American researchers have developed a technique that allows manufacturers of metal parts using 3D printing technologies to automatically control the quality of parts during finishing. The method designed in this way enables identification of potential defects without the need to remove parts from the production equipment.
Innovation in quality control of metal parts
Brandon McConnell,North Carolina State University and co-author of an article about this work, explains: “ One of the reasons people are drawn to 3D printing and other additive manufacturing technologies is that these technologies enable rapid replacement of critical machine components that are otherwise difficult to manufacture outside of a factory. »
Additive manufacturing tools can produce these parts on demand, avoiding supply chains that can lead to long wait times. This usually means using 3D printing to make small batches of machine parts as needed.
Automated finishing process
After the metal part is printed, additional finishing is required to ensure the part meets critical tolerances. Currently, this involves removing the part from the production equipment, measuring it and then putting it back into the equipment for adjustment.
“ This process may need to be repeated several times and may take a long time », specifies Brandon McConnell. ” Our work accelerates this process. »
The researchers integrated 3D printing, automated machining, laser scanning and tactile measurement technologies with associated software to create a highly automated system that produces metal machine components within critical tolerances.
How the new technique works
When end users need a specific part, they access a software file that contains the measurements of the desired part. The 3D printer uses this file to print the part, including the metal support structures. Users then mount the printed part into the finishing device using a support structure. At this stage, lasers scan the assembled part to determine its dimensions.
The software program then uses these dimensions and the desired critical tolerances to guide the finishing device, which effectively polishes the irregularities of the part. As this process progresses, the finishing device manipulates the orientation of the printed part so that it can be measured by a tactile robotic probe, ensuring that the part’s dimensions match the required parameters.
Performance test results
To test the performance of this new approach, the researchers fabricated a machine part using conventional 3D printing and finishing techniques and then manufactured the same part using their new process.
“ We were able to complete the piece in 200 minutes using conventional techniques; the same section was completed in 133 minutes using our new technique Brandon McConnell added. ” Depending on the situation, saving 67 minutes can be extremely important. Time is money in most business contexts. And in emergency response settings, for example, it could mean the difference between life and death. »
Ricoh Center of Excellence opens in NC State
In related news, Ricoh, a provider of integrated digital services and print and imaging solutions, has opened its Center of Excellence on NC State’s Centennial campus. The university stated that “ proximity to leading talent and research was a key factor in choosing the location “.
NC State is also home to a notable program in the United States additive manufacturing.
“ Ricoh’s new Centennial office and partnership with NC State will help manufacturers accelerate innovation and product development said Gary Turner, general manager of additive manufacturing at Ricoh. ” As additive manufacturing applications grow, 3D printing will improve efficiency in a variety of industries. »
Illustration title: Automated quality control of 3D printed parts during finishing. Photo: North Carolina State University