Relevant bibliographies by topics / Hybrid Metal and Polymer Additive Manufacturing

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  1. Journal articles
  2. Dissertations / Theses
  3. Book chapters
  4. Conference papers

Academic literature on the topic 'Hybrid Metal and Polymer Additive Manufacturing'

Author: Grafiati
Published: 6 September 2023

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Journal articles on the topic "Hybrid Metal and Polymer Additive Manufacturing"

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Silva, Miguel Reis, Jorge Domingues, João Costa, Artur Mateus, and Cândida Malça. "Study of Metal/Polymer Interface of Parts Produced by a Hybrid Additive Manufacturing Approach." Applied Mechanics and Materials 890 (April 2019): 34–42. http://dx.doi.org/10.4028/www.scientific.net/amm.890.34.

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The additive manufacturing of multimaterial parts, e.g. metal/plastic, with functional gradients represents for current market demands a great potential of applications [1]. Metal Polymer parts combine the good mechanical properties of the metals with the low weight characteristics, good impact strength, good vibration and sound absorption of the polymers. Nevertheless, the coupling between metal and polymers is a great challenge since the processing factors for each one of them are very different. In addition, a system that makes the hybrid processing - metal/polymer - using only one operation is unknown [2, 3]. To overcome this drawback, a hybrid additive manufacturing system based on the additive technologies of SLM and SL was recently developed by the authors. The SLM and SL techniques joined enabling the production of a photopolymerization of the polymer in the voids of a 3D metal mesh previously produced by SLM [4]. The purpose of this work is the study on the metal/polymer interface of hybrid parts manufactured from the hybrid additive manufacturing system [5]. For this, a core of tool steel (H13) and two different types of photo-polymers: one elastomeric (BR3D-DL-Flex) and another one rigid (BR3D-DL-Hard) are considered. A set of six samples for each one of metal core/polymer combination was manufactured and submitted to tensile tests.
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Setter, Robert, Jan Hafenecker, Richard Rothfelder, Sebastian-Paul Kopp, Stephan Roth, Michael Schmidt, Marion Merklein, and Katrin Wudy. "Innovative Process Strategies in Powder-Based Multi-Material Additive Manufacturing." Journal of Manufacturing and Materials Processing 7, no. 4 (July 24, 2023): 133. http://dx.doi.org/10.3390/jmmp7040133.

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Multi-material additive manufacturing (AM) attempts to utilize the full benefits of complex part production with a comprehensive and complementary material spectrum. In this context, this research article presents new processing strategies in the field of polymer- and metal-based multi-material AM. The investigation highlights the current progress in powder-based multi-material AM based on three successfully utilized technological approaches: additive and formative manufacturing of hybrid metal parts with locally adapted and tailored properties, material-efficient AM of multi-material polymer parts through electrophotography, and the implementation of UV-curable thermosets within the laser-based powder bed fusion of plastics. Owing to the complex requirements for the mechanical testing of multi-material parts with an emphasis on the transition area, this research targets an experimental shear testing set-up as a universal method for both metal- and polymer-based processes. The method was selected based on the common need of all technologies for the sufficient characterization of the bonding behavior between the individual materials.
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Falck, R., S. M. Goushegir, J. F. dos Santos, and S. T. Amancio-Filho. "AddJoining: A novel additive manufacturing approach for layered metal-polymer hybrid structures." Materials Letters 217 (April 2018): 211–14. http://dx.doi.org/10.1016/j.matlet.2018.01.021.

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Tosto, Claudio, Jacopo Tirillò, Fabrizio Sarasini, and Gianluca Cicala. "Hybrid Metal/Polymer Filaments for Fused Filament Fabrication (FFF) to Print Metal Parts." Applied Sciences 11, no. 4 (February 5, 2021): 1444. http://dx.doi.org/10.3390/app11041444.

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The exploitation of mechanical properties and customization possibilities of 3D printed metal parts usually come at the cost of complex and expensive equipment. To address this issue, hybrid metal/polymer composite filaments have been studied allowing the printing of metal parts by using the standard Fused Filament Fabrication (FFF) approach. The resulting hybrid metal/polymer part, the so called “green”, can then be transformed into a dense metal part using debinding and sintering cycles. In this work, we investigated the manufacturing and characterization of green and sintered parts obtained by FFF of two commercial hybrid metal/polymer filaments, i.e., the Ultrafuse 316L by BASF and the 17-4 PH by Markforged. The Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectrometry (EDS) analyses of the mesostructure highlighted incomplete raster bonding and voids like those observed in conventional FFF-printed polymeric structures despite the sintering cycle. A significant role in the tensile properties was played by the building orientation, with samples printed flatwise featuring the highest mechanical properties, though lower than those achievable with standard metal additive manufacturing techniques.
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Ozlati, A., M. Movahedi, M. Tamizi, Z. Tartifzadeh, and S. Alipour. "An alternative additive manufacturing-based joining method to make Metal/Polymer hybrid structures." Journal of Manufacturing Processes 45 (September 2019): 217–26. http://dx.doi.org/10.1016/j.jmapro.2019.07.002.

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Silva, M., A. Mateus, D. Oliveira, and C. Malça. "An alternative method to produce metal/plastic hybrid components for orthopedics applications." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 231, no. 1-2 (August 20, 2016): 179–86. http://dx.doi.org/10.1177/1464420716664545.

