Existing layered manufacturing systems fabricate parts using a constant build layer thickness. Hence, operators must compromise between rapid production with large surface inaccuracies, and slow production with high precision, by choosing between thick and thin build layers, respectively. Adaptive layered manufacturing methods alleviate this decision by automatically adjusting the build layer thickness to accommodate surface geometry, thereby potentially enabling part fabrication in significantly less time. Unfortunately, conventional adaptive layered manufacturing techniques are often unable to realize this potential when transitioning from the laboratory to an industrial setting. The problem is that they apply the variable build layer thickness uniformly across each horizontal build plane, applying the same build layer thickness to all parts and part features across that plane even though they have different build layer thickness needs. When this happens, the advantage of using adaptive build layer thicknesses is lost. This thesis demonstrates how to minimize fabrication times when implementing adaptive layered manufacturing. Specifically, it presents a new method in which each part or individual part feature is assigned a distinct, independent build layer thickness according to its particular surface geometry. Additionally, this thesis presents a calibration procedure for the Fused Deposition Modeler (FDM) rapid prototyping system that enables accurate, adaptively sliced parts to be physically realizable. Experimental software has been developed and sample parts have been fabricated to demonstrate both aspects of this work. / Master of Science

Este trabalho consiste em realizar um estudo detalhado das vantagens e desvantagens da utilização do FDM (Filter Diagonalization Method) para a análise de dados obtidos pela sequência de Precessão Livre no Estado Estacionário (Steady State Free Precession - SSFP) para aquisição rápida de espectros de Ressonância Magnética Nuclear (RMN). No caso de RMN de baixa resolução, o procedimento de aquisição rápida, SSFP, é uma poderosa ferramenta para melhorar a relação sinal/ruído, apresentando muitas aplicações práticas. Apesar desse sucesso em baixa resolução, a SSFP não é rotineiramente utilizada para aplicações em RMN de alta resolução, provavelmente devido ao (1) artefatos provenientes do truncamento do sinal e (2) as anomalias causadas pela mistura do FID com o eco dos sinais. Existem na literatura inúmeras possíveis técnicas para suprimir este tipo de problemas, porém, nenhuma delas é capaz de realmente eliminar as anomalias geradas devido ao procedimento de aquisição rápida da SSFP. O FDM é um método paramétrico não-linear para fitar sinais no domínio do tempo. Seu objetivo fundamental é resolver o Problema da Inversão Harmônica, HIP, tornando-se robusto e adequado para a análise espectral de sinais no domínio do tempo nos casos onde a Transformada de Fourier falha. Neste trabalho, demonstramos que o FDM pode ser implementado para análises de sinais SSFP, com mais eficiência que os obtidos pelos procedimentos padrões de TF. A temperatura ambiente, espectros de RMN 13C de amostras de brucina, obtidos com tempo entre pulsos de 100ms, podem ser reproduzidos com boa relação sinal/ruído e alta resolução por meio do FDM. A limitação da análise por FDM é mais relevante nos casos de espectros com alta densidade de picos em uma determinada região espectral. Nestes casos, o curto período de observação do sinal na janela do tempo impõe uma série de limitações na resolução obtida pelo FDM. / This work consists in a detailed study of the advantages and disadvantages of the use of the Filter Diagonalization Method, FDM, for data analysis in Steady State Free Precession, SSFP, technique, usually employed to implement fast acquisition of Nuclear Magnetic Resonance, NMR, spectra. In the case of low resolution NMR using fast acquisition procedures, SSFP is a powerful tool to improve signal-to-noise ratio, presenting several important practical applications. Despite its success in the low resolution regime, SSFP is not a routine technique for high resolution applications, so far, mainly because of (1) truncation artifacts and (2) the intrinsic anomalies caused by admixture of free-induction-decay and echo signals. The literature reports many possible techniques to solve such kind of problems, but, none of them is capable to really eliminate the generated spectra anomalies caused by the fast acquisition procedure used in SSFP. FDM is a parametric method for non-liner fitting performed in the time domain. Its main goal is to solve the Harmonic Inversion Problem, HIP, making it robust and suitable for spectral analysis of time signals in the cases where the Fourier Transform, FT, technique fail. In this work we demonstrate that FDM can be used to implement the analysis of the SSFP data, with more efficiency than that achieve by appropriated FT procedures. Room temperature 13C NMR spectra of brucine samples, obtained from pulse sequences with 100 ms repetition time, can be reproduced with good signal-to-noise ratio and high resolution by means of the FDM. The limitation of the FDM analysis is more relevant in the case of spectra with a high density of peaks in a limited spectral frequency region. In these cases, the reduced short observation time window imposes serious limitation to the resolution achieved by the FDM.

