pps proceeding - Abstract Preview
pps proceeding
Symposium: S17 - Special Symposium: Additive manufacturing (3D printing)
Keynote Presentation
 
 

Additive Manufacturing of Large Parts by an Extrusion based Hybrid Approach

Hopmann Christian (1)*, Pelzer Lukas (1)

(1) IKV – Institute for Plastics Processing at RWTH Aachen University - Aachen - Germany

Because of the layer-based process, plasticizing additive manufacturing technologies offer high freedom in terms of geometrical design and functional integration and are therefore not only suitable for prototyping but also for final part production. In both cases, production time is a crucial factor regarding economic efficiency of the process. Furthermore, most parts have to be post-processed before being used. To address these challenges, IKV developed a hybrid manufacturing cell, which is capable of producing large parts in a short amount of time. To achieve this, a screw-based extrusion was utilized which opens up the possibility of using standard pellet material. By using a standardized coupling system, the system is as well able to incorporate subtractive manufacturing to ensure tight tolerances where needed and a pick and place system to insert additional components, such as bearings, bushings or electrical circuits. The machine is therefore capable of producing large functional assemblies autonomously. In the paper mechanical properties analyzed. It can be shown, that by using filled or even highly filled materials i.e. tensile strengths is on a level comparable with injection moulded parts in x and y directions. However, in z direction layer bonding is still subject to further development and research. To improve the mechanical properties of finished parts while reducing the amount of material being introduced, the use of infill structures is necessary. Today, infill is usually homogeneously distributed throughout the component. By load specific redistribution of the material inside the part, in a way that highly stressed regions receive more infill while regions with low strength requirements can be produced with less material, resulting in stronger yet lighter parts. While topology optimization frequently does not consider the production efficiency, this is as well taken into account within our investigation.