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The demand for additive processes that provide components with high technological performance became overriding regardless of the application area. For medical applications, the orthopedics field—multimaterial orthoses and splints—can clearly benefit from direct additive manufacturing using a hybrid process instead of the traditional handmade manufacturing, which is slow, expensive, inaccurate, and difficult to reproduce. The ability to provide faster better orthoses, using innovative services and technologies, resulting in lower recovery times, reduced symptoms, and improved functional capacity, result in a significant impact on quality of life and the well-being of citizens. With these purposes, this work presents an integrate methodology, that includes the tridimensional (3D) scanning, 3D computer-aided design modeling, and the direct digital manufacturing of multimaterial orthoses and splints. Nevertheless, additive manufacturing of components with functional gradients, multimaterial components, e.g. metal/plastic is a great challenge since the processing factors for each one of them are very different. This paper proposes the addition of two advanced additive manufacturing technologies, the selective laser melting and the stereolithography, enabling the production of a photopolymerization of the polymer in the voids of a 3D metal mesh previously produced by selective laser melting. Based on biomimetic structures concept, this mesh is subject to a previous design optimization procedure in order to optimize its geometry, minimizing the mass involved and evidencing increased mechanical strength among other characteristics. A prototype of a hybrid additive manufacturing device was developed and its flexibility of construction, geometrical freedom, and different materials processability is demonstrated through the case study—arm orthosis—presented in this work.
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Chueh, Yuan-Hui, Xiaoji Zhang, Jack Chun-Ren Ke, Qian Li, Chao Wei, and Lin Li. "Additive manufacturing of hybrid metal/polymer objects via multiple-material laser powder bed fusion." Additive Manufacturing 36 (December 2020): 101465. http://dx.doi.org/10.1016/j.addma.2020.101465.

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Silva, M., R. Felismina, A. Mateus, P. Parreira, and C. Malça. "Application of a Hybrid Additive Manufacturing Methodology to Produce a Metal/Polymer Customized Dental Implant." Procedia Manufacturing 12 (2017): 150–55. http://dx.doi.org/10.1016/j.promfg.2017.08.019.

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Barakat, Ali A., Basil M. Darras, Mohammad A. Nazzal, and Aser Alaa Ahmed. "A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures." Polymers 15, no. 1 (December 31, 2022): 220. http://dx.doi.org/10.3390/polym15010220.

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Metal–polymer hybrid structures are becoming desirable due to their wide range of applications in the automotive, aerospace, biomedical and construction industries. Properties such as a light weight, high specific strength, and design flexibility along with the low manufacturing costs of metal–polymer hybrid structures make them widely attractive in several applications. One of the main challenges that hinders the widespread utilization of metal–polymer hybrid structures is the challenging dissimilar joining of metals to polymers. Friction stir welding (FSW) shows a promising potential in overcoming most of the issues and limitations faced in the conventional joining methods of such structures. Several works in the literature have explored the FSW of different metal-to-polymer combinations. In some of the works, the joints are examined based on processing parameter optimization, microstructural characteristics, and mechanical performances. It is, therefore, important to summarize the findings of these works as a means of providing a reference to researchers to facilitate further research on the utilization of FSW in joining metals to polymers. Thus, this work aims to present a comprehensive technical review on the FSW technique for joining metals to polymers by reviewing the reported literature findings on the impact of materials, tools, process parameters, and defects on the strength and microstructure of the produced joints. In addition, this work reviews and presents the latest practices aiming to enhance the metal–polymer joint quality that have been reported in the literature.
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Fernandez, Ellen, Mariya Edeleva, Rudinei Fiorio, Ludwig Cardon, and Dagmar R. D’hooge. "Increasing the Sustainability of the Hybrid Mold Technique through Combined Insert Polymeric Material and Additive Manufacturing Method Design." Sustainability 14, no. 2 (January 13, 2022): 877. http://dx.doi.org/10.3390/su14020877.

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To reduce plastic waste generation from failed product batches during industrial injection molding, the sustainable production of representative prototypes is essential. Interesting is the more recent hybrid injection molding (HM) technique, in which a polymeric mold core and cavity are produced via additive manufacturing (AM) and are both placed in an overall metal housing for the final polymeric part production. HM requires less material waste and energy compared to conventional subtractive injection molding, at least if its process parameters are properly tuned. In the present work, several options of AM insert production are compared with full metal/steel mold inserts, selecting isotactic polypropylene as the injected polymer. These options are defined by both the AM method and the material considered and are evaluated with respect to the insert mechanical and conductive properties, also considering Moldex3D simulations. These simulations are conducted with inputted measured temperature-dependent AM material properties to identify in silico indicators for wear and to perform cooling cycle time minimization. It is shown that PolyJetted Digital acrylonitrile-butadiene-styrene (ABS) polymer and Multi jet fusioned (MJF) polyamide 11 (PA11) are the most promising. The former option has the best durability for thinner injection molded parts, and the latter option the best cooling cycle times at any thickness, highlighting the need to further develop AM options.
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Dissertations / Theses on the topic "Hybrid Metal and Polymer Additive Manufacturing"

1

Gingerich, Mark Bryant. "Joining Carbon Fiber and Aluminum with Ultrasonic Additive Manufacturing." The Ohio State University, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=osu1461161262.

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Zhu, Zicheng. "A process planning approach for hybrid manufacture of prismatic polymer components." Thesis, University of Bath, 2013. https://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.648939.

