viernes, 23 de marzo de 2018

3D printing of RF metamaterials using hydrogel inks



Applications are invited for a fully funded PhD studentship (4 years) within the EPSRC Centre for Doctoral Training in Additive Manufacturing in the Faculty of Engineering at the University of Nottingham. http://www.nottingham.ac.uk/additivemanufacturing/

Materials with intrinsic difference of electrical properties are highly desirable for RF metamaterials. Additively manufacture metamaterials using materials with dissimilar electrical properties will widen the spectrum of controlling the RF response of the printed structures and increase the application prospect to include various frequencies ranging from MHz to THz

The successful PhD student will work alongside a team of other PhD students and post-doctoral researchers involved in related projects. This project is supported by the Engineering and Physical Sciences Research Council (EPSRC) through the EPSRC Centre for Doctoral Training in Additive Manufacturing at the University of Nottingham

Additive Manufacturing to create metallic glass alloys


Researchers have now demonstrated and exposed in the paper "Additive Manufacturing of an iron-based bulk metallic glass larger than the critical casting thickness," the ability to create amorphous metal, or metallic glass, alloys using 3D Printing technology, opening the door to a variety of applications in the UAV industry, such as more efficient electric motors, better wear-resistant materials, higher strength materials, and lighter weight structures. The paper is published in the journal Applied Materials Today. The paper was co-authored by Harvey West, Timothy Horn and Christopher Rock of NC State; Lena Thorsson, Mattias Unosson and Peter Skoglund of Sindre Metals; and Evelina Vogli of Liquidmetal Coatings. The work was done with support from the National Science Foundation under grant number 1549770.

The technique works by applying a laser to a layer of metal powder, melting the powder into a solid layer that is only 20 microns thick. The "build platform" then descends 20 microns, more powder is spread onto the surface, and the process repeats itself. Because the alloy is formed a little at a time, it cools quickly - retaining its amorphous qualities. However, the end result is a solid, metallic glass object - not an object made of laminated, discrete layers of the alloy. 

lunes, 19 de marzo de 2018

Additive Manufacturing for RF Components


The Army Aviation and Missile Research, Development, and Engineering Center (AMRDEC) Weapons Development and Integration (WDI) Directorate has a program known as PRIntable Materials with Embedded Electronics (PRIME2). PRIME2 will integrate RF and electronics into Additive Manufacturing processes to reduce size, weight, and overall cost of these components and subsystems.

This program will advance the state of the art in printable electronics, and deliver a materials database, process development, modeling, and simulation of 3D-printed objects with embedded conductive elements, passive prototypes, and RF prototypes. PRIME2 will create a new fabrication capability (applied to electronics and RF technology areas), weight reduction, higher reliability, and on-demand (local and immediate) spare components in the field.

Additive Manufacturing In Aerospace: Strategic Implications


Aerospace manufacturers have used Additive Fabrication Systems since ’80s. But in the past few years, rapid advancements in Additive Fabrication Technology have led applications of the technology in the aerospace industry to proliferate.

Additive Manufacturing formerly occupied a niche role in aerospace manufacturing as a technology for prototyping. As recent developments suggest, however, Additive Technology is rapidly becoming a strategic technology that will generate revenues throughout the aerospace supply chain.

Firms that are already committed to shifting the strategic dynamics of Additive Manufacturing in Space and Defense Markets include: Airbus, Boeing, Honeywell, Lockheed Martin, and Pratt & Whitney.



sábado, 17 de marzo de 2018

USAF looks for RAAMs


No details as to the type or capabilities of the proposed AAM were disclosed, neither were proposed development and fielding timelines or contract values, but the AFLCMC (Air Force Life Cycle Management Center) Medium Altitude UAS Division disclosed on 7 March that it intended to award the OEM (Original Equipment Manufacturer) a sole-source contract for the development of an MQ-9 RAAM (Reaper Air-to-Air Missile) Aviation Simulation (AVSIM) as the first step in the process of fielding such a capability.


