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Dalla prototipazione
alla produzione additiva:
potenzialità attuali dei materiali polimerici e compositi
Dalla prototipazione
alla produzione additiva:
potenzialità attuali dei materiali polimerici e compositi
Prof. Paolo MinetolaDipartimento di Ingegneria Gestionale e della Produzione(DIGEP)
Stampa 3D - Additive Manufacturing: dalla tecnologia al product designCentro Congressi Torino Incontra – 14 novembre 2019
HISTORICAL DEVELOPMENT
1990 2000 2010
Syst
em
dev
elo
pm
en
t
Conceptual, functional and technical prototypes
Tooling and casting applications,pre-series production
End-usableproducts
RP
RT, RC, RM
AM3D
Printing
2
ADVANTAGES OF LAYERED MANUFACTURING
PRODUCT
• Design freedom
• Lightweight structures
(complex hollow shapes)
• Integrated design and assemblies
• Anatomical personalized
• Ergonometric design
• Customization individualization
PROCESS
• One machine, unlimited forms
• No mould required, no special tools
• Jig and fixture not required
• Undercuts admitted
• One manufacturing step
• Reduced operator intervention
• Time and cost only related
to size, not complexity
3
MACHINES
• Limited build rates
• Machine size limits product size
• Machine speed is limited
• Machines able to handle few materials or colors
PRODUCTS
• Overhangs require support structures
• Scarce superficial finish (post-processing required)
• Limited number of commercially available materials
mostly polymers (limited specifications and functionality)
• Most materials are still expensive
even if machines costs are coming down rapidly
DRAWBACKS OF LAYERED MANUFACTURING
Part
4
POLYMER
StratasysDimensionElite
Selective Laser SinteringEOS Formiga
INVESTMENTS
MarkforgedMark Two
Fused Deposition Modeling
MaterialsABS M30ABS ASAPC-ABSPLAHIPSNylon CarbonPA66 GFPETGTPUNylonOnyxCarbon fiberFiberglassKevlar
Stereolithography
MaterialsNylonNylon glass filledNylon Al filledNylon carbon filled
3ntrA4
Polyjet
Direct Ligth Processing
PhotopolymersMaterialsdevelopment
StratasysF370
CHARACTERIZATION
Computer Tomography
INVESTMENTS
SEM MicroscopeScan Box
New design approach
7
€ perpart
Complexity
TraditionalManufacturing
AdditiveManufacturing
Design for Manufacturing Design for Functionality
DESIGN FOR ADDITIVE MANUFACTURING
DESIGN FOR ADDITIVE MANUFACTURING
Analysis of theoriginal component
CAEOptimization
RedesignDesign for AM production
and CNC finishing
Production of conceptualprototyper
Objective: Minimization of the weight of the main bracket of ahinge for car doors by exploiting the potential of AdditiveManufacturing processes
ValidationFinal
validation
-63%
DESIGN EXPLORATION
POLYMERRESEARCH
Case study of
a polymeric component
Injection Moulding (IM) Additive Manufacturing (AM)
POLYMERRESEARCH
Case study of
a polymeric component
Break-even analysis
POLYMERRESEARCH
POLYMERRESEARCH
POLYMERRESEARCH
POLYMERRESEARCH
2015 – CubeSat Challenge
“FoldSat” model printed by Stratasys in ASA material by
means of a Fortus 400 mc system
Among over two hundred projects, the 1st prize was awarded to the "FoldSat" model of PaoloMinetola and Giovanni Marchiandi of the Department of Management and ProductionEngineering of the Politecnico di Torino, members of the Additive Manufacturing research groupcoordinated by Prof. Luca Iuliano.
The goal of this challenge was to design a small satellite frame optimized for additive manufacturing. By using the benefits of design for additive manufacturing (DFAM) principles:
- Mass distributions and materials can be rethought to minimize weight - Part count can be reduced to improve producibility and ultimately, cost can be reduced.
