Researchers at North Carolina State University have unveiled a new technique that facilitates automated quality control in the manufacture of 3D printed metal parts. This methodology allows the identification of defects during the finishing process, without the need to remove the parts from the manufacturing equipment, thus improving production time efficiency.
Optimization and efficiency in industrial production
Brandon McConnell, co-lead author of the study and a research assistant professor in the Edward P. Fitts Department of Industrial and Systems Engineering at NC State explains that 3D printing and other additive manufacturing technologies are attractive because they allow critical machine components to be replaced quickly. This is especially useful for parts that would be difficult to manufacture outside of an industrial environment, avoiding long supply chain lead times.
In addition, McConnell points out that after printing a metal part, additional finishing is necessary to ensure that it meets critical tolerances. Currently, this process involves removing the part from the equipment, measuring it and replacing it for adjustments, a procedure that can be repetitive and time-consuming.
How does this new 3D printing technique work?
The new technique developed by the researchers integrates 3D printing technologies and 3D printing automated machining, laser scanning and touch-sensitive measurement with specialized software. This automated system makes it possible to produce metal components that meet the required tolerances without the need for constant manual intervention.
The operation of this technique begins when end users obtain a software file with the measurements of the desired part. A 3D printer uses this file to create the part, which includes metal support structures. The printed part is then mounted on a finishing device, where lasers scan its dimensions. A software program uses these dimensions to guide the finishing device, which polishes out any irregularities.
As the process progresses, the part is manipulated by a finishing device that uses a touch-sensitive robotic probe to ensure that the dimensions are within the required parameters. This approach has proven to be more efficient in comparative tests, reducing finishing time from 200 minutes to 133 minutes, according to McConnell. This 67-minute optimization can be crucial in professional and emergency response environments.
3D Printing: Adaptation to new parts
It is important to note that although this method focuses on parts that include circles or cylinders, such as pistons, it could be adapted to other types of machine parts. McConnell stresses that all the hardware used is commercially available and the required software is clearly detailed in the study, facilitating immediate adoption by the industry.
Finally, the article entitled “ Feature-based automatic inspection and qualification for additively manufactured parts with critical tolerances. ” has been published in the International Journal of Manufacturing Technology and Management, and the project has been supported by the U.S. Army Research Office.
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Source: metrologynews
Photo: Shutterstok
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