Manufacturing Commons^™

Process Improvement And Lift Design For The Installation Of A Metrology Machine Assembly, Dalt J. Lasell, James Mitchell O'Meara, Matthew Steensma

Industrial and Manufacturing Engineering

The objective is to work with Onto Innovations, a leading provider of semiconductor metrology and manufacturing solutions, to develop a system that safely installs a 250lb optics plate into the Atlas III: one of their metrology machines. Based in Milpitas, CA, Onto Innovations utilizes a variety of operations to create different products and assembles each product on site. The 250lb optics plates are WIP that are transferred between fixtures and the Atlas III using a combination of lifts and human workers. The WIP have long lead times, high tolerances, and large costs associated with their manufacturing process.

Onto Innovations identified …

Automation Of Data Analysis In Formula 1, Adam Joseph Mourad, Prescott Jeanne Delzell, Patrick Conner Mccabe

Industrial and Manufacturing Engineering

This paper explores economic solutions for Formula 1 racing companies who are interested in data visualization tools. The research was conducted on the current development of data gathering, data visualization, and data interpretation in Formula 1 racing. It was found that a large chunk of racing companies within the league needs an affordable, effective, and automated visualization tool for data interpretation. As data collection in Formula 1 arises, the need for faster and more powerful software increases. Racing companies profit off-brand exposure and the more a racing team wins, the more exposure they receive. The goal of the paper focuses …

Design And Testing Of A Modular Laser System With Laser Machining And Bioprinting Capabilities, Jesus Gonzalez

Theses and Dissertations

This thesis introduces the applications of ultrafast lasers while focusing on their bioprinting capabilities. A custom system was designed to utilize a femtosecond laser for 2D and 3D applications. The characteristics of lasers allow them to be efficiently used in machining, 3D printing, research, and more. Their power and precision allow them to be used for delicate work such as bioprinting. Bioprinting is a field holding great potential to benefit society. Studies conducted over the years prove its usefulness in printing cells and biomaterials, while showing there is still much to improve upon before being able to print fully functioning …

Exploring Convergence Of Snake Skin-Inspired Texture Designs And Additive Manufacturing For Mechanical Traction, Catherine Sue Tiner

Graduate Theses and Dissertations

This research focuses on the understanding, development, and additive manufacture of a 3D printed snake skin-inspired texture pattern. The design functionalities of snake skin were determined through the study of the snake species Python Regius otherwise known as the ball python. Each scale of a snake has hierarchical texture with hexagonal macro-patterns aligned on the ventral surface of the skin with overriding anisotropic micro textured patterns such as denticulations and fibrils. Using a laser-powder bed fusion (L-PBF) process, 420 stainless steel samples were 3D printed which closely resemble the above described directional texture of natural snake skin. This printed surface …

An Investigation Of High-Speed Consolidation And Repair Of Carbon Fiber - Epoxy Composites Through Ultrasonic Welding, David A. Hoskins

LSU Master's Theses

Adhesive repair of carbon fiber composite structures is commonly done on damaged structures to extend the service life. This method requires careful preparation of the damaged surface with intricate steps to ensure good bonding between the repair patch and the parent structure by means of an adhesive film. As with many forms of composite manufacturing, it is required to perform vacuum bagging, debulking, and a heated cure depending on the resin. All these steps make the repair process costly and time consuming.

In this present work, an alternative method of repair is investigated which explores the experimental feasibility of using …

The Business Case For Industrial Safety: Revealing The Comprehensive Value Of Ergonomic Investments For Manufacturing Enterprises In Industry 4.0, Shane Stan

Honors Program: Senior Projects (Public)

How can today’s manufacturing enterprises construct, implement, and optimize modern safety initiatives in a manner that will present maximum return on investment and facilitate enterprise growth? Furthermore, how can these manufacturers assure individual ergonomic investments become part of a larger strategy to facilitate organizational change in safety? This work addresses these questions by placing industrial ergonomics in a business improvement context which comprehensively presents the financial returns and growth opportunities poised by modern safety initiatives. Additionally, to further strengthen the business case for industrial safety, an ergonomic action planning framework is established to guide the creation of holistic safety programs …

Development Of A Robotized Laser Directed Energy Deposition System And Process Challenges, Meysam Akbari

Mechanical Engineering Research Theses and Dissertations

Metal additive manufacturing (AM) is a disruptive technology, enabling fabrication of complex and near net shaped parts by adding material in a layer-wise fashion. It offers reduced lead production time, decreased buy-to-fly ratio, and repair and remanufacturing of high value components. AM processes are finding applications in many industrial sectors such as aerospace, automotive, biomedical and mold tooling. However, beside tremendous advantages of AM, there are still some challenges that prevent the adoption of this technology into high standard applications. Anisotropy and inhomogeneity in mechanical properties of the as-built parts and existence of pores and lack-of-fusion defects are considered as …

