![]() ![]() Schematic showing required linkages between experimental and modeling thrusts in order to achieve science-based qualification. ![]() An example of a metal lattice structure is the Eiffel Tower with its Figure 1. Also, the AM processes are beneficial because they permit the fabrication of unique geometries, such as miniaturized metal lattice structures, that cannot be achieved using traditional techniques. This makes the technology much more flexible than traditional, subtractive techniques where new tooling or forming equipment is usually needed to accommodate design changes. ![]() Adjustments to the final structure are relatively straightforward and can be simply achieved by adjusting the 3D computer model. The additive process more » often involves less waste when compared to subtractive techniques because material is only added when and where it is needed. Conversely, in an AM process, material is added in individual volume elements and built up in a way similar to interlocking building blocks, but with volume elements that are typically the size of a grain of sand. « lessĪdditive manufacturing (AM), or three-dimensional (3D) printing as it is more commonly known, is defined as the process of joining materials and creating objects by melting, sintering, or fusing material in a layer-by-layer fashion coordinated via 3D model data.1 Subtractive, or traditional, manufacturing methodologies often consist of machining/removing material-like a sculptor-or forming material through the application of pressure-like a potter. The excavator was then used for digging as part of an equipment exposition validating the metallurgy of the printed part. The distal link of an excavator arm was printed using a wire feed metal inert gas (MIG) process. All hydraulics and electrical cabling passageways were printed into the manipulator there are no external hoses or cables. A dual arm hydraulic manipulator was printed in titanium using the ebeam process. Part definition decreases, but part size can be on the order of tens of cubic feet and hundreds of pounds.Two implementation examples are presented in this paper to illustrate the possibilities and to identify issues that remain. Larger parts are currently done with wire feed systems based on laser or arc (metal inert gas (MIG) or tungsten inert gas (TIG)) processes. While metal powder systems produce high definition parts, part size is limited. Metal powder spray can be done with laser or plasma. ![]() Electron beam (ebeam), laser, and binder jet are common methods to fuse metal powder-based systems. Large scale polymer builds often rely on post processing (machining) to provide a smooth finish to the part surface.Metal printing processes are much more diverse than polymer print processes. The larger the deposition rate, the lower the print resolution. Print resolution is based on the deposition rate of the printer. While polymer processes use a variety of materials, all polymer printers basically lay down a heated extruded bead of a certain width and height. However Oak Ridge National Laboratory (ORNL) has pioneered large scale polymer additive manufacturing with sufficient strength to print a car and frame, a small house, a “wet” submarine, and tooling to mold wind generator blades. Polymer-based AM has been available commercially for quite some time and is regularly used to facilitate prototyping and more » test fitting of parts later to be fabricated in metal or to produce low production quantity parts that do not require high structural strength. AM design rules are still being developed and must be applied differently based on the process and purpose of the final component, but progress is being made in practical implementation. While AM is not a panacea to fix bad design concepts, properly used AM can create features and capabilities otherwise not possible in machined or cast products. = ,Īdditive manufacturing (AM) in both polymer and metal has advanced to the point where it can substantially facilitate robot and remote system design and implementation. ![]()
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