, 1988. The purpose of the meeting was to transfer significant, ongoing results gained during the second year of the joint NASA/FAA Airborne Wind Shear Program to the technical industry and to pose problems of current concern to the combined group. It also provided a forum for manufacturers to review forward-look technology concepts and for technologists to gain an understanding of the problems encountered by the manufacturers during the development of airborne equipment and the FAA certification requirements.

Technology: Manufacturing, Transportation, Construction, Communication.

ERIC Educational Resources Information Center

North Carolina State Dept. of Public Instruction, Raleigh. Div. of Vocational Education.

The technology-based student activities in this curriculum resource book are intended to be incorporated into any industrial arts/technology education program. The activities are classified according to one of four technological systems--construction, communications, manufacturing, and transportation. Within the four parts of the guide, individual…

Computers in manufacturing

NASA Astrophysics Data System (ADS)

Hudson, C. A.

1982-02-01

CAD/CAM advances and applications for enhancing productivity in industry are explored. Wide-spread use of CAD/CAM devices are projected to occur by the time period 1992-1997, resulting in a higher percentage of technicians in the manufacturing process, while the cost of computers and software will continue to fall and become more widely available. Computer aided design is becoming a commercially viable system for design and geometric modeling, engineering analysis, kinematics, and drafting, and efforts to bridge the gap between CAD and CAM are indicated, with particular attention given to layering, wherein individual monitoring of different parts of the manufacturing process can be effected without crossover of unnecessary information. The potentials and barriers to the use of robotics are described, with the added optimism that displaced workers to date have moved up to jobs of higher skill and interest.

Literature Review on Dynamic Cellular Manufacturing System

NASA Astrophysics Data System (ADS)

Nouri Houshyar, A.; Leman, Z.; Pakzad Moghadam, H.; Ariffin, M. K. A. M.; Ismail, N.; Iranmanesh, H.

2014-06-01

In previous decades, manufacturers faced a lot of challenges because of globalization and high competition in markets. These problems arise from shortening product life cycle, rapid variation in demand of products, and also rapid changes in manufcaturing technologies. Nowadays most manufacturing companies expend considerable attention for improving flexibility and responsiveness in order to overcome these kinds of problems and also meet customer's needs. By considering the trend toward the shorter product life cycle, the manufacturing environment is towards manufacturing a wide variety of parts in small batches [1]. One of the major techniques which are applied for improving manufacturing competitiveness is Cellular Manufacturing System (CMS). CMS is type of manufacturing system which tries to combine flexibility of job shop and also productivity of flow shop. In addition, Dynamic cellular manufacturing system which considers different time periods for the manufacturing system becomes an important topic and attracts a lot of attention to itself. Therefore, this paper made attempt to have a brief review on this issue and focused on all published paper on this subject. Although, this topic gains a lot of attention to itself during these years, none of previous researchers focused on reviewing the literature of that which can be helpful and useful for other researchers who intend to do the research on this topic. Therefore, this paper is the first study which has focused and reviewed the literature of dynamic cellular manufacturing system.

Reliability Standards of Complex Engineering Systems

NASA Astrophysics Data System (ADS)

Galperin, E. M.; Zayko, V. A.; Gorshkalev, P. A.

2017-11-01

Production and manufacture play an important role in today’s modern society. Industrial production is nowadays characterized by increased and complex communications between its parts. The problem of preventing accidents in a large industrial enterprise becomes especially relevant. In these circumstances, the reliability of enterprise functioning is of particular importance. Potential damage caused by an accident at such enterprise may lead to substantial material losses and, in some cases, can even cause a loss of human lives. That is why industrial enterprise functioning reliability is immensely important. In terms of their reliability, industrial facilities (objects) are divided into simple and complex. Simple objects are characterized by only two conditions: operable and non-operable. A complex object exists in more than two conditions. The main characteristic here is the stability of its operation. This paper develops the reliability indicator combining the set theory methodology and a state space method. Both are widely used to analyze dynamically developing probability processes. The research also introduces a set of reliability indicators for complex technical systems.

Optimization Manufacture of Virus- and Tumor-Specific T Cells

PubMed Central

Lapteva, Natalia; Vera, Juan F.

2011-01-01

Although ex vivo expanded T cells are currently widely used in pre-clinical and clinical trials, the complexity of manufacture remains a major impediment for broader application. In this review we discuss current protocols for the ex vivo expansion of virus- and tumor-specific T cells and describe our experience in manufacture optimization using a gas-permeable static culture flask (G-Rex). This innovative device has revolutionized the manufacture process by allowing us to increase cell yields while decreasing the frequency of cell manipulation and in vitro culture time. It is now being used in good manufacturing practice (GMP) facilities for clinical cell production in our institution as well as many others in the US and worldwide. PMID:21915183

Making Ceramic/Polymer Parts By Extrusion Stereolithography

NASA Technical Reports Server (NTRS)

Stuffle, Kevin; Mulligan, A.; Creegan, P.; Boulton, J. M.; Lombardi, J. L.; Calvert, P. D.

1996-01-01

Extrusion stereolithography developmental method of computer-controlled manufacturing of objects out of ceramic/polymer composite materials. Computer-aided design/computer-aided manufacturing (CAD/CAM) software used to create image of desired part and translate image into motion commands for combination of mechanisms moving resin dispenser. Extrusion performed in coordination with motion of dispenser so buildup of extruded material takes on size and shape of desired part. Part thermally cured after deposition.

Mechanical strength of welding zones produced by material extrusion additive manufacturing.

PubMed

Davis, Chelsea S; Hillgartner, Kaitlyn E; Han, Seung Hoon; Seppala, Jonathan E

2017-08-01

As more manufacturing processes and research institutions adopt customized manufacturing as a key element in their design strategies and finished products, the resulting mechanical properties of parts produced through additive manufacturing (AM) must be characterized and understood. In material extrusion (MatEx), the most recently extruded polymer filament must bond to the previously extruded filament via polymer diffusion to form a "weld". The strength of the weld limits the performance of the manufactured part and is controlled through processing conditions. Under-standing the role of processing conditions, specifically extruder velocity and extruder temperature, on the overall strength of the weld will allow optimization of MatEx-AM parts. Here, the fracture toughness of a single weld is determined through a facile "trouser tear" Mode III fracture experiment. The actual weld thickness is observed directly by optical microscopy characterization of cross sections of MatEx-AM samples. Representative data of weld strength as a function of printing parameters on a commercial 3D printer demonstrates the robustness of the method.

Emerging technologies in arthroplasty: additive manufacturing.

PubMed

Banerjee, Samik; Kulesha, Gene; Kester, Mark; Mont, Michael A

2014-06-01

Additive manufacturing is an industrial technology whereby three-dimensional visual computer models are fabricated into physical components by selectively curing, depositing, or consolidating various materials in consecutive layers. Although initially developed for production of simulated models, the technology has undergone vast improvements and is currently increasingly being used for the production of end-use components in various aerospace, automotive, and biomedical specialties. The ability of this technology to be used for the manufacture of solid-mesh-foam monolithic and coated components of complex geometries previously considered unmanufacturable has attracted the attention of implant manufacturers, bioengineers, and orthopedic surgeons. Currently, there is a paucity of reports describing this fabrication method in the orthopedic literature. Therefore, we aimed to briefly describe this technology, some of the applications in other orthopedic subspecialties, its present use in hip and knee arthroplasty, and concerns with the present form of the technology. As there are few reports of clinical trials presently available, the true benefits of this technology can only be realized when studies evaluating the clinical and radiographic outcomes of cementless implants manufactured with additive manufacturing report durable fixation, less stress shielding, and better implant survivorship. Nevertheless, the authors believe that this technology holds great promise and may potentially change the conventional methods of casting, machining, and tooling for implant manufacturing in the future. Thieme Medical Publishers 333 Seventh Avenue, New York, NY 10001, USA.

Colloidal-based additive manufacturing of bio-inspired composites

NASA Astrophysics Data System (ADS)

Studart, Andre R.