The Reaper can currently carry up to 16 Lockheed Martin AGM-114P Hellfire missiles. It has also been cleared for the carriage of two GBU-12 Paveway II laser-guided bombs and the GBU-38 500 lb variant of the Joint Direct Attack Munition (JDAM), and for mixed loads of these weapons. Now, the US Air Force (USAF) is looking to equip its General Atomics Aeronautical Systems Inc (GA-ASI) MQ-9 Reaper unmanned aircraft systems (UASs) with an air-to-air missile (AAM) capability for the first time.


To date, the Reaper has been employed for intelligence, surveillance, and reconnaissance (ISR) and strike missions only, and the inclusion of air-to-air combat in its mission set would represent a significant expansion of its capabilities. While such an enhancement would be a first for the Reaper, the USAF has fitted short-range AAMs to UAVs previously.

Afghanistan: 4 IS killed in UAV strike


In a statement, the 201st Silab Corps of the Afghan National Army (ANA) said that the US military carried out an airstrike on an IS hideout in the last 24 hours by using an UAV, Khaama Press reported.


It added that the airstrike was carried out in Lechalam area in Manogi district of Kunar province and four IS militants were confirmed dead by the ANA. One militant was also injured in the airstrike.


The ANA said that the airstrike did not affect the local residents and security personnel in the province. The latest round of airstrike comes after 15 Tehrik-e-Taliban Pakistan (TTP) militants were killed in an airstrike in Kunar province last week.

viernes, 16 de marzo de 2018

Additive Fabrication of UAS: Commercial Outlook for a New Industry


Major parts of UAVs have traditionally been assembled from components made of molded plastic, but the development of Additive Fabrication presents the option of printing UAV parts instead: The National Aeronautics and Space Administration (NASA) is using Additive Fabrication Technology to develop UAV prototypes that may someday be used to explore the surface of Mars, and The Pentagon has developed an Additive Manufacturing Strategic Roadmap to get customized UAVsNow, some new technologies and pending federal regulations are enabling the manufacture and use of UAVs in domestic commerce, giving rise to a growing commercial UAV industry.

The Additive Manufacturing Revolution


Additive Manufacturing (AM) doesn’t offer anything like that economy of scale. However, it avoids the downside of standard manufacturing: a lack of flexibility. Because each unit is built independently, it can easily be modified to suit unique needs or, more broadly, to accommodate improvements or changing fashion. And setting up the production system in the first place is much simpler, because it involves far fewer stages. That’s why Additive Fabrication has been so valuable for producing one-offs such as prototypes and rare replacement parts.


Additive Fabrication Technology is at a tipping point, about to go mainstream in a big way: Among the numerous companies using Additive Technology to ramp up production are GE (jet engines, medical devices, and home appliance parts), Lockheed Martin and Boeing (aerospace and defense), Aurora Flight Sciences (UAVs), Invisalign (dental devices), Google (consumer electronics), and the Dutch company LUXeXcel (lenses for light-emitting diodes, or LEDs). Regarding UAVs, in Iraq and Afghanistan the U.S. military has been using UAVs from the Aurora Flight Sciences company, which prints the entire body of these UAVs some with wingspans of 132 feet—in one build.

Additive Manufacturing of Fuel Cells for UAVs


Dr. Benjamin D. Gould is a Chemical Engineer in the Chemistry Division of the Naval Research Laboratory (NRL). He’s an expert in fuel cell power systems and specializes in the development of next-generation power sources for the US Navy.

Dr. Gould earned his Ph.D. in Chemical Engineering from the University of Michigan in 2007 and his B.S. in Chemical Engineering from the Colorado School of Mines in 2002.  His research interests include Additive Manufacture of Fuel Cells, fuel cell recovery processes, bipolar plate design, open cathode fuel cells, and hydrogen safety.


In this podcast, Dr. Gould talks about the research the NRL is conducting with fuel cells and the Ion Tiger UAV. We learn how fuel cells produce electricity, and the reasons fuel cells are attractive for UAVs. Dr. Gould also explains the application of Additive Manufacturing to fuel cells, future research projects, and the availability of the hydrogen used as the fuel.

lunes, 12 de marzo de 2018

UAVs to Aid in Mountain Rescue Efforts


All joking about St. Bernard unemployment aside, it is undeniably a good thing that these dogs be largely replaced with mechanized vehicles for the initial phases of search and rescue.

