The objective of this dissertation is to provide key methodological advancements towards the use of transfer learning in Laser-Based Additive Manufacturing (LBAM), to assist practitioners in producing high-quality repeatable parts. Currently, in LBAM processes, there is an urgent need to improve the quality and repeatability of the manufacturing process. Fabricating parts using LBAM is often expensive, due to the high cost of materials, the skilled machine operators needed for operation, and the long build times needed to fabricate parts. Additionally, monitoring the LBAM process is expensive, due to the highly specialized infrared sensors needed to monitor the thermal evolution of the part. These factors lead to a key challenge of improving the quality of additively manufactured parts, because additional experiments and/or sensors is expensive. We propose to use transfer learning, which is a statistical technique for transferring knowledge from one domain to a similar, yet distinct, domain, to leverage previous non-identical experiments to assist practitioners in expediting part certification. By using transfer learning, previous experiments completed in similar, but non-identical, domains can be used to provide insight towards the fabrication of high-quality parts. In this dissertation, transfer learning is applied to four key domains within LBAM. First, transfer learning is used for sensor fusion, specifically to calibrate the infrared camera with true temperature measurements from the pyrometer. Second, a Bayesian transfer learning approach is developed to transfer knowledge across different material systems, by modelling material differences as a lurking variable. Third, a Bayesian transfer learning approach for predicting distortion is developed to transfer knowledge from a baseline machine system to a new machine system, by modelling machine differences as a lurking variable. Finally, compensation plans are developed from the transfer learning models to assist practitioners in improving the quality of parts using previous experiments. The work of this dissertation provides current practitioners with methods for sensor fusion, material/machine calibration, and efficient learning of compensation plans with few samples.

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This is a material driven study that explores how post-processing of a 3D-printed biocomposite may increase its utility in the public furniture industry. The study thereby aims to contribute insights in material development and inspire a shift in practices that pushes the industry towards a more sustainable design process. By studying theories on sustainable development, biocomposites, and additive manufacturing, the surface defects in large-scale 3D-printing are put in relation to the industry-specific requirements placed on public furnishings. The potentials for the biocomposite to satisfy these demands are assessed using the four actions steps of material driven design. This includes hands-on exploration of several post-processing methods to minimize the material’s distinctive surface roughness. The most effective surface treatment, a combination of subtractive and additive processing, is subsequently applied in a product development phase to exemplify the feasibility of these methods in the context of furniture. This resulted in a design concept which, although a time-consuming process, proves the possibility of post-processing to influence the ability of the material to meet the requirements for public use. The increased material utility achieved in this study should, however, be considered relative to the economic and ecological consequenses associated with biocomposite processing.

Additive manufacturing has become a very popular and well mentioned technique in recent years. The technique, where 3 dimensional (3D) printing is included, creates opportunities to develop new designs and processing systems. As a research institute within the forest based processes and products, Innventia AB has an idea of combining 3D printing with cellulose. The addition of cellulose will increase the proportion of renewable raw material contributing to more sustainable products. However, when cellulose is added the composition of the filaments changes. The main aim for the project is to devise methodologies to improve properties of composite filaments used for 3D printing. Filament in 3D printing refers to a thread-like object made of different materials, such as PLA and ABS, that is used for printing processes. A literature study was combined with an extensive experimental study including extrusion, 3D printing and a new technique that was tested including 3D scanning for comparing the printed models with each other. The extruding material consisted of polypropylene and cellulose at different ratios, and filaments were produced for 3D printing. The important parameters for extruding the material in question was recorded. Because the commingled material (PPC) was in limited amount, UPM Formi granulates, consisting of the same substances, was used first in both the extrusion and printing process. Pure polypropylene filaments were also created in order to strengthen the fact that polypropylene is dimensional unstable and by the addition of cellulose, the dimensional instability will decrease. After producing filaments, simple 3D models were designed and printed using a 3D printing machine from Ultimaker. Before starting to print, the 3D model needed to be translated into layer-by-layer data with a software named Cura. Many parameters were vital during printing with pure polypropylene, UPM and PPC. These parameters were varied during the attempts and marked down for later studies. With the new technique, in which 3D scanning was included, the 3D printed models were compared with the original model in Cura in order to overlook the deformation and shape difference. The 3D scanner used was from Matter and Form. Photographs of the printed models, results from the 3D scanner, and screenshots on the model in Cura were meshed together, in different angles, using a free application named PicsArt. The result and conclusion obtained from all three parts of the experimental study was that polypropylene’s dimensional stability was improved after the addition of cellulose, and the 3D printed models’ deformation greatly decreased. However, the brittleness increased with the increased ratio of cellulose in the filaments and 3D models. / Additiv tillverkning har på den senare tiden blivit en mycket populär och omtalad teknik. Tekniken, där tredimensionell (3D) utskrivning ingår, ger möjligheter att skapa ny design och framställningstekniker. Som ett forskningsinstitut inom massa- och pappersindustrin har Innventia AB en ny idé om att kombinera 3D-utskrivning med cellulosa. Detta för att höja andelen förnybar råvara som leder till mer hållbara produkter. Dock kommer filamentens sammansättning vid tillsättning av cellulosa att ändras. Det främsta syftet med detta projekt är att hitta metoder för att förbättra egenskaperna hos de kompositfilament som används för 3D-utskrifter. Filament inom 3D-utskrivning är det trådlika objektet gjort av olika material, såsom PLA och ABS, som används vid utskrivningsprocessen. En enkel litteraturstudie kombinerades med en experimentell studie. Det experimentella arbetet var i fokus i detta projekt som omfattade extrudering, 3D-utskrivning samt en ny teknik som prövades, där 3D-scanning ingick, för att jämföra de utskrivna modellerna med varandra. Extruderingsmaterialet bestod av polypropen och cellulosa av olika halter, och av detta material tillverkades filament för 3D-utskrivning. De viktiga parametrarna för extrudering med det önskade materialet antecknades. Eftersom mängden cominglat material (PPC) var begränsat, användes först UPM Formi granuler, som består av samma substanser som i PPC, i både extruderingen och utskrivningen. Filament av ren polypropen tillverkades också för att stärka det faktum att polypropen är dimensionellt instabil. Genom att tillsätta cellulosa minskades dimensionsinstabiliteten. Efter att filamenten hade tillverkats, designades enkla 3D-modeller för utskrivning med en 3D-utskrivare från Ultimaker. Innan utskrivningen kunde börja behövde 3D-modellen bli översatt till lager-på-lager-data med hjälp av en programvara vid namn Cura. Många parametrar är viktiga vid utskrivning med ren polypropen, UPM samt PPC. Temperatur och hastighet varierades för de olika försöken och antecknades för senare studier.Med den nya tekniken, där 3D-scanning ingår, jämfördes de utskrivna 3D-modellerna med originalmodellen i Cura för att se över deformationen och formskillnaden. Den 3D-scanner som användes kom från Matter and Form. Fotografier på de utskrivna modellerna, resultaten från 3D-scannern och bilder på modellerna i Cura sammanfogades i olika vinklar med hjälp av ett gratisprogram som heter PicsArt. Det resultat som erhölls och den slutsats som kunde dras utifrån alla tre delarna av den experimentella studien var att polypropens dimensionsinstabilitet minskades efter tillsatsen av cellulosa, och att de 3D-utskrivna modellernas deformation minskade kraftigt. Skörheten ökade ju högre halt cellulosa som filamenten och de utskrivna modellerna innehöll.