Digital Manufacturing

Definition
• Digital manufacturing is the use of an integrated, computer-based system comprised of
simulation, 3D visualization, analytics and collaboration tools to create product and
manufacturing process definitions simultaneously.
• Digital manufacturing evolved from manufacturing initiatives such as design for
manufacturability (DFM), computer-integrated manufacturing (CIM), flexible
manufacturing and lean manufacturing that highlight the need for collaborative product
and process design.
• Many of the long-term benefits from product lifecycle management (PLM) cannot be
achieved without a comprehensive digital manufacturing strategy.
• Digital manufacturing is a key point of integration between PLM and shop floor
applications and equipment, enabling the exchange of product-related information
between design and manufacturing groups.
• This alignment allows manufacturing companies to achieve time-to-market and volume
goals, as well as realize cost savings by reducing expensive downstream changes.
Digital Manufacturing Applications
• Digital manufacturing is utilized across industries. An automotive
original equipment manufacturer (OEM) can design the entire
manufacturing process digitally (tooling, machining, assembly
sequencing, and factory layout) at the same time that designers are
designing the next vehicle program.
• This enables manufacturing engineers to provide immediate feedback
to designers if there are constraints in the part manufacturability.
• This collaboration between manufacturing engineers and designers
creates a holistic view of product and process design.
Digital Manufacturing Applications
• A high tech supplier can use a digital manufacturing system to create
a 3D simulation of a complete production line, and analyze the
different production variants and concepts as part of the request for
quote (RFQ) process.
• This transparency and precision in planning and proposal preparation
help the company gain greater customer confidence, and ultimately
win the contract.
Digital Manufacturing Applications
• Current initiatives in the development of digital manufacturing tools
involve improving user experience, so information is presented in the
context of tasks performed, allowing users to make better decisions
faster.
• Steps are being taken to provide direct connectivity with shop floor
hardware, such as programmable logic controllers (PLCs), machine
controllers and computer numerically controlled (CNC) machines.
• Unified platforms have also been developed to manage both PLM and
manufacturing execution system (MES) information.
Benefits of Digital Manufacturing
 Enables product, process, plant and resource information to be associated, viewed and taken
through change processes, with a consistent and comprehensive approach to production
design.
 Allows part manufacturing processes to be optimized within a managed environment to
produce flexible work instructions capable of displaying 2D/3D part information, along with
machining and tooling instructions.
 Reduces commissioning costs through simulation by validating robotics and automation
programs virtually.
 Helps you create factory models faster and ensure they are operating under optimal layout,
material flow and throughput before production ramp-up.
 Supports six-sigma and lean initiatives by providing a graphical environment to analyze
dimensional variation.
 Facilitates the sharing of quality data across your organization by generating complete,
verifiable CAD-based machine inspection programs for coordinate measuring machines (CMMs)
and numerical control (NC) machine tools.
 Executes production processes with real-time access to lifecycle data.
Benefits of Digital Manufacturing
 Enables product, process, plant and resource information to be associated, viewed and taken
through change processes, with a consistent and comprehensive approach to production
design.
 Allows part manufacturing processes to be optimized within a managed environment to
produce flexible work instructions capable of displaying 2D/3D part information, along with
machining and tooling instructions.
 Reduces commissioning costs through simulation by validating robotics and automation
programs virtually.
 Helps you create factory models faster and ensure they are operating under optimal layout,
material flow and throughput before production ramp-up.
 Supports six-sigma and lean initiatives by providing a graphical environment to analyze
dimensional variation.
 Facilitates the sharing of quality data across your organization by generating complete,
verifiable CAD-based machine inspection programs for coordinate measuring machines (CMMs)
and numerical control (NC) machine tools.
 Executes production processes with real-time access to lifecycle data.
CONCEPT OF DM
Fusion Deposition Modelling
• Fused deposition modeling (FDM) is a additive manufacturing
technology commonly used for modeling, prototyping, and
production applications.
Fusion Deposition Modelling
The Technology:
• The Fused Deposition Modelling (FDM) process constructs three-
dimensional objects directly from 3D CAD data. A temperature-
controlled head extrudes thermoplastic material layer by layer.
• The FDM process starts with importing an STL file of a model into a pre-
processing software. This model is oriented and mathematically sliced
into horizontal layers varying from +/- 0.127 - 0.254 mm thickness. A
support structure is created where needed, based on the part's position
and geometry. After reviewing the path data and generating the
toolpaths, the data is downloaded to the FDM machine.
Fusion Deposition Modelling
The system operates in X, Y and Z axes, drawing the model one layer at
a time. This process is similar to how a hot glue gun extrudes melted
beads of glue. The temperature-controlled extrusion head is fed with
thermoplastic modelling material that is heated to a semi-liquid state.
The head extrudes and directs the material with precision in ultrathin
layers onto a fixtureless base. The result of the solidified material
laminating to the preceding layer is a plastic 3D model built up one
strand at a time. Once the part is completed the support columns are
removed and the surface is finished.
Fusion Deposition Modelling
Process:
• FDM begins with a software process, developed by Stratasys, which
processes an STL file (stereolithography file format) in minutes,
mathematically slicing and orienting the model for the build process.
If required, support structures are automatically generated. The
machine dispenses two materials – one for the model and one for a
disposable support structure.
Fusion Deposition Modelling
Process:
• The thermoplastics are liquefied and deposited by an extrusion head, which follows a
tool-path defined by the CAD file. The materials are deposited in layers as fine as
0.04 mm (0.0016") thick, and the part is built from the bottom up – one layer at a
time. FDM works on an "additive" principle by laying down material in layers. A
plastic filament or metal wire is unwound from a coil and supplies material to an
extrusion nozzle which can turn the flow on and off. The nozzle is heated to melt the
material and can be moved in both horizontal and vertical directions by a numerically
controlled mechanism, directly controlled by a computer-aided manufacturing (CAM)
software package. The model or part is produced by extruding small beads of
thermoplastic material to form layers as the material hardens immediately after
extrusion from the nozzle. Stepper motors or servo motor are typically employed to
move the extrusion head.
Fusion Deposition Modelling
Process:
Several materials are available with different trade-offs between
strength and temperature properties. As well as acrylonitrile butadiene
styrene (ABS) polymer, polycarbonates, polycaprolactone,
polyphenylsulfones and waxes. A "water-soluble" material can be used
for making temporary supports while manufacturing is in progress, this
soluble support material is quickly dissolved with specialized
mechanical agitation equipment utilizing a precisely heated sodium
hydroxide solution.
Stereolithography
• Stereolithography – more commonly referred to as SLA 3D printing –
is one of the most popular and widespread techniques in the world of
additive manufacturing. It works by using a high-powered laser to
harden liquid resin that is contained in a reservoir to create the
desired 3D shape. In a nutshell, this process converts photosensitive
liquid into 3D solid plastics in a layer-by-layer fashion using a low-
power laser and photopolymerization.
Stereolithography
Every standard SLA 3D printer is generally composed of four primary
sections:
• A tank filled with the liquid photopolymer: The liquid resin is usually a
clear and liquid plastic.
• A perforated platform immersed in a tank: The platform is lowered into
the tank and can move up and down according to the printing process.
• A high-powered, ultraviolet laser
• A computer interface, which manages both the platform and the laser
movements
Stereolithography
Stereolithography
Stereolithography
Software
• As is the case for many additive manufacturing processes, the first step consists of
designing a 3D model through CAD software. The resulting CAD files are digitalized
representations of the desired object.
• If they are not automatically generated as such, the CAD files must be converted into
STL files. Standard tessellation language (STL), or “standard triangle language”, is a
file format native to the stereolithographic software created by the Abert Consulting
Group specifically for 3D Systems back in 1987. STL files describe the surface
geometry of the 3D object, neglecting other common CAD model attributes, such as
color and texture.
• The pre-printer step is to feed an STL file into a 3D slicer software, such as Cura. Such
platforms are responsible for generating G-code, the native language of 3D printers.
Stereolithography
SLA 3D Printing
• When the process starts, the laser “draws” the first layer of the print into the
photosensitive resin. Wherever the laser hits, the liquid solidifies. The laser is
directed to the appropriate coordinates by a computer-controlled mirror.
• At this point, it’s worth mentioning that most desktop SLA printers work upside-
down. That is, the laser is pointed up to the build platform, which starts low and is
incrementally raised.
• After the first layer, the platform is raised according to the layer thickness (typically
about 0.1 mm) and the additional resin is allowed to flow below the already-
printed portion. The laser then solidifies the next cross-section, and the process is
repeated until the whole part is complete. The resin that is not touched by the
laser remains in the vat and can be reused.
Stereolithography
Post-Processing
• After finishing the material polymerization, the platform rises out of
the tank and the excess resin is drained. At the end of the process, the
model is removed from the platform, washed of excess resin, and
then placed in a UV oven for final curing. Post-print curing enables
objects to reach the highest possible strength and become more
stable.
