Optimization of lattice infill in material extrusion using technopolymers.

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Journal Title

Journal ISSN

Volume Title

Insinööritieteiden korkeakoulu | Master's thesis

Date

2023-12-11

Department

Major/Subject

Additive Manufacturing for Full Flexibility

Mcode

Degree programme

Master’s programme in Manufacturing, Additive Manufacturing for Full Flexibility

Language

en

Pages

44

Series

Abstract

The modern marine/shipbuilding industry is a mature one that hasn’t seen many major manufacturing innovations in the recent past. As the world has gone from landlines with switchboards in the 1970s to internet-enabled smartphones, ships have primarily remained the same in the past half a century. However, with Industry 4.0, this is set to change, bringing unprecedented data and sophistication to building and maintaining ships. Additive Manufacturing promises to be one of the significant advances in the area. With the availability of high-performance polymers like ULTEM 1010 that have the properties required to be used in a marine environment and are designed for additive manufacturing, there are excellent prospects in replacing some components with additively manufactured parts as well as using the technology as a perfect way to upgrade parts throughout the service life of the ship. This study intends to characterise the material properties of ULTEM 1010, which has been additively manufactured using material extrusion, to evaluate the optimal infill type and parameters for mass and cost reduction. The experiment is carried out with an ASTM D638 standard tensile test specimen with four infill variations (hexagonal, re-entrant, triangular, and gyroid) with a solid sample as a control. These results are then used to optimise the infill in a use-case part in the marine industry to reduce the weight, cost and lead time. A field-driven design approach is used to dynamically vary the thickness of each unit cell in the lattice infill to achieve these targets. The optimised part had a 10% reduction in mass and a 17% reduction in cost compared to an unoptimised part.

Description

Supervisor

Salmi, Mika

Thesis advisor

Ghadimi, Pezhman

Keywords

infill optimization, additive manufacturing, field driven design, ULTEM 1010

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