Improving the Accuracy and Precision of the Fused Deposition Modelling Additive Manufacturing Technology
Lead Research Organisation:
University of Cambridge
Department Name: Engineering
Abstract
Additive manufacturing (AM) is an attractive alternative to conventional manufacturing techniques due to its geometric freedom and versatility. Fused deposition modelling (FDM) is a relatively low cost form of AM, which is able to produce complex features via layer-by-layer extrusion, however, it is commonly characterised by poor quality. Thus, this project investigates how the dimensional, geometrical accuracy, and repeatability (precision) of the FDM process could be improved through the evaluation and modifications of its current mechanisms. These mechanisms include the filament behaviour characterised via the extrusion method, a set of design rules to reduce errors in part design, and revision of the slicing software that takes in to account the filament level behaviour. It is also envisaged that adjustments to the current equipment set-up, such as nozzle positioning and an experimental investigation into parameter optimisation will also be undertaken to elucidate errors and inaccuracies in part generation.
Planned Impact
The major beneficiaries of the research outputs from the Centre for Doctoral Training in Ultra Precision (CDT-UP) include UK manufacturing companies (especially SMEs), the University partners, including the two primary universities, and the wider UK universities engaged in Ultra Precision research, in addition to society in general. Benefits will be realised in terms of:- increased economic activity in the field of UP through spin-out companies, licensed technology outputs, and the realisation of new products made possible with the application of UP manufacturing capabilities; greater knowledge of and a wider appreciation of the technical capabilities of UP systems; the provision of highly trained PhD level personnel for UK industry to spearhead new ultra precision competencies; and the creation of new products for the market based on UP competencies and technologies, which have the potential for significant societal impacts in areas such as health-care, transport, energy generation, and communications.
The importance of ultra precision manufacturing to the UK economy and the key issues and barriers to economic success are highlighted in the main proposal which demonstrate the central role of ultra precision manufacturing technology in ensuring economic growth. Many emerging sectors and next generation products will demand ultra precise components (nanometre, and sub-micron-level tolerance). To date semiconductor systems, and microsystems (optical, mechanical, or electrical) use complex expensive process steps in their production. Such extensive process chains are needed to create even initial pre-production prototypes. This issue has become a significant barrier to SME's realising their innovative products requiring UP. We aim to develop ultra precision manufacturing technologies that will offer precision capabilities, with a reduced level of capital investment compared to traditional semiconductor fabrication routes. These include:- wide area roll-to-roll printing of electronic devices, optical films, and structured surfaces; novel micro machining technologies for the production of 3-dmensional components such as micro-mechanical elements, embossing and injection mould tools, and micro-embossing tools.; direct writing and accretion of nanoscale features of semiconductor materials for low cost prototyping of micro and nano systems.
Manufacturing success requires not only the generation of new knowledge, it also requires people with the ability to invent and innovate. The education and research training of the CDT-UP will be developed in partnership with the new EPSRC centre for Ultra Precision, a wide range of industrial collaborators, and other UK universities working in the field of UP. This leading educational centre will respond to both the industrial need of UK companies, and the educational development strategies of UK universities, in developing the people with the technical capabilities necessary to move from the inventive steps to innovation platforms, thereby increasing the potential for wealth creation in the UK. We ensure that UK manufacturing can meet the future technical and business challenges needed to compete globally. The potential of the UK's innovation capacity to create new high-end manufacturing jobs is significant. Maximising this wealth generation opportunity within the UK will however depend on successfully realising next generation innovative production systems. Without relevant production research, r&d infrastructure, and an effective technology supply chain, there will be a limit to the UK's direct employment growth from its innovation capacity, leading to a constant migration of UK wealth creation potential into overseas economies. CDT-UP will develop a significant number of highly trained manufacturing engineers who will be essential to provide the leadership necessary to drive UK high value manufacturing forward and provide the vision for future prosperity.
