<p>Additive manufacturing (AM) can be an advantageous substitute to various traditional manufacturing techniques. Due to the ability to rapidly create products, AM has been traditionally used to prototype more efficiently. As the industry has progressed, however, use cases have gone beyond prototyping into production of complex parts with unique geometries. Amongst the most popular of AM processes is fused deposition modeling (FDM). FDM fabricates products through an extrusion technique where plastic filament is heated to the glass transition temperature and extruded layer by layer onto a build platform to construct the desired part. The purpose of this research is to elaborate on the potential of this technology, while considering environmental impact as it becomes more widespread throughout industry, research, and academia.</p> <p>Although AM consumes resources more conservatively than traditional methodologies, it is not free from having environmental impacts. Several studies have shown that additive manufacturing can affect human and environmental health by emitting particles of a dynamic size range into the surrounding environment during a print. To begin this study, chapters investigate emission profiles and characterization of emissions from FDM 3D printers with the intention of developing a better understanding of the impact from such devices. Background work is done to confirm the occurrence of particle emission from FDM using acrylonitrile butadiene styrene (ABS) plastic filament. An aluminum bodied 3D printer is enclosed in a chamber and placed in a Class 1 cleanroom where measurements are conducted using high temporal resolution electrical low-pressure impactor (ELPI), scanning mobility particle sizer (SMPS), and optical particle sizer (OPS), which combined measure particles of a size range 6-500nm. Tests were done using the NIST standard test part and a honeycomb infill cube. Results from this study show that particle emissions are closely related to filament residence time in the extruder while less related to extruding speed. An initial spike of particle concentration is observed immediately after printing, which is likely a result of the long time required to heat the extruder and bed to the desired temperature. Upon conclusion of this study, it is theorized that particles may be formed through vapor condensation and coagulation after being released into the surrounding environment.</p> <p>With confirmation of FDM ultrafine particle emission at notable concentrations, an effort was consequently placed on diagnosing the primary cause of emission and energy consumption based on developed hypotheses. Experimental data suggests that particle emission is mainly the result of condensing and agglomerating semi-volatile organic compounds. The initial emission spike occurs when there is dripping of semi-liquid filament from the heated nozzle and/or residue left in the nozzle between prints; this supports the previously stated hypothesis regarding residence time. However, the study shows that while printing speed and material flow influence particle emission rate, the effects from these factors are relatively insignificant. Power profile analysis indicates that print bed heating and component temperature maintaining are the leading contributors to energy consumption for FDM printers, making time the primary variable driving energy input.</p> <p>To better understand the severity of FDM emissions, further investigation is necessary to diligence the makeup of the process output flows. By collecting exhaust discharge from a Makerbot Replicator 2x printing ABS filament and diffusing it through a type 1 water solution, we are able to investigate the chemical makeup of these compounds. Additional exploration is done by performing a filament wash to investigate emissions that may already be present before extrusion. Using solid phase micro-extraction, contaminants are studied using gas chromatography mass spectrometry (GCMS) thermal desorption. Characterization of the collected emission offers more comprehensive knowledge of the environmental and human health impacts of this AM process.</p> <p>Classification of the environmental performance of various manufacturing technologies can be achieved by analyzing their input and output material, as well as energy flows. The unit process life cycle inventory (UPLCI) is a proficient approach to developing reusable models capable of calculating these flows. The UPLCI models can be connected to estimate the total material and energy consumption of, and emissions from, product manufacturing based on a process plan. The final chapter focuses on using the knowledge gained from this work in developing UPLCI model methodology for FDM, and applying it further to the second most widely used AM process: stereolithography (SLA). The model created for the FDM study considers material input/output flows from ABS plastic filament. Energy input/output flows come from the running printer, step motors, heated build plate, and heated extruder. SLA also fabricates parts layer by layer, but by the use of a photosensitive liquid resin which solidifies when cured under the exposure of ultraviolet light. Model material input/output flows are sourced from the photosensitive liquid resin, while energy input/output flows are generated from (i) the projector used as the ultraviolet light source and (ii) the step motors. As shown in this work, energy flow is mostly time dependent; material flows, on the other hand, rely more on the nature of the fabrication process. While a focus on FDM is asserted throughout this study, the developed UPLCI models show how conclusions drawn from this work can be applied to different forms of AM processes in future work.</p>

No description available.