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The 21st century demand for innovation is leading towards a revolution in the way products are perceived. This will have a major impact on manufacturing technologies as current product innovation is constrained by the available manufacturing processes, which function independently. One of the most significant developments is the emergence of hybrid manufacturing technologies integrating various individual manufacturing processes. Hybrid processes utilise the advantages of the independent processes whilst minimising their weaknesses as well as extending application areas. Despite the fact that the drawbacks of the individual processes have been significantly reduced, the application of state of the art hybrid technology has always been constrained by the capabilities of their constituent processes either from technical limitations or production costs. In particular, it is virtually impossible to machine complex parts due to limited cutting tool accessibility. By contrast, additive manufacturing (AM) techniques completely solve the tool accessibility issue, but this increased flexibility and automation is achieved by compromising on part accuracy and surface quality. Furthermore, the shape and size of raw materials have to be specific for each hybrid process. More importantly, process planning methods capable of effectively utilising manufacturing resources for hybrid processes are highly limited. In this research, a hybrid process, entitled iAtractive, combining additive, subtractive and inspection processes is proposed. An experimental methodology has been designed and implemented, by which a generative reactionary process planning algorithm (GRP2A) and feature-based decision-making logic (FDL) is developed. GRP2A enables a complex part to be accurately manufactured as one complete unit in the shortest production time possible. FDL provides a number of manufacturing strategies, allowing existing parts to be reused and transformed into final parts with additional features and functionalities. A series of case studies have been manufactured from zero and existing parts, demonstrating the efficacy of the iAtractive process and the developed GRP2A and FDL, which are based on a manual process. The major contribution to knowledge is the new vision for a hybrid process, which is not constrained by the capability of the individual processes and raw material in terms of shape and size. It has been demonstrated that the hybrid process together with GRP2A and FDL provides an effective solution to flexibly and accurately manufacture complex part geometries as well as remanufacture existing parts.
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Falck, Rielson [Verfasser]. "A new additive manufacturing technique for layered metal-composite hybrid structures / Rielson Miler Moreira Falck." Hamburg : Universitätsbibliothek der Technischen Universität Hamburg-Harburg, 2020. http://d-nb.info/1224270835/34.

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Chen, Tianran. "Generation of Recyclable Liquid Crystalline Polymer Reinforced Composites for Use in Conventional and Additive Manufacturing Processes." Diss., Virginia Tech, 2021. http://hdl.handle.net/10919/103439.

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The application of glass fiber reinforced composites has grown rapidly due to their high strength-to-weight ratio, low cost, and chemical resistance. However, the increasing demand for fiber reinforced composites results in the generation of more composite wastes. Mechanical recycling is a cost-effective and environmentally-friendly recycling method, but the loss in the quality of recycled glass or carbon fiber composite hinders the wide-spread use of this recycling method. It is important to develop novel composite materials with higher recyclability. Thermotropic liquid crystalline polymers (TLCPs) are high-performance engineering thermoplastics, which have comparable mechanical performance to that of glass fiber. The TLCP reinforced composites, called in situ composites, can form the reinforcing TLCP fibrils during processing avoiding the fiber breakage problem. The first part of this dissertation is to study the influence of mechanical recycling on the properties of injection molded TLCP and glass fiber (GF) reinforced polypropylene (PP). The processing temperature of the injection molding process was optimized using a differential scanning calorimeter (DSC) and a rheometer to minimize the thermal degradation of PP. The TLCP and GF reinforced PP materials were mechanically recycled up to three times by repeated injection molding and grinding. The mechanical recycling had almost no influence on the mechanical, thermal, and thermo-mechanical properties of TLCP/PP because of the regeneration of TLCP fibrils during the mold filling process. On the other hand, glass fiber/PP composites decreased 30% in tensile strength and 5% in tensile modulus after three reprocessing cycles. The micro-mechanical modeling demonstrated the deterioration in mechanical properties of GF/PP was mainly attributed to the fiber breakage that occurred during compounding and grinding. The second part of this dissertation is concerned with the development of recyclable and light weight hybrid composites through the use of TLCP and glass fiber. Rheological tests were used to determine the optimal processing temperature of the injection molding process. At this processing temperature, the thermal degradation of matrix material was mitigated and the processability of the hybrid composite was improved. The best formulation of TLCP and glass fiber in the composite was determined giving rise to the generation of a recyclable hybrid composite with low melt viscosity, low mechanical anisotropy, and improved mechanical properties. Finally, TLCP reinforced polyamide composites were utilized in an additive manufacturing application. The method of selecting the processing temperature to blend TLCP and polyamide in the dual extrusion process was devised using rheological analyses to take advantage of the supercooling behavior of TLCP and minimize the thermal degradation of the matrix polymer. The composite filament prepared by dual extrusion was printed and the printing temperature of the composite filament that led to the highest mechanical properties was determined. Although the tensile strength of the TLCP composite was lower than the glass fiber or carbon fiber composites, the tensile modulus of 3D printed 60 wt% TLCP reinforced polyamide was comparable to traditional glass or carbon fiber reinforced composites in 3D printing.
Doctor of Philosophy
The large demand for high performance and light weight composite materials in various industries (e.g., automotive, aerospace, and construction) has resulted in accumulation of composite wastes in the environment. Reuse and recycling of fiber reinforced composites are beneficial from the environmental and economical point of view. However, mechanical recycling deteriorates the quality of traditional fiber reinforced composite (e.g., glass fiber and carbon fiber). There is a need to develop novel composites with greater recyclability and high-performance. Thermotropic liquid crystalline polymers (TLCP) are attractive high performance materials because of their excellent mechanical properties and light weight. The goal of this work is to generate recyclable thermotropic liquid crystalline polymer (TLCP) reinforced composites for use in injection molding and 3D printing. In the first part of this work, a novel recyclable TLCP reinforced composite was generated using the grinding and injection molding. Recycled TLCP composites were as strong as the virgin TLCP composites, and the mechanical properties of TLCP composites were found to be competitive with the glass fiber reinforced counterparts. In the second part, a hybrid TLCP and glass fiber reinforced composite with great recyclability and excellent processability was developed. The processing conditions of injection molding were optimized by rheological tests to mitigate fiber breakage and improve the processability. Finally, a high performance and light weight TLCP reinforced composite filament was generated using the dual extrusion process which allowed the processing of two polymers with different processing temperatures. This composite filament could be directly 3D printed using a benchtop 3D printer. The mechanical properties of 3D printed TLCP composites could rival 3D printed traditional fiber composites but with the potential to have a wider range of processing shapes.
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Perini, Matteo. "Additive manufacturing for repairing: from damage identification and modeling to DLD processing." Doctoral thesis, Università degli studi di Trento, 2020. http://hdl.handle.net/11572/268434.