Composite materials in nature exhibit heterogeneous architectures that are tuned to fulfill the functional demands of the surrounding environment. Examples range from the cellulose-based organic structure of plants to highly mineralized collagen-based skeletal parts like bone and teeth. Because they are often utilized to combine opposing properties such as strength and low-density or stiffness and wear resistance, the heterogeneous architecture of natural materials can potentially address several of the technical limitations of artificial homogeneous composites. However, current man-made manufacturing technologies do not allow for the level of composition and fiber orientation control found in natural heterogeneous systems. In this talk, I will present two additive manufacturing technologies recently developed in our group to build composites with exquisite architectures only rivaled by structures made by living organisms in nature. Since the proposed techniques utilize colloidal suspensions as feedstock, understanding the physics underlying the stability, assembly and rheology of the printing inks is key to predict and control the architecture of manufactured parts. Our results will show that additive manufacturing routes offer a new exciting pathway for the fabrication of biologically-inspired composite materials with unprecedented architectures and functionalities.

Autonomous Agents for Dynamic Process Planning in the Flexible Manufacturing System

NASA Astrophysics Data System (ADS)

Nik Nejad, Hossein Tehrani; Sugimura, Nobuhiro; Iwamura, Koji; Tanimizu, Yoshitaka

Rapid changes of market demands and pressures of competition require manufacturers to maintain highly flexible manufacturing systems to cope with a complex manufacturing environment. This paper deals with development of an agent-based architecture of dynamic systems for incremental process planning in the manufacturing systems. In consideration of alternative manufacturing processes and machine tools, the process plans and the schedules of the manufacturing resources are generated incrementally and dynamically. A negotiation protocol is discussed, in this paper, to generate suitable process plans for the target products real-timely and dynamically, based on the alternative manufacturing processes. The alternative manufacturing processes are presented by the process plan networks discussed in the previous paper, and the suitable process plans are searched and generated to cope with both the dynamic changes of the product specifications and the disturbances of the manufacturing resources. We initiatively combine the heuristic search algorithms of the process plan networks with the negotiation protocols, in order to generate suitable process plans in the dynamic manufacturing environment.

40 CFR 86.1838-01 - Small volume manufacturer certification procedures.

Code of Federal Regulations, 2013 CFR

2013-07-01

... miles, a manufacturer may demonstrate to the satisfaction of the Agency that, based on owner survey data... means of support of economic value from any related manufacturers for purposes of vehicle design, vehicle parts procurement, research and development, and production facilities and operation. Any...

Multi-orifice deposition nozzle for additive manufacturing

DOEpatents

Lind, Randall F.; Post, Brian K.; Cini, Colin L.

2017-11-21

An additive manufacturing extrusion head includes a nozzle for accepting and depositing a heated material onto a work surface and/or part. The nozzle includes a valve body and an internal poppet body moveable between positions to permit deposition of at least two bead sizes of heated material onto a work surface and/or part.

Big Data Analysis of Manufacturing Processes

NASA Astrophysics Data System (ADS)

Windmann, Stefan; Maier, Alexander; Niggemann, Oliver; Frey, Christian; Bernardi, Ansgar; Gu, Ying; Pfrommer, Holger; Steckel, Thilo; Krüger, Michael; Kraus, Robert

2015-11-01

The high complexity of manufacturing processes and the continuously growing amount of data lead to excessive demands on the users with respect to process monitoring, data analysis and fault detection. For these reasons, problems and faults are often detected too late, maintenance intervals are chosen too short and optimization potential for higher output and increased energy efficiency is not sufficiently used. A possibility to cope with these challenges is the development of self-learning assistance systems, which identify relevant relationships by observation of complex manufacturing processes so that failures, anomalies and need for optimization are automatically detected. The assistance system developed in the present work accomplishes data acquisition, process monitoring and anomaly detection in industrial and agricultural processes. The assistance system is evaluated in three application cases: Large distillation columns, agricultural harvesting processes and large-scale sorting plants. In this paper, the developed infrastructures for data acquisition in these application cases are described as well as the developed algorithms and initial evaluation results.

Issues related to processability during the manufacture of thermoplastic composites using on-line consolidation techniques

NASA Astrophysics Data System (ADS)

Ghasemi Nejhad, M. N.

1993-04-01

The on-line consolidation of thermoplastic composites is a relatively new technology that can be used to manufacture composite parts with complex geometries. The localized melting/solidification technique employed in this process can reduce the residual stresses and allow for improved dimensional stability and performance. An additional advantage of this technique is the elimination of the curing steps which are necessary in the processing of thermoset-matrix composites. This article presents the effects of processing parameters on processability in on-line consolidation of thermoplastic composites for tape-laying and filament-winding processes employing anisotropic thermal analyses. The results show that the heater size, preheating conditions, and tow thickness can significantly affect the processing window which, in turn, affects the production rate and the quality of the parts.

A Delphi Study of Additive Manufacturing Applicability for United States Air Force Civil Engineer Contingency Operations

DTIC Science & Technology

2015-03-26

10 Table 2. Additive Manufacturing Categories (ASTM International , 2012) ..................... 14 Table 3. Delphi... flexibility in the design and structure of manufactured parts. It also allows for the creation of thousands of possible parts or tools from a single...machine. These benefits of 3 precision and flexibility in design and manufacturing show promising possibilities for addressing the general nature of

Modular Hydropower Engineering and Pilot Scale Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chesser, Phillip C.

Emrgy has developed, prototyped and tested a modular hydropower system for renewable energy generation. ORNL worked with Emrgy to demonstrate the use of additive manufacturing in the production of the hydrofoils and spokes for the hydrokinetic system. Specifically, during Phase 1 of this effort, ORNL printed and finished machined patterns for both the hydrofoils and spokes that were subsequently used in a sand casting manufacturing process. Emrgy utilized the sand castings for a pilot installation in Denver, CO, where the parts represented an 80% cost savings from the previous prototype build that was manufactured using subtractive manufacturing. In addition, themore » castings were completed with ORNL’s newly developed AlCeMg alloy that will be tested for performance improvements including higher corrosion resistance in a water application than the 6160 alloy used previously« less

Neutron residual stress measurement and numerical modeling in a curved thin-walled structure by laser powder bed fusion additive manufacturing

DOE PAGES

An, Ke; Yuan, Lang; Dial, Laura; ...

2017-09-11

Severe residual stresses in metal parts made by laser powder bed fusion additive manufacturing processes (LPBFAM) can cause both distortion and cracking during the fabrication processes. Limited data is currently available for both iterating through process conditions and design, and in particular, for validating numerical models to accelerate process certification. In this work, residual stresses of a curved thin-walled structure, made of Ni-based superalloy Inconel 625™ and fabricated by LPBFAM, were resolved by neutron diffraction without measuring the stress-free lattices along both the build and the transverse directions. The stresses of the entire part during fabrication and after cooling downmore » were predicted by a simplified layer-by-layer finite element based numerical model. The simulated and measured stresses were found in good quantitative agreement. The validated simplified simulation methodology will allow to assess residual stresses in more complex structures and to significantly reduce manufacturing cycle time.« less

Neutron residual stress measurement and numerical modeling in a curved thin-walled structure by laser powder bed fusion additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

An, Ke; Yuan, Lang; Dial, Laura

Severe residual stresses in metal parts made by laser powder bed fusion additive manufacturing processes (LPBFAM) can cause both distortion and cracking during the fabrication processes. Limited data is currently available for both iterating through process conditions and design, and in particular, for validating numerical models to accelerate process certification. In this work, residual stresses of a curved thin-walled structure, made of Ni-based superalloy Inconel 625™ and fabricated by LPBFAM, were resolved by neutron diffraction without measuring the stress-free lattices along both the build and the transverse directions. The stresses of the entire part during fabrication and after cooling downmore » were predicted by a simplified layer-by-layer finite element based numerical model. The simulated and measured stresses were found in good quantitative agreement. The validated simplified simulation methodology will allow to assess residual stresses in more complex structures and to significantly reduce manufacturing cycle time.« less

Perfusion mammalian cell culture for recombinant protein manufacturing - A critical review.

PubMed

Bielser, Jean-Marc; Wolf, Moritz; Souquet, Jonathan; Broly, Hervé; Morbidelli, Massimo

The manufacturing of recombinant protein is traditionally divided in two main steps: upstream (cell culture and synthesis of the target protein) and downstream (purification and formulation of the protein into a drug substance or drug product). Today, cost pressure, market uncertainty and market growth, challenge the existing manufacturing technologies. Leaders in the field are active in designing the process of the future and continuous manufacturing is recurrently mentioned as a potential solution to address some of the current limitations. This review focuses on the application of continuous processing to the first step of the manufacturing process. Enabling technologies and operation modes are described in the first part. In the second part, recent advances in the field that have the potential to support its successful future development are critically discussed. Copyright © 2018 The Authors. Published by Elsevier Inc. All rights reserved.