<p> Laser powder bed fusion (LPBF) is a rapidly emerging manufacturing technology capable of producing complex part geometries through the repeated, precise laser melting of metallic powder layers. At present, the process is primarily employed in high-value-added applications which exist in the aerospace, biomedical, and dental industries. As industrial implementation of LPBF has matured, research has focused on established materials for which there are already large bodies of literature and regulatory approval, such as Inconel 718, Inconel 625, Ti-6Al-4V, and 316 stainless steel. However, the rapid solidification process inherent to LPBF leads to vastly different microstructures with improved strength compared to these traditional materials in cast or wrought forms. In general, the high solidification velocity and thermal gradients result in cellular and dendritic solidification structures with finer grain and precipitate sizes than conventionally processed alloys. These microstructure changes warrant the exploration of new alloy systems and reevaluation of historically cast compositions with optimized microstructures, especially considering the tunability of a digitally controlled fabrication process. This work examines laser powder bed fusion of Mar-M 509, a carbide-strengthened cobalt alloy that is typically investment cast directly into complex-shaped components such as nozzle guide vanes (NGVs). NGVs are stationary components in gas turbine engines for propulsion and energy production which require strength under moderate mechanical loading at high temperatures. Investment cast microstructures have porosity defects in slower-cooled regions due to lack of liquid feed to interdendritic regions. As-printed, the cellular and dendritic Mar-M 509 LPBF microstructures lead to the formation of continuous, fiber-like, eutectic carbide structures in the intercellular and interdendritic regions, which limit macroscopic ductility. Thermo-Calc is used for calculation of phase diagrams (CALPHAD) to estimate the equilibrium transformation temperatures of MC, M23C6, and M7C3-type carbides, which informs design of isothermal heat treatments to engineer microstructures with enhanced ductility over the as-printed or cast versions of Mar-M 509 while maintaining tensile strength. Scanning and transmission electron microscopy reveals the composition and distribution of carbide phases as a function of heat treatment temperature. Lastly, heat treatment recommendations for nozzle guide vanes are made.  </p>

Additive Manufacturing (AM) is a technology that enables to print three dimensional solid objects which can be metal, plastic, and similar. AM has a lot of advantages such as lead time reduction and reduction in the number of steps required for manufacturing compared to the traditional manufacturing (TM) method.    This research is focused on adoption of AM in the food manufacturing industry. The use of AM in the food industry currently seems to be low. Therefore, the main aim of the research is to understand adoption of AM through marketing, sales, and after-sales strategies, which can be best suited for introduction and saturation of AM products and applications in the food industry.  The primary data is gathered from the potential customers (experts from the food industry), sales personnel who sell products and machinery in the food industry and the employees of the sponsor company, and it consists of thirteen different interviews. Qualitative interviews were conducted to obtain an in-depth knowledge about the perceptions and perspectives of AM in the food industry. AM has the potential to be adopted as the main manufacturing method for spare parts in the food industry. But, considering the market today, the potential of adoption seems to be wasted. Three different analyses help in determining the current situation of the AM industry and help to understand the potential that AM brings to the food industry. Outcomes of the qualitative interviews present the researchers with in-depth knowledge of facilitators and barriers that AM companies may face when approaching customers from the food industry. Outcomes of the qualitative interviews also suggest that there is limited knowledge about AM in the food industry. There is also a knowledge gap about the regulations and possibilities to use AM in the food industry based on these regulations. Indeed, food manufacturers are interested in the adoption of newer technologies and present the researchers with the formation of various themes to develop strategies for adoption of AM, through a recommendable marketing, sales and aftersales strategy that can be employed by AM companies.