The international competition was promoted by the company Stratasys Vertical Solutions -Aerospace in collaboration with the GrabCAD platform. It required to design a frame forCubeSat-type satellites that was optimized for production through additive manufacturing(additive manufacturing) or 3D printing (3D printing) .
Award motivation:«FoldSat is an elegant design that leverages geometries only available with 3D printing. Paolo takes the concept even further by illustratinghow the design also implements DFAM (design for additive manufacturing) best practices. FoldSat also gets a bonus for incorporating allthe common CubeSat features, including PCB mounting slots and features for easy maintenance. Great job!»
http://goo.gl/juPLmH
POLYMERRESEARCH
17
MANUFACTURING
Part material
Support material
POLYMERRESEARCH
The production time by FDM can be cut down to an estimated 40% bymanufacturing the cube in its unfolded configuration together with areduction of about 30% of support material if compared to the foldedconfiguration (cube shape).
POLYMERRESEARCH
Main materials
currently
available
POLYMERRESEARCH
Main materials
currently
available
Material
Sintering (SLS)
Selective LaserFused DepositionModelling (FDM)
Drop on Demand (DoD)
Jetting Photopolymerization
Stereolithography(SLA)
Polyjet / Projet
Extrusion
Powder SolidLiquid
UV Lamp Laser
3 Dimensional
Printing (3DP)
1 Material1 Material+
+ Binder:
Digital Light Processing (DLP)
POLYMERRESEARCH
Multi Jet
Fusion (MJF)
+ Agents:
POLYMERRESEARCH
Performances of AM
polymeric parts
with fillers (Graphene, Carbon fibres, …)
FDM machine with 3 extruder heads
Different strategies for deposition of the graphite filled filament
POLYMERRESEARCH
Inserts(print paused)
POLYMERRESEARCH
Flexible parts
POLYMERRESEARCH
Flexible parts
with lattice structure
Self-supportinglattice by generativedesign
POLYMERRESEARCH
Actuators(one piece sealed parts)
Courtesy of HP
Courtesy of Festo
POLYMERRESEARCH
Heat
exchangers(one piece sealed parts)
POLYMERRESEARCH
Pellet
3D Printer
Pellet dimension:about 3 mm
Extrusion temperature:up to 280 °C
Bed temperature:Up to 90 °C
1. Detaching from the building platform and removal of support structures
2. Post curing: completely polymerization of the part
3. Sand papering and application of coatings
• Basic Step 3: Detachment + Post-curing + Coating
STEREO-LITHOGRAPHY (SLA)
POLYMERRESEARCH
Parameter Value
Return loss ≥ 30 dB
Insertion loss ≤ 0.4 dB
Rejection ≥ 40 dB
Dimension (width x height x length)
30 mm x 30 mm x 48 mm
Weight 16 g
Measured performance of the prototype
• Fifth-order WR51 stub filter in ABS-like
RF BENCHMARK: SLA PROTOTYPES
POLYMERRESEARCH
To 50 Micron Layer Resolution50 – 200microns
100microns
100microns
● Nylon/Onyx
● Fiberglass
● Kevlar
● Carbon Fiber 125microns
Two nozzle heads
One part - thousands ofcontinuous fibers
Markforged patented Technology
CONTINUOUS FIBER FILAMENT (CFF)
Nylon
Fiber
POLYMERRESEARCH
The reinforcement strategy can be changed layer by layer
REINFORCEMENT STRATEGIES
POLYMERRESEARCH
Materials for CFF(by Markforged)
FDM SACRIFICIAL CORES AND MANDRELS FOR COMPOSITE LAYUPS
Potential application: customized sacrificial tooling for repairing
POLYMERRESEARCH
Prof. Paolo Minetola
Associate Professor of Manufacturing SystemsPolitecnico di Torino – DIGEPDep. Management and Production EngineeringC.so Duca degli Abruzzi 24 - 10129 TorinoTel. +39-011-090.7210 or 7254Mob. +39-331-668.49.76 Fax. +39-011-090.7299e-mail: paolo.minetola@polito.itwww: iam.polito.itWinner of “The CubeSat Challenge”http://goo.gl/juPLmH
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