In as we speak’s 3D Printing Information Briefs, we’ll get issues began with a complete post-processing survey by PostProcess Applied sciences. Jacksonville State College is partnering with EOS Additive Minds to develop AM curriculum, and Eplus3D and UCL Rocket developed and examined a regeneratively cooled, 3D printed rocket engine. We’ll finish with supplies analysis, first by Technical College Munich, Friedrich-Alexander College Erlangen-Nuremberg, and Colibrium Additive for aluminum alloys in aerospace, after which a evaluation of ultra-high-performance concrete rheological properties by China’s Southeast College and the Missouri College of Science and Know-how.
PostProcess Applied sciences Relaunches AM Trade Put up-Processing Survey
From 2018 by way of 2022, automated post-printing options supplier PostProcess Applied sciences despatched out a complete Additive Manufacturing Put up-Processing Survey. Now, the corporate is relaunching its survey to the AM business, in an effort to collect insights into the critically essential step of post-processing and assist form the way forward for AM. The survey presents data-driven insights about post-printing workflows that may assist guarantee customer-ready components, similar to resin, help supplies, powder removing, and floor ending. Earlier iterations of this survey revealed post-processing challenges, like consistency, labor calls for, time to complete components, scaling manufacturing, and well being and security issues. The 2025 Additive Manufacturing Put up-Processing Survey will discover funding priorities, like lowering cycle instances; traits in post-processing strategies throughout numerous AM applied sciences, together with materials extrusion and powder mattress fusion; finances allocation insights; and ache factors, similar to sustainability and throughput.
“Put up-processing stays essentially the most under-reported but essential step in additive manufacturing workflows. By relaunching this survey, we intention to present the business a transparent voice in figuring out obstacles, sharing greatest practices, and shaping the trail towards a extra environment friendly and scalable future for additive manufacturing,” mentioned Dean VonBank, Chief Expertise Officer at PostProcess Applied sciences.
AM business professionals are invited to finish the survey right here. The findings will later be compiled into the 2025 Additive Put up-Processing Traits Report.
Jax State Increasing AM Curriculum with EOS Additive Minds Academy
Jax State metallic AM lab
With the intention to develop and develop its AM curriculum, Jacksonville State College (Jax State) in Florida is partnering with EOS North America’s Additive Minds Academy Ignite program. This just lately launched program additionally counts College of Illinois Urbana-Champaign, Columbia Gorge Neighborhood School, and Launch Canada as companions, and is supposed to speed up AM training and workforce improvement. The Ignite Program presents structured, scalable on-line and hybrid studying options, serving to to show the basics and functions of business AM and giving college students entry to industrial-grade AM coaching and assets. As such, Jax State has additionally acquired a second EOS M 290 metallic laser powder mattress fusion (LPBF) printer as a part of the initiative. This system presents two versatile tiers, primarily based on a college’s entry to EOS printers: AM Fundamentals, which supplies entry to on-line programs, and Certification Companion, which incorporates AM Fundamentals content material, plus an EOSPRINT 2 introduction, native EOSPRINT SW licenses, operation certifications, and extra.
“We’re excited to deepen our dedication to additive manufacturing training by way of the Ignite Program. By combining EOS’s industrial coaching assets with our increasing AM lab and school experience, we’re making ready college students for real-world careers in superior manufacturing and giving them the abilities they want to reach this quickly rising area,” mentioned Matt Rosser, Director of the Middle for Manufacturing Help at Jax State. “With the addition of our second EOS M 290, our AM property now whole greater than $3 million, underscoring our dedication to being a pacesetter in superior manufacturing innovation and workforce improvement.”
UCL Rocket & Eplus3D Design, Print, & Check Regeneratively Cooled Rocket Engine
3D printed engine and swirl injectors contained in the EP-M400S
Eplus3D partnered with the student-led UCL Rocket staff from College School London (UCL) to design, 3D print, and take a look at a regeneratively cooled, bipropellant rocket engine for the Race 2 Area 2025 competitors within the UK. The staff is considered one of six UCL Racing (UCLR) groups with the college’s Mechanical Engineering division, and Eplus is the technical manufacturing accomplice for the Excelsior engine venture, providing DfAM consultations and utilizing LPBF at its German facility to print the engine’s injector parts and thrust chamber out of AlSi10Mg on the EP-M400S quad-laser printer. There have been a number of technical challenges the staff confronted, together with tight dimensional tolerances, coaxial swirl injector components, and 58 inner coolant channels within the design, which required superior manufacturing capabilities. The fabric needed to steadiness mechanical energy, density, thermal conductivity, and machinability, and a sturdy cooling technique was wanted so the fabric wouldn’t fail, was temperatures within the combustion chamber are upwards of two,500 Ok. Lastly, a quick and cost-efficient manufacturing course of was wanted for this pupil venture and its restricted timeframe.
