Browse Topic: Rapid prototyping
A digital twin is a virtual model that accurately imitates a physical asset. This can be as complex as an entire vehicle, a subsystem, and down to a small functioning component. The digital twin has a level of fidelity that aligns to the goals of the project team. The usage of a digital twin inside a digital engineering (DE) ecosystem permits architecture and design decisions for optimized product behavior, performance, and interactions. This paper demonstrates a methodology to incorporate the digital twin concept from requirement analysis, low fidelity feature level simulation, rapid prototypes running inside a System Integration Lab, and high fidelity virtual prototypes executing in an entirely virtual environment
The Software Production Factory (SPF) is a cyber physical construct of computers, hardware and software integrated together to serve as an ideation and rapid prototyping environment. SPF is a virtual dynamic environment to analyze requirements, architecture, and design, assess trade-offs, test Ground Vehicle development artifacts such as structural and behavioral features, and deploy system artifacts and operational qualifications. SPF is utilized during the product development as well as during system operations and support. The white paper describes the components of the SPF to build relevant Ground Vehicle Rapid Prototyping (GVRP) models in accordance with the model-centric digital engineering process guidelines. The factory and the processes together ensure that the artifacts are produced as specified. The processes are centered around building, maintaining, and tracing single source of information from source all the way to final atomic element of the built system
Tohoku University Sendai, Japan
Additive manufacturing (AM) is a common way to make things faster in manufacturing era today. A mix of polypropylene (PP) and carbon fiber (CF) blended filament is strong and bonded well. Fused deposition modeling (FDM) is a common way to make things. For this research, made the test samples using a mix of PP and CF filament through FDM printer by varying infill speed of 40 meters per sec 50 meters per sec and 60 meters per sec in sequence. The tested these samples on a tribometer testing machine that slides them against a surface with different forces (from 5 to 20 N) and speeds (from 1 to 4 meters per sec). The findings of the study revealed a consistent linear increase in both wear rate and coefficient of friction across every sample analyzed. Nevertheless, noteworthy variations emerged when evaluating the samples subjected to the 40m/s infill speed test. Specifically, these particular samples exhibited notably lower wear rates and coefficients of friction compared to the remaining
This article explores the impact of As-built versus annealed Fused Deposition Modeling (FDM) on the mechanical properties of test samples fabricated from two distinct materials: Polyamide 6 (PA6) and PA6 with carbon fiber filament. Employing the FDM technique, these samples were meticulously produced, with significant process parameters maintained at optimal values. Two sets of printed specimens were prepared for examination, one composed of PA6 and the other of PA6 with carbon fiber (CF) reinforcement. The first set was subjected to mechanical testing in its As-built condition, while the second set underwent an annealing process utilizing a muffle furnace. The annealing reduces internal stresses, enhances interlayer adhesion, and promotes crystallinity. For both the sent samples exposed to comprehensive assessments to evaluate various mechanical performance attributes, including hardness, impact strength, tensile strength and flexural strength. The results of this study elucidate that
Purdue University researchers have developed a patent-pending method to add particles to filament and disperse them evenly through a traditional fused deposition modeling, or FDM, 3D printer, which will aid industry in manufacturing functional parts
Additive manufacturing produces parts by adding material layer by layer with respect to time based on a computerized 3D solid model. The design model of Robotic arm was prepared using the solid works. The various components such as fingers, gripper, etc., were created and connected. After meticulous mathematical calculations, the design features of the robotic arm, including force analysis, are arrived at, and the arm is prepared to be operated using Bluetooth. Major challenges were faced during conversion of the designed model to prototype model. Furthermore, the components were created utilising fast rapid prototyping, which is more efficient than other traditional approaches. This technology has been effectively used in the production of light weight prototypes, tooling and the development low-cost bespoke designs. Finally, all the parts are assembled with Bluetooth control systems and validated with payload up to maximum of 10kgfor lowering and lifting
