An overview of functionally graded additive manufacturing (original) (raw)
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Building a conceptual understanding of Functionally Graded Additive Manufacturing
2019
Technological progress in Additive Manufacturing (AM) hardware, software, as well as the opening of new markets and applications has encouraged research into novel materials with functionally graded and high performance capabilities. Functionally Graded Additive Manufacturing (FGAM) is a layer-by-layer fabrication technique that gradationally varies the ratio of the material organization within a component to achieve an intended function. As research in this field has gained worldwide interest, the interpretations of the FGAM concept requires greater clarification. The objective of this paper is to present a conceptual understanding of FGAM by clarifying key terms associated with FGAM. The current stateof-the-art and capabilities of FGAM technology are reviewed alongside with current technological obstacles and limitations, followed by recommendations on possible strategies to overcome those barriers for FGAM to take off.
Additive Manufacturing of Functionally Graded Objects: A Review
Volume 1A: 36th Computers and Information in Engineering Conference, 2016
Functionally graded materials (FGM) have recently attracted a lot of research attention in the wake of the recent prominence of additive manufacturing (AM) technology. The continuously varying spatial composition profile of two or more materials affords FGM object to simultaneously possess ideal properties of multiple different materials. Additionally, emerging technologies in AM domain enables one to make complex shapes with customized multifunctional material properties in an additive fashion, where laying down successive layers of material creates an object. In this paper, we focus on providing an overview of research at the intersection of AM techniques and FGM objects. We specifically discuss the FGM modeling representation schemes and outline a classification system to classify existing FGM representation methods. We also highlight the key aspects such as the part orientation, slicing, and path planning processes that are essential for fabricating a quality FGM object through ...
Functionally Graded Additive Manufacturing: Bridging the Gap between Design and Material Extrusion
Applied Sciences
Nowadays, the use of 3D printing is becoming a key process for on-demand and customized manufacturing. One of the most flexible 3D printing techniques is fused deposition modeling (FDM), where the combination of multiple materials was recently introduced. A quantum leap in part design is possible by integrating local variations between materials that allow for expanded functionality to be built into a single part. Therefore, the process of co-extrusion and material mixing is becoming more and more popular. The process of management and design of the engineered part are still complicated, and there are no commercially available tools that follow the process from design to production of these highly engineered products. This paper proposes a methodology to fill this gap and allow any designer to be able to produce multi-material parts by editing a G-code (computer numerical control programming language) with engineered gradients for FDM technology. More specifically, the proposed appr...
Design and additive manufacture of functionally graded structures based on digital materials
Journal of Additive Manufacturing, 2019
Voxel-based multimaterial jetting additive manufacturing allows fabrication of digital materials (DMs) at the meso-scale (∼1 mm) by controlling the deposition patterns of soft elastomeric and rigid glassy polymers at the voxel-scale (∼90 μm). The digital materials can then be used to create heterogeneous functionally graded material (FGM) structures at the macro-scale (∼10 mm) programmed to behave in a predefined manner. This offers huge potential for design and fabrication of novel and complex bespoke mechanical structures. This paper presents a complete design and manufacturing workflow that simultaneously integrates material design, structural design, and product fabrication of FGM structures based on digital materials. This is enabled by a regression analysis of the experimental data on mechanical performance of the DMs i.e., Young's modulus, tensile strength and elongation at break. This allows us to express the material behavior simply as a function of the microstructural descriptors (in this case, just volume fraction) without having to understand the underlying microstructural mechanics while simultaneously connecting it to the process parameters. Our proposed design and manufacturing approach is then demonstrated and validated in two series of design exercises to devise complex FGM structures. First, we design, computationally predict and experimentally validate the behavior of prescribed designs of FGM tensile structures with different material gradients. Second, we present a design automation approach for optimal FGM structures. The comparison between the simulations and the experiments with the FGM structures shows that the presented design and fabrication workflow based on our modeling approach for DMs at meso-scale can be effectively used to design and predict the performance of FGMs at macro-scale.
A study of 4D printing and functionally graded additive manufacturing
Assembly Automation, 2017
The purpose of this paper is to clarify the concept of Functionally Graded Additive Manufacturing and 4D printing. We defined that Functionally Graded Additive Manufacturing (FGAM) is a single AM process that includes the gradationally mixing of materials to fabricate freeform geometries with variable-properties within one component. This should not be used interchangeably with the term 4D Printing in which refers to the use of smart materials in Additive Manufacturing to produce parts that have the ability to change when exposed to an environmental stimuli. In this paper, we highlight that FGAM requires better computational tools for modelling, simulation and fabrication as current CAD systems are incapable of supporting the complex workflow, suggesting that future work should focus on aspects of material characterization and better control processes.