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The arrival on the market of a new kind of CNC machines which can both add and remove material to an object paved the way to a new approach to the problem of repairing damaged components. The additive operation is performed by a Direct Laser Deposition (DLD) tool, while the subtractive one is a machining task. Up to now, repair operations have been carried out manually and for this reason they are errors prone, costly and time consuming. Refurbishment can extend the life of a component, saving raw materials and resources. For these reasons, using a precise and repeatable CNC machine to repair valuable objects is therefore very attractive for the sake of reliability and repeatability, but also from an economical and environmental point of view. One of the biggest obstacles to the automation of the repairing process is represented by the fact that the CAM software requires a solid CAD model of the damage to create the toolpaths needed to perform additive operations. Using a 3D scanner the geometry of the damaged component can be reconstructed without major difficulties, but figuring out the damage location is rather difficult. The present work proposes the use of octrees to automatically detect the damaged spot, starting from the 3D scan of the damaged object. A software named DUOADD has been developed to convert this information into a CAD model suitable to be used by the CAM software. DUOADD performs an automatic comparison between the 3D scanned model and the original CAD model to detect the damaged area. The detected volume is then exported as a STEP file suitable to be used directly by the CAM. The new workflow designed to perform a complete repair operation is described placing the focus on the coding part. DUOADD allows to approach the repairing problem from a new point of view which allows savings of time and financial resources. The successful application of the entire process to repair a damaged die for injection molding is reported as a case study. In the last part of this work the strategies used to apply new material on the worn area are described and discussed. This work also highlights the importance of using optimal parameters for the deposition of the new material. The procedures to find those optimal parameters are reported, underlying the pros and cons. Although the DLD process is very energy efficient, some issues as thermal stresses and deformations are also reported and investigated, in an attempt to minimize their effects.
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Perini, Matteo. "Additive manufacturing for repairing: from damage identification and modeling to DLD processing." Doctoral thesis, Università degli studi di Trento, 2020. http://hdl.handle.net/11572/268434.

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The arrival on the market of a new kind of CNC machines which can both add and remove material to an object paved the way to a new approach to the problem of repairing damaged components. The additive operation is performed by a Direct Laser Deposition (DLD) tool, while the subtractive one is a machining task. Up to now, repair operations have been carried out manually and for this reason they are errors prone, costly and time consuming. Refurbishment can extend the life of a component, saving raw materials and resources. For these reasons, using a precise and repeatable CNC machine to repair valuable objects is therefore very attractive for the sake of reliability and repeatability, but also from an economical and environmental point of view. One of the biggest obstacles to the automation of the repairing process is represented by the fact that the CAM software requires a solid CAD model of the damage to create the toolpaths needed to perform additive operations. Using a 3D scanner the geometry of the damaged component can be reconstructed without major difficulties, but figuring out the damage location is rather difficult. The present work proposes the use of octrees to automatically detect the damaged spot, starting from the 3D scan of the damaged object. A software named DUOADD has been developed to convert this information into a CAD model suitable to be used by the CAM software. DUOADD performs an automatic comparison between the 3D scanned model and the original CAD model to detect the damaged area. The detected volume is then exported as a STEP file suitable to be used directly by the CAM. The new workflow designed to perform a complete repair operation is described placing the focus on the coding part. DUOADD allows to approach the repairing problem from a new point of view which allows savings of time and financial resources. The successful application of the entire process to repair a damaged die for injection molding is reported as a case study. In the last part of this work the strategies used to apply new material on the worn area are described and discussed. This work also highlights the importance of using optimal parameters for the deposition of the new material. The procedures to find those optimal parameters are reported, underlying the pros and cons. Although the DLD process is very energy efficient, some issues as thermal stresses and deformations are also reported and investigated, in an attempt to minimize their effects.
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Mathias, Spencer D. "Investigation of Thermoplastic Polymers and Their Blends for Use in Hybrid Rocket Combustion." DigitalCommons@USU, 2019. https://digitalcommons.usu.edu/etd/7416.

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This thesis set out to find a blend of thermoplastics that had better combustion properties than the current ABS (acrylonitrile butadiene styrene) plastic or “Lego TM plastic” used by Utah State University. The current work is in an effort to eliminate toxic propellants from small space applications. High and low density polyethylene plastics were used because they are common plastic waste items. In this way rocket fuel can be made from these items to reduce the waste found in landfills. Three plastics were considered for replacement and as mixture components with the ABS plastic, namely low and high density polyethylene, and high impact polystyrene. These plastics failed to have superior combustion properties when used in rockets designed to achieve 12 pounds or less of thrust compared to the current ABS plastic.
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Bradford-Vialva, Robyn L. "Development of a Metal-Metal Powder Formulations Approach for Direct Metal Laser Melting of High-Strength Aluminum Alloys." University of Dayton / OhioLINK, 2021. http://rave.ohiolink.edu/etdc/view?acc_num=dayton1620259752540201.

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Gante, Lokesha Renukaradhya Karthikesh. "Metal Filament 3D Printing of SS316L : Focusing on the printing process." Thesis, KTH, Maskinkonstruktion (Avd.), 2019. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-259686.

