<p>This dissertation presents research work related to laser micro sintering, laser micro machining and laser-induced plasma. Firstly, we present extensive experimental studies of double-pulse laser micro sintering (DP-LMS), which typically utilizes the high pressure generated by laser-induced plasma over the powder bed surface to promote molten flow and enhance densification. Chapter 2 shows a single-track experimental study of the DP-LMS process using cobalt powder. The related fundamental mechanisms and effects of different laser parameters on the sintering results are analyzed with the help of <em>in-situ</em> time-resolved temperature measurements. Chapter 3 shows a multi-track experimental study of the DP-LMS process using iron powder. The sintered materials are characterized via the top surface porosity, elemental composition, grain microstructure, nanohardness and metal phase. Three strategic guidelines for laser parameter selection are summarized in the end. Chapter 4 shows time-resolved imaging and OES measurements for plasma induced during DP-LMS. The plasma temperature and free electron number density are deduced by its optical emission spectra (OES). These three chapters have clearly demonstrated DP-LMS can produce much more continuous and densified materials than LMS only using the sintering or pressing laser pulses.</p> <p><br></p> <p>Then, we present laser micro grooving of silicon carbide (SiC) in Chapter 5 by ultrasound-assisted water-confined laser micromachining (UWLM), in comparison with laser machining in water without ultrasound and laser machining in air. UWLM applies <em>in-situ</em> ultrasound to the water-immersed workpiece surface to improve the machining quality and/or productivity. Time-resolved water pressure measurements are carried out to help analyze relevant mechanisms. It has been demonstrated UWLM can be a competitive approach to produce high-quality micro grooves on SiC. The crack problem appears to be effectively solved using a high pulse repetition rate.</p> <p><br></p> <p>Finally, we report a double-front phenomenon for plasma induced by high-intensity nanosecond laser ablation of aluminum in Chapter 6. An additional plasma front is observed via an intensified CCD (ICCD) camera, which propagates very fast at the beginning but stops propagating soon after the laser pulse mostly ends. Its formation could be caused by the inverse bremsstrahlung absorption of laser energy by the ionized ambient gas. Three possible mechanisms on how the ambient gas breakdown is initiated are proposed. </p>

