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University of Waterloo: Cellulosic Nanocomposites in Additive Manufacturing & Electrospinning

Andrew Finkle recently presented a thesis to the University of Waterloo, exploring the potential for more effective materials. In ‘Cellulosic Nanocomposites for Advanced Manufacturing: An Exploration of Advanced Materials in Electrospinning and Additive Manufacturing,’ Finkle continues the trend in refining techniques and additives for better performance.

This study centers around polymer nanocomposites; however, today researchers and manufacturers around the world are engaged in research using additives to create other unique materials too like composite hydrogels, bronze PLA, and composite SLS—all in hopes of accentuating specific projects which may require different mechanical properties or distinct features related to functionality.

Schematic diagram of typical electrospinning technique [3].

In terms of hardware and techniques, Finkle examines both electrospinning and fused filament fabrication (FFF) for use with thermoplastic nanocomposites in the production of electrospun fiber mats and 3D printed parts. The new filaments developed in this study contain reinforcements like nanocrystalline cellulose (NCC), meant to improve mechanical properties over traditional methods.

Typical morphology of electrospun polyamide-6 nanofibers observed with scanning electron microscope [4].

Schematic diagrams of fused deposition modeling (FDM) of thermoplastics from the patent “Apparatus and method for creating three-dimensional objects” by S. Crump including an FDM i) 3D printer and ii) extrusion head [8]

Nanocrystalline cellulose (NCC) is a derivative of wood pulp and has demonstrated potential for use as an additive for polymer composites—and specifically for this study, to accompany polycarbonate (PC)—a material offering a wide range of benefits, to include:

Heat resistance
Impact strength
Rigidity
Toughness

“The typical NCC whisker is on the order of 10 nm by 200 nm comprised of many cellulose β-glucan chains tightly bound together to form a very strong crystalline material,” explained Finkle. “The theoretical strength of NCC is on the order 9 of stainless steel and carbon nanotubes but unlike these inorganic reinforcements, is made from renewable and biocompatible sources.”

“The high strength makes this nanoparticle a great candidate for incorporation into composites and more specifically electrospun nanofibers.”

Electrospun mat morphology was based on the following:

Fiber diameter
Bead diameter
Bead density

Schematic diagram of a typical vertical electrospinning apparatus.

SEM micrographs of 15 wt-% PC nanofibers electrospun using chloroform. Fibers i) and ii) were electrospun using Vapp = 20 kV and iii) using Vapp = 15 kV over a gap distance of 15 cm.

“The formulation parameters chosen to explore within the DOEs are the polymer concentration in the solution, the concentration of additives (NCC). The processing parameters chosen to explore within each DOE included the applied voltage, Voltage, and gap distance, Gap Distance. Between the DOEs two other formulation parameters were explored,” explained Finkle.

“This included the solvent the polycarbonate solution was made in either a 60/40 (w/w) THF/DMF mixture or chloroform, both good solvents for PC. The second variable introduced between DOEs with the same solvent was 2-wt.-% of NCC (or DDSA-modified NCC, cNCC) in the solid mass (not including solvent).”

Summary of factors, levels, and formulation parameters for each DOE#0 through DOE#5

Standard order of experiments for a 23 full factorial DOE including the treatment shorthand notation and coded factor levels; high (1), center (0), and low (-1)

Design of experiments (DOEs) were investigated in terms of response to model fiber diameters in terms of:

Function of the PC concentration
NCC concentration
Applied voltage
Gap distance

Center-point measurements evaluated curvatures in the model, and solution properties were noted.

full factorial DOE#1, including the three different factors tested (coded a, b, and c) with their low (-1), high (+1), and center point (0) values

“For most of the experimentation, this involved: following a schedule, often electrospinning as soon as possible following sample preparation; minimizing any error in formulation and mixing of solutions; repeatable collection of nanofiber mats, as well as sample collection, preparation, and imaging of experimental specimens,” concluded Finkle.

