2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024): Data, Economics, and Education I
Program Organizers: Joseph Beaman, University of Texas at Austin
Tuesday 8:00 AM
August 13, 2024
Room: Salon G
Location: Hilton Austin
Session Chair: Yash Parikh, EOS of North America, Inc.
8:00 AM
Establishing a Crowdsourcing-based Data Collection Tool to Identify Sources of Build Failure in Novice AM Designs: Ethan Gross1; Nicholas Meisel1; 1Pennsylvania State University
The maker movement has led to an increase in publicly available makerspaces, where communities can work with design and manufacturing equipment, including additive manufacturing (AM) machines. A low barrier-to-entry is essential to maintaining inclusivity, allowing inexperienced patrons to use AM technology. However, this lack of experience subsequently encourages frequent print failures, which contributes to increased maintenance or user frustration. Build failures are caused by several variables, but commonly stem from build preparation, the slicing process, or user interference. To identify key causes behind failed AM builds in a student-focused makerspace, this paper outlines the formulation of a crowdsourcing-based data collection tool that automatically extracts design and build information through printer files and correlates it with student evaluations of their part’s final quality. This data allows for common sources of failure within the space to be readily identified. A case study is analyzed to demonstrate the tool’s general effectiveness and applicability.
8:20 AM
Networking and Cybersecurity Enabled Distributed Additive Manufacturing for Production of Critical Components at the Destination: Satyajayant Misra1; Chaitanya Mahajan1; 1New Mexico State University
Additive Manufacturing (AM) has emerged as a transformative approach to industrial production, offering unparalleled flexibility and efficiency in fabricating critical components directly at their point of use. The vision for AM is distributed at the destination, secure, intelligent, and privacy preserving manufacturing. To achieve this vision, there is a need for the creation of a holistic network and cybersecurity infrastructure that undergird the AM innovation and deployment. The design of a holistic networking and security architecture that truly enables AM requires use-inspired innovation to provide the infrastructural foundation. The holistic design requires a convergent approach across multiple disciplines and dimensions, collaborating to create a vision for use-inspired challenges and potential solutions. This proposed research will build a holistic networking and cybersecurity framework to enable decentralized AM manufacturing processes by supporting distributed operations, intellectual property protection, supply chain visibility, and remote quality control.
8:40 AM
Feasibility Analyses of Distributed Digital Factories Integrating Additive and Subtractive Manufacturing: A Case Study: Md Sazol Ahmmed1; Asad Waqar Malik2; Muhammad Arif Mahmood2; Sriram Praneeth Isanaka1; Frank Liou1; 1Missouri University of Science and Technology; 2Intelligent Systems Center, Missouri University of Science and Technology
Many small and medium additive and subtractive manufacturing industries face challenges in global competition due to limited access to advanced machinery and high overhead costs from frequent line changes. To tackle this challenge, the concept of a distributed digital factory (DDF) has emerged. For this purpose, a queuing model has been developed for feasibility analysis on traditional isolated co-located factory environments and DDFs. The proposed model uses global balance conditions to obtain actual performance measurements to identify variables efficiency and correlations. Several manufacturing scenarios integrating additive and subtractive industries aimed at pinpointing the threshold at which the distributed overhead impact reduces. Through these scenarios, the specific factors at which the DDF setup becomes more efficient and cost-effective have been postulated. The results demonstrate that the implementation of DDF led to a reduction in queue time by 31.18% and 33.15% in distributed facilities, compared to the traditional.
9:00 AM
Industrial Targets for High Productivity AM, Progress and Next Steps: Todd Spurgeon1; Elizabeth Chang-Davidson2; Ajay Krishnan1; 1Buffalo Manufacturing Works; 2NorthEastern University
Development and Maturation of high productivity L-PBF processing parameters must consider industry-dependent accepted post processes and quality thresholds. Additive Manufacturing for aerospace historically prioritizes material quality over process cost, whereas for automotive, reduction of process costs while maintaining an acceptable level of quality is the name of the game. Laser stirring has the potential to increase throughput and decrease part costs towards targets cited by the automotive industry. This study explores the potential impact of laser stirring on build rate and ultimate part cost, leveraging experimental data and simulation. The challenges and key phases in technology maturation and transition of laser stirring will also be illustrated.
9:20 AM
Finding a Middle Ground: Local Makerspaces as a Driver for the Circular Economy in Additive Manufacturing: Elijah Hudson1; Ismail Fidan1; Mohammad Alshaikh Ali1; Vivekanand Naikwadi1; Mushfig Mahmudov1; Shamil Gudavasov1; 1Tennessee Tech University
Additive manufacturing (AM) has been one of the driving forces behind the recent push for greater sustainability in the manufacturing sector, one of the main defining features of the industry 4.0 revolution. However, even though additive manufacturing is more environmentally friendly than traditional machining, it is far from a waste-free process, although it does make the goal of achieving a circular economy for supply chains in manufacturing more achievable. The complexity of reworking large-scale supply chains to include recycled material sources, along with the desire for more point of use supply of daily goods, points towards community makerspaces as a middle ground solution for achieving a full circular economy in manufacturing. The goal of this paper is to outline the challenges present in the current industry setup, and offer a proposal for why makerspaces could be used to push for more sustainable manufacturing.