The importance of ultra precision manufacturing to the UK economy and the key issues and barriers to economic success are highlighted in the main proposal which demonstrate the central role of ultra precision manufacturing technology in ensuring economic growth. Many emerging sectors and next generation products will demand ultra precise components (nanometre, and sub-micron-level tolerance). To date semiconductor systems, and microsystems (optical, mechanical, or electrical) use complex expensive process steps in their production. Such extensive process chains are needed to create even initial pre-production prototypes. This issue has become a significant barrier to SME's realising their innovative products requiring UP. We aim to develop ultra precision manufacturing technologies that will offer precision capabilities, with a reduced level of capital investment compared to traditional semiconductor fabrication routes. These include:- wide area roll-to-roll printing of electronic devices, optical films, and structured surfaces; novel micro machining technologies for the production of 3-dmensional components such as micro-mechanical elements, embossing and injection mould tools, and micro-embossing tools.; direct writing and accretion of nanoscale features of semiconductor materials for low cost prototyping of micro and nano systems.
Manufacturing success requires not only the generation of new knowledge, it also requires people with the ability to invent and innovate. The education and research training of the CDT-UP will be developed in partnership with the new EPSRC centre for Ultra Precision, a wide range of industrial collaborators, and other UK universities working in the field of UP. This leading educational centre will respond to both the industrial need of UK companies, and the educational development strategies of UK universities, in developing the people with the technical capabilities necessary to move from the inventive steps to innovation platforms, thereby increasing the potential for wealth creation in the UK. We ensure that UK manufacturing can meet the future technical and business challenges needed to compete globally. The potential of the UK's innovation capacity to create new high-end manufacturing jobs is significant. Maximising this wealth generation opportunity within the UK will however depend on successfully realising next generation innovative production systems. Without relevant production research, r&d infrastructure, and an effective technology supply chain, there will be a limit to the UK's direct employment growth from its innovation capacity, leading to a constant migration of UK wealth creation potential into overseas economies. CDT-UP will develop a significant number of highly trained manufacturing engineers who will be essential to provide the leadership necessary to drive UK high value manufacturing forward and provide the vision for future prosperity.
Organisations
People |
ORCID iD |
| James Moultrie (Primary Supervisor) | |
| Mark Golab (Student) |
| Description | This work experimentally investigates how the dimensional quality of printed parts from the material extrusion additive manufacturing (MEAM) technology is influenced by the underlying mechanisms of the process (i.e. printing parameters, materials, artefact geometry, and machine software). As a result of this funded awarded, thus far we have achieved one conference publication, which was presented at the Additive Manufacturing for Products and Applications 2020 Conference and we have published one journal publication to the Heliyon Journal. Through this work, we have discovered that the material extrusion additive manufacturing process is far more complex than initially understood, whereby an array of variables can significantly affect the micro and macro geometries of printed parts. Furthermore, it has been discovered that at a local level, the printing parameters can greatly influence the magnitude of morphological variation of single deposited stands of material. Additionally, the precision of the MEAM process is significantly influenced by the flow of the material when it is extruded out of the nozzle, and the first layer adhesion between the material and the print bed substrate. It can also be concluded that process precision is greater when using a direct drive AM machine in comparison to a Bowden extruder AM machine. Importantly, a critical element in achieving desired dimensional quality is ensuring the extruded material comes into contact with the print bed substrate before the nozzle or the print bed moves. Overall, we have experimentally demonstrated the fundamental limitations of ME AM process and proposed novel methods in which the performance of the ME AM machines can be evaluated. |
| Exploitation Route | The research outcomes of this funding will hopefully enable advanced insights in material extrusion additive manufacturing and ultimately generate greater adoption of this technology as a primary production process within the manufacturing sector. From an industrial point of view, if the dimensional quality of printed parts is improved, it is envisaged that a larger number of engineering and manufacturing companies could adopt this process, and therefore integrate the use of its technology in their respective engineering/design development procedures. The wide scale adoption of this technology could potentially reduce material wastage, increase throughput, reduce costs, and ultimately foster competitive advantage, which in turn drives innovation. Within the academic environment, it is envisaged that academics and researchers could potentially use the outcomes of this work to find alternative and novel ways to improve the process even further. Additional process improvements undertaken within an academic environment could include the enhanced repeatability of printed parts, the use of new composite materials, and further reduce the local variational magnitude of the process. |
| Sectors | Creative Economy,Education,Manufacturing, including Industrial Biotechology |