Additive Manufacturing (AM), commonly known as 3D printing, represents manufacturing technology that creates objects layer by layer based on 3D model data. AM technologies have capabilities that provide engineers with new design opportunities outside the constraints of traditional subtractive manufacturing. These capabilities of AM have made it attractive for manufacturing components in the space industry., where parts are often bespoke and complex. In particular, Laser Powder Bed Fusion (LPBF) has attracted attention due to its ability to produce components with the part properties required for space applications. Additionally, the precision of the laser enables the production of innovative near-net shape and low-weight part designs.  However, due to the powdered metal material, the LPBF process is categorised with rough surfaces in the as-built state. The extent and effect of surface roughness are closely linked to geometrical design variables, including build orientation, overhangs, support structure, and build parameters; hence the more intricate the design, the more difficult the removal of this roughness. Consequently, the as-built surface for most applications is too rough and could adversely affect proprieties, i.e., fatigue. Hence, practical Design for AM (DfAM) supports should be developed that understand how design factors, such as surface roughness, will impact a part’s performance. This thesis therefore presents literature reviews on research related to LPBF surface roughness and design support, exploring the trends in managing surface roughness and investigations on the characteristics of design support. Additionally, through a space industry case study, a proposed process involving additive manufacturing design artefacts (AMDAs) is considered to investigate and describe the relationship between design, surface roughness, and performance. The review found that, in general, research focuses on the relationship between surface roughness and LPBF build parameters, material properties, or post-processing. There is very little support for design engineers to consider how surface roughness from an AM process affects the final product (less than 1% of the review articles). In investigating surface roughness, the AMDA process identified characteristics that impact roughness levels and geometric adherence to part design. Additionally, twelve characteristics of design support were identified and considered to review the AMDA process. The process aided the evaluation of design uncertainties and provided indications of part performance. However, iterations of the process can be required to clarify product-specific design uncertainties. Though, the designer obtains a better understanding of their design and the AM process with each iteration. The inclusion of the requirement to set evaluation criteria for artefacts was recommended to develop the AMDA process as design support.

<p>  </p> <p>This thesis is motivated by the author’s observation that no systematic methodology is available to characterize and model mechanical behaviors of 3D printed parts in terms of their elastic modulus and critical loading capacities. Note that the more controlled and steadier printing process is, the easier the mechanical properties parts can be predicted. This research focuses on the methods for the prediction and validation of mechanical properties of 3D printed parts, and the focus is the responses of the printed parts subjected to tensile loads. The mathematic models are derived to characterize the mechanical properties of a part along three principal directions, and the models are validated experimentally by following the American Society for Testing and Materials (ASTM) D638 testing standards. It is assumed that a unidirectional plane stress occurs to each lamina to (1) simplify a compliance matrix with a size 3 by 3 and (2) characterize the mechanical properties by the elastic modules and strengths in three principal directions. Two mathematical models are developed using the experimental data from the classical laminate theory and finite element analysis (FEA) by the SolidWorks. Both of the developed models are used to predict the ultimate tensile strength and Young’s modulus of the specimens that are printed by setting different raster angles on different layers. This thesis work aims to (1) gain a better understanding of the impact of printing parameters on the strengths of printed parts and (2) explore the feasibility of using the classical laminate theory to predict the mechanical properties of the parts printed with different raster angles and patterns. To validate the proposed mathematic models, parts by FDM are tested by following the ASTM testing standards; moreover, it testifies if the selected ASTM-D638 is suitable to test 3D printed parts by FDM. </p>

