3D Printing and Ubiquitous Manufacturing

98 Pages·2020·3.365 MB·English

by  Tin-Chih Toly Chen

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APPLIED SCIENCES AND TECHNOLOGY
Tin-Chih Toly Chen
3D Printing
and Ubiquitous
Manufacturing
123
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Tin-Chih Toly Chen
3D Printing and Ubiquitous
Manufacturing
123
Tin-Chih TolyChen
Department ofIndustrial Engineering
andManagement
National Chiao TungUniversity
Hsinchu, Taiwan
ISSN 2191-530X ISSN 2191-5318 (electronic)
SpringerBriefs inApplied SciencesandTechnology
ISBN978-3-030-49149-9 ISBN978-3-030-49150-5 (eBook)
https://doi.org/10.1007/978-3-030-49150-5
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Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Three-Dimensional Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Ubiquitous Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Various Types of Ubiquitous Manufacturing Systems. . . . . . . . . . 6
1.4 Application of Three-Dimensional Printing to Ubiquitous
Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Organization of This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Application of Ubiquitous Manufacturing to a Conventional
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Migrating to Three-Dimensional Printing . . . . . . . . . . . . . . . . . . . 13
2.2 Applicability of Ubiquitous Manufacturing to a Conventional
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Production Planning by Prioritizing Self-Owned Capacity. . . . . . . 15
2.4 Production Planning by Considering Both Self-Owned
and Foundry Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Resorting to Cloud-Based Capacity . . . . . . . . . . . . . . . . . . . . . . . 23
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Three-Dimensional Printing Capacity Planning . . . . . . . . . . . . . . . . 29
3.1 Three-Dimensional Printing Capacity. . . . . . . . . . . . . . . . . . . . . . 29
3.2 Selecting the Most Suitable Three-Dimensional Printer:
An Analytic Hierarchy Process Approach . . . . . . . . . . . . . . . . . . 30
3.3 Selecting Diversified Three-Dimensional Printers: The
Decomposition Analytic Hierarchy Process Approach. . . . . . . . . . 36
3.4 A Fuzzy Analytic Hierarchy Process Approach for Selecting
the Most Suitable Three-Dimensional Printer . . . . . . . . . . . . . . . . 40
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
v
vi Contents
4 Capacity Planning for a Ubiquitous Manufacturing System
Based on Three-Dimensional Printing. . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Capacity and Production Planning Procedure . . . . . . . . . . . . . . . . 47
4.2 System Architecture of a Three-Dimensional Printing-Based
Ubiquitous Manufacturing System. . . . . . . . . . . . . . . . . . . . . . . . 49
4.3 Assessing and Choosing Three-Dimensional Printing Facilities . . . 50
4.3.1 Determining the Weights of Criteria . . . . . . . . . . . . . . . . . 50
4.3.2 Assessing the Overall Performance of a Three-
Dimensional Printing Facility . . . . . . . . . . . . . . . . . . . . . . 54
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5 Production and Transportation Planning for a Ubiquitous
Manufacturing System Based on Three-Dimensional Printing . . . . . 63
5.1 A Ubiquitous Manufacturing System Based on Three-
Dimensional Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 Balancing the Workloads on Three-Dimensional Printing
Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3 Identifying the Shortest Delivery Path . . . . . . . . . . . . . . . . . . . . . 68
5.4 An Aggregate Production and Transportation Planning Model. . . . 70
5.5 An Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.6 A Production Planning Model Considering Uncertainty . . . . . . . . 76
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6 QualityControlina3DPrinting-BasedUbiquitousManufacturing