The way for such small UAVs (SUAVs) has been paved by Amazon as it has forged ahead with the technology as part of its delivery fleet.

Since their heyday in the rescue arena, there have been a number of advances in technology that have led to the development of mechanized rescue apparatus that means that if you have the bad luck of needing a rescue after an avalanche, the air moving on your face might not be the hot breath of a gargantuan panting canine, but rather the wind from the rotor blades of an unmanned aerial vehicle, aka drone.

The latest advance in this technology comes out of the University of Warwick School of Engineering in Coventry, England where they have developed a UAV capable of delivering immediate assistance to those in distress before any larger rescue team arrives to complete the mission. The creation of such a creature required a lot of complex geometry as the UAV doesn’t have a stabilizing tail, still needs to be able to glide, and has to be able to carry its batteries and radio equipment.

The drone was not the product of a massive R&D program by a company with extensive resources, but rather the result of the efforts of seven fourth-year students working as part of an industry and government supported program called Horizon (AM).

This program has as its aim the advancement of Additive Manufacturing in the aerospace industry and these students knew just what they wanted to do as part of this effort. They are currently looking at customized software that would provide a plan for the payload for each emergency. Professor of Engineering Simon Leigh served as the faculty guide during this project explained how such a program would work: “It would suggest the load out you would need an how to balance it to get the right center of gravity. So we cataloged the supplies we want to put in it and worked out where they might sit in the airframe.”

With a large-format 3D printer at their disposal, it quickly became clear that this was the perfect technology for the fabrication of their machine, freeing them up to approach the more daunting task of the design itself. Rather than utilizing a traditional fuselage, which adds more weight than desired to the UAV, they decided to create their own, as Ed Barlow, who served as the project’s design lead, described: “They all use an airframe that you can go and buy from a shop. We needed our own custom airframe, made specifically for long-distance flight with a heavy payload. The fuselage is essentially dead weight. It doesn’t generate any lift on the aircraft. We went with a blended-wing body, or ‘flying wing,’ where the fuselage is built into the wing such that the fuselage, as well as the wings, generate lift.”

jueves, 8 de marzo de 2018

Integration of Topological and Functional Optimization in Design for Additive Manufacturing


Additive Manufacturing (AM) technologies has brought unprecedented freedom to the fabrication of functional parts with high complex, multi-material and gradient density structure.

However, currently only traditional design methods are available for AM design process, which do not take full advantage of AM capabilities. Therefore, a new design method with the consideration of all aspects of AM advantages is urgently in need.

A detailed literature review on traditional design methods is presented with focused attention on the potential of using these methods to design functional parts for Additive Manufacturing processes. Based on thorough understanding and comparison of current structure design methods, a new design approach that integrates topological and functional optimizations for AM products is presented.

With this method, an essential link is established between topological optimization result and various functional parameters of complex structure. Parts can be designed in multi levels for multi functions simultaneously. This design method provides an important foundation for future research on designing AM products with improved multiple functions and optimized topology.

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AeroDef Manufacturing 2018


AeroDef Manufacturing is the leading exposition and technical conference for the aerospace and defense manufacturing industry.
Produced by the SME, in partnership with industry OEMs, its mission is to foster innovation across the extended enterprise to reduce costs, expedite production times and maintain manufacturing competitiveness in the global economy.
AeroDef showcases the industry’s most advanced technologies across an innovative floor plan designed to facilitate interaction and business relationships between exhibitors and buyers looking for integrated solutions.
Its keynote speakers and panelists come from the highest level of government and business. They come to share their vision of the potential of technology, collaboration and public policy to transform manufacturing – concepts that attendees can actually experience on the exposition floor and in its in-depth conference sessions.
It’s the one event that brings together high-concept, integrated solutions and real-world applications. If you have a stake in aerospace and defense manufacturing, you can’t afford to miss AeroDef Manufacturing.


Why you need to attend AeroDef


If you have a stake in aerospace and defense manufacturing, you must be at AeroDef 2018.
AeroDef attracts thinkers, doers and decision makers and is the place where significant technology decisions are made.

