L’acide polylactique (PLA) est l’un des polymères biosourcés qui suscite le plus d’intérêt, mais ses propriétés thermomécaniques nécessitent d’être améliorées. Pour ce faire, les méthodes les plus utilisées et étudiées sont de le mélanger avec d’autres polymères ou bien d’y ajouter des charges minérales nanométriques (nanoparticules), afin de constituer un nanocomposite à matrice PLA. C’est dans la combinaison de ces deux approches que s’inscrivent ces travaux de thèse, consacrés à l’élaboration et à la caractérisation des propriétés de nanocomposites à base d’un alliage de PLA et de polyamide 11 (PA11) 80/20 m/m. L’objectif de cette thèse est l’obtention d’un matériau biosourcé aux propriétés thermiques, mécaniques et de réaction au feu améliorées par le contrôle de sa morphologie et l’ajout de nanoparticules et de retardateurs de flamme (RF). Pour y parvenir, deux techniques de compatibilisation, destinées à améliorer l’adhésion interfaciale entre le PLA et le PA11, ont été évaluées. La première consistait à incorporer des nanoparticules de silice. Il a été noté d’importantes modifications de la morphologie et des propriétés rhéologiques du mélange d’étude, selon leur localisation dans le mélange étudié fonction de la nature chimique de la surface de la silice. La deuxième consistait à introduire un copolymère époxyde multifonctionnel réactif, dénommé Joncryl. La réactivité de ce copolymère avec le PLA et le PA11 a permis de compatibiliser le mélange d’étude, conduisant à une morphologie plus fine et à l’obtention de propriétés mécaniques supérieures à celles du mélange d’étude, en particulier avec l’ajout de 3%m de Joncryl. Des échantillons basés sur les mélanges compatibilisés par cette méthode ont été préparés par le procédé de fabrication additive FDM. Une étude de l’impact de ce procédé sur la morphologie et les propriétés mécaniques obtenues a été entreprise. Enfin, une meilleure réaction au feu pour le mélange compatibilisé avec 3%m de Joncryl a pu être obtenue par l’ajout combiné de nanoparticules de phyllosilicates et de RF. / Polylactic acid (PLA) is one of the biobased polymers that generates the most interest, but its thermomechanical properties need to be improved. To do that, the most used and studied methods consist of blending PLA with other polymers or adding nanoscaled mineral fillers (nanoparticles) to get a PLA based nanocomposite. This PhD work is dedicated to the elaboration and properties characterization of nanocomposites based on a filled PLA and polyamide 11 80/20 wt/wt blend. The aim is to obtain a biobased material with improved thermal, mechanical and fire reaction properties by controlling its morphology through the addition of nanoparticles and flame retardants additives.To achieve that, two compatibilization techniques, aiming to improve PLA-PA11 interfacial adhesion, were evaluated. The first one consisted of adding silica nanoparticles. Important changes of the blend morphology and rheological properties were noticed, depending on the localization of the two different silica nanoparticles used into the polymer blend phases. The second one consisted of introducing a reactive multifunctional epoxy copolymer, named Joncryl. The reactivity of this copolymer with PLA and PA11 allowed to compatibilize the blend, leading to a fine morphology and higher mechanical properties compared to those of the pristine blend. Samples of compatibilized blends obtained through this method were processed using FDM additive manufacturing process. A study of the influence of this process on the morphology and mechanical properties obtained for these samples was performed. Finally, a better fire reaction of compatibilized polymer blend with 3%wt Joncryl was obtained by the combined addition of phyllosilicates nanoparticles and flame retardants.