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As a cutting edge manufacturing methodology, 3D printing or additive manufacturing (AM) brings much more attention to the fabrication of complex structure, especially in the manufacturing of metal parts.A number of various metal AM techniques have been studied and commercialized. However, most of them are expensive and less available, in comparison with Selective Laser Melting manufactured stainless steel 316L component.The purpose of this Master Thesis is to introduce an innovative AM technique which focuses on material extrusion-based 3D printing process for creating a Stainless Steel 316L part using a metal-polymer composite filament. The Stainless Steel test specimen was printed using an Fused Deposition Modelling based 3D printer loaded with a metal infused filament, followed by industrial standard debinding and sintering process. Investigation was performed on the specimen to understand the material properties and their behaviour during the postprocessing method. In addition effects of debinding, sintering and comparison of the test Specimen before and after debinding stages was also carried out. Metal polymer filaments for 3D printing could be an alternative way of making metal AM parts.
Som en avancerad tillverkningsmetodik ger 3D-printing eller additiv tillverkning (AM) mycket mer uppmärksamhet vid tillverkning av komplex struktur, särskilt vid tillverkning av metallkomponenter. Ett antal olika AM-tekniker vid tillverkningen av olika typer av metallkomponenter har studerats och kommersialiserats.De flesta av dessa AM-tekniker är dyra och mindre tillgängliga, i jämförelse med Selective Laser Melting vid tillverkningen av en komponent i rostfritt stål 316L. Syftet med detta examensarbete är att introducera en innovativ AM-teknik som fokuserar på materialsträngsprutningsbaserad 3D-printingprocess för att skapa ekomponent i rostfritt stål 316Lkomponent med ett metallpolymerkompositfilament. Ett prov bestående av rostfritt stål skrevs ut med en FDM-baserad 3D-skrivare laddad med filament av polymer och metal, följt av industriell avdrivnings-och sintringsprocess. Provet studerades för att förstå materialegenskaperna och dess beteende under efterbehandlingsmetoden. Dessutom genomfördes också resultat från avdrivning och sintring på provet och en jämförelse av provet före och efter avdrivnlngssteget. Metallpolymertrådar för 3D-printing kan vara ett alternativt sätt att tillverka AM-metallkomponenter.
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Dias, Rita de Cássia Costa. "Microescultura por laser de superfícies metálicas para manufatura de laminados híbridos metal/fibra." Universidade de São Paulo, 2013. http://www.teses.usp.br/teses/disponiveis/88/88131/tde-19042013-205354/.

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Este trabalho objetivou a manufatura de laminados híbridos metal-fibra (LMF) empregando-se chapas com 0,5 mm de espessura de liga-\'TI\'6\'AL\'4\'V\' com superfícies modificadas por laser de fibra de modo a otimizar a sua adesão com polímero termoplástico poli-sulfeto de fenileno (PPS). Observou-se que a microtextura superficial da liga metálica dependeu fortemente da potência do feixe laser, quando potências mais baixas levaram à verdadeira texturização da superfície metálica, enquanto que potências mais elevadas conduziram à ablação da mesma. A texturização superficial metálica sob laser de baixa potência aparentou ser a condição mais apropriada para a adesão metal-polímero por ancoragem mecânica de macromoléculas, o que foi contrabalanceado por elevados níveis de tensão residual das chapas metálicas, gerando grande distorção das mesmas e inviabilizando sua utilização. O emprego de uma potência intermediária (160 W) mostrou-se propício à otimização entre a adesão física entre metal-polímero e o nível de tensões residuais criado nas chapas metálicas. Concluiu-se que os espécimes extraídos do centro dos laminados metal-fibra exibem uma tensão limite média para falha por cisalhamento interlaminar consideravelmente superior à dos espécimes usinados a partir da borda dos LMF. O LMF manufaturado sob maiores pressão e temperatura exibiu uma maior compactação e melhor consolidação, culminando num máximo desempenho médio sob carga de cisalhamento interlaminar. Evidências de uma correlação entre o mecanismo de falha por cisalhamento interlaminar do corpo de prova e o seu nível de resistência a este tipo de carregamento mecânico foram documentadas e discutidas.
This work aimed at manufacturing hybrid fiber-metal laminates (FML) by employing 0,5 mm-thick \'TI\'6\'AL\'4\'V\'-alloy plaques with fiber laser modified surface in order to optimize metal adhesion with poli-phenylene sulfide (PPS) thermoplastic polymer. The surface microtexture of metallic alloy strongly depended upon the laser power, inasmuch as low-power laser led to true texturization of metal surface, whereas high-power laser light drove to its ablation. Surface metal texturization under low-power laser apparently was the most appropriate condition to metal-polymer adhesion via mechanical entanglement of macromolecules, which was offset by high levels of residual stresses on metallic plaques, bringing them quite warped and useless. The use of an intermediate laser power (160 W) has been shown benign to the optimization between metal-polymer physical adhesion and the residual stress level created in the metal plates. It has been concluded that testpieces machined from the FML central position exhibited average ultimate interlaminar shear strenght considerably higher than those extracted from the FML borders. The FML manufactured under higher pressure and temperature was more compacted and better consolidated, so that it displayed the greatest average performance under interlaminar shear loading. Evidences of a correlation between the failure mechanism by interlaminar shearing of test coupon and its allowance to this type of mechanical loading were documented and discussed.
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Book chapters on the topic "Hybrid Metal and Polymer Additive Manufacturing"

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Wang, Hao, Yan Jin Lee, Yuchao Bai, and Jiong Zhang. "Hybrid Additive Manufacturing." In Post-Processing Techniques for Metal-Based Additive Manufacturing, 203–24. New York: CRC Press, 2023. http://dx.doi.org/10.1201/9781003272601-9.

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Al-Obaidi, Anwer, and Candice Majewski. "Ultrasonic Welding of Polymer–Metal Hybrid Joints." In Transactions on Intelligent Welding Manufacturing, 21–38. Singapore: Springer Singapore, 2019. http://dx.doi.org/10.1007/978-981-13-3651-5_2.

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Sagbas, Binnur, and Numan M. Durakbasa. "Profile and Areal Surface Characterization of Additive Manufacturing Polymer and Metal Parts." In Lecture Notes in Mechanical Engineering, 240–46. Cham: Springer International Publishing, 2019. http://dx.doi.org/10.1007/978-3-030-18177-2_22.