[ES] En los últimos años, la fabricación aditiva a través de la extrusión de materiales ha experimentado un desarrollo y adopción acelerados gracias a la amplia disponibilidad de máquinas y materiales de bajo costo. El tamaño de estas máquinas se ha reducido del tamaño del taller al tamaño del escritorio, lo que permite su uso en configuraciones de oficina o en el hogar. Este cambio ha permitido la adopción de la tecnología por la gama más amplia de usuarios que nunca, con o sin experiencia en diseño de ingeniería. Este nuevo paradigma ha creado el desafío de cómo habilitar que estos nuevos usuarios aprovechen las capacidades proporcionadas por esta tecnología. Esta tecnología permite la creación de geometrías complejas y productos personalizados con un coste inferior a los procesos de fabricación convencionales. Además, la gran cantidad de usuarios dispuestos a compartir sus diseños permite encontrar soluciones de diseño desde otros diseñadores. Sin embargo, la amplia gama de configuraciones de máquina, parámetros y materiales requiere brindar soporte para obtener resultados exitosos para cualquier combinación. Esta tesis aborda este desafío identificando las características de diseño y fabricación a considerar e investigando las consideraciones mecánicas y de pos procesamiento. Se propone y evalúa un nuevo marco de diseño que permite a los nuevos usuarios aprovechar las capacidades y considerar las limitaciones. Esta investigación encuentra que es posible crear un conjunto de herramientas de diseño que permita a los usuarios no capacitados diseñar productos utilizando la complejidad habilitada por la tecnología al tiempo que garantiza la funcionalidad y la capacidad de fabricación del producto. / [CA] En els últims anys, la fabricació additiva a través de l'extrusió de materials ha experimentat un desenvolupament i adopció accelerats gràcies a l'àmplia disponibilitat de màquines i materials de baix cost. La grandària d'aquestes màquines s'ha reduït de la grandària del taller a la grandària de l'escriptori, la qual cosa permet el seu ús en configuracions d'oficina o en a casa. Aquest canvi ha permés l'adopció de la tecnologia per la gamma més àmplia d'usuaris que mai, amb o sense experiència en disseny o enginyeria. Aquest nou paradigma ha creat el desafiament de com habilitar que aquests nous usuaris aprofiten les capacitats proporcionades per aquesta tecnologia. Aquesta tecnologia permet la creació de geometries complexes i productes personalitzats amb un cost inferior als processos de fabricació convencionals. A més, la gran quantitat d'usuaris disposats a compartir els seus dissenys permet trobar solucions de disseny des d'altres dissenyadors. No obstant això, l'àmplia gamma de configuracions de màquina, paràmetres i materials requereix brindar suport per a obtindre resultats reeixits per a qualsevol combinació. Aquesta tesi aborda aquest desafiament identificant les característiques de disseny i fabricació a considerar i investigant les consideracions mecàniques i de post processament. Es proposa i avalua un nou marc de disseny que permet als nous usuaris aprofitar les capacitats i considerar les limitacions. Aquesta investigació troba que és possible crear un conjunt d'eines de disseny que permeta als usuaris no capacitats dissenyar productes utilitzant la complexitat habilitada per la tecnologia al mateix temps que garanteix la funcionalitat i la capacitat de fabricació del producte. / [EN] In recent years, additive manufacturing through material extrusion has experienced accelerated development and adoption thanks to the wide availability of low-cost machines and materials. The size of these machines has been reduced from shop floor to desktop size, enabling their usage in office setups or at home. This change has allowed the adoption of the technology by the broadest range of users than ever, with or without an engineering design background. This new paradigm has created the challenge of how to enable these novel users to leverage the capabilities provided by this technology. This technology allows the creation of complex geometry and customised products with a cost lower than conventional manufacturing processes. Furthermore, the large number of users willing to share their designs allows finding design solutions from other designers. However, the wide range of machine configurations, parameters and materials requires providing support to obtain successful results under any combination. This thesis addresses this challenge by identifying the design and manufacturing characteristics to be considered and investigating the mechanical and post-processing considerations. A new design framework that enables new users to leverage the capabilities and consider the limitations is proposed and evaluated. This research finds that it is possible to create a design toolkit that enables untrained users to design products using the complexity enabled by the technology whilst ensuring the product's functionality and manufacturability. / Fernández Vicente, M. (2022). Analysis to Support Design for Additive Manufacturing with Desktop 3D Printing [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/185344 / TESIS

<p dir="ltr">Generation IV high-temperature gas-cooled reactors (HTGR) are designed to exhibit passive safety under all off-normal circumstances. One such scenario, known as depressurized loss of forced circulation (DLOFC), occurs after a break in the coaxial inlet/outlet header. As the headers are traditionally located at the base of the reactor vessel, the low-density helium coolant is preserved in the core following the initial rupture accident. Upon depressurization, however, air from the surrounding reactor environment slowly enters the coolant channel through molecular diffusion. As the incoming fluid continues to deplete the helium concentration, the onset of natural circulation (ONC) can occur causing bulk air ingress leading to the oxidation and degradation of core components. Therefore, investigating methods to improve the time to ONC is critical in impeding reactor core component damage brought about by DLOFC in an HTGR.</p><p dir="ltr">The Transformational Challenge Reactor (TCR) has similar features to those of an HTGR, but the primary difference is the use of a more complex, additively manufactured (AM) fuel geometry. The more compact, AM, ceramic fuel elements can be conveniently produced with optimally configured channels that suppress the air ingress progress and improve thermofluidic performance. DLOFC and air ingress are experimentally studied in a scaled HTGR flow test setup. Distributed temperature measurements and time to ONC data are collected for the experiments conducted. Multiple geometries are analyzed throughout the investigation. The thermal transient and time to ONC data gathered for the different test geometries and temperatures are compared. The results show that the AM and pebble bed elements deter ONC significantly longer than the baseline geometry representative of a prismatic fuel coolant channel. The AM part delayed ONC as compared to the pebble bed test piece at higher temperatures. The distributed temperature sensor shows intra-leg circulation at higher temperature tests.</p><p dir="ltr">Thermophysical properties of the 316 stainless steel AM component are compared to those of a standard 316 stainless steel round bar. The properties ascertained include the density, emissivity, specific heat, and thermal conductivity. The density of the AM part is 1.5% greater than the density of the standard bar. The emissivity of the AM part is determined to be over three times greater than the emissivity of the polished standard stainless steel round. The specific heat of the AM element is 16% greater than that of the standard 316 stainless steel specific heat. The thermal conductivity of the AM component is measured to be within 1.5% of the standard 316 stainless steel round bar thermal conductivity.</p>

