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Innovation in composite additive manufacturing

Muir, Euan LU (2015) MMK820 20132
Product Development
Abstract
This master thesis contains an overview of existing additive manufacturing methods and considers possible new methods. The purpose being to develop a method for additive manufacturing that can create 3D objects with composite material and/or out of metal. Further this method should work on a low cost additive manufacturing machine. A development process is used in order to select an appropriate method. The method is then divided into parts that are individually analysed in order to produce a proof of concept model.
Initially an overview of existing patents regarding additive manufacturing was conducted in order to see if the devised problem was addressed and how. A patent search regarding both additive manufacturing of composites and of... (More)
This master thesis contains an overview of existing additive manufacturing methods and considers possible new methods. The purpose being to develop a method for additive manufacturing that can create 3D objects with composite material and/or out of metal. Further this method should work on a low cost additive manufacturing machine. A development process is used in order to select an appropriate method. The method is then divided into parts that are individually analysed in order to produce a proof of concept model.
Initially an overview of existing patents regarding additive manufacturing was conducted in order to see if the devised problem was addressed and how. A patent search regarding both additive manufacturing of composites and of metallic objects was performed.
The next phase was conducting a market overview of existing low cost 3D printers and selecting one model that was appropriate for purchase. The purchased 3D printer was then assembled and tested to build up a general experience of properties and limitations of low cost printers. These properties regard both control parameters, mechanical properties (such as eigen frequencies, resolution) and print limitations (typical errors, materials etc.).
Concept generation took place by brainstorming a wide range of possible ideas to address the project goal. Existing manufacturing methods and processes that inspired the concepts are described in the theory.
The final concept was selected by a process of first concept screening followed by concept scoring and selection. After screening the bulk of four concepts remained. One mainly addressed the goal of manufacturing metallic parts and the others composites. Further literary study of material properties and manufacturing processes relevant to these methods was conducted for the scoring step. Also appropriate retailers of materials and parts and machines were contacted for relevant cost information.
The selected concept uses photopolymers cured by UV radiation. In order to finalise the proof of concept a print head was constructed and several tests were conducted in order to observe possible fill rates and required radiation levels in order to achieve a required flow rate and curing times respectively.
Finally suggestions for further development and studies is summarised. (Less)
Popular Abstract
This project aimed to look at low cost 3D manufacturing technologies and develop a method to expand existing material options. Existing manufacturing methods for sets of materials were conducted in order to map out possible manufacturing steps. A review of existing models of 3D-printers was done and one was purchased and assembled. Design concepts were developed inspired by existing manufacturing methods and one method was selected using a pre-mixed compound and UV curing matrix material extruded through a nozzle and solidified with directed UV-LEDs in order to allow for manufacturing of composites. The method was verified to work and suggestions for further improvements and studies were made.
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author
Muir, Euan LU
supervisor
organization
course
MMK820 20132
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Composites Additive Manufacturing 3D-printing
ISSN
LUTMDN/TMKT 15/5525 SE
language
English
id
5468866
date added to LUP
2015-06-10 09:14:31
date last changed
2015-06-30 13:56:07
@misc{5468866,
  abstract     = {This master thesis contains an overview of existing additive manufacturing methods and considers possible new methods. The purpose being to develop a method for additive manufacturing that can create 3D objects with composite material and/or out of metal. Further this method should work on a low cost additive manufacturing machine. A development process is used in order to select an appropriate method. The method is then divided into parts that are individually analysed in order to produce a proof of concept model. 
Initially an overview of existing patents regarding additive manufacturing was conducted in order to see if the devised problem was addressed and how. A patent search regarding both additive manufacturing of composites and of metallic objects was performed.
The next phase was conducting a market overview of existing low cost 3D printers and selecting one model that was appropriate for purchase. The purchased 3D printer was then assembled and tested to build up a general experience of properties and limitations of low cost printers. These properties regard both control parameters, mechanical properties (such as eigen frequencies, resolution) and print limitations (typical errors, materials etc.).
Concept generation took place by brainstorming a wide range of possible ideas to address the project goal. Existing manufacturing methods and processes that inspired the concepts are described in the theory.
The final concept was selected by a process of first concept screening followed by concept scoring and selection. After screening the bulk of four concepts remained. One mainly addressed the goal of manufacturing metallic parts and the others composites. Further literary study of material properties and manufacturing processes relevant to these methods was conducted for the scoring step. Also appropriate retailers of materials and parts and machines were contacted for relevant cost information.
The selected concept uses photopolymers cured by UV radiation. In order to finalise the proof of concept a print head was constructed and several tests were conducted in order to observe possible fill rates and required radiation levels in order to achieve a required flow rate and curing times respectively.
Finally suggestions for further development and studies is summarised.},
  author       = {Muir, Euan},
  issn         = {LUTMDN/TMKT 15/5525 SE},
  keyword      = {Composites Additive Manufacturing 3D-printing},
  language     = {eng},
  note         = {Student Paper},
  title        = {Innovation in composite additive manufacturing},
  year         = {2015},
}