Mechanical properties of sheet metal components with local reinforcement produced by additive manufacturing

NASA Astrophysics Data System (ADS)

Ünsal, Ismail; Hama-Saleh, R.; Sviridov, Alexander; Bambach, Markus; Weisheit, A.; Schleifenbaum, J. H.

2018-05-01

New technological challenges like electro-mobility pose an increasing demand for cost-efficient processes for the production of product variants. This demand opens the possibility to combine established die-based manufacturing methods and innovative, dieless technologies like additive manufacturing [1, 2]. In this context, additive manufacturing technologies allow for the weight-efficient local reinforcement of parts before and after forming, enabling manufacturers to produce product variants from series parts [3]. Previous work by the authors shows that the optimal shape of the reinforcing structure can be determined using sizing optimization. Sheet metal parts can then be reinforced using laser metal deposition. The material used is a pearlite-reduced, micro-alloyed steel (ZE 630). The aim of this paper is to determine the effect of the additive manufacturing process on the material behavior and the mechanical properties of the base material and the resulting composite material. The parameters of the AM process are optimized to reach similar material properties in the base material and the build-up volume. A metallographic analysis of the parts is presented, where the additive layers, the base material and also the bonding between the additive layers and the base material are analyzed. The paper shows the feasibility of the approach and details the resulting mechanical properties and performance.

Advanced Engineering Environments: Implications for Aerospace Manufacturing

NASA Technical Reports Server (NTRS)

Thomas, D.

2001-01-01

There are significant challenges facing today's aerospace industry. Global competition, more complex products, geographically-distributed design teams, demands for lower cost, higher reliability and safer vehicles, and the need to incorporate the latest technologies quicker all face the developer of aerospace systems. New information technologies offer promising opportunities to develop advanced engineering environments (AEEs) to meet these challenges. Significant advances in the state-of-the-art of aerospace engineering practice are envisioned in the areas of engineering design and analytical tools, cost and risk tools, collaborative engineering, and high-fidelity simulations early in the development cycle. These advances will enable modeling and simulation of manufacturing methods, which will in turn allow manufacturing considerations to be included much earlier in the system development cycle. Significant cost savings, increased quality, and decreased manufacturing cycle time are expected to result. This paper will give an overview of the NASA's Intelligent Synthesis Environment, the agency initiative to develop an AEE, with a focus on the anticipated benefits in aerospace manufacturing.

Flexible Design and Manufacturing Systems for Automotive Components and Sheet Metal Parts

DTIC Science & Technology

1999-10-01

sometimes shocking discoveries you will make, discoveries that can help you avoid potential crises down the road if you take the necessary steps now...ISSUE Guest Lecture John Swanson, VP Qualcomm 10-Feb Fast, Flexible, Lilly, US Robotics, Economist, Upton & Agile Manufacturing Readings

Nonterrestrial material processing and manufacturing of large space systems

NASA Technical Reports Server (NTRS)

Von Tiesenhausen, G.

1979-01-01

Nonterrestrial processing of materials and manufacturing of large space system components from preprocessed lunar materials at a manufacturing site in space is described. Lunar materials mined and preprocessed at the lunar resource complex will be flown to the space manufacturing facility (SMF), where together with supplementary terrestrial materials, they will be final processed and fabricated into space communication systems, solar cell blankets, radio frequency generators, and electrical equipment. Satellite Power System (SPS) material requirements and lunar material availability and utilization are detailed, and the SMF processing, refining, fabricating facilities, material flow and manpower requirements are described.

Airborne Wind Shear Detection and Warning Systems. Second Combined Manufacturers' and Technologists' Conference, part 2

NASA Technical Reports Server (NTRS)

Spady, Amos A., Jr. (Compiler); Bowles, Roland L. (Compiler); Schlickenmaier, Herbert (Compiler)

1990-01-01

The Second Combined Manufacturers' and Technologists' Conference was hosted jointly by NASA Langley (LaRC) and the Federal Aviation Administration (FAA) in Williamsburg, Virginia, on October 18 to 20, 1988. The meeting was co-chaired by Dr. Roland Bowles of LaRC and Herbrt Schlickenmaier of the FAA. The purpose of the meeting was to transfer significant, ongoing results gained during the second year of the joint NASA/FAA Airborne Wind Shear Program to the technical industry and to pose problems of current concern to the combined group. It also provided a forum for manufacturers to review forward-look technology concepts and for technologists to gain an understanding of the problems encountered by the manufacturers during the development of airborne equipment and the FAA certification requirements.

Assessment of the mechanical performance of titanium cranial prostheses manufactured by super plastic forming and single point incremental forming

NASA Astrophysics Data System (ADS)

Sgambitterra, Emanuele; Piccininni, Antonio; Guglielmi, Pasquale; Ambrogio, Giuseppina; Fragomeni, Gionata; Villa, Tomaso; Palumbo, Gianfranco

2018-05-01

Cranial implants are custom prostheses characterized by quite high geometrical complexity and small thickness; at the same time aesthetic and mechanical requirements have to be met. Titanium alloys are largely adopted for such prostheses, as they can be processed via different manufacturing technologies. In the present work cranial prostheses have been manufactured by Super Plastic Forming (SPF) and Single Point Incremental Forming (SPIF). In order to assess the mechanical performance of the cranial prostheses, drop tests under different load conditions were conducted on flat samples to investigate the effect of the blank thickness. Numerical simulations were also run for comparison purposes. The mechanical performance of the cranial implants manufactured by SPF and SPIF could be predicted using drop test data and information about the thickness evolution of the formed parts: the SPIFed prosthesis revealed to have a lower maximum deflection and a higher maximum force, while the SPFed prostheses showed a lower absorbed energy.

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA Technical Reports Server (NTRS)

Babai, Majid; Phillips, Steven; Griffin, Brian; Munafo, Paul M. (Technical Monitor)

2002-01-01

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA's Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aid in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI.

Additive manufactured x-ray optics for astronomy

NASA Astrophysics Data System (ADS)

Atkins, Carolyn; Feldman, Charlotte; Brooks, David; Watson, Stephen; Cochrane, William; Roulet, Melanie; Doel, Peter; Willingale, Richard; Hugot, Emmanuel

2017-08-01

Additive manufacturing, more commonly known as 3D printing, has become a commercially established technology for rapid prototyping and the fabrication of bespoke intricate parts. Optical components, such as mirrors and lenses, are now being fabricated via additive manufacturing, where the printed substrate is polished in a post-processing step. One application of additively manufactured optics could be within the astronomical X-ray community, where there is a growing need to demonstrate thin, lightweight, high precision optics for a beyond Chandra style mission. This paper will follow a proof-of-concept investigation, sponsored by the UK Space Agency's National Space Technology Programme, into the feasibility of applying additive manufacturing in the production of thin, lightweight, precision X-ray optics for astronomy. One of the benefits of additive manufacturing is the ability to construct intricate lightweighting, which can be optimised to minimise weight while ensuring rigidity. This concept of optimised lightweighting will be applied to a series of polished additively manufactured test samples and experimental data from these samples, including an assessment of the optical quality and the magnitude of any print-through, will be presented. In addition, the finite element analysis optimisations of the lightweighting development will be discussed.

24 CFR 3280.3 - Manufactured home procedural and enforcement regulations and consumer manual requirements.

Code of Federal Regulations, 2010 CFR

2010-04-01

... 24 Housing and Urban Development 5 2010-04-01 2010-04-01 false Manufactured home procedural and enforcement regulations and consumer manual requirements. 3280.3 Section 3280.3 Housing and Urban Development... consumer manual requirements. A manufacturer must comply with the requirements of this part 3280, part 3282...

Manufacturing of Smart Structures Using Fiber Placement Manufacturing Processes

NASA Technical Reports Server (NTRS)

Thomas, Matthew M.; Glowasky, Robert A.; McIlroy, Bruce E.; Story, Todd A.

