09:50
Session 1: Technologies for Additive Manufacturing
09:50
20 mins
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Photogrammetry in Large Format Additive Manufacturing: an alternative tool for machining setup and inspection
Pedro Andre Garcia Camino, Lucas Abia Hof, Simon Joncas
Abstract: Fused Granular Fabrication (FGF) based Large Format Additive Manufacturing (LFAM) combined with a subsequent machining step has recently been proven efficient in producing small to medium sized composite tooling such as moulds and trim jigs. After printing, the part’s working coordinate system (WCS) is generally precisely repositioned in the machining environment with respect to the true printed geometry. This step is currently performed using laser scanners or probes. Before machining, the printed part is also usually laser scanned for quality control purposes (in and after process) to ensure dimensional accuracy.
In this paper, photogrammetry is investigated as an alternative solution to laser scanning to determine the printed part WCS and dimensions. This method could lead to a drastic reduction in investment costs and processing time required for both steps. A series of experiments were conducted to qualify photogrammetry as a metrological tool. First, a test part of 300 x 300 x 150 mm was scanned with a Hexagon Absolute ARM 7-AXIS 8525-7 to create a benchmark digital part. Then, the same part was submitted to photogrammetry using a high resolution C1 camera and a custom scaling system. Images were then processed using MetaShape software. Both methods produced STL files that were overlayed using Polywork’s Metrology Suite to compare accuracy.
Preliminary results show that an accuracy of ± 1.5 mm can be easily achieved when compared to laser scanning. The primary source of error lies within the scaling artefacts used in the photogrammetry process, and these will be refined. Once this is addressed, an accuracy of ± 0.5 mm is expected. The final paper will present the integration of the photogrammetry system on a CEAD Flexbot large scale 3D printer on which WCS location and printed part measurement will be validated.
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10:10
20 mins
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Cost-effective large scale 3D printing of continuous fibre-reinforced thermoplastic composites using UD tapes
Erik Kramer, Menno Jan Rietema, Bert Weteringe
Abstract: Additive manufacturing with continuous fibre-reinforced thermoplastic composites offers significant potential for producing high-strength, lightweight structures. In this research, a novel 3D printing device was developed to print thermoplastic composites reinforced with continuous fibres, embedded directly within the printed bead. Unlike conventional continuous fibre 3D printing methods that require costly pre-manufactured filaments, this approach allows the direct use of standard unidirectional tapes ranging from 6 to 10 mm in width, eliminating an additional production step and reducing costs. The key innovation of this technique lies in its cost-effectiveness and scalability, making large-scale 3D printing with continuous fibres more accessible for industrial applications. This study presents an overview of the developed printing process, focusing on the integration of continuous fibres within thermoplastic materials, process optimization, and the resulting mechanical performance. Experimental results demonstrate significant improvements in the mechanical performance of printed components compared to traditional 3D printing techniques. This work contributes to advancing large-scale additive manufacturing by providing a more economical and efficient method for printing high-performance composite structures.
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