This paper focuses on the local additive manufacturing AM for life science ecosystem. It aims to study the roles of the different stakeholders, and the strengths and weaknesses of the local AM ecosystem through the lens of the research on Innovation ecosystems (IE), Innovation Systems (IS), and Innovation clusters (IC). The main framework used in this study is technological innovation systems (TIS). The methodology of this research relies on a mixed-methods approach that involved surveys administered through structured interviews and self-completion questionnaire. The stakeholders involved in the study include organizations from the industrial sector, healthcare providers, academia, public agencies, and innovation support. Data collected from twenty-two participants was compiled and used to determine response frequencies on nine multiple response questions, and mean scores for thirty-two Likert scale questions. The frequency response tables were used to determine the stakeholder roles, while mean scores were used to determine the TIS functional components ratings and overall standings.  The roles of the stakeholders were determined through the lens of the existing literature on IE. The stakeholders have mixed involvement across the ecosystem, sometimes occupying multiple role categories within the ecosystem. It was found that healthcare stakeholders, and industry stakeholders fill direct value creation and value support roles due to their active participation in defining medical needs and supporting the ecosystem. Next, Public agency stakeholders fill leadership roles, due to their regulatory and actor integration roles. Finally Academic stakeholders fill leadership roles by providing research and knowledge to the ecosystem.   In terms of strengths and weaknesses, the TIS framework was used to evaluate the seven original functional components, and an additional component that was added based on the IE research. It was found that Function 3 Knowledge Diffusion was the strongest function, due to the noncompetitive environment that the local AM ecosystem has established. Meanwhile, Function 2 Knowledge Development scored lowest and was determined to be the weakest functional component due to a lack in the number of patents within the innovation ecosystem. In addition, individual strengths and weaknesses within the functional components were highlighted for a more nuanced look into the strengths and weaknesses of individual functional components. The highest rated strength of the ecosystem was determined to be collaboration, and its weakest area was the noncompetitive environment.

<p dir="ltr">The long-term goal of this research is to develop advanced manufacturing technologies that enable fabrication of dissolvable load-bearing devices with customized degradation rates. In pursuit of this goal, the overarching research objective was to understand how interlayer coldworking treatments like laser and ultrasonic peening performed improved mechanical and chemical behavior of printed parts by locally altering stress fields and microstructure. The challenge in such a hybrid additive manufacturing approach involving interlayer coldworking was that the corrosion behavior of printed structures was largely unexplored. Furthermore, there was limited scientific advancement in optimizing the selection of appropriate layer interfaces for coldworking to attain the required degradation rates from printed devices. This dissertation was aimed at addressing the challenges in hybrid AM by investigating the corrosion kinetics of a magnesium alloy printed by coupling powder bed fusion with interlayer ultrasonic peening. This exploratory investigation was the first to demonstrate the ability of interlayer coldworked interfaces to delay the corrosion kinetics of powder bed fusion printed magnesium. A finite element framework was developed to investigate residual stress formation in parts subjected to cyclic thermal and mechanical loading from printing and cold working. An analytical model was established to accelerate residual stress simulations and develop design principles for directing stress concentration within parts that customize mechanical and chemical performance. This research forms the basis for fabricating time-resolved loadbearing orthopedic implants and dissolvable hydraulic fracking plugs.</p>

Published Aticle / The Centre for Rapid Prototyping and Manufacturing (CRPM) made a humble start in 1997 as a spin-off from a proposed research activity in 1995, at a stage when Technikons were still being seen as occupational training institutions rather than higher education institutions and and as such, were not funded for research. Addressing an area of high importance to the South African industry, the research activity soon grew into a research unit, commercial centre / centre of excellence, technology transfer unit and innovation support centre. Above all, the research started to impact on product development practices to deliver improved products. The paper considers the development of the available technology platforms at the CUT'S CRPM to become a technology power-house on the African continent, and how it impacted on Institutional Research Development in South Africa.