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.1 Quality and Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2 Quality of a Three-Dimensional Printed Object . . . . . . . . . . . . . . 83
6.2.1 Quality and QC Standards for 3D Printing . . . . . . . . . . . . 85
6.2.2 Aesthetics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.2.3 Conformance to Specifications . . . . . . . . . . . . . . . . . . . . . 86
6.2.4 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.3 QC for 3D Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.3.1 Product Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.3.2 Process Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.3.3 Cause-and-Effect Analysis . . . . . . . . . . . . . . . . . . . . . . . . 91
6.3.4 DOE and Taguchi Method . . . . . . . . . . . . . . . . . . . . . . . . 92
6.4 Quality Control in a Three-Dimensional Printing-Based
Ubiquitous Manufacturing System. . . . . . . . . . . . . . . . . . . . . . . . 93
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Chapter 1
Introduction
1.1 Three-DimensionalPrinting
Three-dimensional (3D) printing is a new approach for additive manufacturing,
whichistocreatea3Dobjectbyformingsuccessivelayersofmaterialsbyusinga
3Dprintercontrolledbyacomputer[1].Inthisway,3Dprintingcanfabricateprod-
uctsorcomponentswithverycomplexshapes.Anotheradvantageof3Dprintingis
theeasinessofintegratingwithcomputer-aideddesign(CAD)andcomputer-aided
manufacturing (CAM), so that a 3D object can be directly made from the model
generated by a CAD/CAM software package. Naturally, existing CAD/CAM soft-
ware vendors were pioneers in this field. For example, AutoCAD has supported
reading a 3D model in the stereolithography (STL) file format and output an STL
filetoa3DprintersinceAutoCAD2011.Catiacanalsosavea3DmodelintheSTL
format [2]. Other acceptable 3D printing file formats include OBJ, VRML, PLY,
and ZIP. 3D printer vendors, CAD/CAM software companies, 3D printing service
providers,and3D-printingcommunitieshavebeenmaintainingonlinedatabasesof
3Dobjects.Ausercandownloada3Dmodelresemblinghisorherideafromthese
websitesandthenmodifyit.Inaddition,offlinedatabasessuchas3Danthropometry
databases and medical databases (including computed tomography and magnetic
resonanceimagingdatabases)canalsobeconvertedtobeprintable,asillustratedin
Fig.1.1.
Thedevelopmentof3Dprintingdatesbacktotheearly1980s[3].Afterdecadesof
researchanddevelopment,theapplicationof3Dprintinghastransitedfromvisual-
izationandprototypingtomasscustomizationandmassproduction[4–6].American
Society for Testing and Materials classified additive manufacturing processes into
sevencategories[7]:
(cid:129)
Vatphotopolymerization,
(cid:129)
Materialjetting(MJ),
(cid:129)
Binderjetting(BJ),
©TheAuthor(s),underexclusivelicensetoSpringerNatureSwitzerlandAG2020 1
T.-C.Chen,3DPrintingandUbiquitousManufacturing,
SpringerBriefsinAppliedSciencesandTechnology,
https://doi.org/10.1007/978-3-030-49150-5_1
2 1 Introduction
Online 3D
Object
Databases
n n
o o
si si
er 3D Printing er
v v
n Databases n
o o
c c
Medical CAD/CAM
Databases Drawings
n
o
si
r
e
v
n
o Scanned
c
3D
3D Objects
Anthropometry
Databases
3D Printers
Fig.1.1 Datasourcesfor3Dprinting
(cid:129)
Materialextrusion,
(cid:129)
Powderbedfusion,
(cid:129)
Sheetlamination,and
(cid:129)
Directedenergydeposition.
Currently, the most popular 3D printing technologies include fused deposition
modeling (FDM), stereolithography (SLA), masked stereolithography (MSLA),
digital light processing (DLP), selective laser sintering (SLS), direct metal laser
sintering (DMLS), selective laser melting (SLM), electron beam melting (EBM),
MJ,drop-ondemand(DOD),andBJ.These3Dprintingtechnologiesdifferinthe
types of raw materials used, forms of raw materials, and principles followed. The
majortypesofmaterialsfor3Dprintingincluderesin(orplastics),metal,gypsum,
andsand.Anintroductionofvarious3DprintingtechnologiesreferstoAll3DP[8].