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Shakerin, Sajad, and Mohsen Mohammadi. "Hybrid Additive Manufacturing of MS1-H13 Steels via Direct Metal Laser Sintering." In TMS 2020 149th Annual Meeting & Exhibition Supplemental Proceedings, 277–83. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-36296-6_26.

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Durga Prasada Rao, V., V. Navya Geethika, and P. S. Krishnaveni. "Multi-objective Optimization of Mechanical Properties of Aluminium 7075-Based Hybrid Metal Matrix Composite Using Genetic Algorithm." In Advances in 3D Printing & Additive Manufacturing Technologies, 79–93. Singapore: Springer Singapore, 2016. http://dx.doi.org/10.1007/978-981-10-0812-2_7.

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Borg Costanzi, Christopher. "Proposed Hybrid WAAM and Thin Sheet Metal Welding." In Reinforcing and Detailing of Thin Sheet Metal Using Wire Arc Additive Manufacturing as an Application in Facades, 99–172. Wiesbaden: Springer Fachmedien Wiesbaden, 2023. http://dx.doi.org/10.1007/978-3-658-41540-2_6.

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Rajendran, Ashokraj, Pavendhan Rajangam, and Kumaragurubaran Balasubramanian. "Microstructure and mechanical properties of Al7075 and Al7075-based hybrid metal matrix composites by additive manufacturing." In Mechanical Properties and Characterization of Additively Manufactured Materials, 141–58. Boca Raton: CRC Press, 2023. http://dx.doi.org/10.1201/9781003430186-10.

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Suresh, Ganzi. "Advancements in Manufacturing Technology With Additive Manufacturing and Its Context With Industry 4.0." In Handbook of Research on Advancements in Manufacturing, Materials, and Mechanical Engineering, 1–24. IGI Global, 2021. http://dx.doi.org/10.4018/978-1-7998-4939-1.ch001.

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Additive manufacturing (AM) is also known as 3D printing and classifies various advanced manufacturing processes that are used to manufacture three dimensional parts or components with a digital file in a sequential layer-by-layer. This chapter gives a clear insight into the various AM processes that are popular and under development. AM processes are broadly classified into seven categories based on the type of the technology used such as source of heat (ultraviolet light, laser) and type materials (resigns, polymers, metal and metal alloys) used to fabricate the parts. These AM processes have their own merits and demerits depending upon the end part application. Some of these AM processes require extensive post-processing in order to get the finished part. For this process, a separate machine is required to overcome this hurdle in AM; hybrid manufacturing comes into the picture with building and post-processing the part in the same machine. This chapter also discusses the fourth industrial revolution (I 4.0) from the perspective of additive manufacturing.
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Santiago, Carolyn Carradero, Eric MacDonald, Jose Coronel, Dominic Kelly, Ryan Wicker, and David Espalin. "Ultrasonic and Thermal Metal Embedding for Polymer Additive Manufacturing." In Additive Manufacturing Processes, 456–61. ASM International, 2020. http://dx.doi.org/10.31399/asm.hb.v24.a0006558.

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Behera, Ajit. "Processes and Application in Additive Manufacturing." In Advances in Civil and Industrial Engineering, 25–47. IGI Global, 2020. http://dx.doi.org/10.4018/978-1-7998-4054-1.ch002.

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Additive manufacturing (AM) is going to cover all the segments of industries from missile industry to biomedical industry. This marked change of technology is due to the distinctive potential of AM to fabricate the parts with intricate designs and reduce fabrication expenditure (free from machining, waste generation, assembly of various parts) with small production runs and short turnaround times. This chapter extensively discussed industrially practiced AM technology. In this chapter, all additive manufacturing materials like metal, alloys, polymer, ceramics, composite, etc. have been given focus for various applications. Additive manufacturing technology is cost effective: no loss of metal and easy to fabricate both larger and intricate shapes. This technology already has taken a primary position in aerospace industries as well as the medical and household industries.
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Conference papers on the topic "Hybrid Metal and Polymer Additive Manufacturing"

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Whitney, Thomas J., Thao Gibson, Khalid Lafdi, and Brian Welk. "A Hybrid Metal-to-Composite Joint Fabricated Through Additive Manufacturing Processes." In ASME 2012 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2012. http://dx.doi.org/10.1115/imece2012-89540.

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Devices and machines which perform additive manufacturing (adding material in a layer-wise or bead-wise manner to produce complex structure rather than removing material through machining) are maturing and entering the commercial market. While small prototype parts are routinely made using these devices, a number of industries, including biomedical and aerospace, are considering using these techniques for production parts. New materials which take advantage of the unique capability of additive manufacturing are beginning to evolve. Hybridization of materials at smaller scales now becomes possible with the precision of additive manufacturing devices. However, the fundamentals of structural performance of materials that can be produced by these methods are still to be explored and understood.. The current effort focuses on characterizing and describing the fundamental processing of hybrid materials produced using a combination of laser sintering of metals combined with polymer infusion of advanced carbon fabric. Ultimately, the work seeks to develop a fundamental understanding of the structural mechanics of these novel graphite-metal materials produced through hybrid processes. By understanding development and location of weak structural planes, effects of voids and discontinuities, load transfer from nano to macro scale, reinforcement distribution, gradients in properties, and effects of residual stress, a complete materials design process beginning with structural requirements and ending with material and process selection can be developed. This paper will summarize the first experimental steps taken to process and fabricate a metal-to-composite hybrid joint using a combination of additive manufacturing and conventional composite processes. Experimental conditions are described and morphology of the resulting hybrids is discussed. Future plans for testing are described.
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Alaboudi, S. F. "The Innovation in wire arc additive manufacturing (WAAM): A review." In Advanced Topics in Mechanics of Materials, Structures and Construction. Materials Research Forum LLC, 2023. http://dx.doi.org/10.21741/9781644902592-54.

