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- Industry 4.0 - Digital Twin Applied to Direct Digital ManufacturingPublication . Vitorino, João; Ribeiro, Eliseu; Silva, Rúben; Santos, Cyril; Carreira, Pedro; Mitchell, Geoffrey; Mateus, ArturMarinha Grande is a city in Leiria’s district, Portugal. Marinha Grande is known as the moulding city, influenced by the glass, plastic and rapid manufacturing industry. Its history comes from the 18th century with the first glass factory. In order to improve technological development in the local industry, Centre for rapid and sustainable product development (CDRsp) was established in 2007. With that historical know-how and data-based moulding manufacturing, this work goal is to link that data with today’s technology, implementing the Industry 4.0. That information would be stored in a Cloud-Based Design and Manufacturing (CBDM) as well as the real-time operational data. Accessing to that cloud, the design and production engineers can work together to digitally create a product without having to stop the machinery. To implement these concepts, this paper suggests a Digital Twin (DT) to take advantage of the historical information allied to the existent industrial machinery. It suggests a digital twin of a robotic arm with an additive or hybrid manufacturing tool, printing big parts (e.g. garden benches or urban furniture) with reused materials such as tire, cork, wood or stone pow loads.
- High Efficiency Cooling and Heating Channels for Injection MouldingPublication . Freitas, Paulo; Santos, Cyril; Carreira, Pedro; Mateus, ArturFor many years traditional injection moulding has been the norm for obtaining polymer based products, and yet this cycle still shows potential for improvement. This paper will encompass the potential in the thermal part of the cycle, by introducing a novel approach to conventional tubular cooling designs, empowered by additive technologies this reiterates what’s being known as conformal cooling. Different geometries and techniques are compared to determine the optimal cross section layout of the fluid channels and inner surface of the moulding parts. If the cooling achieved is sufficiently fast the crystallographic growth of the material can be manipulated to obtain specific properties observable in the mesoscale. This however can be transversely applied in other heat exchanging structures in future studies.
- Produção de peças biodegradáveis de parede fina por injeçãoPublication . Santos, C.; Mendes, A.; Carreira, P.; Mateus, A.; Alves, N.Actualmente, a indústria dos moldes para responder às exigências do mercado procura diversificar os seus mercados, apostando em produtos diferenciados e de valor acrescentado. Foi neste sentido que se desenvolveu o projecto de concepção e fabrico de vasos biodegradáveis para germinação de plantas. O objectivo deste artigo de investigação passa pela concepção e desenvolvimento de um vaso para germinação de plantas produzido em material biodegradável. A validação do projecto desenvolvido para uma peça de paredes finas em material biodegradável, foi realizada através da fabricação da ferramenta (molde) e o processamento de peças (vasos biodegradáveis). Este estudo demonstrou-se promissor como pilar de apoio para o desenvolvimento de futuros produtos em materiais biodegradáveis de paredes finas, obtidos pelo processo de injecção de termoplásticos. Os resultados alcançados permitiram validar o processo desenvolvido, bem como o produto obtido de paredes finas em material biodegradável, que neste caso foi um vaso biodegradável para germinação de plantas.
- Uma solução híbrida integrada de elevado nível criptográfico para autenticação de produtosPublication . Silva, Daniel P.; Silva, Ruben J. G.; Mateus, Gonçalo N. S.; Mateus, Artur J. S.; Carreira, Pedro J. S.; Santos, CyrilDevido à crescente contrafação de produtos nos mais variados setores de atividade, surge a necessidade de incorporar nesses mesmos, sistemas de identificação que permitam determinar a sua autenticidade e suportar as investidas de falsificação pela replicação indevida das tecnologias atuais. O presente projeto pretende apresentar uma nova abordagem que assenta na incorporação de um dispositivo híbrido patenteado, com propriedades óticas que lhe conferem um grau de criptografia elevado, em peças obtidas por moldação por injeção (embalagens e peças estruturais ou funcionais) com o intuito de obter uma solução integrada inviolável, mas eficaz e de análise intuitiva.
- Direct Digital Manufacturing of NanocompositesPublication . Mohan, Saeed D.; Nazhipkyzy, Meruyert; Carreira, Pedro; Santos, Cyril dos; Davis, Fred J.; Mateus, Artur; Mitchell, Geoffrey R.Additive manufacturing has surged in popularity as a route to designing and preparing functional parts. Depending on the parts function, certain attributes such as high mechanical performances may be desired. We develop a route for improving the mechanical properties of polymer devices, fabricated through additive manufacturing by combining electrospinning and stereo-lithography into one automated process. This process utilises the impressive mechanical properties of carbon nanotubes by encapsulating and aligning them in electrospun fibres. Composite fibres will be incorporated into polymer resins prepared with stereo-lithography, thereby providing resins that benefit from the composite fibres properties, enhancing their overall mechanical properties.
- I. Film: Using Electrospinning to Create Bioactive FilmsPublication . Silva, António Raimundo; Carreira, Pedro; Santos, Cyril dos; Reis, Miguel; Mateus, ArturWith increasing competition between companies, they are increasingly striving to produce higher quality products and to improve their production processes, and the food industry is no different. In order to preserve food for longer, this type of company has dedicated its attention to intelligent packaging, capable of preserving food for longer and of acting as a sensor of the state of food. To develop a film capable of fulfilling the new ambitions of the companies various manufacturing processes have been studied. This document gives an overview of the electrospinning process, capable of producing nano-fibres of biological materials. This document aims to serve as a study base for the I.film project through the study of the process that will provide the polymer film with the necessary biological characteristics.