“Although controlled as best as possible, some anomalies have still appeared. In particular, the center point replicates of DOE#4 – DDSA-modified Nanocrystalline Cellulose (cNCC) + Chloroform observed in Figure 4.30 show significant variance even though the experimental conditions were identical. This demonstrates that not only that electrospinning in volatile solvents like chloroform at room temperature is difficult to control, but that all possible variables for electrospinning must be considered carefully to achieve desired results.”

What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

[Source / Images: ‘Cellulosic Nanocomposites for Advanced Manufacturing: An Exploration of Advanced Materials in Electrospinning and Additive Manufacturing’]

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80 additive manufacturing experts predict the 3D printing trends to watch in 2020

Predicting the future is impossible. But that doesn’t stop us at 3D Printing Industry from inviting CEOs, CTOs and other AM experts to give us 3D printing predictions for 2020. If you want to stay up to date with the latest 3D printing news, subscribe to our free 3D Printing Industry newsletter. You’ll be among […]

How Hybrid Manufacturing Blends The Best of Both Worlds

For decades the manufacturing sector has been dominated by a single manufacturing principle – the principle of subtractive manufacturing. Subtractive manufacturing solved numerous problems, becoming a dominant force in the manufacturing industry, all while building everything from nuts & bolts to complex automotive and aerospace components.

Around three decades ago we saw the invention of a new technology that challenged the traditional manufacturing process – the additive manufacturing process. Additive manufacturing technology has several striking advantages over the subtractive processes, like the time-to-market, costs savings for batch productions, design freedom, and manufacturing complexity.

While some have weighed the advantages of each technology against the other, engineers developed a new technology by combing the best of both subtractive & additive technologies in a single technology – Hybrid Manufacturing.

Hybrid Manufacturing

In the last decade, we’ve seen a rapid and unprecedented rise in the demand & supply of 3D printers across the world thanks to revolutionary predictions industry experts have made. There’s no doubt that 3D printing has shown unprecedented advantages over previous manufacturing technologies, but it also has a higher purpose to achieve.

Experts believe that 3D printing also has the ability to shape more advanced manufacturing technologies like hybrid manufacturing. Hybrid manufacturing is the combination of additive and subtractive manufacturing technologies, which can perform multiple manufacturing and post-processing operations on a single machine.

Additive manufacturing has ignited the spark and led engineers to think, design and develop hybrid systems. Engineers believe that a measured use of both additive and subtractive (more specifically, manufacturing by additive and post-processing by subtractive) will be the most focused approach to developing the hybrid systems of the future.

This is the central philosophy behind the development of hybrid manufacturing systems; a system that is not purely subtractive nor additive, but a perfect blend of both.

Hybrid Manufacturing: A Blend of Subtractive & Additive Manufacturing

By combining additive and subtractive methods, hybrid manufacturing takes advantages of both these technologies by blended them to eliminate their respective drawbacks.

For example, a hybrid system blends the advantages of CNC Machining like repeatability, precision, high-quality surface finish, and high productivity and those of additive technology, such as less material wastage, design and manufacturing freedom, and new material options.

By combining methods, the system can eliminate certain drawbacks of either method, making hybrid manufacturing a highly desirable proposition for manufacturers.

Types of Hybrid Manufacturing Technologies

While hybrid manufacturing is still a relatively new concept, a good deal of processes and machines are already out there. They can be categorized into the following types, depending on the process used.

Wire-Arc Additive Manufacturing (WAAM)

While the typical additive manufacturing processes use metal powder to add layers, the Wire Arc Additive Manufacturing (WAAM) technology uses a metal wire. This wire is melted using an electric arc. The melted wire, in the form of beads, is then deposited and stuck together creating a layer of material. This process is carried out repeatedly in a layer-by-layer form until the complete solid object is formed.

WAAM has predominantly been used for local repairs on damaged or worn components, and to manufacture round components and pressure vessels for decades. But with the advent of strong CAD/CAM suites and better knowledge of additive manufacturing technology, WAAM can now be used to build objects from scratch itself.

Additionally, in recent years, a lot of materials have been integrated into the process. As a general rule, any material that is available as a welding wire can be used in WAAM systems. Some prominently used materials include stainless steel, nickel-based alloys, titanium alloys, and aluminum alloys.