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Abstract. This review or research paper is illustrated to analytically assess and address one of potential industrial revolutions, which is Wire Arc Additive Manufacturing (WAAM). WAAM is classified from Hybrid Manufacturing (HM) processes. Thus, one of the Hybrid Manufacturing ultimate goals has always been to transcend the limitation aspects associated with the tradition process. As Artificial Intelligence (AI) has evolved and expanded all over the globe, Additive Manufacturing (AM) has been gradually developed and introduced to the world to be one of a distinguished innovative impact in the history of manufacturing. Additive Manufacturing (AM) has been improved over the conventional methods in the manufacturing world due to its advanced complexity, consistency, quality of work, and various advantages and contribution that satisfy the costumers needs and requirements. Various applications in the industry have proven the AM applicability to replace the conventional processes such as casting and machining as it can deal with very coplex shapes [3]. In spite of the fact that there are numerous materials that can be manufactured in the modern technologies of AM, such as polymers, metals, ceramic, and composites, the contribution of Metal Additive Manufacturing (MAM) arguably has been a significant influence in the industries in comparison to the others [1]. In this review paper the detailed deliverable information and materials which will be established and communicated in this paper will concentrate on the history of (WAAM) including its pros and cons, latest contribution to the industries, AM classifications, materials, and primary materials and practices in industry.
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Zhao, Ningxiner, Hongqi Guo, Leon M. Headings, and Marcelo J. Dapino. "Analytical and Computational Modeling of FRP-Metal Joints Made by Ultrasonic Additive Manufacturing." In ASME 2022 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2022. http://dx.doi.org/10.1115/imece2022-96827.

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Abstract Previous research has developed a process for producing strong fiber reinforced polymers (FRP)-metal joints via ultrasonic additive manufacturing (UAM), and structural tests have been conducted to characterize the mechanical properties of the joints. In this research, an analytical model and a finite element analysis (FEA) model are developed for UAM-produced FRP-metal joints to provide better joint design and application insights. The analytical model applies both the thick-wall cylindrical pressure vessel theory and Tsai-Wu failure criterion to characterize the stress condition in the embedded fibers and the failure mode when tension is applied to the joint. Comparing the analytical model and experimental results of two different sample configurations, the model is able to predict the peak load of the joint with given material properties and joint geometries. Based on the analytical model, an FEA model is built using LS-DYNA to simulate the tensile testing of FRP-metal joint using shell mesh by homogenizing the hybrid portion of the joint. The stress maps obtained from the FEA model for two joint designs show similar distributions when compared to measured digital image correlation (DIC) strain maps, indicating that the failure modes match the experimental results. The FEA simulation results agree well with the experimental result for peak load and displacement at fracture, with an error of less than 5%.
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Li, Ye, and Ragha Rapthadu. "Bending-Additive-Machining Hybrid Manufacturing of Sheet Metal Structures." In ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing. American Society of Mechanical Engineers, 2017. http://dx.doi.org/10.1115/msec2017-3062.

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The ever-increasing industry innovation demands a paradigm of manufacturing process that is capable of accomplishing multiple tasks on a single component. Majority of structural parts require bending of metal sheets with high degree of accuracy. In many applications bent parts with additional features are sought out for various special purposes. Clearly there is a need calling for the integration of different manufacturing processes to reach a synergistic effect [4, 5]. Traditionally a combination of additive manufacturing and machining is used to alleviate the constraints set forth by machining alone. However this hybrid approach is still constrained by both the limited cutter accessibility and gravity-imposed deposition direction. This paper presents a new Hybrid Manufacturing configuration by combining bending, deposition and machining processes. The major advantage of this new approach hinges on the deliberate use of bending process by providing additional accessibility that is not available on traditional additive – machining setup. Essentially the accessibility issue is overcome by introducing an intermediate bending step so that both metal deposition and removal can be conducted in the process-required orientation. As bending is part of this new hybrid process, springback is also inherent to this new hybrid manufacturing approach. This research incorporates the consideration of both springback compensation and cold hardening effect in the selection of intermediate bending step. Examples are also provided to show the efficacy of this new hybrid manufacturing approach.
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Landgrebe, Dirk, Roland Müller, Rico Haase, Peter Scholz, Matthias Riemer, Andre Albert, Raik Grützner, and Frank Schieck. "Efficient Manufacturing Methods for Hybrid Metal-Polymer Components." In ASME 2016 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2016. http://dx.doi.org/10.1115/imece2016-65621.

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Lightweight design for automotive applications gains more and more importance for future products, independent from the powertrain concept. One of the key issues in lightweight design is to utilize the right material for the right application using the right value at the right place. This results irrevocably in a multi-material design. In order to increase the efficiency in manufacturing car components, the number of single parts in a component is decreased by increasing the complexity. Examples for the state of the art are tailored welded blanks in cold forming, tailored tempering in press hardening or metallic inlays in injection molding of polymers. The challenge for future production scenarios of multi-material components is to combine existing technologies for metal- and polymer-based applications in efficient hybrid process chains. This paper shows initial approaches of hybrid process chains for efficient manufacturing of hybrid metal-polymer components. These concepts are feasible for flat as well as for tubular applications. Beside the creation of the final geometric properties of the component by a forming process, integrated joining operations are increasingly required for the efficiency of the production process and the performance characteristics of the final component. Main target of this production philosophy is to create 100% ready-to-install components. This is shown in three examples for hybrid process combinations. The first example deals with the combination of metal forming and injection molding of polymers. Example number two is the application of hybrid metal-polymer blanks. Finally, example number three shows the advantages of process integrated forming and joining of single basic components.
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Tičkūnas, Titas, Mangirdas Malinauskas, Domas Paipulas, Yves Bellouard, and Roaldas Gadonas. "Hybrid laser 3D microprocessing in glass/polymer micromechanical sensor: towards chemical sensing applications." In 3D Printed Optics and Additive Photonic Manufacturing, edited by Georg von Freymann, Alois M. Herkommer, and Manuel Flury. SPIE, 2018. http://dx.doi.org/10.1117/12.2307533.