Three-dimensionalprintinghasbeenappliedinnumerousindustries.Forexample,
in the automotive manufacturing industry, automotive makers have applied 3D
1.1 Three-DimensionalPrinting 3
printingtechnologiestoprototyping,designvalidation,small-scalemassproduction,
andfinalinspection[9].Everyyear,automotivemakersapply3Dprintingtoproto-
type or manufacture more than 100,000 parts and/or molds [10]. Functional spare
partsofvehicles,engines,andplatformsarealsotestedusing3Dprinting[9].Inthe
medicalandhealthcareindustry,3Dprintingtechnologieshavebeenwidelyapplied
tomakepersonalizedproductssuchashearingaids,artificialears,prostheses,reha-
bilitationaids,orthopedicsurgeryguideplates,artificialjoints,anddentalimplants
[11].Medicalproductsmadeusingmetalprintinghaveporoustitaniumstructures,
aremoreergonomic,andhavehigherperformance,farexceedingthelimitationsof
traditionalmanufacturingprocesses.3D-printedtitaniumpartsorproductsarepreva-
lentinvariousindustriessuchasaerospace,chemical,andbiomedicalindustriesdue
toexcellentpropertiesincludinglightweight,highspecificstrength,highchemical
resistance,andbiocompatibility[12].Inthebiomedicalindustry,titaniumisusedto
makeimplantsbecauseofitsload-bearingandbiocompatibility,whileintheavia-
tionindustry,theresistancetocorrosionandlightweightoftitaniumisemphasized
[13–15]. Titanium is about 45% lighter than steel [16]. The replacement of steel
with titanium has reduced the weight of a 777 airplane by 5800 lb [17]. A lighter
weightalsoreducestherequiredfuelsandcarbonemission,whichfurtherpromoted
theusageoftitaniuminaircraft.Inaddition,titaniumistwiceasstrongasaluminum
thatisfrequentlyusedtobuildtheoverallstructureofanairplane[16,17].Inaddition,
atraditionalmanufacturingprocessmayberelativelycomplex,havelongcycletime,
andbedifficulttomaintainprecision.Theapplication of3Dprintingtechnologies
hasovercometheseproblemstoreducemanufacturingcostsandshortencycletime
[13].Forexample,intheconstructionindustry,3Dprintingtechnologieshavebeen
appliedtobuildsimpleandaffordablemodelsrapidly.Theapplicationof3Dprinting
technologiesalsomotivatesinnovativewaysofproduction.Forexample,architects
proposedadirectmethodofconstructionbyapplying3Dprintingtechnologies[18].
3D printing, cyberphysical systems, and the Internet of things (IoT) have brought
aboutthethirdindustrialrevolution[19].
Fourtechnicalchallengesfacedby3Dprintingresearchersandpractitionersare
time-consuming3Dobjectdesign,limitedtypesofusablematerials,lowprecision,
andlowproductivity,asillustratedinFig.1.2[2].Toaddressthesechallenges,the
followingtreatmentshavebeentaken:
(1) Amajorresearchtrendinthisfieldistoincreasethenumberoftypesorsuitability
ofmaterialsthatsupporttheprintingofaspecific3Dobject[5].
(2) Anotherfocusisonhowtoimprovethequalityofaprinted3Dobject[20,21].
(3) 3Dscannersthatcanbeusedtoscanobjectstoproduce3Dmodelshavebecome
more and more popular and affordable [22]. However, this does not work for
3Dobjectsthatdonotphysicallyexist.
(4) Ubiquitousmanufacturing(UM)systemsbasedon3Dprintinghavebeenestab-
lished to enhance the productivity of mass customization using 3D printers
[23].
Further, to further enhance the effectiveness and efficiency of 3D printing
applications,thefollowingmanagerialissuesneedtobeaddressed[2]: