Additive Fertigung

Simulated Production Environment Today

Simulated Production Environment Today

Evaluation of the numerical process simulation of selective laser melting
Emre Sahin ORCID Icon, Lennart Grüger ORCID Icon, Sebastian Härtel ORCID Icon
Numerical simulation for the optimization of conventional manufacturing processes is common practice in industry, but isn’t yet fully developed for generative manufacturing processes. The simulation of powder bed fusion (PBF) especially, with their more than 130 influencing factors, poses major challenges. Nevertheless, the methods developed can substantially accelerate product development, as an examination of common procedures and innovative approaches shows.
Industry 4.0 Science | Volume 40 | 2024 | Edition 4 | Pages 70-77 | DOI 10.30844/I4SE.24.4.70
Additive Manufacturing 4.0 Learning Factory

Additive Manufacturing 4.0 Learning Factory

Digitalization for batch size 1
Fabian Riß, Nicolas Rolinck, Stefan Böhm ORCID Icon, Alessandro Morath
In the course of digitalization, collaboration between humans and machines is inevitable. This should be considered as early as possible in further training. There’s a major obstacle to this in mechanical engineering: the lack of access to the knowledge needed for success. This can have a negative impact on the acceptance of digitalized processes. A teaching and learning platform teaching digitalization on real machines does important work here.
Industry 4.0 Science | Volume 40 | 2024 | Edition 4 | Pages 57-62
Spare Part Production of Vehicle Gearbox Bearings

Spare Part Production of Vehicle Gearbox Bearings

A method using additive manufacturing
Norbert Babel, Tobias Empl, Raimund Kreis ORCID Icon, Peter Roider
Spare parts for older products are often difficult to obtain or cannot be produced in an economically viable way using conventional manufacturing techniques. This article examines whether damping elements for gearbox bearings (in/for the automotive sector) can be manufactured from thermoplastic polyurethanes (TPU) with the same or compatible properties as the original part alternatively using additive manufacturing.
Industry 4.0 Science | Volume 40 | 2024 | Edition 2 | Pages 16-22
Sustainability in Industrial Manufacturing

Sustainability in Industrial Manufacturing

Resource-efficient circular economy through the use of a pellet 3D printer
Bruno Gallace, Michael Blug, Adrian Huwer ORCID Icon, Michael Mattern, Michael Wahl
In additive manufacturing – which is also known as 3D printing – plastic waste is produced, for example in the form of required support structures or faulty prints. One option for resource recirculation in additive manufacturing is direct use in a pellet 3D printer that incorporates fused granulate fabrication (FGF). The elimination of the filament production process step reduces the manufacturing time and the energy required for recirculation.
Industry 4.0 Science | Volume 40 | 2024 | Edition 1 | Pages 14-21
Improving Individual Patient Care and Hand Orthosis

Improving Individual Patient Care and Hand Orthosis

Implementing modern production processes using CAE Methods
Raimund Kreis ORCID Icon, Norbert Babel, Helmut Ersch
Finger fractures are usually still casted with plaster bandages. However, to avoid acampsia of the finger joints, flexibility exercises are necessary. Further disadvantages of the rigid plaster bandages are insufficient breathability and water resistance, weightiness and the necessity to apply wet and pliable plaster bandages to the injured patient. This article describes how individually designed hand orthoses without these disadvantages are attainable. With scans, modern software like STL editors (STL: Standard Tessellation Language) or CAD systems (CAD: Computer Aided Design) and additive manufacturing, complex, light weight and breathable structures are possible. Contrary to the solely mechanical art of casting with plaster, the new approach requires expertise in data processing and additive manufacturing seldom found in medical facilities. But this opens opportunities for service providers.
Industrie 4.0 Management | Volume 39 | 2023 | Edition 6 | Pages 37-41
Industrial Robots in Additive Manufacturing

Industrial Robots in Additive Manufacturing

Norbert Babel
The use of industrial robots in additive manufacturing has been increasing in recent years. Particularly due to the voluminous installation space and the great flexibility, they are predestined for the production of large-volume, individualised components. The multi-axis movement options of the print head attached to the end effector in conjunction with a swivel-tilt unit of the build platform mean that support structures can be dispensed with, which represents a major economic advantage.
Industrie 4.0 Management | Volume 39 | 2023 | Edition 2 | Pages 60-63
Sustainable and Intelligent Additive Manufacturing

