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Additive Manufacturing,Things must be known:

9/1/2016

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​Information and expertizes have spread all over the internet in form of videos and articles, showing how easily anyone can print the products simply through CAD modeling and pushing the print button. But, if you are into design and manufacturing, you’re probably guessing that there’s more to it.

And you’re right; there are few important things to know more about the additive manufacturing technology, if you’re seriously planning to develop products through this technology in near future.

Software for Rapid Prototyping:

​Software technology plays a crucial role in additive manufacturing process, and is constantly evolving to compliment the advancing 3D printing capabilities of the printer. The use of software spans across the additive manufacturing lifecycle right from sourcing ideas, designing the model and providing formatted data to printers, to monitoring and managing the printing process. It serves as an important link, enabling interfaces between computers and printers to allow entire 3D printing ecosystem to function efficiently.

In general, printing a part require 4 different software to ensure accuracy, reduced cost and quality. Also, special software packages are also required to convert solid geometries to lattice structures along with tools to perform simulations.

The journey from idea to the additive manufactured final part begins with sourcing the model either through rapidly growing 3D libraries or through 3D scanning techniques or through custom designs. This is followed by the design process where an exact 3D model of the product is prepared that will be printed, considering proper dimensions and geometrical accuracies. The next step is to optimize the geometry using software to suit the printing process and reduce material wastage. Finally, the software is also required to actually print the part and monitor the process to make print runs successful.

CAD Modeling Process:

​Unlike conventional modeling processes, developing 3D models for additive manufacturing requires a different approach. One of the important things to consider is the resolution of the geometry; too high resolution will consume more time to load and simultaneously print the part. On the contrary, a low-res model would develop prototype with poor quality. Moreover, the geometry to be developed is also material-sensitive.

As an example, products to be printed in plastic would require the dimensions of the holes in the design to be resized, as they would expand or contract during heating and cooling applications. Also, the geometry to be printed has to be thoroughly inspected for any open spaces and must be converted to “watertight”, to avoid errors in printing.

Design Optimization:

​Design optimization is a key to successful and cost effective utilization of additive manufacturing techniques. The purpose of using this advanced manufacturing technology is to reduce development cost and time, and thus, reducing material wastage during printing process remains a vital strategy. This requires the design engineers to understand the process of printing that requires rafts and supports to build the desired structure. Engineers have to identify a design that uses minimal support material that can also be removed easily once the part gets printed. Also, the design engineer must identify a balance between part density, strength and surface finish, and accordingly choose the material, printing speed and the used additive manufacturing technolgy.

To summarize, Right from sourcing the model, through designing and optimizing to monitoring printing process, the role of software is important across every step in the prototype or product development. Modeling methods require a good knowledge on the printing process, material to be used and the printing technology adopted.

Moreover, the need to optimize the design and apply lattice structures instead of solid geometry should be considered to reduce material consumption while maintaining the required strength of the product being developed. Successfully implementing rapid prototyping to gain the benefits of cost reduction and faster development schedules require manufacturers and engineers to adopt right processes and software technologies.

As such, 3D printing technology isn’t as easy as it seems. There’s so much more to it than simply creating a CAD model and pushing the print button.
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ASTM Committee F42 on Additive Manufacturing Technologies:

1/1/2016

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Definition:

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​ASTM Committee F42 on Additive Manufacturing Technologies was formed in 2009. F42 meets twice a year, usually in January and July, with about 70 members attending two days of technical meetings. The Committee, with a current membership of approximately 215, has up to now 4 technical subcommittees; all standards developed by F42 are published in the Annual Book of ASTM Standards, Volume 10.04.

Committee Scope:

​The promotion of knowledge, stimulation of research and implementation of technology through the development of standards for additive manufacturing technologies. The work of this Committee will be coordinated with other ASTM technical committees and other national and international organizations having mutual or related interestes.

F42 subcommittees and standards under the jurisdiction of F42:

1- Subcommittee F42.01 on Test Methods:

Current Standards:
  • F2971-13 Standard Practice for Reporting Data for Test Specimens Prepared by Additive Manufacturing.
  • F3122-14 Standard Guide for Evaluating Mechanical Properties of Metal Materials Made via Additive Manufacturing Processes.
  • ISO/ASTM52921-13 Standard Terminology for Additive Manufacturing-Coordinate Systems and Test Methodologies.

Work item under development:
  • WK49798 New Guide for Intentionally Seeding Flaws in Additively Manufactured (AM) Parts.
  • WK49229 New Guide for Anisotropy Effects in Mechanical Properties of AM Parts.
  • WK49272 New Test Methods for Characterization of Powder Flow Properties for AM Applications.

2- Subcommittee F42.04 Design:

Current Standards:
  • ISO/ASTM52915-13 Standard Specification for Additive Manufacturing File Format (AMF) Version 1.1.

Work item under development:
  • WK38342 New Guide for Design for Additive Manufacturing.
  • WK48549 New Specification for AMF Support for Solid Modeling: Voxel Information, Constructive Solid Geometry Representations and Solid Texturing.
  • WK51841 Principles of Design Rules in Additive Manufacturing.

3- Subcommittee F42.05 Materials and Processes:

Current Standards:
  • F2924-14 Standard Specification for Additive Manufacturing Titanium-6 Aluminum-4 Vanadium with Powder Bed Fusion.
  • F3001-14 Standard Specification for Additive Manufacturing Titanium-6 Aluminum-4 Vanadium ELI (Extra Low Interstitial) with Powder Bed Fusion.
  • F3049-14 Standard Guide for Characterizing Properties of Metal Powders Used for Additive Manufacturing Processes.
  • F3055-14a Standard Specification for Additive Manufacturing Nickel Alloy (UNS N07718) with Powder Bed Fusion.
  • F3056-14e1 Standard Specification for Additive Manufacturing Nickel Alloy (UNS N06625) with Powder Bed Fusion.
  • F3091/F3091M-14 Standard Specification for Powder Bed Fusion of Plastic Materials.

Work item under development:
  • WK51282 Additive Manufacturing, General Principles, Requirements for Purchased AM Parts.
  • WK51329 New Specification for Additive Manufacturing Cobalt-28 Chromium-6 Molybdenum Alloy (UNS R30075) with Powder Bed Fusion.
  • WK37654 New Guide for Directed Energy Deposition of Metals.
  • WK46188 New Practice for Metal Powder Bed Fusion to Meet Rigid Quality Requirements.
  • WK48732 New Specification for Additive Manufacturing Stainless Steel Alloy (UNS S31603) with Powder Bed Fusion.

4- Subcommittee F42.06 Environment, Health, and Safety: 
(Under development).

5- Subcommittee F42.90 Executive: 
(Under development).

6- Subcommittee F42.91 Terminology:

Current Standards:
  • F2792-12a Standard Terminology for Additive Manufacturing Technologies

7- Subcommittee F42.94 Strategic Planning:
(Under development).

8- Subcommittee F42.95 US TAG to ISO TC 261:
(Under development).
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    Eng. Rami Khalil

    Mechanical Design and Production Engineer.

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