Este trabalho consiste em realizar um estudo detalhado das vantagens e desvantagens da utilização do FDM (Filter Diagonalization Method) para a análise de dados obtidos pela sequência de Precessão Livre no Estado Estacionário (Steady State Free Precession - SSFP) para aquisição rápida de espectros de Ressonância Magnética Nuclear (RMN). No caso de RMN de baixa resolução, o procedimento de aquisição rápida, SSFP, é uma poderosa ferramenta para melhorar a relação sinal/ruído, apresentando muitas aplicações práticas. Apesar desse sucesso em baixa resolução, a SSFP não é rotineiramente utilizada para aplicações em RMN de alta resolução, provavelmente devido ao (1) artefatos provenientes do truncamento do sinal e (2) as anomalias causadas pela mistura do FID com o eco dos sinais. Existem na literatura inúmeras possíveis técnicas para suprimir este tipo de problemas, porém, nenhuma delas é capaz de realmente eliminar as anomalias geradas devido ao procedimento de aquisição rápida da SSFP. O FDM é um método paramétrico não-linear para fitar sinais no domínio do tempo. Seu objetivo fundamental é resolver o Problema da Inversão Harmônica, HIP, tornando-se robusto e adequado para a análise espectral de sinais no domínio do tempo nos casos onde a Transformada de Fourier falha. Neste trabalho, demonstramos que o FDM pode ser implementado para análises de sinais SSFP, com mais eficiência que os obtidos pelos procedimentos padrões de TF. A temperatura ambiente, espectros de RMN 13C de amostras de brucina, obtidos com tempo entre pulsos de 100ms, podem ser reproduzidos com boa relação sinal/ruído e alta resolução por meio do FDM. A limitação da análise por FDM é mais relevante nos casos de espectros com alta densidade de picos em uma determinada região espectral. Nestes casos, o curto período de observação do sinal na janela do tempo impõe uma série de limitações na resolução obtida pelo FDM. / This work consists in a detailed study of the advantages and disadvantages of the use of the Filter Diagonalization Method, FDM, for data analysis in Steady State Free Precession, SSFP, technique, usually employed to implement fast acquisition of Nuclear Magnetic Resonance, NMR, spectra. In the case of low resolution NMR using fast acquisition procedures, SSFP is a powerful tool to improve signal-to-noise ratio, presenting several important practical applications. Despite its success in the low resolution regime, SSFP is not a routine technique for high resolution applications, so far, mainly because of (1) truncation artifacts and (2) the intrinsic anomalies caused by admixture of free-induction-decay and echo signals. The literature reports many possible techniques to solve such kind of problems, but, none of them is capable to really eliminate the generated spectra anomalies caused by the fast acquisition procedure used in SSFP. FDM is a parametric method for non-liner fitting performed in the time domain. Its main goal is to solve the Harmonic Inversion Problem, HIP, making it robust and suitable for spectral analysis of time signals in the cases where the Fourier Transform, FT, technique fail. In this work we demonstrate that FDM can be used to implement the analysis of the SSFP data, with more efficiency than that achieve by appropriated FT procedures. Room temperature 13C NMR spectra of brucine samples, obtained from pulse sequences with 100 ms repetition time, can be reproduced with good signal-to-noise ratio and high resolution by means of the FDM. The limitation of the FDM analysis is more relevant in the case of spectra with a high density of peaks in a limited spectral frequency region. In these cases, the reduced short observation time window imposes serious limitation to the resolution achieved by the FDM.

