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A process for estimating minimum feature size in selective laser sintering

Weiss, Benjamin; Diegel, Olaf LU ; Storti, Duane and Ganter, Mark (2018) In Rapid Prototyping Journal 24(2). p.436-440
Abstract

Purpose: Manufacturer specifications for the resolution of an additive manufacturing (AM) machine can be ten times smaller (more optimistic) than the actual size of manufacturable features. Existing methods used to establish a manufacturable design rule-set are conservative piecewise-constant approximations. This paper aims to evaluate the effectiveness of a first-order model for producing improved design rule-sets for feature manufacturability, accounting for process variation. Design/methodology/approach: A framework is presented which uses an interpolation method and a statistical model to estimate the minimum size for a wide range of features from a set of iterative experiments. Findings: For an SLS process, using this approach... (More)

Purpose: Manufacturer specifications for the resolution of an additive manufacturing (AM) machine can be ten times smaller (more optimistic) than the actual size of manufacturable features. Existing methods used to establish a manufacturable design rule-set are conservative piecewise-constant approximations. This paper aims to evaluate the effectiveness of a first-order model for producing improved design rule-sets for feature manufacturability, accounting for process variation. Design/methodology/approach: A framework is presented which uses an interpolation method and a statistical model to estimate the minimum size for a wide range of features from a set of iterative experiments. Findings: For an SLS process, using this approach improves the accuracy and reliability of minimum feature size estimates for a wider variety of features than assessed by most existing test artifacts. Research limitations/implications: More research is needed to provide better interpolation models, broaden applicability and account for additional geometric and process parameters which significantly impact the results. This research focuses on manufacturability and does not address dimensional accuracy of the features produced. Practical implications: An application to the design of thin channels in a prosthetic hand shows the utility of the results in a real-world scenario. Originality/value: This study is among the first to investigate statistical variation of “pass/fail” features in AM process characterization, propose a means of estimating minimum feature sizes for shapes not directly tested and incorporate a more efficient iterative experimental protocol.

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Please use this url to cite or link to this publication:
author
organization
publishing date
type
Contribution to journal
publication status
published
subject
keywords
Benchmarking, Design rules, Minimum feature size, Process characterization, Selective laser sintering
in
Rapid Prototyping Journal
volume
24
issue
2
pages
5 pages
publisher
Emerald Group Publishing Limited
external identifiers
  • scopus:85045394832
ISSN
1355-2546
DOI
10.1108/RPJ-01-2017-0001
language
English
LU publication?
yes
id
1b5518ce-0a98-4f71-83ec-30b70f6714db
date added to LUP
2018-04-24 15:54:15
date last changed
2019-06-11 03:45:58
@article{1b5518ce-0a98-4f71-83ec-30b70f6714db,
  abstract     = {<p>Purpose: Manufacturer specifications for the resolution of an additive manufacturing (AM) machine can be ten times smaller (more optimistic) than the actual size of manufacturable features. Existing methods used to establish a manufacturable design rule-set are conservative piecewise-constant approximations. This paper aims to evaluate the effectiveness of a first-order model for producing improved design rule-sets for feature manufacturability, accounting for process variation. Design/methodology/approach: A framework is presented which uses an interpolation method and a statistical model to estimate the minimum size for a wide range of features from a set of iterative experiments. Findings: For an SLS process, using this approach improves the accuracy and reliability of minimum feature size estimates for a wider variety of features than assessed by most existing test artifacts. Research limitations/implications: More research is needed to provide better interpolation models, broaden applicability and account for additional geometric and process parameters which significantly impact the results. This research focuses on manufacturability and does not address dimensional accuracy of the features produced. Practical implications: An application to the design of thin channels in a prosthetic hand shows the utility of the results in a real-world scenario. Originality/value: This study is among the first to investigate statistical variation of “pass/fail” features in AM process characterization, propose a means of estimating minimum feature sizes for shapes not directly tested and incorporate a more efficient iterative experimental protocol.</p>},
  author       = {Weiss, Benjamin and Diegel, Olaf and Storti, Duane and Ganter, Mark},
  issn         = {1355-2546},
  keyword      = {Benchmarking,Design rules,Minimum feature size,Process characterization,Selective laser sintering},
  language     = {eng},
  month        = {01},
  number       = {2},
  pages        = {436--440},
  publisher    = {Emerald Group Publishing Limited},
  series       = {Rapid Prototyping Journal},
  title        = {A process for estimating minimum feature size in selective laser sintering},
  url          = {http://dx.doi.org/10.1108/RPJ-01-2017-0001},
  volume       = {24},
  year         = {2018},
}