L'Organisation des Nations Unies vise à moderniser les industries afin de les rendre durables et plus respectueuse de l'environnement d'ici 2030. Afin de répondre à ces attentes, il faut mettre en place des voies d'améliorations des procédés de fabrication d'un point de vue environnemental. Cette démarche nécessite une connaissance fine des flux entrants et sortants lors de la fabrication d'un produit. Néanmoins, ce n'est pas le cas pour les procédés de fabrication additives ou les impacts environnementaux générés lors de la fabrication d'un produit sont encore méconnus. Par conséquent, il est primordial de bien "compter" les différentes sources de consommations et de rejets. Pour cela, une évaluation quantitative des flux intervenants pendant la fabrication de pièces est nécessaire pour améliorer la connaissance de la performance environnementale d'un procédé. Les travaux de cette thèse portent sur la proposition d'une méthodologie d'évaluation multicritère pour les procédés de fabrication additive afin de pouvoir prédire, dès l'étape de conception d'un produit, des informations sur les aspects techniques, économiques et environnementaux du couple pièce/procédé. Afin de proposer aux concepteurs la possibilité d'évaluer un produit dès son étape de conception, des modèles de consommation fins traduisant le comportement du procédé ont été mis en place. La méthodologie développée s’intéresse à l'ensemble des sources de consommation et de rejets ainsi qu'à l'ensemble des étapes nécessaires à la fabrication d'une pièce mécanique.Ce manuscrit est divisé en six chapitres qui permettent de présenter le contexte général de l'étude, l'état de l'art, la méthodologie d'évaluation multicritère, l'application sur les procédés de fabrication additive et l'exploitation sur un cas industriel. Le dernier chapitre se consacre à la conclusion sur les apports de ces travaux et propose des perspectives de recherche. / The United Nations aims to modernize industries in order to make them sustainable and more environmentally friendly by 2030. In order to meet these expectation, it is necessary to put in place ways of improving production processes from an environmental point of view. This approach requires a detailed knowledge of the incoming and outgoing flows during the manufacturing of a product. However, this is not the case for additive manufacturing processes where the environmental impacts generated during this stage are still unknown. For that, a quantitative evaluation of the flows involved during the manufaturing of parts is necessary in order to improve the knowledge of the environmental performance of a process. The work of this thesis focuses on the development of methodology for additive manufacturing processes in order to predict information on the technical, economic, and environmental aspects of a product during the design stage of a part. The methodology developped is increasingly interested in all the sources of consumption as well as all the stages necessary for the manufacturing of a mechanical part.This manuscript is divided into six chapters that can present the general context of the study, the state of the art, the methodology developped, a application of the methodology to additive manufacturing processes and the computer tool developed during this thesis. The last chapter is devoted to the conclusion on the contributions of this work and provides research perspectives.

No description available.

Les technologies de fabrication additive(FA) basées sur la technique de fusion laser sur lit de poudres, telles que les procédés de fusion sélective laser (Selective Laser Melting ‘SLM’) et de fusion par faisceau d'électrons (Electron Beam Melting ‘EBM’), ne cessent de se développer afin de produire des pièces fonctionnelles principalement dans les domaines aérospatial et médical. Le procédé de fabrication additive offre de nombreux avantages, tels que la liberté de conception, la réduction des étapes de fabrication, la réduction de la matière utilisée, et la réduction de l'empreinte carbone lors de la fabrication d'un composant. Néanmoins, les pièces obtenues nécessitent une opération d’usinage de finition afin de satisfaire les tolérances dimensionnelles et l’état de surface. / Additive Manufacturing (AM) techniques based on powder bed fusion like Selective Laser Melting(SLM) and Electron Beam Melting processes(EBM) are being developed to make fully functional parts mainly in aerospace and medical sectors. There are several advantages of using AM processes like design freedom, reduced process steps, minimal material usage and reduced carbon footprint while producing a component. Nevertheless, the parts are built with near net shape and then finish machined to meet the demands of surface quality and dimensional tolerance.