Sustainable and Intelligent Additive Manufacturing

Early Recognition of Manufacturing Defects in 3D-Printing with Artificial Intelligence
Kai Scherer ORCID Icon, Sebastian Bast ORCID Icon, Julien Murach, Stephan Didas, Guido Dartmann, Michael Wahl
Additive manufacturing is an increasingly important manufacturing technology with huge economical potential. However, its popularity is accompanied by high material and time losses, as defects are often detected at a very late stage. One solution for a more sustainable production is the automated detection of manufacturing defects using artificial intelligence. This article describes the digitization of the defect detection process in additive manufacturing using a system based on a neural network. In addition to the steps for automated defect detection, system performance is also discussed.
Industrie 4.0 Management | Volume 39 | 2023 | Edition 2 | Pages 56-59
Development of a Camera for Abrasive Blasting

Development of a Camera for Abrasive Blasting

Stefan-Alexander Arlt, Norbert Babel, Raimund Kreis ORCID Icon, Thomas Andreas Schiffmann, Robin Schinko
Abrasive blasting is often used to clean work pieces. During the process an abrasive medium is propelled with compressed air toward a given surface. Common abrasives are sand, glass beads, steel or corundum. For safety reasons the blasting process is carried out in closed blast cabinets or rooms. Abrasives and cut off material are filling the air so that the visibility is limited. Quality assurance and safety monitoring of workers in blast rooms are therefore difficult which is essential e. g. in atomic power plant demolition. This article describes the development and test of a camera to improve this situation. Compressed air flows through the camera housing to keep particles away from the lens. The air flow was optimized by computational fluid dynamics. A prototype was made by 3D printing and tested in an blast cabinet.
Industrie 4.0 Management | Volume 39 | 2023 | Edition 1 | Pages 32-36
Digital Product Optimisation for the Use of Additive Manufacturing

Digital Product Optimisation for the Use of Additive Manufacturing

Michael Wahl, Martin Bonenberger, Julian Morbach, Adrian Huwer ORCID Icon, Lauri Hoffmann
Additive manufacturing, i.e. the printing of three- dimensional workpieces from different materials, offers the possibility of quickly producing functional prototypes. Digital optimisation is an important building block for the rapid implementation of functional product ideas. Based on digital models, the product is virtually optimised and continuously improved. Once the product has been digitally optimised in terms of its properties, it is checked and, if necessary, adapted for additive manufacturing. The product is then manufactured, reworked and finally tested. The article shows the optimisation possibilities using the example of a dispenser from the food industry. An existing component is digitised, a flow optimisation is carried out on the digital model and the improved product is additively manufactured.
Industrie 4.0 Management | Volume 38 | 2022 | Edition 5 | Pages 25-29 | DOI 10.30844/IM_22-5_25-29
Additive Manufacturing Value Chain

Additive Manufacturing Value Chain

Development of an SME-specific value chain of additively manufactured final metal parts
Tim Niklas Mai, Martin Brylowski, Ayman Nagi, Wolfgang Kersten ORCID Icon
Additive manufacturing processes are becoming increasingly important in industry and enable the cost-e ective production of complex components in small quantities. Small and medium-sized enterprises (SMEs) in particular can bene t from the high customization potential enabling the development of new business models. However, the widespread use of additive processes faces high production costs and technological challenges. Meanwhile, scienti c research focuses on the optimization of individual process steps of additive manufacturing and does not o er su cient support for SMEs. Therefore, this paper deals with the development of a cross-process value chain of additive manufacturing for SMEs. Based on a systematic analysis of scienti c literature, relevant additive manufacturing processes were investigated, and a cross-process value chain was derived. The results were veri ed by expert interviews and central research and development requirements were extracted.
Industrie 4.0 Management | Volume 38 | 2022 | Edition 3 | Pages 25-30 | DOI 10.30844/I40M_22-3_25-30
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