Adhesion Testing Of Printed Inks While Varying The Surface Treatment Of Polymer Substrates, Clayton Neff, Edwin Elston, Amanda Schrand, Nathan B. Crane

Faculty Publications

Additive manufacturing with conductive materials enables new approaches to printed electronics that are unachievable by standard electronics manufacturing processes. In particular, electronics can be embedded directly into structural components in nearly arbitrary 3D space. While these methods incorporate many of the same materials, the new processing methods require standard test methods to compare materials, processing conditions, and determine design limits. This work demonstrates a test method to quantitatively measure the adhesion failure of printed inks deposited on a substrate without changing the ink printing conditions. The proposed method is an adaption of single lap shear testing in which the lap …

Bridging The Gap Between Automated Manufacturing Of Fuel Cell Components And Robotic Assembly Of Fuel Cell Stacks, Devin C. Fowler, Vladimir Gurau, Daniel Cox

Manufacturing Engineering: Faculty Publications (2015-2023)

Recently demonstrated robotic assembling technologies for fuel cell stacks used fuel cell components manually pre-arranged in stacks (presenters). Identifying the original orientation of fuel cell components and loading them in presenters for a subsequent automated assembly process is a difficult, repetitive work cycle which if done manually, deceives the advantages offered by either the automated fabrication technologies for fuel cell components or by the robotic assembly processes. We present for the first time a robotic technology which enables the integration of automated fabrication processes for fuel cell components with a robotic assembly process of fuel cell stacks into a fully …

Materials Selection Of 3d Printing Filament And Utilization Of Recycled Polyethylene Terephthalate (Pet) In A Redesigned Breadboard, Mark Keanu James E. Exconde, Julie Anne A. Co, Jill Z. Manapat, Eduardo R. Magdaluyo Jr.

Goal 12: Responsible Consumption and Production

The demand for a novel and sustainable alternative materials for 3D printer filaments has been knowingly increasing. One alternative source for the filament is to reuse and recycle post-consumer plastic products, which is also a compelling approach to conserve energy and sustain the environment. Thus, this study is focused on the materials selection of virgin polymer resins and recycled post-consumer plastics for use in 3D printer filaments. A multi-criteria decision method of Elimination and Choice Expressing the Reality (ELECTRE) was utilized to determine the best materials for 3D printer filaments. The study has shown that the virgin low-density polyethylene (LDPE) …

Mechanical And Temperature Resilience Of Multi-Material Systems For Printed Electronics Packaging, Clayton Neff, Justin Nussbaum, Chris Gardiner, Nathan B. Crane, James L. Zunino, Mike Newton

Faculty Publications

In this work, two AM technologies were utilized to compare the effectiveness of fabricating a simple electronic device with a conductive trace and hollow cylinder representative of ‘printed packaging’ that would survive harsh environmental conditions. The printed packaging cylinder delineates printed potting for electronics packaging. An nScrypt direct write (DW) system was the primary manufacturing system but a developing technology—coined large area projection sintering (LAPS)—manufactured a subset of samples for comparison. The tests follow Military Standard (MIL STD) 883K and include resiliency evaluation for die shear strength, temperature cycling, thermal shock, and high G loading by mechanical shock. Results indicate …

Applications Of Laser Machining For Fiber Optic Sensor Development, Lauren Sailor

The Journal of Purdue Undergraduate Research

No abstract provided.

Frequency Inspection Of Additively Manufactured Parts For Layer Defect Identification, Aimee Allen, Kevin Johnson, Jason R. Blough, Andrew Barnard, Troy Hartwig, Ben Brown, David Soine, Tristan Cullom, Douglas A. Bristow, Robert G. Landers, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additive manufactured (AM) parts are produced at low volume or with complex geometries. Identifying internal defects is difficult as current testing techniques are not optimized for AM processes. The goal of this paper is to evaluate defects on multiple parts printed on the same build plate. The technique used was resonant frequency testing with the results verified through Finite Element Analysis. From these tests, it was found that the natural frequencies needed to detect the defects were higher than the excitation provided by a modal hammer. The deficiencies in this range led to the development of other excitation methods. Based …

Simulated Effect Of Laser Beam Quality On The Robustness Of Laser-Based Am System, Aaron Flood, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In many metal AM techniques, a laser is used as the heat source and in some applications, it can be advantageous to work off of the focal plane. When operating outside of focus, the beam quality of the laser can have drastic impacts on the ability to manufacture quality parts. This study investigates the effect of the beam quality and distance from the focal plan on the ability to deposit Ti-64, aluminum, and steel through the simulation of the blown powder process.