Explore innovative advances in processes and materials:


  • Digital Manufacturing
  • Additive Manufacturing & 3D Technologies
  • Composites
  • Precision Machining
  • Automation & Robotics
  • Quality, Measurement & Inspection
  • Simulation
  • Finishing & Coatings
  • Advanced Materials
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lunes, 5 de marzo de 2018

Ansys: Additive Manufacturing Simulation

Additive Manufacturing Simulation

ANSYS offers a complete simulation workflow for Additive Manufacturing (AM) that allows you to transition your R&D efforts for metal AM into a successful manufacturing operation.
Additive manufacturing (3D printing) is a technology that produces three-dimensional parts layer by layer from a variety of materials. It has been rapidly gaining popularity as a true manufacturing process in recent years.
ANSYS’ best-in-class solution for additive manufacturing enables simulation at every step in your AM process. It will help you optimize material configurations and machine and parts setup before you begin to print.
As a result, you’ll greatly reduce — and potentially eliminate — the physical process of trial-and- error testing.
Additive Workflow
ANSYS Additive simulation process
ANSYS AM simulation tools will help you:
  • Design for AM (DfAM) utilizing topology optimization and lattice structures
  • Conduct design validation
  • Improve build setup — with additional design features for part manufacturing, including part orientation and automatic generation of physics-based support structures
  • Simulate print process
  • Explore and gain greater understanding of materials
The ANSYS solution is especially designed for these users:
  • Aerospace OEMs and suppliers
  • Metal AM print services bureaus
  • Biotech companies with AM efforts
  • Automotive OEMs and suppliers
  • AM materials R&D companies
  • Metal AM machine manufacturers

Additive Manufacturing: Making Imagination the Major Limitation


Additive Manufacturing (AM) refers to an advanced technology used for the fabrication of three-dimensional near-net-shaped functional components directly from computer models, using unit materials.

The fundamentals and working principle of AM offer several advantages, including near-net-shape capabilities, superior design and geometrical flexibility, innovative multi-material fabrication, reduced tooling and fixturing, shorter cycle time for design and manufacturing, instant local production at a global scale, and material, energy, and cost efficiency.

Well suiting the requests of modern manufacturing climate, AM is viewed as the new industrial revolution, making its way into a continuously increasing number of industries, such as aerospace, defense, automotive, medical, architecture, art, jewelry, and food.

This overview was created to relate the historical evolution of the AM technology to its state-of-the-art developments and emerging applications. Generic thoughts on the microstructural characteristics, properties, and performance of AM-fabricated materials will also be discussed, primarily related to metallic materials.

This write-up will introduce the general reader to specifics of the AM field vis-à-vis advantages and common techniques, materials and properties, current applications, and future opportunities.

Stratasys Composite Production


Stratasys’ development of high-temperature materials, as well as the increased throughput of its Fortus 3D Production Systems, enable the manufacture of high-temperature lay-up / sacrificial tooling in hours or days, rather than the weeks or months it would take to produce and procure tooling made from traditional methods.

3D printed tooling also offers disruptive cost-savings compared to traditional tooling materials and numerous other less quantified benefits, such as dramatic weight savings. This is being exemplified by Dutch 3D service bureau, Visual First, who is using FDM Nylon 12CF carbon-filled thermoplastic to replace metal machine parts for its customer, The Chocolate Factory.

This has significantly reduced machine downtime, ensuring production line continuity for the company. In fact, the replacement time of broken machine parts has been reduced from one month to one week using Stratasys additive manufacturing compared to traditional handmade metal replacements, with cost reductions of 60%.

Alpha: Image Stabilization Technology


Alpha Unmanned Systems, the manufacturer of the Alpha 800 gasoline-powered helicopter UAV, has partnered with Sightec, a developer of video image stabilization and object detection software: “Sightec’s onboard processing eliminates the shakiness caused by vibration on 1, 2 and 3 axes and makes the images recorded easier to analyze than ever before. Using Sightec, we significantly reduce man-hours previously needed to detect moving objects,” said Eric Freeman, CEO of Alpha. “Flying at 1,100 meters altitude, imagery from the Alpha 800 taken over Jaén, Spain appears crystal clear. Man-hours are reduced and bandwidth requirements needed for transmission are minimized.”