An Overview: Different Manufacturing Techniques used for Fabricating Functionally Graded Material
Materials Today: Proceedings, 2019
The industrial applications of functionally graded material (FGM) have increased with its specific capability. This makes curiosity among the researchers how to optimize the design and manufacturing technique as well as the numerical analysis methodology in the priority basis. Contrast to composite material, the properties of the FG material can be varied through the dimension. Usually, the properties are varied along the thickness direction by power distribution formula. However, it is possible to vary the properties of FG material along longitudinal and transverse direction with better improvised technique. Present study is an overview of FGM modelling, design and various manufacturing techniques used by past researchers as well as achieved current stage industrial applications. Further, this study can show a road map to current authors for improvising fabrication techniques in their research on FGM.
Development of 3D printer for functionally graded material using fused deposition modelling method
IOP Conference Series: Earth and Environmental Science
3D printing employed in additive manufacturing, converts digital data based on a computer-aided design (CAD) model into an object by adding material layer by layer. Unlike subtractive manufacturing, complex geometries can be printed with minimal wastage. The additive manufacturing process for 3D printers features several types of technology ranging from fused deposition modelling (FDM), laser sintering, stereolithography and laser melting to binder jetting and others. However, these technologies are limited to process one material at a time, which poses a challenge to print functionally graded material (FGM). This difficulty can be overcome by offering a unique solution which is proposed in this paper - by applying FDM customized with an extrusion screw to incorporate mixing and blending of the polymer matrix and filler as a continuous process during printing. The intent of this technique is to ease the production of FGMs (which vary in mechanical, electrical and texture gradually o...
Additive manufacturing: scientific and technological challenges, market uptake and opportunities
Materials Today
Additive manufacturing (AM) is fundamentally different from traditional formative or subtractive manufacturing in that it is the closest to the 'bottom up' manufacturing where a structure can be built into its designed shape using a 'layer-by-layer' approach rather than casting or forming by technologies such as forging or machining. AM is versatile, flexible, highly customizable and, as such, can suite most sectors of industrial production. Materials to make these parts/objects can be of a widely varying type. These include metallic, ceramic and polymeric materials along with combinations in the form of composites, hybrid, or functionally graded materials (FGMs). The challenge remains, however, to transfer this 'making' shapes and structures into obtaining objects that are functional. A great deal of work is needed in AM in addressing the challenges related to its two key enabling technologies namely 'materials' and 'metrology' to achieve this functionality in a predictive and reproductive ways. The good news is that there is a significant interest in industry for taking up AM as one of the main production engineering route. Additive Manufacturing, in our opinion, is definitely at the crossroad from where this new, much-hyped but somewhat unproven manufacturing process must move towards a technology that can demonstrate the ability to produce real, innovative, complex and robust products.
Functionally Graded Additive Manufacturing: A Teaching Case Study of Inex-Adam
Proceedings of the Design Society: DESIGN Conference, 2020
The multidisciplinary nature and lack of comprehensive 'materials-product-manufacturing' knowledge of Functionally Graded Additive Manufacturing (FGAM) require training to support the future Additive Manufacturing experts. INEX-ADAM, an EU funded project is building a transnational platform to promote FGAM. Brunel University London conducted two-day workshop on FGAM at the University of Zagreb in Croatia with academics and industry professionals. The workshop will strengthen the research capabilities to harness the potential of the FGAM and mitigate the constraints to industrial applications.
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2006
The inherent limitation of most solid freeform fabrication (SFF) is deposition in the form of layers. The setup rather than the geometry and the material composition of the part becomes more important in the process planning. For a functionally graded material (FGM), the desired composition variation is of infinitesimal order; however, the finite size of the deposition head and the molten pool allows for a quantized volume addition. Such artificial imposition of the process for the desired geometric morphology and the functional gradience of materials limit the accuracy of the part. The frequent variation in the material composition is yet another issue associated with the fabrication of FGMs. The suitability of a field can be attributed to the desired material distribution of a part. Different features of the field are identified and used as the input for process planning. The mathematical morphing of the material gradience allows a smooth variation of the material composition across the geometry of the part during deposition. The paper describes a framework for FGM representation using maxel, process planning, and implementation of the fabrication of geometries, and the control of the material composition. The experimental results for the suggested approach are described.