This thesis investigates the differences in the design process when developing a product for additive manufacturing (AM) compared to traditional manufacturing methods, such as CNC machining. In recent years, additive manufacturing (AM), including metal-based laser powder bed fusion (L-PBF), has gained popularity, leading to increased adoption by companies. The design process for AM, particularly in the context of metals, differs compared to for traditional manufacturing methods. L-PBF, being a method based on highly concentrated laser beam fusion, offers a higher level of design freedom, enabling the creation of intricate shapes, internal structures, and varying wall thicknesses. In contrast, traditional manufacturing methods based on subtractive processes impose limitations on design possibilities due to tooling and machining constraints. Adapting to L-PBF requires designers to reconsider, re-think and redesign parts specifically for AM, taking into account factors suchas cost, knowledge requirements and build volume limitations. The application of L-PBF extends to various industries, including aerospace and performance automobiles. Designing for L-PBF opens up new possibilities for product development by leveraging the advantages of AM, such as design flexibility and topology optimization. Topology optimization allows for the creation of lightweight components while maintaining structural integrity. However, transitioning from traditional manufacturing to L-PBF presents challenges, requiring designers to navigate the unique considerations and constraints associated with AM. This research aims to enhance the understanding of the design process for AM, with a specific focus on L-PBF, and its implications for product development. By exploring the differences between AM and traditional manufacturing methods, this study contributes to the broader adoption and effective implementation of AM technologies in various manufacturing sectors. / Detta arbete undersöker skillnaderna i designprocessen vid utveckling av produkter för additive manufacturing (AM) jämfört med traditionella tillverkningsmetoder, såsom CNC bearbetning. På senare år har additiv tillverkning (AM), inklusive Laser Powder Bed Fusion (L-PBF), blivit populärt och allt fler företag använder sig av tekniken. Designprocessen för AM, skiljer sig jämnfört med för traditionella tillverkningsmetoder. L-PBF erbjuder en hög grad av designfrihet och möjliggör avancerade former, interna strukturer och varierande väggtjocklekar. I kontrast begränsar traditionella tillverkningsmetoder, som bygger på subtraktiva processer, designmöjligheterna på grund av verktygs- och bearbetningsbegränsningar. Att anpassa sig till L-PBF kräver att designers omprövar och omdesignar delar specifikt för AM och tar hänsyn till faktorer som kostnad, kunskapskrav och begränsningar i byggvolymen. Användningen av L-PBF sträcker sig till olika branscher, inklusive luft- och rymdindustrin samt prestandabilar. Att designa för L-PBF öppnar upp nya möjligheter för produktutveckling genom att utnyttja fördelarna med AM, såsom designflexibilitet och topologioptimering. Topologioptimering möjliggör skapandet av lätta komponenter samtidigt som den strukturella integriteten bibehålls. Övergången från traditionell tillverkning till L-PBF innebär dock utmaningar och kräver att designers hanterar de unika övervägandena och begränsningarna som är förknippade med AM. Denna forskning syftar till att förbättra förståelsen för designprocessen för AM, med särskilt fokus på L-PBF, och dess implikationer för produktutveckling. Genom att utforska skillnaderna mellan AM och traditionella tillverkningsmetoder bidrar denna studie till en bredare användning och effektiv implementering av AM-teknologier inom olika tillverkningssektorer.

<p>    An all-additive manufacturing technique was developed to print piezoelectrically active polymeric materials, primarily poly(vinylidene fluoride) (PVdF), for use in pressure sensors in soft robotics. The research proceeded in three stages. The initial stage used Fused Deposition Modeling (FDM) and electric poling independently to create piezoelectric PVdF pressure sensors. The second stage merged FDM and electric poling processes. The third stage introduced electrospinning to create flexible, high-output piezoelectric PVdF materials, which were combined with three-dimensional (3D) printed soft structures for stretchable pressure sensors.</p> <p>    The main achievement of the research was the development of the Electric Poling-assisted Additive Manufacturing (EPAM) technique, combining electric poling and FDM 3D printing to print piezoelectric materials with custom structures at lower costs. β-phase in semicrystalline PVdF materials is mainly responsible for piezoelectricity. A higher β-phase content results in superior sensor performance. This technique was evaluated by measuring the piezoelectric output voltage of the printed PVdF films, and β-phase content was quantified using Fourier-transform Infrared spectroscopy (FTIR). The developed EPAM technique was combined with Direct Ink Writing (DIW), becoming a hybrid 3D printing technique. This is the first demonstration of applying a hybrid printing technique to print piezoelectric PVdF-based sensors directly. The sensor was constructed using FDM printed PVdF film as the dielectric sandwiched between two parallel DIW printed silver electrodes. The PVdF sensors have both piezoelectric pressure sensing and capacitive temperature sensing functionalities. The application of the capacitive temperature sensor was demonstrated by applying heating-and-cooling cycles while measuring the capacitance as a function of temperature at a constant frequency, showing improved sensitivities at higher frequencies (i.e., 105 Hz) after dielectric polarization.</p> <p>    The third stage of research was motivated by the need for soft piezoelectric pressure sensors for soft robotics. Challenges were twofold: requiring soft piezoelectric materials with high coefficients for excellent sensors and fabrication techniques to incorporate soft materials into designed structures. Inspired by the EPAM technique, a method combining electrospinning and DIW was used to create soft piezoelectric PVdF/thermal plastic polyurethane (TPU) blend microfiber-based pressure sensors. The soft sensor was integrated with an FDM printed soft structure for a stretchable pressure sensor with both piezoelectric sensing and capacitive sensing mechanisms.</p>