This diploma thesis deals with the construction proposal of a small multifunctional modeller CNC milling machine that enables milling of aluminium alloys and 3D printing using the FDM method. Based on the research, analyzes and defined entry requirements the construction proposal is created and verified by calculations. The thesis contains a description of all the construction parts including the printhead, the tool tray and the safety cover. The other part of the thesis describes the machine geometry adjustment and specifies the choice of control system. The thesis includes a 3D model and the drawing documentation of selected structural nodes.

Die additive Fertigungstechnologie hat in den vergangenen Jahren durch kostengünstige Systeme Einzug in den Massen- und Consumer-Markt erhalten. Diese Entwicklung befähigte die sogenannte Maker-Szene, eine Gruppierung von Heimwerkern mit Bezügen zur Hacker- und Do-it-yourself-Kultur, kostengünstig und schnell Produktideen in Funktionsprototypen umzusetzen. Neben der reinen Hobbyanwendung bietet die Entwicklung der letzten Jahre aus Sicht der Produktentwicklung auch neue Chancen für die Strategie des Open Design. Demgegenüber steht das Problem der unterschiedlichsten Bildungs- und Ausbildungshintergründe der sich freiwillig beteiligenden Entwickler, eine stark iterative Vorgehensweise in der Produktentwicklung mit häufigen Anpassungszyklen und vielen physischen Teilprototypen, sowie einer lokal sehr unterschiedlichen qualitativen Fertigungsinfrastruktur. Diese Umstände führen derzeit zu einer schwankenden Qualitätsgüte der Ergebnisse und stellen gerade im Hinblick auf die Produktsicherheit eine immense Herausforderung dar. Aus den genannten Gründen soll die Maker-Szene mit Hilfe des vorliegenden Beitrags zur Erzeugung funktional abgesicherter Geometriemodelle befähigt werden.

Normada arbetar med att utveckla additivt tillverkade (3D-printade) möbler i skandinavisk stil och vill nuutöka sin produktportfölj med mindre produkter, såsom en sänglampa. Denna rapport fokuserar på att lösa ettvanligt problem med sänglampor idag, nämligen att de oftast antingen ger riktat ljus lämpligt för läsning ellerspritt ljus som skapar en mysig atmosfär. Det innebär att de sänglampor som människor har hemma antingeninte kan erbjuda en mysig spridd ljusstämning eller att det är svårt att läsa i det utstrålande ljuset. Detta projekthar hotell som målgrupp.Detta projekt syftar till att lösa detta problem genom en designprocess som identifierar dagensanvändarcentrerade utmaningar för att sedan lösa dem under processens gång. Målet är att utveckla en fulltfungerande produkt som är så nära produktionsklar som möjligt. Detta projekt utförs under vårterminen 2023på Luleå tekniska universitetet och är ett examensarbete på kandidatnivå som en del av utbildningen tekniskdesign.Projektet resultera i en sänglampa i skandinavisk stil som är fullt fungerande. Lampan kommer ha riktbarlampskärm med en avbländare som ger en mer spridd ljusupplevelse samtidigt som den tillgodoser möjlighetenatt kunna läsa i ljuset. Lampan har kvar optimeringsmöjligheter men är redo att produceras i små skalor. / Normada specializes in the development of additive manufactured (3D-printed) furniture in Scandinavian styleand aims to expand its product portfolio to include smaller items, such as a bedside lamp. This report focuseson addressing a common problem with bedside lamps today, namely that they typically either provide focusedlight suitable for reading or diffuse light that creates a cozy atmosphere. This means that the bedside lampspeople have at home either cannot offer a pleasant, diffuse lighting experience or it is challenging to read inthe emitted light. This project has hotels as the target group.This project aims to solve this problem through a design process that identifies current user-centered challengesand addresses them throughout the process. The goal is to develop a fully functional product that is as closeto production-ready as possible. The project is conducted during the spring semester of 2023 at LuleåUniversity of Technology as part of the bachelor's degree program in Industrial Design EngineeringThe project will result in a fully functional bedside lamp in Scandinavian style. The lamp will have adirectionally adjustable lampshade and a screen that provides a more even light distribution while fulfilling therequirements for reading. Although the lamp still has optimization possibilities, it is ready for production insmall scales.