Upper extremity splinting is a popular treatment method for a range of conditions, such as rheumatoid arthritis. The intent of this treatment approach is multifaceted, but fundamentally, the provision of tools to enable and encourage patients to carry out everyday activities and to improve their quality of life is paramount. However, the aesthetic and functional limitations of wrist immobilisation splints demonstrate various weaknesses in terms of wear duration and frequency. Patient compliance is often compromised due to a number of factors, including the perceived stigma associated with assistive devices. Additive Manufacturing (AM) has proved its worth in a number of applications relating to the design of assistive devices; builds of complex, bespoke fitting geometries make AM an ideal fabrication method for upper extremity splints. However, recent advances in system technology to enable multi-material builds have been limited in this field, and a distinct need for a specialised three-dimensional (3D) Computer Aided Design (CAD) software approach is required to allow therapists to design splints for AM. Furthermore, the intent to keep practising therapists at the forefront of splint prescription is of utmost importance. This research proposes a digitised splinting approach, specifically through development of a 3D CAD software strategy to allow therapists to capture their design intent without compromising creativity. Furthermore, the approach proposes the exploration of AM build capabilities by allowing the integration of more creative features, such as aesthetically pleasing lattice structures for increased skin ventilation. The approach also proposes the integration of multiple materials to replicate and improve upon current splint design and fabrication practises. The approach therefore explores an exciting new paradigm for upper extremity splinting, the driving characteristics of which have not been proposed before as a collective medium. This research describes the feasibility of capturing therapists design intent in a 3D CAD virtual environment, whilst capturing therapists opinions of the approach with suggestions for future research and development. Results concluded that therapists were excited by the proposed transition in AM splinting, but that significant development is required elsewhere to establish a supporting infrastructure in order to make the approach a viable option in future upper extremity splinting.

Construction project performance and worker productivity are often tied to the availability and effective presentation of information, tools, materials, and equipment. While advancements in technology have improved much of the processes on a construction project, the medium of information dissemination at the construction work face has consistently relied on the use of two dimensional drawings and specifications. Industry initiatives are driving increased collaboration through three dimensional BIM (Building Information Modeling) models. However, the added dimension partially loses its effect when presented on a two dimensional computer monitor. Other computer forms of presentation intended for mobility (PDAs, laptops, and tablets) can be difficult to use in the field due to glare, durability in a harsh working environment, and the required skill level for effective use. Three dimensional (3D) physical printers now provide the capability to develop scaled and color models of a project directly from a BIM model. 3D physical printers represent a potential transformative change of providing engineering information to construction crews, but how to develop 3D models that leverage the cognitive benefits of viewing engineering information in a physical 3D form is unknown. The primary contribution to the overall body of knowledge of this dissertation is to scientifically examine the effect that different engineering information mediums have on an individual’s cognitive ability to effectively and accurately interpret spatial information. First, the author developed a robust scientific experiment for construction practitioners and students to complete. This experiment included outcomes measures on mental workload, cognitive demand, productivity, efficiency, demographics, and preferences. After collecting data, the author analyzed the outcomes through a series of statistical analyses to measure the differences between groups and quantify the affect and relationship among key variables. From the results, there are statistically significant improvements in productivity and efficiency of practitioners and students when using a physical model compared to two dimensional drawings and a three dimensional computer model. In addition, the average cognitive demand for a physical model was lower than the average cognitive demand for two dimensional drawings and three dimensional computer model.