Stereolithography
Pros
• SLA is one of the most precise 3D printing techniques on the market.
• Prototypes can be created with extremely high quality, with finely detailed
features (thin walls, sharp corners, etc…) and complex geometrical shapes. Layer
thicknesses can be made as low as 25 μm, with minimum feature sizes between
50 and 250 μm.
• SLA provides the tightest dimensional tolerances of any rapid prototyping or
additive manufacturing technology: +/- 0.005″ (0.127 mm) for the first inch, and
an additional 0.002″ for each additional inch.
• Print surfaces are smooth.
• Build volumes can be as high as 50 x 50 x 60 cm³ without sacrificing precision.
Stereolithography
Cons
• Printing tends to take a long time.
• Steep slopes and overhangs require support structures during the building
process. Such parts may potentially collapse during printing or curing phases.
• Resins are comparatively fragile and therefore not suitable for functional
prototypes or mechanical testing.
• SLA offers limited material and color choice, usually offering black, white, grey
and clear material. Resins are oftentimes proprietary and therefore cannot be
easily exchanged between printers from different brands.
• SLA printing costs are comparatively high (e.g. machine, materials, lab
environment).
Stereolithography
Solid Ground Curing
Solid ground curing (SGC) is a photograph polymer-based added
substance assembling or 3D printing innovation utilized for delivering
models, models, examples, and creation parts. In which the generation
of the layer geometry is completed by methods for a powerful UV light
through a veil. As the premise of strong ground curing is the
presentation of each layer of the model by methods for a light through
a cover, the preparing time for the age of a layer is free of the nature of
the layer.
Solid Ground Curing
Solid Ground Curing
Solid Ground Curing
Solid Ground Curing
Solid Ground Curing Process
• Ascertaining cross segments. You need ascertaining a cross segment of each cut layer in light of the geometric
model of the part and the coveted layer thickness.
• Optical cover. The optical cover is produced fitting in with each cross segment.
• Covering the platform. In the wake of leveling, the stage is secured with a thin layer of fluid photopolymer.
• Mask positioning. The cover relating to the present layer is situated over the surface of the fluid pitch, and the
gum is presented to a powerful UV light.
• Residual fluid. The lingering fluid is expelled from the work piece by a streamlined wiper.
• Filling voids. A layer of softened wax is spread over the work piece to fill voids. The wax is then hardened by
applying a cool plate to it.
• The layer surface is trimmed to the coveted thickness by a processing plate.
• Covering work piece. The present work piece is secured with a thin layer of the fluid polymer, and stage 4 to
seven are rehashed for each succeeding upper layer until the point that the highest layer has been prepared.
• Melting. The wax is liquefied endless supply of the part.
Solid Ground Curing
Advantages of Solid Ground Curing
• Solid Ground curing framework do not need a help structure. No extra support
is needed since wax is utilized to fill the voids.
• Accuracy of procedure. The model created by Solid Ground Curing process is
nearly precise in the Z-bearing in light of the fact that the layer is processed after
each light-presentation process.
Disadvantages of Solid Ground Curing
• Too much waste. In spite of the fact that it offers great exactness combined with
high throughput, it delivers excessively waste.
• High operational costs. Its working expenses are relatively high because of the
frameworks many-sided quality.
Selective Laser Sintering (SLS)
• Selective Laser Sintering (SLS) is an additive manufacturing process
that belongs to the Powder Bed Fusion family.
• In SLS 3D printing, a laser selectively sinters the particles of a polymer
powder, fusing them together and building a part, layer by layer.
• The materials used in SLS are thermoplastic polymers that come in a
granular form.
• A SLS 3D printing service is used for both prototyping of functional
polymer components and for small production runs.
Selective Laser Sintering (SLS)
Selective Laser Sintering (SLS)
The process works as follows:
• The powder bin and the build area are first heated to just below the melting temperature of
the polymer.
• A re-coating blade spreads a thin layer of powder over the build platform.
• A CO2 laser then scans the contour of the next layer and selectively sinters—fuses together—
the particles of the polymer powder.
• When a layer is complete, the build platform moves downwards and the blade re-coats the
surface. The process then repeats until the whole part is complete.
• After printing, the parts are fully encapsulated in the unsintered powder. The powder bin must
cool before the parts can be unpacked, which can take a considerable amount of time—
sometimes up to 12 hours.
• The parts are then cleaned with compressed air or another blasting media, then they are ready
to use or further post-process.
Selective Laser Sintering (SLS)
Selective Laser Sintering (SLS)