This technology has a wide range of applications in industries like aerospace, marine, automobiles, and architecture.

Directed Energy Deposition (DED)

Directed Energy Deposition (DED) technology is a common AM technology that closely resembles the Powder-Bed Fusion (PBF) process. Here, a laser is used to melt the powdered material. However, the process of powder deposition and its subsequent melting differs and is more cost-effective, making it easily scalable while producing larger parts.

Cold Spray (CS)

In a Cold Spray manufacturing technology, the solid-state coating is deposited to build products in a layer by layer fashion. This technology is mainly used in repairing damaged parts like those in marine and aerospace industries. It’s great for parts that undergo severe wear and tear, but cannot be discarded due to the heavy initial investment to produce them.

The advantage of Cold Spray technology is that there is no heat breakdown of the feedstock, making it so the technology allows retaining of the materials’ original properties involved and creating oxide-free deposits. It’s a new technology and its inherent benefits are garnering a lot of attention among the science and manufacturing communities.

Ultrasonic Additive Manufacturing (UAM)

In this path-breaking process, sound waves are harnessed to join layers upon layers of the metal stock foil. This process results in an actual metallurgical fusion, which can use several metals.

Hybrid Manufacturing Applications

Hybrid manufacturing has several diverse applications, including molds and tooling. It can also be used for part repair and maintenance applications.

However, the most popular application for hybrid lies in the aerospace and healthcare industry. The core reason is that both these industries rely heavily on industry standards and adherence to strict regulations. For new technologies like additive manufacturing, the technology, the process, material, printed part, and even the machine has to be qualified before it can be used in a real-world application.

Additive manufacturing has been quite instrumental in the early development of hybrid systems. This not only shows the versatility of the technology, but also the capability it has to accommodate itself and even other new technologies to augment the entire manufacturing process. The world may think that hybrid is the way forward but the core still remains firmly rooted in the additive manufacturing technology.

The post How Hybrid Manufacturing Blends The Best of Both Worlds appeared first on Shapeways Magazine.

Main Challenges and Investments for 3D Printing of Medical Devices

Ahead of the Additive Manufacturing for Medical Devices Forum, we asked leading industry professionals about the biggest advantages and challenges in using additive manufacturing compared to traditional manufacturing processes. The results have been compiled into an infographic report to highlight opportunities and solutions to close the gap between research and commercialisation.

The survey results will provide insights on the following questions and more:

Is your organisation looking to introduce additive manufacturing, or expand its use in the next 12 months?
What do you feel are the biggest advantages and opportunities in using additive manufacturing for the medical device industry compared to traditional manufacturing processes?
How much is your organisation planning to spend on additive manufacturing services and solutions in the next 12 months?
What is the biggest challenge your organisation is facing in adopting, implementing and/or using additive manufacturing?

View the infographic to receive:

A full analysis on the key benefits and challenges associated with adapting additive manufacturing in highly regulated industries
Solutions to close the gap between research and commercialisation
Top predictions to ensure additive manufacturing maintains a leading position globally

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How 3D Printing is Changing the Cosmetics Industry

Everyday products that fill a household seem simple enough to make. However, most require a complex mold process. First, a liquid is poured into a mold cavity. After it dries, the mold is peeled away to reveal the new plastic design.

Items like plastic bottles, soap dispensers and medicine bottles are all made with this process. Most cosmetics also come in plastic containers made with mold releases.

The rise of 3D printing has made it easier than ever to design complex shapes without the need for a mold. The technology is making a significant impact on several industries, including the cosmetics industry.

3D Printing in the Cosmetics Industry

3D printing won’t replace injection molding entirely. In many cases, manufacturers combine the two methods.

For example, 3D printing is preferred for prototyping, since it’s low cost and easily transportable. Injection molding, on the other hand, is fast and highly repeatable — ideal for those who want to produce a huge volume of parts at once.

Experts agree, however, that 3D printing can have a major impact on the cosmetic industry.