- Influence of Metallic Powder Characteristics on Extruded Feedstock Performance for Indirect Additive ManufacturingPublication . Santos, Cyril; Gatões, Daniel; Cerejo, Fábio; Vieira, Maria TeresaMaterial extrusion (MEX) of metallic powder-based filaments has shown great potential as an additive manufacturing (AM) technology. MEX provides an easy solution as an alternative to direct additive manufacturing technologies (e.g., Selective Laser Melting, Electron Beam Melting, Direct Energy Deposition) for problematic metallic powders such as copper, essential due to its reflectivity and thermal conductivity. MEX, an indirect AM technology, consists of five steps—optimisation of mixing of metal powder, binder, and additives (feedstock); filament production; shaping from strands; debinding; sintering. The great challenge in MEX is, undoubtedly, filament manufacturing for optimal green density, and consequently the best sintered properties. The filament, to be extrudable, must accomplish at optimal powder volume concentration (CPVC) with good rheological performance, flexibility, and stiffness. In this study, a feedstock composition (similar binder, additives, and CPVC; 61 vol. %) of copper powder with three different particle powder characteristics was selected in order to highlight their role in the final product. The quality of the filaments, strands, and 3D objects was analysed by micro-CT, highlighting the influence of the different powder characteristics on the homogeneity and defects of the greens; sintered quality was also analysed regarding microstructure and hardness. The filament based on particles powder with D50 close to 11 µm, and straight distribution of particles size showed the best homogeneity and the lowest defects.
- Adaptive Platforms and Flexible Deposition System for Big Area Additive Manufacturing (BAAM)Publication . Silva, Ruben; Sereno, Pedro; Mateus, Artur; Mitchell, Geoffrey; José da Silva Carreira, Pedro; Santos, Cyril; Vitorino, João; Domingues, JorgeThe interest around the additive manufacturing is increasing, with more and more solutions at both the industrial and desktop levels. As this is still a relatively recent issue for several industrial areas, there is a clear opportunity to explore in order to optimize the systems in the face of the needs of these same industries, and with increasing times, there are increasing factors to take into ac- count in initial phases of new product development. Presently, there is also a growing ecological awareness, with the concern of implementing a logic of waste reduction and implementation of the circular economy in new products with a view to the valuation of new alternative materials. With the development of solutions aimed at the optimization and feasibility of large additive manufacturing systems, the introduction of new alternative materials will be a reality, presenting in this article a solution and methodology for future tests for new materials. Thus, herein is studied a way of responding to both problems, new ecological materials and BAAM system optimization, presented through a hybrid and flexible solution based on the Pin Bed Forming principle applied to Big Area Additive Manufacturing systems.
- Microstructure of Thermoplastic Composites Reinforced with Wool and WoodPublication . Batista, Catarina; Martins, Gabriela; Santos, Cyril; Mateus, Artur; Antunes, FilipeIn the last decades the studies on thermoplastic composites reinforced with natural fibres have been mostly focused on vegetable lignocellulosic or cellulosic fibres. These materials provide eco-sustainable solutions for a large range of applications and have been actually adopted by multiple industries. The interest on fibres of animal origin is more recent and research on composites reinforced with these fibres predominantly composed of keratin, such as wool, feathers or silk, is increasing in virtue of some advantageous properties that may overcome some of the intrinsic limitations from vegetable fibres. The combined use of vegetable and animal fibres in composites appropriate for melt blending processing is at early stages of research. After chemical treatments, the fibres of animal origin have been mostly applied as binders between vegetable fibres and polymers, but not as main constituents of these composites. The use of both types of fibres simultaneously in composites of thermoplastic matrices is the subject of the present study where the fibres of animal origin (wool) are sourced from different kinds of residues from a textile industry and the fibres of vegetable origin (wood) are the residues from carpentry activities. The chemical composition, the macro and microstructure of the fibres is analyzed, as well as that of the composites that combine non-biodegradable and biodegradable polymers with diverse ratios of the fibres in different conditions (wool as cards, yarns and felt cloths; wood as sawdust). The addition of coupling agents to enhance the compatibility between wool, wood and different polymers is also analysed.
- Numerical study on injection parameters optimization of thin wall and biodegradable polymers partsPublication . Santos, Cyril; Mendes, A; Carreira, P.; Mateus, Artur; Malça, C.Nowadays, the molds industry searches new markets, with diversified and added value products. The concept associated to the production of thin walled and biodegradable parts mostly manufactured by injection process has assumed a relevant importance due to environmental and economic factors. The growth of a global consciousness about the harmful effects of the conventional polymers in our life quality associated with the legislation imposed, become key factors for the choice of a particular product by the consumer. The target of this work is to provide an integrated solution for the injection of parts with thin walls and manufactured using biodegradable materials. This integrated solution includes the design and manufacture processes of the mold as well as to find the optimum values for the injection parameters in order to become the process effective and competitive. For this, the Moldflow software was used. It was demonstrated that this computational tool provides an effective responsiveness and it can constitute an important tool in supporting the injection molding of thin-walled and biodegradable parts.