The purpose of this thesis is to investigate how to decrease lead-times of conventionally manufactured prototypes of tools and fixtures. Which could lead to increased knowledge of how an operations site within the automotive industry could utilize additive manufacturing when producing company specific prototypes of tools and fixtures.  The research approach applied in this case study combines a literature review to systematically find relevant literature aligned with the research topic of additive manufacturing or 3D printing related to lead-time reduction and generative design terms. With the help of interviews and observations profound knowledge was gained as preparation before continuing the research. Thereafter, a pre-study was conducted in order to further enhance the understanding of the industrial context of the two chosen fixtures (study objects). Rapid prototyping activities with additive manufacturing processes and technologies of experimentation character was conducted iteratively with both 3D CAD and 3D printing software and hardware. Analysis of the data was conducted through a comparison between lead-times of conventionally manufactured and 3D printed prototypes of the two chosen fixtures. Moreover, identifying potential effects with additive manufacturing of prototypes have with a SWOT analysis.  The case study found that additive manufacturing could significantly decrease lead-times when producing prototypes compared to conventional manufacturing. Furthermore, the results showed that the effects of additive manufacturing are plenty and rather complex due to the fact of this new way to manufacture prototypes. Therefore, the term design for additive manufacturing need first class priority if next steps were to be taken in the additive manufacturing field to enhance industrial and academic benefits.  The research on this subject is strongly constrained by the scarcity of empirical experience and, consequently, by the scarcity of available empirical data. Research publication on the topic are fruitful and plenty but their findings specified to their chosen study objects. This case study gives an up-to-date contribution to the topic of additive manufacturing with endless possibilities to reduce lead-time with rapid prototyping activities that utilizes additive manufacturing. Moreover, the research approach used in this thesis combines 3D CAD data through theoretical concepts and physical objects with additive manufacturing practice. Overall, the results can be used to improve academic research in the topic and promote discussion among different actors entering or within the additive manufacturing field.

Manufatura aditiva é um processo de fabricação de objetos que tem chamado a atenção de acadêmicos, empresas e órgãos de governo. Alguns setores específicos possuem demandas que podem ser mais bem atendidas com a utilização da manufatura aditiva na produção de peças de alto valor agregado. O problema prático que motiva a realização deste trabalho é a dificuldade enfrentada pelas empresas em avaliar as tecnologias de manufatura aditiva existentes para decisão de adoção ou não adoção delas em seus fluxos produtivos. A análise da situação atual na literatura indica que falta um modelo de processo específico de avaliação para adoção da manufatura aditiva na indústria de alto valor agregado. Visando preencher essa lacuna e propor uma solução para o problema identificado, este trabalho tem como objetivo a definição de um modelo de processo específico de avaliação para adoção de manufatura aditiva na indústria de alto valor agregado. Tal modelo é desenvolvido a partir de modelos de processo existentes para avaliar a adoção de outras tecnologias de manufatura avançada (Advanced Manufaturing Technologies - AMTs) e do levantamento das características específicas da manufatura aditiva. O modelo de processo de avaliação para adoção da manufatura aditiva na indústria de alto valor agregado proposto contempla nove passos para decidir sobre a adoção ou a não adoção da manufatura aditiva. A aplicabilidade do modelo proposto foi avaliada por meio de entrevistas com especialistas. A avaliação dos resultados indica que os passos e as atividades propostos no modelo contribuem para auxiliar na avaliação para adoção da manufatura aditiva na indústria de alto valor agregado. / Additive manufacturing is a manufacturing process that has gained attention of scholars, companies and government bodies. Some specific sectors have demands that can be better met with the use of additive manufacturing to produce high added value parts. The practical problem that motivates this work is the difficulty met by companies in assessing additive manufacturing technologies for decision to adopt or not adopt them in their production flows. The analysis of the current situation in the literature indicates a gap of a specific process model to evaluate the adoption of additive manufacturing in the high added value industry. To fill this gap and to propose a solution for the identified problem, this work has the goal to define a specific process model to evaluate the adoption of additive manufacturing in the high added value industry. This model is developed based on existing process models to evaluate the adoption of other Advanced Manufacturing Technologies and the study of specific characteristics of additive manufacturing. The model proposed contemplates nine steps to decide on the adoption or not adoption of additive manufacturing. The applicability of the proposed model was evaluated through interviews with experts. The evaluation of the results indicates that the steps and the activities proposed in the model contribute to assist in the evaluation of the adoption of additive manufacturing in high added value industry.