Increasing application of Additive Manufacturing (AM) in industrial production demands product reimagination (assemblies, subsystems) from an AM standpoint. Simulation driven design tools play an important part in achieving this with design optimization subject to the capabilities of AM technologies. Therefore, the bus frames department (RBRF) in Scania CV AB, Södertälje wanted to examine the synergies between topology optimization and Design for AM (DfAM) in the context of this thesis. In this thesis, a methodology is developed to establish a DfAM framework involving topology optimization and is accompanied by a manufacturability analysis stage. A case study implementation of this developed methodology is performed for validation and further development. The case study replaces an existing load bearing cross member with a new structure optimized with respect to weight and manufacturing process. It resulted in a nearly self supporting AM friendly design with improved stiffness along with a 9.5% weight reduction, thereby proving the benefit of incorporating topology optimization and AM design fundamentals during the early design phase. / Ökad användning av Additive Manufacturing (AM) i industriell produktion kräver ett nytänkade av produkter (enheter, delsystem) ur AM-synvinkel. Simuleringsdrivna designverktyg spelar en viktig roll för att nå detta med designoptimering med hänsyn taget till AM-teknikens möjligheter. Därför ville bussramavdelningen (RBRF) på Scania CV AB, Södertälje undersöka synergierna mellan topologioptimering och Design för AM (DfAM) i detta examensarbete. I examensarbetet utvecklas en metodik för att skapa en DfAM-ramverk som involverar topologioptimering och åtföljs av ett tillverkningsanalyssteg. En fallstudieimplementering av denna utvecklade metodik utförs för validering och fortsatt utveckling. Fallstudien ersätter en befintlig lastbärande tvärbalk med en ny struktur optimerad med avseende på vikt och tillverkningsprocess. Det resulterade i en nästan självbärande AM-vänlig design med förbättrad styvhet tillsammans med en viktminskning på 9,5 %, vilket visar fördelen med att integrera topologioptimering och grundläggande AM-design tidigt i designfasen.

<p dir="ltr">The goal of this work is to enhance acceptance of cultured meat by replicating traditional meat behavior. This research focuses on the design, manufacture, and mechanics of scaffolds, which provide essential structural support for cell alignment and tissue formation in cultured meat. The integration of biopolymer scaffolds in the final product necessitates a thorough understanding of the thermo-mechanical behavior of scaffolding materials during critical stages like culturing and cooking. Two primary studies were conducted using additive manufacturing processes: (1) vat polymerization and (2) fused filament fabrication. A novel sustainable photocurable soy-based resin was evaluated for high-temperature degradation. The key challenge was ensuring printability and understanding the curing kinetics of the soy resin. For fused filament fabrication, the approach employed an innovative manufacturing-for-design paradigm aimed at mimicking the contraction properties of meat during cooking. The geometry, material properties, and printing process gave rise to a class of novel metamaterials with tunable negative thermal expansions. The key results showed that the thermo-mechanical behavior of soy-based scaffolds could be assessed without the need for costly and time-consuming culturing, as heat did not compromise structural integrity. Furthermore, cooking semi-crystalline biopolymers in an aqueous environment led to material crystallization, which altered the expected deformation mechanisms in the scaffolds. This unexpected behavior was captured in an analytical model accounting for non-linear material properties and print process parameters. By understanding the impact of manufacturing techniques on scaffold behavior, this work established a critical process-property-performance relationship for cultured meat production.</p>