In this bachelor thesis, I examine how automation of fused filament fabrication (FFF) can be implemented, and what the limitations are for different kinds of automation solutions for FFF. Fused filament fabrication is a 3D-printing technology where a material is extruded through a nozzle, layer by layer, to create a print. The thesis also provides a calculation for the commercial feasibility of small batch rapid production with the implementation of an automation solution for FFF. The approach was a qualitative study containing five interviews, combined with empirical knowledge and data from the additive manufacturing company Svensson 3D. This was complemented with an analysis of which criteria to use when evaluating FFF automation solutions, and a framework for looking at FFF from an operator perspective. To calculate commercial feasibility of automation solutions for FFF, Internal Rate of Return and Payback Time were used. This resulted in six criteria to evaluate solutions for automation of FFF, three evaluations of problems within three solutions for automation of FFF, and a finding showing that small batch rapid production is commercially feasible with automated FFF. Lastly, the thesis contains a discussion regarding what the future is for FFF, and the limitations of the framework presented for evaluating automated FFF systems. Possible promising solutions for automated FFF are presented, together with ideas for how design for additive manufacturing can help shape the future of automated FFF. / I det här kandidatarbetet undersöker jag hur automatisering inom fused filament fabrication (FFF) kan implementeras, och vad begränsningarna är för olika sorters automatiseringslösningar för FFF. Det läggs även fram en uträkning för den kommersiella gångbarheten för small batch rapid production med implementeringen av ett automatiskt FFF-system. Tillvägagångsättet bestod av en kvalitativ studie baserad på fem intervjuer, kombinerad med empirisk kunskap och data från additiva tillverkningsföretaget Svensson 3D. Det här kompletterades med en analys av vilka parametrar som bör användas för att utvärdera lösningar för FFF-automatisering, och ett ramverk där automatiseringslösningarna betraktas ur ett operatörs-perspektiv. För att räkna ut den kommersiella gångbarheten för automatiseringslösningar av FFF användes internränta och återbetalningstid. Det här resulterade i sex parametrar för att utvärdera automatiseringslösningar för FFF, tre utvärderingar av vilka problem som finns i tre existerande automatiseringslösningar, och slutsatsen att small batch rapid production är kommersiellt gångbart för automatiserad FFF. Slutligen innehåller arbetet en diskussion gällande framtiden för FFF och begränsningarna hos det ramverk som presenterades för att utvärdera automatiserade FFF system. Möjliga lovande lösningar för automatiserad FFF presenteras och hur design för additiv tillverkning kan hjälpa till att forma framtiden för automatiserad FFF.