Avoiding the pitfalls of 3D printing requires knowing the process limitations - and how to work around them. An expert at a leading AM specialist shares insights on getting it right. As additive manufacturing (AM) technology and its applications expand, engineers are recognizing that different industrial 3D printing processes have different constraints that can affect designed parts in production. Some constraints are universal across the different processes, and some are more specific to the type of process used. It is thus essential to understand the technology you are working with to maximize its potential as a production method. With this understanding it is possible to design around the general limitations of AM as well as the specific process constraints that could impact a product or part. While design for manufacture (DfM) is not a new concept, the rules for designing for additive manufacture (DfAM) require design engineers to take a different approach. This article is
Senior level military members are constantly evaluating risk and finding ways to articulate and mitigate risks on the battlefield. When it comes to new technology adoption and consideration, these same leaders must take a similar approach to justify spending taxpayer dollars and implementing new processes to improve operational outcomes
Engineers have created a highly effective way to paint complex 3D-printed objects, such as lightweight frames for aircraft and biomedical stents, that could save manufacturers time and money and provide new opportunities to create “smart skins” for printed parts
When weight reduction is the primary goal, 3D-printed aluminum alloys are a frequent choice for aerospace and high-performance motorsports applications. Aluminum is much lighter than nickel alloys and has been particularly popular for laser powder-bed fusion (LPBF) because it’s good for prototyping and easy to post-process
Marotta Controls Montville, NJ 973-334-7800
The utilization of Additive Manufacturing (AM) technology in the current manufacturing sector is growing day - by - day. This is made possible by the constant development of new materials and techniques to overcome the difficulties that are encountered while fabricating a part. In AM, parts are fabricated by laying successive layers on one another till the complete part is build. This gives AM an edge over conventional manufacturing. Even intricate or hollow parts can be fabricated with the same ease as fabricating a solid part. The key objective of this project is to evaluate and compare mechanical properties of Polyethylene Terephthalate - Glycol modified (PETG) and Carbon fiber reinforced Polyethylene Terephthalate - Glycol modified (CF - PETG), which are fabricated using Fused Deposition Modelling (FDM) process of AM. The ASTM standards D638 and D790 were followed for fabricating tensile test and Flexural test specimens respectively. Subsequently, fractured specimens are analyzed
Fiber-reinforced polymer composites propose exceptional directional mechanical properties, and combining their advantages with the potential of 3D printing has resulted in many novel research fronts. Industries have started using 3D printed components which are rapidly replacing conventional material components in most of the industries. Carbon fiber reinforced Polylactic Acid (PLA) often finds its application in reasonably high loading conditions working at lesser speed like lightweight gears, spanners, nuts, and bolts. Wear reduction is an important factor that plays an important role in prolonging the component's life. Hence, it is crucial to optimize 3D printing parameters to get desired strength according to the application. The aim of this paper is to conduct the wear rate test on the Fused Deposition Modelled (FDM) printed carbon fiber reinforced PLA parts, to identify the optimum printing parameters which are crucial for wear reduction. Two process parameters i.e. fill density
Assessment of the boundaries for self-ignition of unburned charge in spark ignition engines (also related to knock) is required for development of the engine concepts and controls with respect to charge composition, spark advance and valve timing when designing the gas engines with wide range of the fuel compositions and converting compression ignition engines to gas engines. In this paper the combination of the single-zone model of the SI engine and chemical kinetics modeling is evaluated as a rapid prototyping tool for prediction of the self-ignition of the unburned charge in SI engine. The single-zone model simulates the cylinder pressure history based on Wiebe heat release function. The simulation of the self-ignition of the unburned charge is performed with coupled solution of the system of ordinary differential equations for temperature and species concentration with detailed chemical kinetic mechanism. Three fuels were considered: primary reference fuel, methane, hydrogen. The
3D printing has the potential to revolutionize product design and manufacturing in a vast range of fields, from custom components for consumer products, to 3D-printed bone and medical implants. But the process also creates a large amount of expensive and unsustainable waste and takes a long time, making it difficult for 3D printing to be implemented on a wide scale
Additive manufacturing, also known as 3D printing, allows the fast and cost-effective production of complex high-quality components in a range of materials. The rise of this technology has been fast, and it is rapidly altering the manufacturing landscape
