Additive Manufacturing Reliability Based on Microscope Analysis
Faculty Mentor Name
Nazir Gandur, Desirae Grumbine
Format Preference
Poster
Abstract
Additive manufacturing (AM) has revolutionized the production of aerodynamic components by enabling the rapid prototyping of complex geometries. However, the reliability of these components remains an active area of research. This study investigates: How do varying 3D printer parameters affect the reliability of additively manufactured aerospace components? Three objectives were defined: first, to identify optimal printing temperatures; second, to determine optimal thickness and velocity for the 3D printer settings; and third, to integrate the results using global optimization to determine the ideal set of parameters. Nozzle and bed temperatures were varied independently, and the results were compared using microscopic analysis. Nozzle speed and layer height were also tested independently to determine optimal settings. Systematic variations were applied to temperature, speed, and layer height, following a statistical approach. Wing test sections were 3D printed to test the reliability of varying AM parameters. Polyethylene terephthalate glycol (PETG) was selected as the AM material due to its ease of printing and impact resistance. Microscopic analysis was then conducted to examine the reliability of the external surface of each print, capturing variations due to the different parameters. Next, the wing models were cut and analyzed internally using microscopic analysis to determine the characteristics of the internal structures. Finally, a global optimization was performed in order to determine the ideal set of AM printing parameters. This work bridged the gap between the reliability of AM and its applications in aerodynamics.
Additive Manufacturing Reliability Based on Microscope Analysis
Additive manufacturing (AM) has revolutionized the production of aerodynamic components by enabling the rapid prototyping of complex geometries. However, the reliability of these components remains an active area of research. This study investigates: How do varying 3D printer parameters affect the reliability of additively manufactured aerospace components? Three objectives were defined: first, to identify optimal printing temperatures; second, to determine optimal thickness and velocity for the 3D printer settings; and third, to integrate the results using global optimization to determine the ideal set of parameters. Nozzle and bed temperatures were varied independently, and the results were compared using microscopic analysis. Nozzle speed and layer height were also tested independently to determine optimal settings. Systematic variations were applied to temperature, speed, and layer height, following a statistical approach. Wing test sections were 3D printed to test the reliability of varying AM parameters. Polyethylene terephthalate glycol (PETG) was selected as the AM material due to its ease of printing and impact resistance. Microscopic analysis was then conducted to examine the reliability of the external surface of each print, capturing variations due to the different parameters. Next, the wing models were cut and analyzed internally using microscopic analysis to determine the characteristics of the internal structures. Finally, a global optimization was performed in order to determine the ideal set of AM printing parameters. This work bridged the gap between the reliability of AM and its applications in aerodynamics.