Die Photobiotechnologie nutzt photosynthesegetriebene Bioprozesse zur nachhaltigen Synthese von Wertstoffen und Energieträgern. Diese Bioprozesse rücken vor allem durch die stoffliche Nutzung von CO2 als Kohlenstoff- und Licht als regenerative Energiequelle in den Fokus von Forschung und Entwicklung. Trotz der enormen Vielfalt von geschätzten 500.000 Algenspezies werden zurzeit nur ca. 15 Mikro- und 220 Makroalgen technisch genutzt. Dieser Umstand ist u.a. dem geringen Prozessverständnis und den spezifischen Anforderungen der photobiotechnologische Prozesse an die technischen Systeme geschuldet. Im Rahmen der vorliegenden Arbeit wurden Kultivierungssysteme für die photosynthetisch aktiven Mikroorganismen Rhodobacter sphaeroides DSM158, Chlamydomonas reinhardtii 11.32b und Chlorella sorokiniana UTEX1230 entwickelt und evaluiert. Die photofermentative Wasserstoffproduktion mittels R. sphaeroides DSM158 erfolgte in einem eigens dafür konzipierten gerührten Halogen-Photobioreaktor durchgeführt. Im Satzbetrieb wurde der Einfluss des volumetrischen Leistungseintrages (P0/VL) und der mittlere Bestrahlungsstärke (I0) untersucht. Es konnte gezeigt werden, dass R. sphaeroides DSM158 bei einer durchschnittlichen I0 von 2250 W m-2 und einem P0/VL von 0,55 kW m-3 im Satzbetrieb eine maximale Wasserstoffproduktionsrate (rH2) von 195 mL L-1 h-1 erzielt. Das Reaktorsystem wurde mittels optischer Ray Tracing Simulation, einer empirischer Simulation der Strahlungsverteilung und Computational Fluid Dynamics (CFD) charakterisiert, um die Prozessbedingungen für R. sphaeroides DSM158 zu analysieren. Der photofermentative Prozess wurde in ein kontinuierliches Verfahren überführt, welches unter optimalen Bedingungen von I0 = 2250 W m-1, einer Durchflussrate von 0,096 h-1 und einem C:N-Verhältnis von ca. 22,5 eine rH2 von 170,5 mL L-1 h-1 lieferte. Für Mikroalgen wurden Kultivierungssysteme für Suspensions- und immobilisierte Kulturen entwickelt und charakterisiert. Zur Kultivierung immobilisierter Mikroalgen wurde die Methode des Green Bioprinting etabliert, die auf der 3D-Bioprinting Technologie des Tissue Engineerings beruht. Bei diesem Verfahren werden Algenzellen über einen Extrusionsprozess in ein strukturiertes Hydrogel eingebettet. In vergleichenden Studien zum Wachstum in Suspensionskulturen konnte gezeigt werden, dass die Hydrogelumgebung ideale Bedingungen für das photoautotrophe Wachstum und die Zellviabilität von C. reinhardtii 11.32b und C. sorokiniana UTEX1230 liefert. Der MicrOLED-Bioreaktor bezeichnet ein miniaturisiertes Flat-Panel-Airlift (FPA)-Bioreaktor-system mit 15 mL Arbeitsvolumen und nichtinvasiver optischer Prozessüberwachung in Bezug auf zellspezifische Parameter (Zelldichte und Fluoreszenz) und Suspensionsparameter (pH, dO2 und dCO2). Hydrodynamische Untersuchungen der miniaturisierten FPA-Kultivierungskammer zeigten vergleichbare und damit skalierbare Eigenschaften zu Labor- und Produktions-FPA-Bioreaktoren. Im Zuge des MicrOLED-Bioreaktors wurden erstmals organische Leuchtdioden für den Einsatz in Photobioreaktoren verwendet und charakterisiert. Die geometrisch komplexen Bioreaktorkomponenten wurden mittels additiver Fertigungstechnologien aus Polyamid hergestellt und erlauben die Integration der optischen Elemente zur Überwachung des Bioprozesses in Echtzeit.

A novel paste deposition process was developed to widen the range of possible materials and applications. This experimental process developed an increasingly complex series of additive manufacturing machines, resulting in new combinations of novel materials and deposition paths without sacrificing many of the design freedoms inherit in the craft process. The investigation made use of open-source software together with an approach to programming user originated infill geometries to form structural parts, differing from the somewhat automated processing by 'closed' commercial RP systems. A series of experimental trials were conducted to test a range of candidate materials and machines which might be suitable for the PDM process. The combination of process and materials were trailed and validated using a series of themed case studies including medical, food industry and jewellery. Some of the object created great interest and even, in the case of the jewellery items, won awards. Further evidence of the commercial validity was evidenced through a collaborative partnership resulting in the development of a commercial version of the experimental system called Newton3D. A number of exciting potential future directions having been opened up by this project including silicone fabrics, bio material deposition and inclusive software development for user originated infills and structures.