1996-01-01

Smart structures research and development, with the ultimate aim of rapid commercial and military production of these structures, are at the forefront of the Synthesis and Processing of Intelligent Cost-Effective Structures (SPICES) program. As part of this ARPA-sponsored program, MDA-E is using fiber placement processes to manufacture integrated smart structure systems. These systems comprise advanced composite structures with embedded fiber optic sensors, shape memory alloys, piezoelectric actuators, and miniature accelerometers. Cost-effective approaches and solutions to smart material synthesis in the fiber-placement process, based upon integrated product development, are discussed herein.

40 CFR Table 1 to Subpart Vvvv of... - Compliance Dates for New and Existing Boat Manufacturing Facilities

Code of Federal Regulations, 2013 CFR

2013-07-01

... Boat Manufacturing Facilities 1 Table 1 to Subpart VVVV of Part 63 Protection of Environment... Pollutants for Boat Manufacturing Pt. 63, Subpt. VVVV, Table 1 Table 1 to Subpart VVVV of Part 63—Compliance Dates for New and Existing Boat Manufacturing Facilities As specified in § 63.5695, you must comply by...

40 CFR Table 1 to Subpart Vvvv of... - Compliance Dates for New and Existing Boat Manufacturing Facilities

Code of Federal Regulations, 2014 CFR

2014-07-01

... Boat Manufacturing Facilities 1 Table 1 to Subpart VVVV of Part 63 Protection of Environment... Pollutants for Boat Manufacturing Pt. 63, Subpt. VVVV, Table 1 Table 1 to Subpart VVVV of Part 63—Compliance Dates for New and Existing Boat Manufacturing Facilities As specified in § 63.5695, you must comply by...

40 CFR Table 1 to Subpart Vvvv of... - Compliance Dates for New and Existing Boat Manufacturing Facilities

Code of Federal Regulations, 2012 CFR

2012-07-01

... Boat Manufacturing Facilities 1 Table 1 to Subpart VVVV of Part 63 Protection of Environment... Pollutants for Boat Manufacturing Pt. 63, Subpt. VVVV, Table 1 Table 1 to Subpart VVVV of Part 63—Compliance Dates for New and Existing Boat Manufacturing Facilities As specified in § 63.5695, you must comply by...

Automotive Manufacturers' Cost/Revenue, Financial and Risk Analysis : Projected Impact of Automobile Manufacturing on the Plastics Industry

DOT National Transportation Integrated Search

1979-08-01

The report is part of a study to update the historical and projected cost/revenue analysis of the U.S. domestic automobile manufacturers. It includes the evaluation of the historical and projected financial data to assess the corporate financial posi...

Manufacturing challenges in the commercial production of recombinant coagulation factor VIII.

PubMed

Jiang, R; Monroe, T; McRogers, R; Larson, P J

2002-03-01

Advances in gene technology have led to the development of a method to manufacture recombinant coagulation Factor VIII (rFVIII) for haemophilia A. Because rFVIII is a large and complex protein, its commercialization has required that many challenges in manufacturing, purification and processing be overcome. In order to license the first generation of rFVIII (Kogenate) in 1993, Bayer Corporation invested over 10 years in research and manufacturing development. Seven additional years were subsequently devoted to research and manufacturing improvements in order to accomplish the recent licensing of a second rFVIII product (KOGENATE Bayer or Kogenate FS). This product differs from its predecessor, in that human albumin is removed from the purification and the formulation steps. In addition, fewer chromatography steps are involved resulting in greater yields per mL of conditioned medium, and a solvent-detergent viral inactivation step replaces the heat-processing step used for the previous product. Despite these changes in the manufacturing, the protein backbone and carbohydrate structure of the final rFVIII molecule are identical. The complexity of the production processes is reflected by over 100 000 manufacturing data entries and by 600 quality control tests for each batch of rFVIII. Manufacturers are continuing to develop the next generation of rFVIII, which will be produced without the addition of any human or animal proteins or byproducts. Investments in research, development and manufacturing technology are expected to result in the development of new products with enhanced safety profiles, and in an increase in the production capacity for products that are chronically in short supply.

Additive Manufacturing in Offsite Repair of Consumer Electronics

NASA Astrophysics Data System (ADS)

Chekurov, Sergei; Salmi, Mika

Spare parts for products that are at the end of their life cycles, but still under warranty, are logistically difficult because they are commonly not stored in the central warehouse. These uncommon spare parts occupy valuable space in smaller inventories and take a long time to be transported to the point of need, thus delaying the repair process. This paper proposes that storing the spare parts on a server and producing them with additive manufacturing (AM) on demand can shorten the repair cycle by simplifying the logistics. Introducing AM in the repair supply chain lowers the number of products that need to be reimbursed to the customer due to lengthy repairs, improves the repair statistics of the repair shops, and reduces the number of items that are held in stock. For this paper, the functionality of the concept was verified by reverse engineering a memory cover of a portable computer and laser sintering it from polyamide 12. The additively manufactured component fit well and the computer operated normally after the replacement. The current spare part supply chain model and models with AM machinery located at the repair shop, the centralized spare part provider, and the original equipment manufacturer were provided. The durations of the repair process in the models were compared by simulating two scenarios with the Monte Carlo method. As the biggest improvement, the model with the AM machine in the repair shop reduced the duration of the repair process from 14 days to three days. The result points to the conclusion that placing the machine as close to the need as possible is the best option, if there is enough demand. The spare parts currently compatible with AM are plastic components without strict surface roughness requirements, but more spare parts will become compatible with the development of AM.

Computed Tomography Inspection and Analysis for Additive Manufacturing Components

NASA Technical Reports Server (NTRS)

Beshears, Ronald D.

2017-01-01

Computed tomography (CT) inspection was performed on test articles additively manufactured from metallic materials. Metallic AM and machined wrought alloy test articles with programmed flaws and geometric features were inspected using a 2-megavolt linear accelerator based CT system. Performance of CT inspection on identically configured wrought and AM components and programmed flaws was assessed to determine the impact of additive manufacturing on inspectability of objects with complex geometries.

Holdup measurement for nuclear fuel manufacturing plants

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zucker, M.S.; Degen, M.; Cohen, I.

1981-07-13

The assay of nuclear material holdup in fuel manufacturing plants is a laborious but often necessary part of completing the material balance. A range of instruments, standards, and a methodology for assaying holdup has been developed. The objectives of holdup measurement are ascertaining the amount, distribution, and how firmly fixed the SNM is. The purposes are reconciliation of material unbalance during or after a manufacturing campaign or plant decommissioning, to decide security requirements, or whether further recovery efforts are justified.

The impact of fit manufacturing on green manufacturing: A review

NASA Astrophysics Data System (ADS)

Qi, Ang Nian; Sin, Tan Chan; Fathullah, M.; Lee, C. C.

2017-09-01

Fit manufacturing and Green manufacturing are a new trend principle and concept. They are getting popular in industrial. This paper is identifying the impact between Fit manufacturing and Green manufacturing. Besides Fit manufacturing, Lean manufacturing, Agile manufacturing and Sustainable manufacturing gives big impacts to Green Manufacturing. On top of that, this paper also discuss the benefits of applying Fit manufacturing and Green manufacturing in industrial as well as environment. Hence, applications of Fit manufacturing and Green Manufacturing are increasing year by year.

Laser and electron-beam powder-bed additive manufacturing of metallic implants: A review on processes, materials and designs.

PubMed

Sing, Swee Leong; An, Jia; Yeong, Wai Yee; Wiria, Florencia Edith

2016-03-01

Additive manufacturing (AM), also commonly known as 3D printing, allows the direct fabrication of functional parts with complex shapes from digital models. In this review, the current progress of two AM processes suitable for metallic orthopaedic implant applications, namely selective laser melting (SLM) and electron beam melting (EBM) are presented. Several critical design factors such as the need for data acquisition for patient-specific design, design dependent porosity for osteo-inductive implants, surface topology of the implants and design for reduction of stress-shielding in implants are discussed. Additive manufactured biomaterials such as 316L stainless steel, titanium-6aluminium-4vanadium (Ti6Al4V) and cobalt-chromium (CoCr) are highlighted. Limitations and future potential of such technologies are also explored. © 2015 Orthopaedic Research Society. Published by Wiley Periodicals, Inc.