A Custom Approach to Makeup

In 2014, the first portable 3D makeup printer — coined Mink, a combination of makeup and ink — was unveiled. Instead of a plastic case, consumers can select makeup printed on a thin sheet of paper. Using the Mink app, consumers choose a photo, then print either the whole image or a specific color.

In 15 seconds, you can have an entire palette of printed makeup — including eye shadow, blush, brow powder, etc. — in a custom creation of up to 16.7 million hues. Grace Choi, the printer’s inventor, says lipstick, lip gloss and nail polish will soon be available.

A New Type of Mascara Brush

Photo by Breakingpic from Pexels

Chanel has decided to utilize 3D printing in their mascara brush. The brand claims they can print micro cavities directly into the brush’s bristles, allowing smooth and even application without clumping. The new bristle design also avoids the need to redip the brush. The product is on the market and is being sold worldwide.

This revolutionary change is one of the firsts since Revlon introduced the classic tube and spiral brush design in the early 1900s. The new mascara, called Le Volume Revolution, will undoubtedly have an impact on the market. Will other manufacturers follow in the brand’s footsteps?

The Creation of Human Skin

Photo by NeONBRAND on Unsplash

One Shanghai-based cosmetic brand is set to disrupt the industry with a mission to develop cosmetics suitable for Asian women. The scientists used skin models and bio-ink technology to successfully create printed skin, complete with a dermis, epidermis and basement membrane.

Many believe this breakthrough could lead to less animal testing in the cosmetic industry. Plus, 3D printing live tissue allows cosmetic brands to invest more research into developing customized products.

An Advanced Skincare Routine

Face masks that promote skin health are extremely popular. At CES 2019, Neutrogena unveiled their new 3D printed product, MaskiD. Each mask is crafted to fit the individual wearer’s face, with ingredients suited to meet specific skin concerns, such as acne or dryness.

The tech works with a smartphone and the MaskiD app. Attach the Skin360 device, which scans the size of your pores and skin moisture levels, then offers recommendations. If you don’t have the Skin360, you’ll be asked to fill out a questionnaire and take a selfie. Afterward, a mask is 3D printed to fit your unique needs.

3D printing has already made an impact on the cosmetic industry. Many brands are turning toward the new tech as a way to create innovative designs and offer extreme personalization. Some brands have already made the leap, but will others follow suit? Only time will tell.

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Arcam EBM Center of Excellence: GE Additive Expands Additive Manufacturing Site by Three Times

If you had any questions regarding a potential slow down in 3D printing or additive manufacturing endeavors around the world, industry leaders like GE Additive should put those to rest, evidenced by a momentum that just doesn’t quit. Now, they are announcing the opening of another facility dedicated to AM, at the Arcam EBM Center of Excellence in Gothenburg, Sweden.

Featuring 15,000 square meters, the new site is centered in the Mölnlycke Business Park, within the Härryda municipality, southeast of Gothenburg. Up to 500 employees are expected to be working at the center, offering three times as much floor space as their previous building in Mölndal—and housing all production, research and development, and training and support divisions in one place.

GE Additive will now be able to place an even stronger focus on lean manufacturing, maximizing operations and production capacity, along with inviting more of their customers to learn about and make the transition to serial manufacturing with Arcam EBM systems. The plan is to continue expanding their ‘footprint’ in manufacturing, along with increasing research and development in both Europe and the US.

Today, GE Additive is comprised of Arcam EBM, Concept Laser, and additive material provider AP&C. Their highly integrated team is made up of experts in additive manufacturing, offering advanced technology and materials—all encouraging the clients they work with to strive for innovation within their industries, focusing on:

Solving manufacturing challenges
Improving business outcomes
Helping change the world for the better

“The Arcam EBM team in Gothenburg is energized to be in its new home—a dynamic, sustainable workplace—in a great location. We will harness that energy and continue to research, innovate and drive EBM technology further,” said Karl Lindblom, general manager GE Additive Arcam EBM.

“Throughout, we have benefited immensely from GE’s experience and know-how in applying lean manufacturing. Customers joining our annual user group meeting next month will be the first to see our Center of Excellence—which we hope will become a focal point for the entire additive industry,” added Lindblom.