To realize positive inner channel decision and easy surfaces, a 60 µm layer thickness was used for printing, and AlSi10Mg was chosen due to its roughly 165 W/m·Ok thermal conductivity after stress reduction, which allowed for fast warmth switch to the coolant within the inside channels. Because of Eplus3D’s DfAM expertise, the scholars optimized the design for printability, fabricating it as two built-in assemblies to cut back half rely and meeting complexity. The regeneratively cooled Excelsior engine efficiently withstood three hot-fire checks at Airborne Engineering Ltd. for the Race 2 Area 2025 competitors, and achieved its goal thrust of 5kN. The staff ranked fourth within the Nitrous Bipropellant class, and out of 17 engines, the Excelsior was considered one of solely eight to outlive all hot-fire checks. As Eplus3D concluded, this venture confirmed “that superior LPBF in AlSi10Mg can produce high-performance regeneratively cooled rocket engines inside the constraints of a college venture. By combining modern design, optimised manufacturing, and rigorous testing, the collaboration between Eplus3D and UCL Rocket exhibits how additive manufacturing can speed up aerospace propulsion improvement.
Joint Analysis into Industrial 3D Printed Aluminum Parts for Aerospace
FRM II scientists perform pattern measurements with neutrons on the analysis reactor in Rez close to Prague. From left to proper: Dr Seda Ulusoy, Dr Massimo Fritton, Simon Sebold, Dr Steffen Neumeier (FAU), Dr Ralph Gilles, Dr Stefan Engel; foreground: Dr Gergely Farkas
Funded with €1.17 million by the German Federal Ministry of Analysis, Know-how, and Area (BMFTR), the brand new AlaAF rUM Switch analysis venture is investigating how industrial 3D printing can manufacture light-weight, resilient aluminum parts for aerospace. Colibrium Additive, Technical College of Munich (TUM) and its analysis reactor FRM II, and the Friedrich-Alexander College Erlangen-Nuremberg (FAU) are working collectively to collectively develop options for the LPBF course of, which presents excessive design freedom however can’t be used with high-strength aluminum alloys as a result of they usually crack as soon as cooled. The staff is specializing in a brand new method, the place particular components in metallic powder chemically react throughout 3D printing and type finely distributed ceramic particles within the sub-micrometer vary. These particles act as “micro-builders,” influencing crystal development within the powder to cut back crack formation. This could make it potential to print aluminum alloys for industrial functions that had been as soon as thought of unimaginable to print.
Colibrium is contributing its industrial AM know-how, working with FAU and TUM to develop LPBF course of parameters. FAU is analyzing the printed supplies and their mechanical properties with microscopic strategies, whereas FRM II researchers are finishing high quality testing with specialised neutron strategies, similar to neutron imaging (radiography and tomography) and neutron diffraction, which permits exact dedication of part distribution and inner stresses. Plus, a particular testing machine developed at FRM II can realistically simulate industrial working situations for materials habits recording. In line with Dr. habil. Ralph Gilles, venture supervisor at TUM and spokesperson for the consortium, “Neutrons have a excessive penetration depth and are subsequently best for analysing massive, additively manufactured parts for business – a process that will be unimaginable with different methods.”
Overview of Advances in Rheological Properties of Extremely-Excessive-Efficiency Concrete
Microstructural view of the rise in static yield stress with relaxation time. Picture: Le Teng, Kamal H. Khayat, Jiaping Liu
Researchers from China’s Southeast College and the Missouri College of Science and Know-how just lately revealed a evaluation of the developments in tailoring the rheological properties of ultra-high-performance concrete (UHPC), and easy methods to optimize its efficiency. UHPC, a sophisticated composite materials, is nice for civil engineering functions resulting from its excessive energy and sturdiness. However, its excessive strong quantity fraction and low water content material could make it difficult to realize the required rheological properties in strategies like pumping, spraying, and 3D printing. The researchers clarify how plenty of chemical, bodily, and physicochemical components, like mixture traits, water-to-binder ratio, and chemical admixtures, can have an effect on UHPC’s viscosity, yield stress, structural build-up, and thixotropy. In addition they talk about the difficulties in characterizing the fabric’s rheological properties, such because the plug move impact, and look into the results of a number of constituents on its rheological properties, similar to including fillers like limestone powder to enhance packing density. Lastly, they talk about methods for tailoring UHPC’s rheological properties for particular functions, together with easy methods to optimize the fabric for 3D printing.
“Extremely-high-performance concrete (UHPC) with tailored rheology continues to draw curiosity contemplating the requirement for novel processing methods similar to self-consolidating, pumping, spraying, and three-dimensional (3D) printing. The rheology of UHPC is complicated resulting from its excessive strong quantity fraction, low water content material, and wide selection of constituent supplies that have an effect on its move properties. This work supplies steerage for tailoring the combination proportioning of UHPC to safe correct rheological properties and efficiency of UHPC for numerous functions,” the researchers clarify within the summary of their paper.
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