Integrated Computer-Aided Manufacturing (ICAM) Architecture Part 2. Volume 6. Dynamics Modeling Manual (IDEF2)

DTIC Science & Technology

1981-06-01

design of manufacturing systems, "ilidation and verification of ICAM modules, integration of ICAM modules and the orderly transition of ICAM modules into...Function Model of "Manufacture Product" (MFGO) VIII - Composite Function Model of " Design Product" (DESIGNO) IX - Composite Information Model of...User Interface Requirements; and the Architecture of Design . This work was performed during the period of 29 September 1978 through 10

Evaluation of Additively Manufactured Metals for Use in Oxygen Systems Project

NASA Technical Reports Server (NTRS)

Tylka, Jonathan; Cooper, Ken; Peralta, Stephen; Wilcutt, Terrence; Hughitt, Brian; Generazio, Edward

2016-01-01

Space Launch System, Commercial Resupply, and Commercial Crew programs have published intent to use additively manufactured (AM) components in propulsion systems and are likely to include various life support systems in the future. Parts produced by these types of additive manufacturing techniques have not been fully evaluated for use in oxygen systems and the inherent risks have not been fully identified. Some areas of primary concern in the SLS process with respect to oxygen compatibility may be the porosity of the printed parts, fundamental differences in microstructure of an AM part as compared to traditional materials, or increased risk of shed metal particulate into an oxygen system. If an ignition were to occur the printed material could be more flammable than components manufactured from a traditional billet of raw material and/or present a significant hazards if not identified and rigorously studied in advance of implementation into an oxygen system.

Wayne Manufacturing: A Teaching Case on the Detection of Misappropriation of Assets

ERIC Educational Resources Information Center

Orchard, Lou X.; Decker, Jeffrey L.; Kizirian, Tim

2007-01-01

This paper is a teaching case intended for use in an undergraduate auditing or fraud examination course. Students are introduced to Wayne Manufacturing, a medium-sized firm in the Midwestern U.S.A. that manufactures parts for companies such as General Motors (GM) and Ford. Wayne Manufacturing has some conditions present that put it at risk for…

Three-Dimensional Printing Based Hybrid Manufacturing of Microfluidic Devices.

PubMed

Alapan, Yunus; Hasan, Muhammad Noman; Shen, Richang; Gurkan, Umut A

2015-05-01

Microfluidic platforms offer revolutionary and practical solutions to challenging problems in biology and medicine. Even though traditional micro/nanofabrication technologies expedited the emergence of the microfluidics field, recent advances in advanced additive manufacturing hold significant potential for single-step, stand-alone microfluidic device fabrication. One such technology, which holds a significant promise for next generation microsystem fabrication is three-dimensional (3D) printing. Presently, building 3D printed stand-alone microfluidic devices with fully embedded microchannels for applications in biology and medicine has the following challenges: (i) limitations in achievable design complexity, (ii) need for a wider variety of transparent materials, (iii) limited z-resolution, (iv) absence of extremely smooth surface finish, and (v) limitations in precision fabrication of hollow and void sections with extremely high surface area to volume ratio. We developed a new way to fabricate stand-alone microfluidic devices with integrated manifolds and embedded microchannels by utilizing a 3D printing and laser micromachined lamination based hybrid manufacturing approach. In this new fabrication method, we exploit the minimized fabrication steps enabled by 3D printing, and reduced assembly complexities facilitated by laser micromachined lamination method. The new hybrid fabrication method enables key features for advanced microfluidic system architecture: (i) increased design complexity in 3D, (ii) improved control over microflow behavior in all three directions and in multiple layers, (iii) transverse multilayer flow and precisely integrated flow distribution, and (iv) enhanced transparency for high resolution imaging and analysis. Hybrid manufacturing approaches hold great potential in advancing microfluidic device fabrication in terms of standardization, fast production, and user-independent manufacturing.

America Makes: The National Additive Manufacturing Innovation Institute (NAMII) Status Report and Future Opportunities (Postprint)

DTIC Science & Technology

2014-09-01

manufacturing, direct part manufacturing, manufacturing institute, public- private partnership, rapid manufacturing, 3D printing 16. SECURITY CLASSIFICATION...Manufacturing Science and Technology Pro- gram and selected Additive Manufacturing (or more popularly known as 3D printing ) as the technical subject. Working...operations, America Makes is starting to hit its stride in developing technology for 3D printing and in leading the way in how the United States should

Printability of alloys for additive manufacturing

DOE PAGES

Mukherjee, T.; Zuback, J. S.; De, A.; ...

2016-01-22

Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal distortion. A theoretical kinetic model is used to examine predisposition of different alloys to AM induced compositional changes. A well-tested numerical heat transfer and fluid flow model is usedmore » to compare susceptibilities of various alloys to lack of fusion defects. These results are tested and validated with independent experimental data. Here, the findings presented in this paper are aimed at achieving distortion free, compositionally sound and well bonded metallic parts.« less

Printability of alloys for additive manufacturing

PubMed Central

Mukherjee, T.; Zuback, J. S.; De, A.; DebRoy, T.

2016-01-01

Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal distortion. A theoretical kinetic model is used to examine predisposition of different alloys to AM induced compositional changes. A well-tested numerical heat transfer and fluid flow model is used to compare susceptibilities of various alloys to lack of fusion defects. These results are tested and validated with independent experimental data. The findings presented in this paper are aimed at achieving distortion free, compositionally sound and well bonded metallic parts. PMID:26796864

Systems and Methods for Designing and Fabricating Contact-Free Support Structures for Overhang Geometries of Parts in Powder-Bed Metal Additive Manufacturing

NASA Technical Reports Server (NTRS)

Cooper, Kenneth (Inventor); Chou, Yuag-Shan (Inventor)

2017-01-01

Systems and methods are provided for designing and fabricating contact-free support structures for overhang geometries of parts fabricated using electron beam additive manufacturing. One or more layers of un-melted metallic powder are disposed in an elongate gap between an upper horizontal surface of the support structure and a lower surface of the overhang geometry. The powder conducts heat from the overhang geometry to the support structure. The support structure acts as a heat sink to enhance heat transfer and reduce the temperature and severe thermal gradients due to poor thermal conductivity of metallic powders underneath the overhang. Because the support structure is not connected to the part, the support structure can be removed freely without any post-processing step.

40 CFR 766.2 - Applicability and duration of this part.

Code of Federal Regulations, 2011 CFR

2011-07-01

... person who, at any time during the duration of this part, manufactures (and/or imports), or processes, a... effective date of this part. (3) Small manufacturers are exempt from reporting process and reaction...

40 CFR 766.2 - Applicability and duration of this part.

Code of Federal Regulations, 2013 CFR

2013-07-01

... person who, at any time during the duration of this part, manufactures (and/or imports), or processes, a... effective date of this part. (3) Small manufacturers are exempt from reporting process and reaction...

40 CFR 766.2 - Applicability and duration of this part.

Code of Federal Regulations, 2014 CFR

2014-07-01

... person who, at any time during the duration of this part, manufactures (and/or imports), or processes, a... effective date of this part. (3) Small manufacturers are exempt from reporting process and reaction...

40 CFR 766.2 - Applicability and duration of this part.

Code of Federal Regulations, 2012 CFR

2012-07-01

... person who, at any time during the duration of this part, manufactures (and/or imports), or processes, a... effective date of this part. (3) Small manufacturers are exempt from reporting process and reaction...

Additive Manufacturing and Casting Technology Comparison: Mechanical Properties, Productivity and Cost Benchmark

NASA Astrophysics Data System (ADS)

Vevers, A.; Kromanis, A.; Gerins, E.; Ozolins, J.

2018-04-01

The casting technology is one of the oldest production technologies in the world but in the recent years metal additive manufacturing also known as metal 3D printing has been evolving with huge steps. Both technologies have capabilities to produce parts with internal holes and at first glance surface roughness is similar for both technologies, which means that for precise dimensions parts have to be machined in places where precise fit is necessary. Benchmark tests have been made to find out if parts which are produced with metal additive manufacturing can be used to replace parts which are produced with casting technology. Most of the comparative tests have been made with GJS-400-15 grade which is one of the most popular cast iron grades. To compare mechanical properties samples have been produced using additive manufacturing and tested for tensile strength, hardness, surface roughness and microstructure and then the results have been compared with the samples produced with casting technology. In addition, both technologies have been compared in terms of the production time and production costs to see if additive manufacturing is competitive with the casting technology. The original paper has been written in the Latvian language as part of the Master Thesis within the framework of the production technology study programme at Riga Technical University.