Both GE Additive and Arcam EBM continue to contribute innovations to both the 3D printing and additive manufacturing realm, from opening a variety of new facilities around the world to working with others in many projects, ranging from development of combat vehicles to 3D printed high fashion, and much more, including accelerating the industry with other partnerships.

Established in 1997, Arcam AB began working with EBM 3D printing technology and delivered their first system in 2003. Just acquired by GE Additive in 2017, they have made huge strides in strengthening their offerings with EBM, along with offering metal part production in volume—and a technology that promotes latitude in design, strong material properties, and stacking ability.

What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

The new Arcam EBM facility interior

[Source / Images: GE Additive]

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3D Systems: Augmenting Your Workflow with Traditional and Additive Manufacturing

Combining Old and New Technology

Remember the days when people thought that we would all end up with our own home desktop 3D printers to make anything our hearts desired and would never have to leave the house to buy consumer goods again? While I’m not saying this future isn’t still in the cards (imagine never having to get in another shopping cart lane battle at the store!), most people have realized this might be just wishful thinking and are focusing on other uses for additive manufacturing – such as combining the technology with traditional forms of manufacturing.

Just because you’re interested in 3D printing doesn’t mean you have to completely forget about all of the existing manufacturing technologies – you can complement your workflow, learn something new, and add that skill to your wheelhouse. And try as you might, it’s not always economically feasible or the right choice for your business to switch completely over to 3D printing. So one more time for the people in the back – by combining conventional manufacturing with 3D printing, companies can truly augment and speed up their workflows.

3D Systems knows a little something about this, as the company offers both additive and subtractive manufacturing capabilities through its On Demand manufacturing services.

“Our online 3D printing portal was designed by engineers for engineers,” the 3D Systems On Demand webpage states. “Our goal is to make the process of ordering 3D printed parts and prototypes the easiest in the industry.”

This is what sets 3D Systems apart from other service bureaus in the market. In fact, the company just released an eBook, titled “The Benefits of Traditional and Additive Manufacturing from a Single Source,” that’s all about combining 3D printing with other types of manufacturing it offers, such as CNC machining, investment casting, injection molding, urethane casting, sheet metal, die casting, etc. The campaign for 3D Systems’ new eBook recently went live, and the book itself discusses different ways to combine additive and traditional manufacturing for the optimal effect, in addition to using your project budget in the most efficient way, speeding up time to market, and the best ways to fulfill design goals.

3D Systems On Demand service bureau offers traditional injection molding for low-volume projects, and most commercially available thermoplastics from production-grade tooling are available. Nearly 20 different materials are available, with ten finish options, including Light Texture, Mirror, and Color-Matching. A urethane casting service is also available for rapid prototyping purposes, with a wide array of materials and three different finishes offered.

“One of the greatest benefits of the Cast Urethane process is the ability to over-mold existing parts or hardware with a second material,” the website states.

Learn more about the traditional Capabilities such as Cast Urethane in the new eBook.

While you can visit many vendors to receive external prototyping and production services, there aren’t too many like 3D Systems that offer a full range of options in both traditional and additive methods. For example, less than a year ago, the company released its ProJet® MJP 2500 IC RealWax 3D printer, which lets existing investment casting operators switch to additive manufacturing for their patterns, using 3D Systems’ MJP 3D printing technology. In addition, its VisiJet® M2 ICast (MJP) material is wax, which means it will work within the existing foundry without requiring any updates or changes to furnaces or temperatures.

Four years ago, 3D Systems also highlighted its digital molding technology for the first time. This is a scalable 3D printing process – backed by the company’s configurable Figure 4® technology – that lets you do tool-less production, and is a good alternative for low-volume plastic part production.

3D Systems’ Figure 4®

Confederate Motors, which has been designing and manufacturing bespoke motorcycles in small batches for over two decades, has been collaborating with 3D Systems On Demand since 2014 in an effort to convert 140 different designs into prototypes and production parts for its P51 Combat Fighter. 3D Systems provides a one-stop shop for Confederate Motors’ motorcycle parts, including everything from the intake manifold and swing arm parts to the front and back fenders and the key to start up the motorcycle.