[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

Detta examensarbete handlar om framställandet av en dokumentation för konstruktörer inom området 3D-skrivning. Arbetet är ett uppdrag från elbilstillverkaren Ecoist i syftet att underlätta för företag med begränsad kunskap och erfarenhet inom 3D-utskrifter att utnyttja tillverkningsmetoden för sina produkter. Dokumentationen skall innehålla riktlinjer för materialval, konstruktionsprinciper, och inställningar för 3D-utskrifter. För att begränsa arbetet till tidsramen läggs fokus på en typ av skrivare. Den valda typen är FDM eftersom det är den bedöms vara mest tillgängliga, både i pris och utbud. De material och dess egenskaper som betonas i dokumentationen är ASA, PETG, PLA, PP och TPU. Det huvudsakliga arbetet kommer främst innefatta faktainsamling och sammanställning från befintliga information, men även laborationer med 3D-skrivare. Kapitelindelningen i dokumentationen är strukturerad för att följa konstruktörens arbetsprocess. Den inleds med materialval, fortsätter med konstruktion och avslutas med inställningar för 3D-skrivare. I materialegenskaper behandlas de grundläggande egenskaperna hos olika material som används inom 3D-utskrift, med särskilt fokus på deras hållfasthet, miljöpåverkan, användningsområde samt för- och nackdelar. Konstruktionsriktlinjer handlar om utformning av detaljer, inklusive minsta detaljtjocklek, hantering av överhäng, fasning, efterbearbetning, integrering av fästelement samt toleranser mellan närliggande delar. Fokus ligger på att säkerställa att detaljerna är konstruerade för att vara hållbara och funktionella efter tillverkning med 3D-skrivare. Inställningar för 3D-skrivare handlar om STL-filer, olika typer av ifyllnadsmönster samt vanliga defekter och åtgärder för att motverka dem. Vidare behandlas materialspecifika inställningar för optimal justering av 3D-skrivaren. Vid utformningen av dokumentet läggs mest fokus på utseende och läsbarhet, samt ordning och struktur genom färgval, text/tabellspresentation och anpassandet av dokumentet för både fysiskt och digitalt exemplar. Hela dokumentationen finns i bilaga 1. / This thesis focuses on creating documentation for designers in the field of 3D printing. The project is commissioned by the electric car manufacturer Ecoist with the aim of helping companies with limited knowledge and experience in 3D printing to utilize this manufacturing method for their products. The documentation will include guidelines for material selection, design principles, and 3D printing settings. To fit the project within the given timeframe, the focus is limited to one type of printer. The selected type is FDM, as it is considered the most accessible in terms of price and availability. The materials and their properties emphasized in the documentation are ASA, PETG, PLA, PP, and TPU. The main work will primarily involve gathering and compiling information from existing sources, but also conducting experiments with 3D printers. The chapters in the documentation are structured to follow the designer's workflow. It begins with material selection, continues with design, and concludes with 3D printer settings. In material properties, the basic characteristics of different materials used in 3D printing are covered, with a particular focus on their strength, environmental impact, areas of use, as well as their advantages and disadvantages. Design guidelines involve the configuration of details, including minimum detail thickness, handling of overhangs, chamfering, post-processing, integration of fasteners, and tolerances between adjacent parts. The focus is on ensuring that the details are designed to be durable and functional after manufacturing with a 3D printer. 3D printer settings cover STL files, different types of infill patterns, and common defects along with countermeasures to avoid them. Furthermore, material-specific settings for optimal adjustment of the 3D printer are presented. In the design of the document, the emphasis is on appearance and readability, as well as order and structure through the choice of colors, text/table presentation, and adapting the document for both physical and digital copies. The entire documentation is included in Appendix 1.

<p>Metal 3D printing typically requires high energy laser or electron sources. Recently, 3D printing using metal filled filaments becomes available which uses PLA filaments filled with metal powders (such as copper, bronze, brass, and stainless steel). Although there are some studies on their printability, the detailed study of their sintering and characterizations is still missing.</p> <p>In this study, the research is focused on 3D printing of bronze filaments. Bronze is a popular metal for many important uses. The objectives of this research project are to study the optimal processing conditions (like printer settings, nozzle, and bed temperatures) to print bronze metal filament, develop the sintering conditions (temperature and duration), and characterization of the microstructure and mechanical properties of 3D printed specimens to produce strong specimens.</p> <p>The thesis includes three components: (1) 3D printing and sintering at selected conditions, following a design of experiment (DOE) principle; (2) microstructure and compositional characterizations; and (3) mechanical property characterization. The results show that it is feasible to print using bronze filaments using a typical FDM machine with optimized printing settings. XRD spectrums show that there is no effect of sintering temperature on the composition of the printed parts. SEM images illustrate the porous structure of the printed and sintered parts, suggesting the need to optimize the process to improve the density. The micro hardness and three-point bending tests show that the mechanical strengths are highly related to the sintering conditions. This study provides important information of applying the bronze filament in future engineering applications.</p>