Knowledge management performance methodology regarding manufacturing organizations

NASA Astrophysics Data System (ADS)

Istrate, C.; Herghiligiu, I. V.

2016-08-01

The current business situation is extremely complicated. Business must adapt to the changes in order (a) to survive on the increasingly dynamic markets, (b) to meet customers’ new request for complex, customized and innovative products. In modern manufacturing organizations it can be seen a substantial improvement regarding the management of knowledge. This occurs due to the fact that organizations realized that knowledge and an efficient management of knowledge generates the highest value. Even it could be said that the manufacturing organizations were and are the biggest beneficiary of KM science. Knowledge management performance (KMP) evaluation in manufacturing organizations can be considered as extremely important because without measuring it, they are unable to properly assess (a) what goals, targets and activities must have continuity, (b) what must be improved and (c) what must be completed. Therefore a proper KM will generate multiple competitive advantages for organizations. This paper presents a developed methodological framework regarding the KMP importance regarding manufacturing organizations. This methodological framework was developed using as research methods: bibliographical research and a panel of specialists. The purpose of this paper is to improve the evaluation process of KMP and to provide a viable tool for manufacturing organizations managers.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

NASA Technical Reports Server (NTRS)

Grady, Joseph E.

2015-01-01

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute, represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies to fabricate polymer matrix composite and ceramic matrix composite turbine engine components. The benefits include: 50 weight reduction compared to metallic parts, reduced manufacturing costs, reduced part count and rapid design iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature polymer filaments. The CMC effort uses a binder jet process to fabricate silicon carbide test coupons and demonstration articles. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The research project includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

Advances in Additive Manufacturing

DTIC Science & Technology

2016-07-14

of 3D - printed structures. Analysis examples will include quantification of tolerance differences between the designed and manufactured parts, void...15. SUBJECT TERMS 3-D printing , validation and verification, nondestructive inspection, print -on-the-move, prototyping 16. SECURITY CLASSIFICATION...researching the formation of AM-grade metal powder from battlefield scrap and operating base waste, 2) potential of 3-D printing with sand to make

A Digital Methodology for the Design Process of Aerospace Assemblies with Sustainable Composite Processes & Manufacture

NASA Astrophysics Data System (ADS)

McEwan, W.; Butterfield, J.

2011-05-01

The well established benefits of composite materials are driving a significant shift in design and manufacture strategies for original equipment manufacturers (OEMs). Thermoplastic composites have advantages over the traditional thermosetting materials with regards to sustainability and environmental impact, features which are becoming increasingly pertinent in the aerospace arena. However, when sustainability and environmental impact are considered as design drivers, integrated methods for part design and product development must be developed so that any benefits of sustainable composite material systems can be assessed during the design process. These methods must include mechanisms to account for process induced part variation and techniques related to re-forming, recycling and decommissioning, which are in their infancy. It is proposed in this paper that predictive techniques related to material specification, part processing and product cost of thermoplastic composite components, be integrated within a Through Life Management (TLM) product development methodology as part of a larger strategy of product system modeling to improve disciplinary concurrency, realistic part performance, and to place sustainability at the heart of the design process. This paper reports the enhancement of digital manufacturing tools as a means of drawing simulated part manufacturing scenarios, real time costing mechanisms, and broader lifecycle performance data capture into the design cycle. The work demonstrates predictive processes for sustainable composite product manufacture and how a Product-Process-Resource (PPR) structure can be customised and enhanced to include design intent driven by `Real' part geometry and consequent assembly. your paper.

40 CFR Appendix I to Part 204 - Appendix I to Part 204

Code of Federal Regulations, 2011 CFR

2011-07-01

... Part 204 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) NOISE ABATEMENT PROGRAMS NOISE EMISSION STANDARDS FOR CONSTRUCTION EQUIPMENT Pt. 204, App. I Appendix I to Part 204 Table I... Noise Data Sheet Test report number: Subject: Manufacturer: Model: Serial No.: Rated speed: Rpm: Rated...

40 CFR Appendix I to Part 204 - Appendix I to Part 204

Code of Federal Regulations, 2010 CFR

2010-07-01

... Part 204 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) NOISE ABATEMENT PROGRAMS NOISE EMISSION STANDARDS FOR CONSTRUCTION EQUIPMENT Pt. 204, App. I Appendix I to Part 204 Table I... Noise Data Sheet Test report number: Subject: Manufacturer: Model: Serial No.: Rated speed: Rpm: Rated...

Additive manufacturing in production: challenges and opportunities

NASA Astrophysics Data System (ADS)

Ahuja, Bhrigu; Karg, Michael; Schmidt, Michael

2015-03-01

Additive manufacturing, characterized by its inherent layer by layer fabrication methodology has been coined by many as the latest revolution in the manufacturing industry. Due to its diversification of Materials, processes, system technology and applications, Additive Manufacturing has been synonymized with terminology such as Rapid prototyping, 3D printing, free-form fabrication, Additive Layer Manufacturing, etc. A huge media and public interest in the technology has led to an innovative attempt of exploring the technology for applications beyond the scope of the traditional engineering industry. Nevertheless, it is believed that a critical factor for the long-term success of Additive Manufacturing would be its ability to fulfill the requirements defined by the traditional manufacturing industry. A parallel development in market trends and product requirements has also lead to a wider scope of opportunities for Additive Manufacturing. The presented paper discusses some of the key challenges which are critical to ensure that Additive Manufacturing is truly accepted as a mainstream production technology in the industry. These challenges would highlight on various aspects of production such as product requirements, process management, data management, intellectual property, work flow management, quality assurance, resource planning, etc. In Addition, changing market trends such as product life cycle, mass customization, sustainability, environmental impact and localized production will form the foundation for the follow up discussion on the current limitations and the corresponding research opportunities. A discussion on ongoing research to address these challenges would include topics like process monitoring, design complexity, process standardization, multi-material and hybrid fabrication, new material development, etc.

Effects of build parameters on linear wear loss in plastic part produced by fused deposition modeling

NASA Astrophysics Data System (ADS)

Mohamed, Omar Ahmed; Masood, Syed Hasan; Bhowmik, Jahar Lal

2017-07-01

Fused Deposition Modeling (FDM) is one of the prominent additive manufacturing technologies for producing polymer products. FDM is a complex additive manufacturing process that can be influenced by many process conditions. The industrial demands required from the FDM process are increasing with higher level product functionality and properties. The functionality and performance of FDM manufactured parts are greatly influenced by the combination of many various FDM process parameters. Designers and researchers always pay attention to study the effects of FDM process parameters on different product functionalities and properties such as mechanical strength, surface quality, dimensional accuracy, build time and material consumption. However, very limited studies have been carried out to investigate and optimize the effect of FDM build parameters on wear performance. This study focuses on the effect of different build parameters on micro-structural and wear performance of FDM specimens using definitive screening design based quadratic model. This would reduce the cost and effort of additive manufacturing engineer to have a systematic approachto make decision among the manufacturing parameters to achieve the desired product quality.

Composite Design and Manufacturing Development for Human Spacecrafts

NASA Technical Reports Server (NTRS)

Litteken, Douglas; Lowry, David

2013-01-01

The Structural Engineering Division at the NASA Johnson Space Center (JSC) has begun work on lightweight, multi-functional pressurized composite structures. The first candidate vehicle for technology development is the Multi-Mission Space Exploration Vehicle (MMSEV) cabin, known as the Gen 2B cabin, which has been built at JSC by the Robotics Division. Of the habitable MMSEV vehicle prototypes designed to date, this is the first one specifically analyzed and tested to hold internal pressure and the only one made out of composite materials. This design uses a laminate base with zoned reinforcement and external stringers, intended to demonstrate certain capabilities, and to prepare for the next cabin design, which will be a composite sandwich panel construction with multi-functional capabilities. As part of this advanced development process, a number of new technologies were used to assist in the design and manufacturing process. One of the methods, new to JSC, was to build the Gen 2B cabin with Out of Autoclave technology to permit the creation of larger parts with fewer joints. An 8-ply pre-preg layup was constructed to form the cabin body. Prior to lay-up, a design optimization software called FiberSIM was used to create each ply pattern. This software is integrated with Pro/Engineer to allow for customized draping of each fabric ply over the complex tool surface. Slits and darts are made in the software model to create an optimal design that maintains proper fiber placement and orientation. The flat pattern of each ply is then exported and sent to an automated cutting table where the patterns are cut out of graphite material. Additionally, to assist in lay-up, a laser projection system (LPT) is used to project outlines of each ply directly onto the tool face for accurate fiber placement and ply build-up. Finally, as part of the OoA process, a large oven was procured to post-cure each part. After manufacturing complete, the cabin underwent modal and pressure

40 CFR 79.10 - Application for registration by fuel manufacturer.

Code of Federal Regulations, 2010 CFR

2010-07-01

... in § 79.11. If the manufacturer produces more than one grade or brand of a designated fuel, a manufacturer may include more than one grade or brand in a single application, provided that the application includes all information required for registration of each such grade or brand by this part. Each...

