Relevant:
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Results:
Additive manufacturing (AM) is a widely used set of techniques used to build objects by adding layer-upon-layer of material. While materials typically used are plastic, metal or concrete, nowadays AM technologies are expanding to include all kind of materials such as ceramic, nanocomposites, glass, and other.
In Z-Fact0r, we exploited AM-based technologies as a tool for repairing of components in a production line. Thanks to the ability for local deposition, i.e. precision placement of material at desired position, AM was the optimum choice to correct or repair a defect. Moreover, AM combined with subtracted manufacturing techniques for the effective repairing. In context, in the case of a defect, material can be subtracted by means of laser ablation or classical machining, thus removing of the problematic area cleaning or preparing the surface. Then, AM is used to fill the defect with the desired material. A final step of sintering or other processing used to finalize the repairing action.
Comment:
Once a “repairable” defect is detected (Z-DETECT), a proper and customized repairing action must be deployed with the minimum time and effort, assuring the best productivity and production flow. In fact, a major challenge for an effective ZD manufacturing is related with the capability to automatically repair the occurred defects without perturbing the overall production flow.
Z-Fact0r is developing a model-based, supervisory control solution that will be able to interpret the interstage quality control measurements together with the monitoring of the process itself, in order to identify the defect sources and generate a proper and customized repairing action. Additive manufacturing in the form of inkjet or paste printing of various materials (metal, ceramic, polymer resins) can successfully be used to fill a missing spot or correct a damaged part. Upon detection of the defected area, the printing head will deliver the patch material in solution or paste form. In the case of inkjet printing, defect as small as 20 μm can be patched. Post printing treatment of the delivered material include solvent evaporation (e.g. in the case of polymer patches), UV curing (e.g. in the case of epoxy resins) and low temperature laser sintering in the case of metal or ceramic nanoparticles, thermal curable resins or paste where a local reflow process is required.
To facilitate the implementation of the five strategies, Z-Fact0r is supporting a “reverse supply-chain” policy in the context of a multi-stage supply-chain attached to a multi-stage production. As a result, the defected products/parts detected in downstream stages (produced during a stage, or provided from suppliers in a particular stage) could be returned to upstream stages for remanufacturing or recycling.