Additive manufacturing (AM) for metals is a manufacturing process that has increased a lot in popularity last few years as it has experienced significant improvements since its beginning, both when it comes to accuracy and deposition rates. There are many different AM processes where the energy sources and deposition methods varies. But the common denominator is their layer wise manufacturing process, melting layer on layer. AM has a great design freedom compared to conventional manufacturing, making it possible to design new structures with decreased weight and increased performance.  A drawback is slow manufacturing speeds, making it more expensive. But when it comes to low lot sizes and complex structures AM is very competitive. So, for the aerospace and space industry AM is a good option as manufacturing cost is less of an issue and where saving weight is of great concern, both environmentally and economically.  There are however many topics left to research before additive manufactured titanium can be widely adopted for critical components, such as microstructure and texture development and its correlation to mechanical properties. The aim of this work has been to investigate the microstructure and texture of various AM processes. Microstructural features such as prior β grains, grain boundary α (GB-α), α laths, α colonies have been characterized along with hardness measurements for 5 different AM processes. Some of these AM processes have also been investigated in the SKAT instrument in Dubna, Russia, to obtain their texture. These textures have then been compared with one another and correlated to previous microstructural investigations and mechanical properties. This is important knowledge as the microstructure and the texture sets the basis for the mechanical properties. In case there is a high texture, the material can have anisotropic mechanical behavior, which could be either wanted or unwanted for different applications.   Some the findings are that α phase was found to increase in the prior β grain boundary for the AM processes with low cooling rates, while it was discontinuous and even non-present for the AM processes with high cooling rates. The prior β size are larger for the directed energy deposition (DED) processes than for the powder bed fusion (PBF) processes. Parallel bands were present for the DED process while being non-present for the PBF processes. Concerning the texture, it was found that LMwD had a higher texture than EBM and SLM. Texture inhomogeneity was also found for the LMwD process., where two parts of the same sample was investigated and the material closer to the surface had higher texture.

La technologie de fabrication additive métal fil permet la fabrication de structures filaires complexes en 3 dimensions. Ce système se base sur l'utilisation d'un procédé de soudage qui va permettre le dépôt de la matière. Ce dernier est embarqué sur un bras robotique qui permettra de déplacer la torche de soudage aux positions désirées. Pour fabriquer de grandes structures filaires, le dépôt s'effectue point par point. L'utilisation d'un procédé de soudage induit des fluctuations sur le dépôt. Pour être adaptable facilement, deux aspects doivent être pris en compte. Premièrement, une instrumentation doit être embarquée. Un contrôle local sur la géométrie déposée doit être utilisé pour atteindre les formes finales désirées. Deuxièmement, certaines stratégies de dépôt doivent êtres implémentées pour piloter notre système dans les intersections de branches. Pour atteindre ces deux objectifs, un slicer adaptatif et modulaire, ainsi qu'un système de supervision et de contrôle du système ont été développés pour permettre l'implémentation du contrôle. Cela permet, si une erreur apparait, de changer la position de notre système de dépôt. Pour obtenir la géométrie désirée, notre système de supervision et de contrôle doit pouvoir : (i) effectuer un slicing de la géométrie à la volée lors de la fabrication avec un pas variable pour pouvoir prendre en compte les variations du procédé de dépôt et (ii) gérer les stratégies de dépôt au niveau des intersections pour décider des paramètres procédés et des trajectoires à employer. / Wire Arc Additive Manufacturing (WAAM) has the possibility to build metallic structures in 3D space. WAAM system is based on welding process to deposit metallic material and on a robot that moves the welding torch to add material at a given position. For large skeleton structures, it was chosen to deposit material point by point. Welding process induces fluctuations.To be fully scalable, two main features must be taken into account. First, monitoring of the process is necessary. Local control on the geometry of the deposition must be used to reach the final shape. Secondly, some deposition strategies must be implemented to manage branch intersections. To reach these two objectives, anadaptive and modular slicer and a process manager have been developed in order to implement this control. It allows us, if an error occurs during the deposition, to change the position of the effector or the process parameters. To obtain the desired geometry, the CAM software have to be able to, (i) do a slicing during the additive process of the part with a variable deposit height in order to take into account variation of the deposition process and (ii) manage the deposition strategy at intersection to output the position of the torch.