3D model of filler melting with micro-beam plasma arc based on additive manufacturing technology

NASA Astrophysics Data System (ADS)

Chen, Weilin; Yang, Tao; Yang, Ruixin

2017-07-01

Additive manufacturing technology is a systematic process based on discrete-accumulation principle, which is derived by the dimension of parts. Aiming at the dimension mathematical model and slicing problems in additive manufacturing process, the constitutive relations between micro-beam plasma welding parameters and the dimension of part were investigated. The slicing algorithm and slicing were also studied based on the dimension characteristics. By using the direct slicing algorithm according to the geometric characteristics of model, a hollow thin-wall spherical part was fabricated by 3D additive manufacturing technology using micro-beam plasma.

Feasibility and Testing of Additive Manufactured Components

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dehoff, Ryan R.; Hummelt, Ed; Solovyeva, Lyudmila

2016-09-01

This project focused on demonstrating the ability to fabricate two parts with different geometry: an arc flash interrupter and a hydraulic manifold. Eaton Corporation provided ORNL solid models, information related to tolerances and sensitive parameters of the parts and provided testing and evaluation. ORNL successfully manufactured both components, provided cost models of the manufacturing (materials, labor, time and post processing) and delivered test components for Eaton evaluation. The arc flash suppressor was fabricated using the Renishaw laser powder bed technology in CoCrMo while the manifold was produced from Ti-6Al-4V using the Arcam electron beam melting technology. These manufacturing techniques weremore » selected based on the design and geometrical tolerances required. A full-scale manifold was produced on the Arcam A2 system (nearly 12 inches tall). A portion of the manifold was also produced in the Arcam Q10 system. Although a full scale manifold could not be produced in the system, a full scale manifold is expected to have similar material properties, geometric accuracy, and surface finish as could be fabricated on an Arcam Q20 system that is capable of producing four full scale manifolds in a production environment. In addition to the manifold, mechanical test specimens, geometric tolerance artifacts, and microstructure samples were produced alongside the manifold. The development and demonstration of these two key components helped Eaton understand the impact additive manufacturing can have on many of their existing products. By working within the MDF and leveraging ORNL’s manufacturing and characterization capabilities, the work will ensure the rapid insertion and commercialization of this technology.« less

Computed Tomography Inspection and Analysis for Additive Manufacturing Components

NASA Technical Reports Server (NTRS)

Beshears, Ronald D.

2016-01-01

Computed tomography (CT) inspection was performed on test articles additively manufactured from metallic materials. Metallic AM and machined wrought alloy test articles with programmed flaws were inspected using a 2MeV linear accelerator based CT system. Performance of CT inspection on identically configured wrought and AM components and programmed flaws was assessed using standard image analysis techniques to determine the impact of additive manufacturing on inspectability of objects with complex geometries.

Precision reconstruction of manufactured free-form components

NASA Astrophysics Data System (ADS)

Ristic, Mihailo; Brujic, Djordje; Ainsworth, Iain

2000-03-01

Manufacturing needs in many industries, especially the aerospace and the automotive, involve CAD remodeling of manufactured free-form parts using NURBS. This is typically performed as part of 'first article inspection' or 'closing the design loop.' The reconstructed model must satisfy requirements such as accuracy, compatibility with the original CAD model and adherence to various constraints. The paper outlines a methodology for realizing this task. Efficiency and quality of the results are achieved by utilizing the nominal CAD model. It is argued that measurement and remodeling steps are equally important. We explain how the measurement was optimized in terms of accuracy, point distribution and measuring speed using a CMM. Remodeling steps include registration, data segmentation, parameterization and surface fitting. Enforcement of constraints such as continuity was performed as part of the surface fitting process. It was found necessary that the relevant algorithms are able to perform in the presence of measurement noise, while making no special assumptions about regularity of data distribution. In order to deal with real life situations, a number of supporting functions for geometric modeling were required and these are described. The presented methodology was applied using real aeroengine parts and the experimental results are presented.

Investigation into the influence of laser energy input on selective laser melted thin-walled parts by response surface method

NASA Astrophysics Data System (ADS)

Liu, Yang; Zhang, Jian; Pang, Zhicong; Wu, Weihui

2018-04-01

Selective laser melting (SLM) provides a feasible way for manufacturing of complex thin-walled parts directly, however, the energy input during SLM process, namely derived from the laser power, scanning speed, layer thickness and scanning space, etc. has great influence on the thin wall's qualities. The aim of this work is to relate the thin wall's parameters (responses), namely track width, surface roughness and hardness to the process parameters considered in this research (laser power, scanning speed and layer thickness) and to find out the optimal manufacturing conditions. Design of experiment (DoE) was used by implementing composite central design to achieve better manufacturing qualities. Mathematical models derived from the statistical analysis were used to establish the relationships between the process parameters and the responses. Also, the effects of process parameters on each response were determined. Then, a numerical optimization was performed to find out the optimal process set at which the quality features are at their desired values. Based on this study, the relationship between process parameters and SLMed thin-walled structure was revealed and thus, the corresponding optimal process parameters can be used to manufactured thin-walled parts with high quality.

National Center for Manufacturing Sciences: Environmentally conscious manufacturing

NASA Technical Reports Server (NTRS)

Vinton, Clare

1995-01-01

The purpose of this presentation is to share the results and some of the thinking of the Environmentally Conscious Manufacturing - Strategic Initiative Group (ECM-SIG) at the National Center for Manufacturing Sciences (NCMS). NCMS is a consortium of more than 185 North American Manufacturing organizations comprised of about 75 percent for profit manufacturing companies and about 25 percent nonprofit organizations that support manufacturing activities. NCMS conducts collaborative R&D programs designed to improve global competitiveness of its members and other North American manufacturers to address common issues that are important to manufacturing industries. NCMS is an industry driven organization whose agenda is established by industry with input from appropriate government agencies.

Laser-based additive manufacturing: where it has been, where it needs to go

NASA Astrophysics Data System (ADS)

Cooper, Khershed P.

2014-03-01

It is no secret that the laser was the driver for additive manufacturing (AM) of 3D objects since such objects were first demonstrated in the mid-1980s. A myriad of techniques utilizing the directed energy of lasers were invented. Lasers are used to selectively sinter or fuse incremental layers in powder-beds, melt streaming powder following a programmed path, and polymerize photopolymers in a liquid vat layer-by-layer. The laser is an energy source of choice for repair of damaged components, for manufacture of new or replacement parts, and for rapid prototyping of concept designs. Lasers enable microstructure gradients and heterogeneous structures designed to exhibit unique properties and behavior. Laserbased additive manufacturing has been successful in producing relatively simple near net-shape metallic parts saving material and cost, but requiring finish-machining and in repair and refurbishment of worn components. It has been routinely used to produce polymer parts. These capabilities have been widely recognized as evidenced by the explosion in interest in AM technology, nationally. These successes are, however, tempered by challenges facing practitioners such as process and part qualification and verification, which are needed to bring AM as a true manufacturing technology. The ONR manufacturing science program, in collaboration with other agencies, invested in basic R&D in AM since its beginnings. It continues to invest, currently focusing on developing cyber-enabled manufacturing systems for AM. It is believed that such computation, communication and control approaches will help in validating AM and moving it to the factory floor along side CNC machines.

Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets

NASA Astrophysics Data System (ADS)

Li, Ling; Tirado, Angelica; Nlebedim, I. C.; Rios, Orlando; Post, Brian; Kunc, Vlastimil; Lowden, R. R.; Lara-Curzio, Edgar; Fredette, Robert; Ormerod, John; Lograsso, Thomas A.; Paranthaman, M. Parans

2016-10-01

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic properties are: intrinsic coercivity Hci = 688.4 kA/m, remanence Br = 0.51 T, and energy product (BH)max = 43.49 kJ/m3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. The present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.