Additive manufacturing, also known as 3D printing, allows the fast and cost-effective production of complex high-quality components in a range of materials. The rise of this technology has been fast, and it is rapidly altering the manufacturing landscape. In 2019, the global additive manufacturing market size was valued at $11.58 billion and is predicted to grow at a CAGR (compound annual growth rate) exceeding 14% from 2020 to 2027 (GVR). Additionally, research from Deloitte shows that additive manufacturing is empowering industry 4.0
Constant innovation in machine design, compatible materials and design software is leading additive manufacturing from the prototype shop to the production floor. While the 3D-printed vehicle remains a dream, the technology also known as additive manufacturing (AM) already has proven its ability to create impressively complex part geometries in concepts such as EDAG's ‘Light Cocoon’ (https://www.edag.com/en/innovation/concept-cars). AM enabled the exquisite 8-piston brake calipers used by Bugatti, among other boutique components, and AM machines are becoming as ubiquitous as Bridgeport mills once were for advanced-prototype builds. Low-volume series production use has arrived - see VW news below. Greater scale is on the horizon, driven by constant innovation in machine design, compatible materials and design software. 3D printing technology and applications are exploding in the mobility space, high-lighted by the following recent examples
Looking for a high-resolution 3D printer? Resolution is an often discussed but seldom understood value in the world of 3D printing and additive manufacturing. How do XY and Z resolution influence the quality of your 3D prints? What’s minimum feature size and what layer thickness should you choose
“Think production!” Perhaps that advice should be posted on the wall of every design office, R&D lab and advanced technology center in the auto industry. Although obeying that warning is clearly not cost-effective in some instances, others are ostensibly perfect to take their place in volume manufacture. An example is 3D printing (aka additive manufacturing, or AM), but despite a broadening scope that now embraces rapid prototyping and tooling by entire houses, it could do better in series production of auto components, particularly in the new world of EVs. Prof. Peter Wilson of the U.K.'s newly established Institute for Advanced Automotive Propulsion Systems (IAAPS) at the University of Bath, noted the growing adoption of high-speed SiC (silicon carbide) and other wide-band-gap semiconductor devices demonstrates the benefits that 3D printing could have in the production of EV inverters. “SiC devices offer so much opportunity to improve inverter performance,” Wilson said. “But system
Dilute combustion with exhaust gas recirculation (EGR) in spark-ignition engines presents a cost-effective method for achieving higher levels of engine efficiency. At high levels of EGR, however, cycle-to-cycle variability (CCV) of the combustion process is exacerbated by sporadic occurrences of misfires and partial burns. Previous studies have shown that temporal deterministic patterns emerge at such conditions and certain combustion cycles have a significant influence over future events. Due to the complexity of the combustion process and the nature of CCV, harnessing all the deterministic information for control purposes has remained challenging even with physics based 0-D, 1-D, and high-fidelity computational fluid dynamics (CFD) models. In this study, we present a data-driven approach to optimize the combustion process by controlling CCV adjusting the cycle-to-cycle fuel injection quantity. Readily available data from in-cylinder pressure was used to train a spiking neural network
A new Cruise Control Algorithm (CCA) commanding the Internal Combustion Engine (ICE) and the Continuous Variable Transmission (CVT) of a 200 hp tractor was implemented on a Rapid Prototyping System (RPS) and successfully tested with an empty vehicle and with 16 t trailer from 0.5 to 50 kph. Low velocities required an extra controller and a good concept for transition to higher velocities
This document gives specific and measurable design requirements to be applied at a design review prior to tooling. The specification is formatted as a checklist to aid in its use. The requirements do not apply in all situations so engineering judgment must be used. This is a specification for design; applicable performance specifications (USCAR-2, etc.) must still be performed. Specific requirements in this document are grouped by component using a prefix as shown in Table 1 and are numbered by an item number following the prefix
Additive manufacturing can reduce the time and material costs in a design cycle and enable on-demand printing of customized parts. New multi-material 3D printers that can print both metal and dielectric materials enable the additive manufacturing of antennas and RF components. Developments in software are critical to leveraging this capability; good tools allow more effort to go towards creation than implementation. Three devices are described in detail in this article to demonstrate the 3D printing of RF components. First, a Marchand balun is presented, demonstrating rapid prototyping of a complex, multilayer RF circuit. Next, a monopole array is shown with an integrated beam-steering network and radome to show rapid prototyping of a complete antenna system. Finally, a bowtie antenna with rounded corners is presented, showing good performance in the Kuband
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