A deformidade em pescoço de cisne é uma postura anormal do dedo caracterizada por hiperextensão da articulação interfalangeana proximal juntamente com a flexão da interfalangeana distal, que pode causar dor e incapacidade funcional. Na prática clínica, as órteses são amplamente aplicadas no tratamento conservador da deformidade, sendo indicados modelos adquiridos comercialmente ou confeccionados sob medida pelos terapeutas. Trabalhos anteriores do grupo de pesquisa propuseram um modelo de órtese articulada para correção da deformidade pescoço de cisne denominada AOA (Anel em Oito Articulado) que teve sua funcionalidade aprovada pelos voluntários da pesquisa. O presente trabalho objetiva a evolução deste projeto na busca de um modelo mais anatômico (maior conforto), mais funcional e melhorar a compreensão acerca da relação entre materiais, manufatura e custo da órtese. Para isto, foram utilizados os processos de Manufatura Aditiva (MA) ou impressão 3D e parametrização, que permite o redezenhar automaticamente a órtese. A metodologia aplicada foi baseada no desenvolvimento de produtos e otimização integrada entre a técnica e a participação de adultos, atendidos nos ambulatórios do HCFMRP-USP, que apresentam a deformidade a fim de identificar sua percepção acerca da experimentação. A metodologia foi dividida didaticamente em duas etapas. Na primeira, foram realizadas as medidas antropométricas de dedos com a deformidade, além da definição das medidas de referência para parametrização através de medidas das mãos dos pesquisadores e de clientes; na segunda etapa, foi realizada a otimização e a parametrização do desenho, foi testada a manufatura da órtese com diferentes materiais, teste de usabilidade, por teste de bancada com os pesquisadores e após aprovação foram experimentadas por dois clientes para avaliar a opinião e na sequencia, foi feita análise descritiva dos dados. As principais alterações do projeto atual sobre o original foram a substituição dos diâmetros das seções dos dedos pela altura e largura que as aproximou de formatos elípticos; aumentos e reposicionamentos dos apoios ao dedo; reposicionamento do eixo de rotação da articulação; alteração do ângulo de bloqueio segundo recomendação do terapeuta pela avaliação da deformidade; modelagem paramétrica e manufatura aditiva em resina de alta resistência. Foram realizados também ensaios mecânicos para avaliação das propriedades das resinas curadas e teste com sensor de força, para conhecimento da distribuição de pressão da órtese no dedo. O presente modelo possibilitou aos usuários um ganho em funcionalidade e conforto e através do desenho paramétrico e manufatura aditiva direta possibilitou a dispensação da órtese personalizada com maior agilidade, em poucas horas. A evolução da AOA foi considerada promissora pois apresenta uma ferramenta inovadora muito próxima da aplicação comercial para a resolução de um problema de saúde crônico. / The swan neck deformity is an abnormal posture of the finger characterized by the hyperextension of the proximal interphalangeal joint with distal interphalangeal flexion, which can cause pain and lead to functional disability. In clinical practice, the orthosis is widely recommended in the conservative treatment of the deformity, and both commercially-acquirable models and on demand models made by therapists can be indicated. The previous work of the research group proposed an articulated orthosis model for the correction of swan neck deformity called AOA (Articulated Eight-shape Ring) that had its functionality approved by the research volunteers. The present work aims to further develop this project by searching for a more anatomical and functional model, providing greater comfort, and seeking a compromise among materials, manufacture and cost of the orthosis. For this, the processes of Additive Manufacturing (MA) or 3D printing and parameterization were used, which allows the automatic redesign of the orthosis The applied methodology was based on the product development and the integrated optimization between the technique and the feedback of adult patients who were affected by the deformity and treated at the HCFMRP-USP ambulatories. The methodology was divided into two steps: firstly, the anthropometric measurements of the fingers with the deformity were carried out, and the reference measurements for parameterization were defined through the measurement of the researchers\' and the patients\' hands; secondly, the optimization and parameterization of the design was performed, followed by the