“With the exception of some engine components, wiring, wheels, tires and lighting, 3D Systems makes every part of the Fighter. We save a tremendous amount of time and hassle by being able to consolidate part production with one primary vendor. Parts go together better coming from the same vendor, and we can be assured that the part finish of everything will match,” said Jordan Cornille, a designer at Confederate Motors.

“We like to move quickly in our decision-making processes and design quickly in order to offer our customers as many solutions as possible within a certain time frame. We don’t produce thousands of copies of each model, and 3D Systems allows us to change designs frequently without committing to thousands of dollars worth of tooling.”

3D Systems used plenty of CNC machining to make the parts for the P51 Combat Fighter motorcycle; according to the 3D Systems On Demand site, this subtractive technology “is the best choice for rapid prototyping of high-quality metal and plastic parts” that need an extremely high degree of dimensional accuracy. The service bureau offers a variety of different materials and finishes for CNC machining and promises a standard delivery time of 1-2 weeks, based on the order.

As noted in its new eBook, the company also offers integrated additive and traditional manufacturing approaches, which is perfect for projects that need to combine the ability to manufacture complex shapes at a faster rate of speed with high precision. Room Temperature Vulcanization (RTV) is just one of these integrated processes – it uses 3D printed masters and silicone molds to produce high-quality parts in low to mid-volume batches, without having to rely on expensive hard tooling. The benefits of RTV include a large material selection, a shorter lead time, and the ability to over-mold existing hardware and parts with an additional material.

“When the 3D Systems On Demand service bureau was established several years ago, the company expanded its expertise and resources through strategic acquisitions, not only for 3D printing and additive manufacturing, but for traditional approaches as well,” the eBook states. “3D Systems On Demand now has a worldwide network of facilities to locally service companies that need a stable, reliable, well-resourced and uniquely experienced partner.”

To learn more about the wide variety of additive and traditional manufacturing processes that 3D Systems offers through its On Demand service bureau, check out the company’s new eBook, or contact us for more details.

[Images: 3D Systems]

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3D Printing and the Circular Economy Part 7: the Viability of 3D Printing

Circular Economy Cycle

It is important to address that waste is less of an issue when a mindset is adopted towards solving it. I make this disclaimer because as we have been looking into this series on the circular economy, we have initially outlined various ideals and thought processes opposed to focusing solely on 3D printing. Any mindset shift towards a more circular economy is necessary before we can utilize a technology to build towards this ideal.

3D printing is a great technology due to its ability to be an additive process versus a typical subtractive process that is found in most manufacturing environments. In this article, we will discuss a bit more on the implications of additive technology and other initiatives associated with it. This will help us to have a larger view of the circular economy as well in relation to additive manufacturing.

Additive technology is amazing in terms of waste reduction overall. When a technical system is built to create product based on building up, there is a larger ability for sustainable development as people print items as they need them. With a subtractive manufacturing process, products are created by taking away from larger materials. This can leave many pieces unusable after the initial product creation. This then leaves a product residue to either be thrown away or in need of further recycling. This then takes a lot of time to conduct, and it becomes an issue of efficiency within the circular economy framework. Not only does this process waste time, but one must now calculate other factors such as transporting residual waste and how much energy that consumes. There are a lot of factors that do not have deeper analysis in terms of the classical manufacturing process.

Image result for 3d printing waste management

3D Printing Waste

The additive manufacturing field is ripe for experimentation as it is a naturally disruptive concept and methodology. A very important thought process within the field currently is a focus on material development. Material development is essential when it comes to sustainability. Depending on polymer structures, we can build various materials that have specific properties that are of our liking. This can lead to materials that are also easier to recycle, as well as they have natural biodegradable properties. It is still important to build out a larger infrastructure of life that would lead to people actually being knowledgeable of their choices and how they affect the greater world. Although 3D printing inherently helps to prevent excess production, it is still a problem of lack of awareness for people in terms of their production and consumption rates. There are a large number of people making prototypes that fail in terms of print standards. This then leads to larger amounts of waste as well.

