Integrating metal 3D printing and flexible post processing | 2 Mers Seas Zeeën

3D&FPP

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Integrating metal 3D printing and flexible post processing

Priority Axis

Technological and Social Innovation

Specific objective

Technological Innovation

Lead partner

Stichting Hogeschool Rotterdam (HR)

Contact

Date de début

01/09/2016

Date de fin

31/12/2019

Project budget

3 553 244

ERDF amount

2 007 085

ERDF rate

56%

    À propos

    Common challenge

    Additive Manufacturing (AM) is the process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. A major challenge for the industry is to move this emergent technology forward from its prototyping history into a true manufacturing capability. The process has the potential to revolutionise design, production and supply of parts, but exploitation has been limited, especially for AM of metal parts, because the post processing of AM manufactured parts is too costly in terms of time and energy. 

    Main Achievements

    In 2017 the research conducted resulted in the definition of the state of art of the different post processing steps and the requirements for integration of post processing. Based on the results in 2017, the focus in 2018 was on the development of the post processing solution (WP2). After finishing Workpackage 1, Design, integration of post processing and 3d metal printing proved to be an IT and interfacing challenge. Each process step has its own, unique requirements, in which data integration of CAD, CAM, scanning and CNC milling is key in creating a flexible post processing procedure. An algortihm was developed, generating a specific machine code, the NC-post. Through this algortihm the CAM NC-code is adjusted by considering the optimal fit and its scanned orientation, resulting in the specific NC post which allows to directly mill the clamped object to its net shape. This algorithm is an universal and flexible post processing solution, fitting most existing CNC machines. 

    In 2018 the partnership succesflly presented the project and results during the RapidPro and Prototype fair, resulting in an increase of targets groups and two extra user cases. The application of the Fast Prototyping Approach resulted in a request for modification of the Application Form. This request was submitted in December 2018 and approved in January, 2019. 

    In 2019 the 3D&FPP partnership finished and presented the results of their research into integrating 3D metal printing and flexible post-processing. The preliminary demo setup was presented during the Future Flux Festival and the setup of the proof of principle and demonstration of the Flexible Post Processing Solution during the 3D&FPP Demo Event on September 19th. After presentations on the project and the research conducted, a live demonstration was given on the flexible post processing solution, addressing both the advantages and benefits of the solution. The partnership wrote one integrative report containing all info on the project, the FPP, the conclusions and reductions achieved, possible applications and some recommendations for future developments. This report comprises output reports O4 (Proof of principle) and O5 (Demonstrated user cases) and is available for downloading on the 3D&FPP website. 

    Partnership

    Partners

    RDM Makerspace BV

    Hittech Multin BV

    3T RPD

    TNO Innovation for Life

    University of Exeter

    ARGON measuring Solutions

    Outputs

    Theme
    Type
    Target
    URL / Download
    31/03/2019

    Development of process and manufacture of prototype tool 

    Thème: Innovation
    Type: Method/tool
    Target: Schools and training centres - SMEs /enterprises - Universities and research centres
    31/12/2019

    Prototype (which may consist of hardware and/or software models) of an integrated 3D printing and high precision postprocessing manufacturing setup

    Thème: Innovation
    Type: Physical equipment/pilot
    Target: Schools and training centres - SMEs /enterprises - Universities and research centres
    31/12/2019

    Demonstrated user cases in pilot

    Thème: Innovation
    Type: Feasibility study
    Target: Schools and training centres - SMEs /enterprises - Universities and research centres
    31/12/2017

    Feasibility study/prepatory research report

    Thème: Innovation
    Type: Method/tool
    Target: Schools and training centres - SMEs /enterprises - Universities and research centres
    31/12/2017

    Feasibility test

    Thème: Innovation
    Type: Method/tool
    Target: Schools and training centres - SMEs /enterprises - Universities and research centres