manufacturing of the orthosis with different materials that were submitted to usability tests and a bench test with the researchers. After approval, the orthosis were tested by two patients in order to obtain their opinion, and subsequently, the descriptive analysis of collected data was established. When comparing the current design to the original one, the main changes were the replacement of the diameters of fingers sections by slightly elliptical formats, the enlargement and repositioning of the finger supports, the repositioning of the rotation axis of the joint, the alteration of the blockage angle according to the recommendation of the therapist to evaluate the evolution of the deformity, and the parametric modelling and additive manufacture in high strength resin. Mechanical tests were also carried out to evaluate the properties of the cured resins as well as load sensor tests to identify the pressure distribution from the orthosis to the finger. The present model provided the users with greater functionality and comfort. Moreover, the personalized orthosis can be fabricated in matter of a few hours due to the parametric design and direct additive manufacture. The evolution of AOA was considered promising as it presents an innovative tool very close to the commercial application for the resolution of a chronic health issue.

Les techniques de fabrication rapide, issues des techniques de prototypage rapide comme l’impression 3D ou la découpe laser permettent de fabriquer des pièces uniques sans demander d’expertise particulière du procédé mis en œuvre. En revanche la modélisation de nouveaux objets tout comme la personnalisation d’objets existants restent difficiles. En effet, les techniques de prototypages rapides imposent des contraintes sur la géométrie du modèle qui doivent être respectées. Cette thèse présente un ensemble de techniques qui ont pour point commun d’assister l’utilisateur dans la modélisation d’un objet, en tenant compte des contraintes du procédé qui permettra de le fabriquer. À cette fin, l’algorithme prend en charge tout ou partie de la modélisation. En particulier, les problématiques suivantes sont abordées : Tout d’abord, je propose d’améliorer la qualité des objets fabriqués avec une imprimante 3D en minimisant certains défauts qui apparaissent lors de la fabrication. Les approches développées modifient uniquement les algorithmes de pilotage de l’imprimante. En second lieu, je propose d’aider l’utilisateur à prendre en compte les contraintes de fabrication pendant la modélisation. Mes techniques utilisent des informations partielles sur la forme que l’utilisateur souhaite fabriquer, comme le dessin en deux dimensions d’un mécanisme, ou un modèle paramétrique qui définit un meuble. L’algorithme optimise une forme finale qui améliore des critères liés à sa fabrication (gaspillage, encombrement, etc.). Enfin, dans certains cas (e.g. grand public) l’utilisateur n’est pas forcément à même de modéliser ces formes via des logiciels spécialisés. Pour ce cas précis, je propose une technique de synthèse de meubles à partir de spécifications fonctionnelles, e.g. la spécification de poids à porter dans l’espace / The Rapid Manufacturing techniques that emerged from Rapid Prototyping techniques such as 3D printing or laser cutting allow to fabricate unique objects. However, the design of those objects with existing CAD software remain a difficult task: rapid prototyping processes impose constraints on the geometry of the model. This thesis presents a set of techniques that assist the user in the design of an object by taking into account the constraints of the fabrication process. To achieve this, the algorithm automatically performs part of the modelling process. The following problems have been tackled: First, I propose to improve the quality of 3D printed objects by minimizing defects that appear during the fabrication. The technique developed impacts only the algorithm that drives the printer. Then, I propose to help the user to take into account the fabrication constraints during the modelling process. My techniques rely on partial information about the shape that the user wants to fabricate like the 2D sketch of a mechanism or a parametric model of a furniture. The algorithm optimizes the initial shape to improve fabrication objectives(Wastage, etc.) Finally, in some cases, the user does not know how to operate dedicated software. In this case, I propose a synthesis technique of furniture from functionnal specification, e.g. loads that have to be supported in space