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Author: Tronserve admin

Wednesday 28th July 2021 03:51 PM

Continuous Process Chain for Additive Manufacturing


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Stuttgart, April 17, 2019 - The European "Bionic Aircraft" research project has hit yet another milestone for additive manufacturing: For the first time ever, components can be printed instantly from the CATIA V5 CAD system. This is made possible with the interface developed by CENIT. With it, there is no need to have to leave the development environment. All process steps, including post-processing, can be mapped in CATIA V5. Now, exact data is available in CATIA V5 for removing the support structures during 3D part post-processing - elaborate reconstructions of the model and the support structures are a thing of the past.

Future users will be able to reduce their time and costs resulting from the sealed process chain for additive manufacturing, because now the development process for a part until series maturity has become significantly leaner. Jochen Michael, Senior Consultant at CENIT, provides background information: "Support structures of additive manufactured components should not be reduced manually in series production, but instead with NC machines. When creating NC programs of this category, the STL format, which in the past was used chiefly for the representation of component and support structures in the 3D print data chain, is inadequate, because it can only portray the geometry imprecisely. In that case, the model and support structures must be reconstructed for refinishing, resulting in unnecessary expense. We can restrict this with the 3D print from CATIA V5 straight, because the exact geometry data for this post-processing is already available."

In order for the 3D print to be worthwhile via CATIA V5, CENIT provides support to the engineer in the preparation of data from topology optimization. During topology optimization, in a computer-aided process, the material for the component is decreased to the amount that is really important to meet the requirements. The CATIA V5 Slicer, newly developed by CENIT, then slices the component into layers. The contours of these slices are sent directly to the 3D printer via the post-processor developed by CENIT.

 New support structures from Fraunhofer IAPT

Another positive interim result of the Bionic Aircraft project: The Fraunhofer Institute for Additive Production Technologies IAPT, has created optimized support structures. Support structures provide the needed support to additive manufactured components at selected areas, for example at overhangs, and must be extracted after the 3D print. "Thanks to an optimized geometry, the new support structures do not need as much powder. We were influenced by nature, which is recognized for its material efficiency. The hierarchically branched structures with gradients that were made as a result reduce powder consumption by 70 to 90 percent as compared to conventional support structures. This allows us to save material and reduce production costs at the same time", says Melanie Gralow of Fraunhofer IAPT. "An additional benefit is that they can be removed easier than conventional support structures. This makes post-processing faster, reducing the risk of problems to the component when they are reduced." The optimized structures are set up in CATIA V5 quickly.

Bionic Aircraft: Less Emissions in Aviation

Since 2016, the objective of the "Bionic Aircraft" research project backed by the European Commission (grant number 690689) has been to reduce emissions in the aviation industry. Ten international consortium partners from industry, research and development, among them also the IT specialist CENIT and Fraunhofer IAPT, are collaborating to come up with new methods and concepts. In this project, 3D print and bionic design play an imperative role in efforts to reduce the weight of aircraft components, thus reducing fuel consumption.



This article is originally posted on manufacturingtomorrow.com


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Posted on : Wednesday 28th July 2021 03:51 PM

Continuous Process Chain for Additive Manufacturing


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Posted by  Tronserve admin
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Stuttgart, April 17, 2019 - The European "Bionic Aircraft" research project has hit yet another milestone for additive manufacturing: For the first time ever, components can be printed instantly from the CATIA V5 CAD system. This is made possible with the interface developed by CENIT. With it, there is no need to have to leave the development environment. All process steps, including post-processing, can be mapped in CATIA V5. Now, exact data is available in CATIA V5 for removing the support structures during 3D part post-processing - elaborate reconstructions of the model and the support structures are a thing of the past.

Future users will be able to reduce their time and costs resulting from the sealed process chain for additive manufacturing, because now the development process for a part until series maturity has become significantly leaner. Jochen Michael, Senior Consultant at CENIT, provides background information: "Support structures of additive manufactured components should not be reduced manually in series production, but instead with NC machines. When creating NC programs of this category, the STL format, which in the past was used chiefly for the representation of component and support structures in the 3D print data chain, is inadequate, because it can only portray the geometry imprecisely. In that case, the model and support structures must be reconstructed for refinishing, resulting in unnecessary expense. We can restrict this with the 3D print from CATIA V5 straight, because the exact geometry data for this post-processing is already available."

In order for the 3D print to be worthwhile via CATIA V5, CENIT provides support to the engineer in the preparation of data from topology optimization. During topology optimization, in a computer-aided process, the material for the component is decreased to the amount that is really important to meet the requirements. The CATIA V5 Slicer, newly developed by CENIT, then slices the component into layers. The contours of these slices are sent directly to the 3D printer via the post-processor developed by CENIT.

 New support structures from Fraunhofer IAPT

Another positive interim result of the Bionic Aircraft project: The Fraunhofer Institute for Additive Production Technologies IAPT, has created optimized support structures. Support structures provide the needed support to additive manufactured components at selected areas, for example at overhangs, and must be extracted after the 3D print. "Thanks to an optimized geometry, the new support structures do not need as much powder. We were influenced by nature, which is recognized for its material efficiency. The hierarchically branched structures with gradients that were made as a result reduce powder consumption by 70 to 90 percent as compared to conventional support structures. This allows us to save material and reduce production costs at the same time", says Melanie Gralow of Fraunhofer IAPT. "An additional benefit is that they can be removed easier than conventional support structures. This makes post-processing faster, reducing the risk of problems to the component when they are reduced." The optimized structures are set up in CATIA V5 quickly.

Bionic Aircraft: Less Emissions in Aviation

Since 2016, the objective of the "Bionic Aircraft" research project backed by the European Commission (grant number 690689) has been to reduce emissions in the aviation industry. Ten international consortium partners from industry, research and development, among them also the IT specialist CENIT and Fraunhofer IAPT, are collaborating to come up with new methods and concepts. In this project, 3D print and bionic design play an imperative role in efforts to reduce the weight of aircraft components, thus reducing fuel consumption.



This article is originally posted on manufacturingtomorrow.com

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additive manufacturing catia