Image result for material development and additive manufacturing

Material Development

In terms of sustainability, additive manufacturing is better than traditional methods. It is still imperative to realize that we are at a loss in terms of sustainability if we are not working on infrastructures. This includes infrastructures of thinking as well as infrastructures of methodology. We must utilize technology such as 3D printing to benefit the world. We should not abuse the benefits that this technology can provide to the larger scale of humanity.

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Domin revamps its fluid power systems with Renishaw’s metal AM technology

UK-based fluid power systems manufacturer Domin has collaborated with metal 3D printing specialist Renishaw to redevelop some of its products. High-performance direct drive servo valves, used for transforming signals into pressure, at the company have been made smaller, cheaper and more efficient using the technology. Renishaw’s metal powder bed fusion printer RenAM 500Q has been […]

Additive Manufacturing Could Prove Promising in Development of Hydraulic Pumps

Saimaa University of Applied Sciences thesis student, Daniil Levchenko, explores the capabilities of complex 3D printing in ‘Design of a Hydraulic Pump for Construction with Additive Manufacturing Tools.’ While was and is well aware of some of the more exaggerated claims often made regarding the magic of 3D printing, Levchenko dedicated his thesis to examining the potential for fabricating a hydraulics system.

Levchenko’s focus is on prosumers, a group of users operating at the more advanced level in AM processes. The initial step was to outline what would be required for the hydraulics unit, and then begin examining the options for materials. After that, the researchers would design the pump, create a 3D model, 3D print the parts, and hopefully, test it in a lab.

“The idea of this study takes its origins in an article dedicated to a project of a group of engineering students from the University of Rhode Island,” states the author. “They designed, constructed, and tested a stabilization platform that would allow them to negate turbulent sea conditions and to use a 3D printer on-board. As one of the students specified, the project was directed to aid work of research ships that were located far from shores and might be needed for timely replacement of any piece of equipment.”

Stratasys Object30 Prime (on the left) and BCN3D Sigma (on the right) (BCN3D Technologies 2019 & Stratasys Ltd. 2016)

The three-month study was made up of two different parts: theoretical, and then a discussion/conclusion. Testing was performed on a Stratasys Objet30 Prime and a BCN3D Sigma 3D printer, with thermoplastic polymers chosen as the material, and tested regarding how it would mix with oil.

Materials that are available for the 3D printers

There were many obstacles encountered during the study, and the hydraulic pump was not completed. While the CAD model of the external gear pump was designed, the project was brought to a halt indefinitely due to complexities with the motor and then lack of a successful PLC-based controller circuit. There were time constraints on the brief three-month project too, with the study finally ending when neither parts for the pump-motor assembly or construction of the piece were coming to fruition.

Proposed gear (driving)

And although there was not an actual product to show for the research, Levchenko still sees the system as promising for developing areas where devices can be created on-site and on-demand; in fact, such pumps could offer critical services in rural or isolated geographies, especially with an accessible, mobile 3D printer that could fabricate affordable parts for wells and other machinery like hydraulic levers.

“The results of the theoretical study could have been implemented in a real-life model build with printers provided by the university. To the greatest regrets of the author, the conditions of the available machines required maintenance and they could not be used for concurrent construction. It should be possible to recreate the designed pump and test in laboratory conditions to acquire actual empirical data about its performance and reliability and to the overall applicability. It would also prove the viability of the concept,” concluded Levchenko.

“Another field to enlarge and improve this study could be the widening of the spectrum of the assessed materials and manufacturing techniques. An assumption of the author is that consideration and usage of selective laser sintering technique may greatly aid design freedom and the final properties of the pump. The technique is capable of creating geometries with good tolerances and surface tolerances.”

3D printing has been used in the design and fabrication of many different parts and systems to aid in helping developing countries and individuals in isolated areas, from the creating of manifolds to other hydraulic development and customized robotics. What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

A scheme of PolyJet printing process (The Technology House/Sea Air Space 2019)

[Source / Image: ‘Design of a Hydraulic Pump for Construction with Additive Manufacturing Tools’]

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