Big area additive manufacturing of high performance bonded NdFeB magnets

DOE PAGES

Li, Ling; Tirado, Angelica; Nlebedim, I. C.; ...

2016-10-31

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic propertiesmore » are: intrinsic coercivity Hci = 688.4 kA/m, remanence B r = 0.51 T, and energy product (BH) max = 43.49 kJ/m 3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. As a result, the present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.« less

Big area additive manufacturing of high performance bonded NdFeB magnets

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, Ling; Tirado, Angelica; Nlebedim, I. C.

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic propertiesmore » are: intrinsic coercivity Hci = 688.4 kA/m, remanence B r = 0.51 T, and energy product (BH) max = 43.49 kJ/m 3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. As a result, the present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.« less

The role of nanocrystalline binder metallic coating into WC after additive manufacturing

NASA Astrophysics Data System (ADS)

Cavaleiro, A. J.; Fernandes, C. M.; Farinha, A. R.; Gestel, C. V.; Jhabvala, J.; Boillat, E.; Senos, A. M. R.; Vieira, M. T.

2018-01-01

Tungsten carbide with microsized particle powders are commonly used embedded in a tough binder metal. The application of these composites is not limited to cutting tools, WC based material has been increasingly used in gaskets and other mechanical parts with complex geometries. Consequently, additive manufacturing processes as Selective Laser Sintering (SLS) might be the solution to overcome some of the manufacturing problems. However, the use of SLS leads to resolve the problems resulting from difference of physical properties between tungsten carbide and the metallic binder, such as laser absorbance and thermal conductivity. In this work, an original approach of powder surface modification was considered to prepare WC-metal composite powders and overcome these constraints, consisting on the sputter-coating of the WC particle surfaces with a nanocrystalline thin film of metallic binder material (stainless steel). The coating improves the thermal behavior and rheology of the WC particles and, at the same time, ensures a binder homogenous distribution. The feasibility of the SLS technology as manufacturing process for WC powder sputter-coated with 13 wt% stainless steel AISI 304L was explored with different laser power and scanning speed parameters. The SLS layers were characterized regarding elemental distribution, phase composition and morphology, and the results are discussed emphasizing the role of the coating on the consolidation process.

Manufacturing technologies for photovoltaics and possible means of their development in Russia (Review). Part 1: General approach to the development of photoelectric converters and basic silicon technologies

NASA Astrophysics Data System (ADS)

Tarasenko, A. B.; Popel', O. S.

2015-11-01

The state and key tendencies of the development of basic technologies for manufacture of photoelectric converters (PECs) in the world are considered, and their advantages and disadvantages are discussed. The first part of the review gives short information on the development of photovoltaics in the world and planes of the development of solar power plants in Russia. Total power of photoelectric plants operating in various countries in 2015 exceeded 150 GW and increased in the last ten years with a rate of approximately 50% per year. Russia made important state decisions on the support of the development of renewable power engineering and developed mechanisms, which were attractive for business, on the stimulation of building of the network of solar power plants with a total power to 1.5 GW in the country to 2020. At the same time, the rigid demands are made with respect to the localization of the production of components of these plants that opens new abilities for the development of the domestic production of photovoltaics manufacture. Data on the efficiency of PECs of various types that are attained in the leading laboratories of the world are given. Particular emphasis has been placed on the consideration of basic silicon technologies of PEC manufacture, which had the widest commercial application. The basic methods for production of polycrystalline silicon and making single-crystal and multicrystal silicon are described. Fundamentals of making techniques for plates, PECs, and photoelectric modules based on single-crystal and polycrystalline silicon are considered. The second part will be devoted to modifications of manufacturing techniques for photoelectric converters, enhancement methods for contact structures, and recommendations of authors with respect to the choice of prospective technologies for the expansion of PEC production in Russia. It will involve formulations and substantiations of the most promising lines of the development of photoelectric

Additive manufacturing of tunable lenses

NASA Astrophysics Data System (ADS)

Schlichting, Katja; Novak, Tobias; Heinrich, Andreas

2017-02-01

Individual additive manufacturing of optical systems based on 3D Printing offers varied possibilities in design and usage. In addition to the additive manufacturing procedure, the usage of tunable lenses allows further advantages for intelligent optical systems. Our goal is to bring the advantages of additive manufacturing together with the huge potential of tunable lenses. We produced tunable lenses as a bundle without any further processing steps, like polishing. The lenses were designed and directly printed with a 3D Printer as a package. The design contains the membrane as an optical part as well as the mechanical parts of the lens, like the attachments for the sleeves which contain the oil. The dynamic optical lenses were filled with an oil. The focal length of the lenses changes due to a change of the radius of curvature. This change is caused by changing the pressure in the inside of the lens. In addition to that, we designed lenses with special structures to obtain different areas with an individual optical power. We want to discuss the huge potential of this technology for several applications. Further, an appropriate controlling system is needed. Wéll show the possibilities to control and regulate the optical power of the lenses. The lenses could be used for illumination tasks, and in the future, for individual measurement tasks. The main advantage is the individuality and the possibility to create an individual design which completely fulfills the requirements for any specific application.

Airborne Wind Shear Detection and Warning Systems. Fourth Combined Manufacturers' and Technologists' Conference, part 2

NASA Technical Reports Server (NTRS)

Vicroy, Dan D. (Compiler); Bowles, Roland L. (Compiler); Passman, Robert H. (Compiler)

1992-01-01

The Fourth Combined Manufacturers' and Technologists' Conference was hosted jointly by NASA Langley Research Center (LaRC) and the Federal Aviation Administration (FAA) in Williamsburg, Virginia, on April 14-16, 1992. The meeting was co-chaired by Dr. Roland Bowles of LaRC and Bob Passman of the FAA. The purpose of the meeting was to transfer significant ongoing results of the NASA/FAA Joint Airborne Wind Shear Program to the technical industry and to pose problems of current concern to the combined group. It also provided a forum for manufacturers to review forward-look technology concepts and for technologists to gain an understanding of the problems encountered by the manufacturers during the development of airborne equipment and the FAA certification requirements. The present document has been compiled to record the essence of the technology updates and discussions which follow each.

Energy absorption capabilities of complex thin walled structures

NASA Astrophysics Data System (ADS)

Tarlochan, F.; AlKhatib, Sami

2017-10-01

Thin walled structures have been used in the area of energy absorption during an event of a crash. A lot of work has been done on tubular structures. Due to limitation of manufacturing process, complex geometries were dismissed as potential solutions. With the advancement in metal additive manufacturing, complex geometries can be realized. As a motivation, the objective of this study is to investigate computationally the crash performance of complex tubular structures. Five designs were considered. In was found that complex geometries have better crashworthiness performance than standard tubular structures used currently.

Electronic Design Automation: Integrating the Design and Manufacturing Functions

NASA Technical Reports Server (NTRS)

Bachnak, Rafic; Salkowski, Charles

1997-01-01

As the complexity of electronic systems grows, the traditional design practice, a sequential process, is replaced by concurrent design methodologies. A major advantage of concurrent design is that the feedback from software and manufacturing engineers can be easily incorporated into the design. The implementation of concurrent engineering methodologies is greatly facilitated by employing the latest Electronic Design Automation (EDA) tools. These tools offer integrated simulation of the electrical, mechanical, and manufacturing functions and support virtual prototyping, rapid prototyping, and hardware-software co-design. This report presents recommendations for enhancing the electronic design and manufacturing capabilities and procedures at JSC based on a concurrent design methodology that employs EDA tools.

Safety Discrete Event Models for Holonic Cyclic Manufacturing Systems

NASA Astrophysics Data System (ADS)

Ciufudean, Calin; Filote, Constantin

In this paper the expression “holonic cyclic manufacturing systems” refers to complex assembly/disassembly systems or fork/join systems, kanban systems, and in general, to any discrete event system that transforms raw material and/or components into products. Such a system is said to be cyclic if it provides the same sequence of products indefinitely. This paper considers the scheduling of holonic cyclic manufacturing systems and describes a new approach using Petri nets formalism. We propose an approach to frame the optimum schedule of holonic cyclic manufacturing systems in order to maximize the throughput while minimize the work in process. We also propose an algorithm to verify the optimum schedule.