“All of a sudden, it does become menacing, because when you have to alter part dimensions to compensate for a print error, the CAD rework is labor and time-intensive. The expert stated that “if you have to change something, you have to go all the way back to the CAD board”.
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But then “the final metal part is probably not exactly CAD intent” so this means that “the system as a whole has no idea it doesn’t fit until the engineer tries to install that part in the application designed”.
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Traditionally 3D printing of metal parts goes through the CAD design stage, then it is uploaded to a software that will automatically generate the 3D printing toolpath, and finally the printed part, which Reilly stated that in many cases is about 20 percent larger than the expected final outcome, which is usually compensated with washing and sintering to reduce the remaining metal powder. Vice President of Product Jon Reilly explained how Blacksmith works and fits into adaptive manufacturing. Markforged, a supplier of metal and carbon fiber AM systems, headquartered in Watertown, Massachusetts, recently hosted a live webinar to introduce Blacksmith, stating that it is the first artificial intelligence-powered software that makes manufacturing systems ‘aware’, enabling them to automatically adjust programming to ensure every part is produced as designed. Last May, spoke to Markforged founder Greg Mark about AI and he highlighted that “our machine learning software is letting the machine rewrite its own code”, so that “the machine can now improve itself”, letting manufacturers create dependable parts the first time, every time. How do you think #software fits into the future of manufacturing? /xt4PSfTqK4 Join VP of Product Jon Reilly on Tuesday, July 23rd at 11am EDT for a LIVE demo of Blacksmith #AI. Blacksmith is also a continuous learning platform, adapting to changes during the process throughout the use of the production machine, and even using cloud-based technologies that enable the connection of all the machines using it in factories around the world, meaning Blacksmith can learn at the speed of global production. In short, the design is analyzed, compared to scans of the part, and then the process is automatically modified to build the part as it was originally intended. Blacksmith AI is a new tool which automatically adjusts programming to ensure accurate additive production, which the company claims will enable more agile design, process adjustment and more dependable manufacturing. The software is said to create a continuous feedback loop to produce each 3D printed part as it has been designed in the CAD stage, cutting waste and reducing time to market in the process. With new software being commercially released later this year, Markforged promises to help companies struggling to accurately 3D print parts. All this basically means that engineers and specialists will need to go back to review the CAD design and processes, which take up a lot of time, and sometimes the problems can’t even be corrected, so the item being produced is good for scrap, which also means money lost. In some cases, parts are predeformed in order to compensate for inaccuracies during the process. And even when all that is done, the part might not fit or work as originally intended. For example, if Direct Energy Deposition (DED) metal 3D printing was used, this typically produces near-net-shape parts that must be CNC machined, but other forms of AM also require some type of smoothing close to the end. Some common 3D printing problems arise on the way to achieving the desired original design, so before a 3D printed metal part leaves the factory, it has probably undergone some kind of post-processing to smooth and perfect the surface.
Companies are working hard at trying to ensure consistency and repeatability throughout the entire manufacturing process since today much more is required of AM systems who need to turn out functional goods that can meet traditional manufacturing standards while being cost-effective in order to be even more competitive. Accuracy in Additive Manufacturing (AM), from the CAD design to the printing process, is not always easy to deliver.
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