Dynamic Defect Detection In Additively Manufactured Parts Using Fea Simulation, Kevin Johnson, Aimee Allen, Jason R. Blough, Andrew Barnard, David Labyak, Troy Hartwig, Ben Brown, David Soine, Tristan Cullom, Edward C. Kinzel, Douglas A. Bristow, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The goal of this paper is to evaluate internal defects in additively manufactured (AM) parts using FEA simulation. The resonant frequencies of parts are determined by the stiffness and mass involved in the mode shape at each resonant frequency. Voids in AM parts will change the stiffness and mass therefore shift the resonant frequencies from nominal. This paper will investigate the use of FEA to determine how much a void size, shape, and location will change the resonant frequencies. Along with where the optimal input and response locations are in order to find these frequency changes. The AM part evaluated …

Application Of Schlieren Technique In Additive Manufacturing: A Review, R. Bharadwaja, Aravind Murugan, Yitao Chen, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additive manufacturing has gained a lot of attention in the past few decades due to its significant advantages in terms of design freedom, lower lead time, and ability to produce complex shapes. One of the pivotal factors affecting the process stability and hence the part quality is the shielding gas flow in additive manufacturing. As extremely beneficial for the process, the shielding gas flow is often set at maximum supply to achieve enough gas cover over the substrate. This causes excessive quantity of shielding gas to be unutilized. Realizing the importance of shielding gas, various studies have been carried out …

Applications Of Supervised Machine Learning Algorithms In Additive Manufacturing: A Review, M. S. Joshi, Aaron Flood, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additive Manufacturing (AM) simplifies the fabrication of complex geometries. Its scope has rapidly expanded from the fabrication of pre-production visualization models to the manufacturing of end use parts driving the need for better part quality assurance in the additively manufactured parts. Machine learning (ML) is one of the promising techniques that can be used to achieve this goal. Current research in this field includes the use of supervised and unsupervised ML algorithms for quality control and prediction of mechanical properties of AM parts. This paper explores the applications of supervised learning algorithms - Support Vector Machines and Random Forests. Support …

Part Remanufacturing Using Hybrid Manufacturing Processes, Xinchang Zhang, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Many users of high-performance metal parts, such as the aerospace industry, the mold/die casting industry, and heavy machinery consumers, extend the service of these damaged parts by employing remanufacturing technology. Additive manufacturing has unique capabilities, such as low heat input, a small heat-affected zone, free-form fabrication, and a near-net-shape. This paper summarizes the effort and the tested results to achieve an automated remanufacturing process using hybrid additive manufacturing and CNC machining processes. It will enable the robust remanufacturing-on-demand to significantly increase operational availability to reduce sustainment costs, thus will lead to robust and quality remanufacturing that is critical for remanufacturing …

Frequency Domain Measurements Of Melt Pool Recoil Pressure Using Modal Analysis And Prospects For In-Situ Non-Destructive Testing, Tristan Cullom, Nicholas Altese, Douglas A. Bristow, Robert G. Landers, Ben Brown, Troy Hartwig, David Soine, Aimee Allen, Andrew Barnard, Jason Blough, Kevin Johnson, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Fielding Additively Manufactured (AM) parts requires evaluating both the part’s geometry and material state. This includes geometry that may be optically hidden. Both the geometry and material state affect the vibration response of the parts and modal analysis (identifying natural frequencies) has been shown to be effective for at least simple geometries using ex-situ methods (shaker table and impact hammer excitations). This paper investigates evaluation of the frequency response of metal parts inside the build chamber using the process laser to excite the parts during printing (Renishaw AM250). Vibrations in the part are measured with accelerometers connected to the build …

The Effect Of Cell Size And Surface Roughness On The Compressive Properties Of Abs Lattice Structures Fabricated By Fused Deposition Modeling, Leah Mason, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Researchers looking to improve the surface roughness of acrylonitrile butadiene styrene (ABS) parts fabricated by fused deposition modeling (FDM) have determined that acetone smoothing not only achieves improved surface roughness but increases compressive strength as well. However, the sensitivity of ABS parts to acetone smoothing has not been explored. In this study we investigated FDM-fabricated ABS lattice structures of various cell sizes subjected to cold acetone vapor smoothing to determine the combined effect of cell size and acetone smoothing on the compressive properties of the lattice structures. The acetone-smoothed specimens performed better than the as-built specimens in both compression modulus …