| dc.description.abstract | Additive manufacturing (AM) is a transformative approach to industrial production that permits the production of parts and can bring flexibility and efficiency to the manufacturing process. It uses CAD software or 3D object scanners to instruct hardware to store material layer by layer, in precise geometric shapes. AM creates less waste than the conventional assembling measure, it works uniquely in contrast to customary assembling. Engineers and scientists have been able to create complex forms and structures, including human organs such as lungs, hearts, and more, that can be printed directly from human tissues.
Visitech AS has been manufacturing DLP exposure heads for three core applications for over 21 years: Direct Imaging Lithography, Additive manufacturing (3D printing), and 3D-Scanning.The basis of all Visitech products is the DLP (Digital Light Processing) and DMD (Digital Micromirror Device) technology from Texas Instruments.
An EU patent was granted to Visitech for the scrolling invasion in 2015, and a World Intellectual Property Organization patent in 2016, and the first prototype for the patent (prototype V.0) was developed and tested in 2020 based on Visitech's 20 years of experience. There were some functional, and structural (instability) issues with the V.0 3D printer that were causing one to not continually get good results from the 3D printer. A new prototype had to be designed to solve the functional and structural (instability) issues for the invention.
The project's main goal has been to investigate, further develop and optimize the LRS scrolling Machine (prototype V.0). With integrated product development (IPD) as framework, focus and resources were allocated to different activities, and it was determined in which order the development process would take place.
Project work was structured in four phases for systematics, goal focus, and quality control: the assessment phase (Framework and Planning), the development phase, construction and design phase, and completion phase.
The study phase began with a literature review that revealed the historical perspective of 3D printing, and the potential for the project. As part of the study phase, a project plan was generated that provided an overview of the project's process and scope. A targeted project is achieved through stipulating main and sub-goals, as well as subordinate activities, resource allocation, and milestones, as well as defining problems, technological bottlenecks, and limitations.
Various product development methods and tools were also discussed such as IPD and IPPD, House of Quality, SCAMPER, Gant, and Pugh's method. IPPD and IPD methodology were tailored to the task and intended to ensure comprehensive and efficient project implementation and to ensure crucial development elements did not get missed. The main purpose of SCAMPER was to contribute inspiration and new viewpoints to brainstorming sessions. To systematically compare alternative solutions, Pugh's methodology has been used in the context of the QFD thinking to measure them against criteria set based on desired product properties. Where machine’s frame, X-Y axis stage and preferred projector calibration methods were selected. A comprehensive theoretical framework for the further development work was mapped at the end of the assessment phase.
In the development phase, objectives for the product and its main characteristics were determined based on prototype V.0. After establishing rough dimensions for prototype V.1 by means of metric boundary specifications, a rough specification for printing area was developed to assist the design and calculation process. An analysis of functions was conducted to make sure all the main functions of prototype V.1 were taken care of. Based on the analysis, different solutions were generated for each function through concept brainstorming. Solutions were evaluated independently and selected, and the preferred options were combined into a comprehensive concept solution. Expert testing was performed by means of discussions and consultations with a variety of test persons from different backgrounds in order to ensure the quality of the concept selections.
An initial 3D model of the concept was created in Solidworks during the construction and design phases. In addition to the calculations of selected components, FEM analyses in SolidWorks were also used to verify some of the results. Based on calculations, simulations, the availability of the materials at the supplier's end, and the recommendations of the supplier, materials were chosen.
A mapping of different production methods was carried out during the completion phase. Additionally, a cost estimate was prepared for the production prototype V.1. Additionally, technical instructions and drawings were prepared.
This project resulted in a functional two-dimensional 3D printer, the product has an original and unique design, further developed from prototype V.0. This product incorporates an innovative wiper assembly with a linear stage for evenly spreading resin when the two MCx V2-es (UV-projectors) are projecting sliced images of 3D models. There will be water cooling on these projectors, in order to provide better efficiency. The product is easy to level, and easy to calibrate the projectors with the camera solution. The outer dimensions of the product are: 1300mm x 1010 mm x 600 mm (X-axis, Y-Axis, Z-Axis), and it weights around 230 KG. The printer is able to print 50 µm layer height (resolution), with a printing area of 400 mm x 192 mm x 110 mm (X-axis, Y-Axis, Z-Axis). Most of the product's custom parts are manufactured with aluminum 6061 T6, which can be recycled and reused, except for the wiper blade, which is made of PTFE. The Products frame is manufactured with Steel S235JR, for better stableness. The product provides a more comprehensive solution to Visitech's prototype V.1 3D printer.
For further work, the wiper assembly's Y-axis linear stage shall be mounted to the frame using aluminum profiles and screws from Protype V.0. The 3D printer should be leveled, and the projector should be aligned. Different 3D models should be printed, the results should be checked in detail for any printing errors, if necessary, in a microscope. If the print results are not satisfactory, dynamic analysis and calculation of construction conditions, such as fluctuations, vibrations, and fatigue, shall be carried out. | |