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Palumbo, Joshua, Ramgopal Varma Ramaraju, Sanjeev Chandra Matthew S. Schwenger, Madison S. Kaminskyj, Francis M. Haas, and Joseph F. Stanzione III. "Mixed-Material Feedstocks for Cold Spray Additive Manufacturing of Metal-Polymer Composites." In ITSC 2023. ASM International, 2023. http://dx.doi.org/10.31399/asm.cp.itsc2023p0186.

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Abstract High-performance polymers such as poly(ether ether ketone) (PEEK) are appealing for a wide variety of industrial and medical applications due to their excellent mechanical properties. However, these applications are often limited by relatively low thermal stability and conductivity compared to metals. Many methods developed to metallize polymers, including vapor deposition and thermal spray processes, can lead to poor quality control, low deposition rate, and high cost. Thus, cold spray is a promising potential alternative to rapidly and inexpensively produce polymer-metal composites. In this study, we investigated the deposition characteristics of metalpolymer composite feedstock, composed of PEEK powder with varying volume fractions of copper (Cu) flake added, onto a PEEK substrate. We prepared the Cu-PEEK composite powder in varying compositions by two methods: hand-mixing the powders and cryogenically milling the powders. Scanning electron microscopy (SEM) of the feed mixtures shows that cryogenically milling the polymer and metal powders together created uniformly distributed micron-scale domains of Cu on PEEK particle surfaces, and vice versa, as well as consolidating much of the porous Cu flake. In lowpressure cold spray, the relatively large volume fractions of PEEK in the composite mixtures allowed for lower operating temperatures than those commonly used in PEEK metallization (300-500 °C). While the deposition efficiencies of each mixture were relatively similar in single-layer experiments, deposits formed after multiple passes showed significant changes in deposition efficiency and composition in PEEK-rich feedstock mixtures. SEM of deposit surfaces and cross-sections revealed multiple co-dominant mechanisms of deposition, which affect both the porosity and final composition of the deposit. Though present in all samples analyzed, the effects of cryogenic milling were more prevalent at lower Cu concentrations.
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Saleeby, Kyle S., Tom Kurfess, Tom Feldhausen, and Lonnie Love. "Production of Medium-Scale Metal Additive Geometry With Hybrid Manufacturing Technology." In ASME 2020 15th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2020. http://dx.doi.org/10.1115/msec2020-8391.

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Abstract Oak Ridge National Lab’s (ORNL) Metal Big Area Additive Manufacturing (mBAAM) and Hybrid Manufacturing teams in the Manufacturing Demonstration Facility (MDF) was tasked with developing a part that exceeded 24 inches in length and 100lbs in weight on a laser hotwire welding system. The Mazak VC-500A/5X AM HWD hybrid 5-axis CNC laser hotwire system was leveraged to complete the task. The proposed geometry was manufactured with 410 stainless steel on AISI1018 steel substrate in just over 36 hours of build time. The proposed geometry was sliced and additively manufactured in three segments; the base, and two extrusions measuring 10 inches in length and 14 inches in length. Production of this component demonstrated hybrid capabilities requiring fixed 5-axis rotations to complete geometry that exceeded the defined build volume of the machine. Multiple repairs of the part were conducted in-situ leveraging the additive and subtractive capabilities of the Mazak hybrid system. Significant overbuilding challenges were encountered and manually addressed by leveraging subtractive capabilities of the hybrid system. Future processes are presented for development to reduce overheating of top layers. Final part measurements exceeded 107 lbs. in weight and 24.5 inches in length along the principal axis; the largest and heaviest part created by a hybrid system at the MDF.
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Chen, Jibing, Guangsong Wu, Yu Xie, Zhanwen He, Nong Wan, and Yiping Wu. "Study on Performance of Metal and Polymer Composites Parts Based by Additive Manufacturing." In 2019 20th International Conference on Electronic Packaging Technology(ICEPT). IEEE, 2019. http://dx.doi.org/10.1109/icept47577.2019.245253.

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Carrico, James D., Nicklaus W. Traeden, Matteo Aureli, and Kam K. Leang. "Fused Filament Additive Manufacturing of Ionic Polymer-Metal Composite Soft Active 3D Structures." In ASME 2015 Conference on Smart Materials, Adaptive Structures and Intelligent Systems. American Society of Mechanical Engineers, 2015. http://dx.doi.org/10.1115/smasis2015-8895.

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This paper describes a new three-dimensional (3D) additive manufacturing (AM) technique in which electroactive polymer filament material is used to build soft active 3D structures, layer by layer. The proposed manufacturing process is well-suited for creating electroactive soft complex structures and devices, whereby the entire system can be manufactured from an electroactive polymer material. For the first time, the unique actuation and sensing properties of ionic polymer-metal composite (IPMC) is exploited and directly incorporated into the structural design to create sub-millimeter scale cilia-like actuators and sensors to macro-scale soft robotic systems. Because ionic polymers such as Nafion are not melt-processable, in the first step a precursor material (non-acid Nafion precursor resin) is extruded into a thermoplastic filament for 3D printing. The filament is then used by a custom-designed 3D printer to manufacture the desired soft polymer structures, layer by layer. Since, at this stage the 3D-printed samples are not yet electroactive, a chemical functionalization process follows, consisting in hydrolyzing the precursor resin in an aqueous solution of sodium hydroxide (NaOH) and dimethyl sulfoxide (DMSO, C2H6OS). Upon functionalization, metal electrodes are applied on the samples through an electroless plating process, which enables selected areas of the 3D-printed electroactive structures to be controlled by voltage signals for actuation, while other parts can function as sensors. This innovative AM process is described in detail and experimental results are presented to demonstrate the potential and feasibility of creating 3D-printed IPMC actuator samples.
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