Gabriel Sachor, President and CEO of Sky Sapience, a tethered drone manufacturer, commented, “the incorporation of Sightec’s technology with the Alpha 800 platform makes video imagery completely stable and makes automated analysis easier than ever. Both Alpha and Sightec provide excellent technology and it is great to harness the power of them working together.” Operating without a gimbal, Sightec’s image stabilization electronic solution eliminates vibrations on 1, 2 or 3 axes. Sightec’s technology helps facilitate many applications for the Alpha 800, from border surveillance to infrastructure inspection. Roy Shmuel, CEO of Sightec, stated, “We are delighted to integrate our technology into the Alpha 800 platform. With 2.5 hours of flight time, our image stabilization system makes the image analysis work very easy and accurate. Alpha is a reliable partner with a world-class helicopter platform and we are very pleased to work together.”

jueves, 1 de marzo de 2018

3D printed hyperspectral imagers to be mounted on UAVs


A team of researchers in Norway has developed a low-cost, 3D printed hyperspectral imager device which could be installed on UAVs to give them advanced imaging capabilities.


A study in the journal Optics Express details how to make the hyperspectral imager for about $700, which is significantly cheaper than existing tools of a similar caliber.


Hyperspectral imaging devices, for those unfamiliar, are not totally unlike color cameras you may be accustomed to, except that instead of only working with a color array based off of just three colors (RGB), they can detect hundreds of colors.


Presently, the research team is working on improving the imaging device’s sensitivity, as it is not quite as powerful as its more expensive counterparts: “There are many ways to use data acquired by hyperspectral imagers,” explains Fred Sigernes, the project’s leader from the University Centre in Svalbard (UNIS) in Norway. “By lowering the cost of these instruments, we hope that more people will be able to use this analytical technique and develop it further.”


The lightweight (200g)  3D printed device was tested using an octocopter UAV. Balanced with the help of a two-axis electronic stabilizing setup, the low-cost hyperspectral imager reportedly “performed well,” successfully detecting different elements of the landscape below it. The research team reportedly used a desktop 3D printer to manufacture customized holders for the device’s optics. According to Sigernes, the team opted to use plastic 3D printing rather than metal to cut back on time and costs: 3D printing with plastic is inexpensive and very effective for making even complex parts, such as the piece needed to hold the grating that disperses the light. I was able to print several versions and try them out,” he said. Down the line, the researchers say metal will be considered to make the device more durable.

Measuring UV curing parameters of commercial photopolymers used in AM


A testing methodology was developed to expose photopolymer resins and measure the cured material to determine two key parameters related to the photopolymerization process: Ec (critical energy to initiate polymerization) and Dp (penetration depth of curing light).

Five commercially available resins were evaluated under exposure from 365 nm and 405 nm light at varying power densities and energies. Three different methods for determining the thickness of the cured resin were evaluated. Caliper measurements, stylus profilometry, and confocal laser scanning microscopy showed similar results for hard materials while caliper measurement of a soft, elastomeric material proved inaccurate.

Working curves for the five photopolymers showed unique behavior both within and among the resins as a function of curing light wavelength. Ec and Dp for the five resins showed variations as large as 10x. Variations of this magnitude, if unknown to the user and not controlled for, will clearly affect printed part quality. This points to the need for a standardized approach for determining and disseminating these, and perhaps, other key parameters.

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Application of 3D printing technology in aerodynamic study


3D printing, as an additive process, offers much more than traditional machining techniques in terms of achievable complexity of a model shape.

That fact was a motivation to adapt discussed technology as a method for creating objects purposed for aerodynamic testing.

The following paper provides an overview of various 3D printing techniques. Four models of a standard NACA 0018 aerofoil were manufactured in different materials and methods: MultiJet Modelling (MJM), Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM).

Various parameters of the models have been included in the analysis: surface roughness, strength, details quality, surface imperfections and irregularities as well as thermal properties.

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