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  • 1.
    Adolfsson, Erik
    et al.
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Lyckfeldt, Ola
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Johansson, Emil
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Visible-Light Curable Ceramic Suspensions for Additive Manufacturing of Dense Ceramic Parts2016Conference paper (Other academic)
  • 2.
    Akbari, Saeed
    et al.
    RISE Research Institutes of Sweden, Digital Systems, Smart Hardware.
    Johansson, Jan
    RISE Research Institutes of Sweden, Materials and Production, Manufacturing Processes.
    Johansson, Emil
    Adaxis, France.
    Tönnäng, Lenny
    RISE Research Institutes of Sweden, Materials and Production, Manufacturing Processes.
    Hosseini, Seyed
    RISE Research Institutes of Sweden, Materials and Production, Manufacturing Processes.
    Large-Scale Robot-Based Polymer and Composite Additive Manufacturing: Failure Modes and Thermal Simulation2022In: Polymers, E-ISSN 2073-4360, Vol. 14, no 9, article id 1731Article in journal (Refereed)
    Abstract [en]

    Additive manufacturing (AM) of large-scale polymer and composite parts using robotic arms integrated with extruders has received significant attention in recent years. Despite the contributions of great technical progress and material development towards optimizing this manufacturing method, different failure modes observed in the final printed products have hindered its application in producing large engineering structures used in aerospace and automotive industries. We report failure modes in a variety of printed polymer and composite parts, including fuel tanks and car bumpers. Delamination and warpage observed in these parts originate mostly from thermal gradients and residual stresses accumulated during material deposition and cooling. Because printing large structures requires expensive resources, process simulation to recognize the possible failure modes can significantly lower the manufacturing cost. In this regard, accurate prediction of temperature distribution using thermal simulations is the first step. Finite element analysis (FEA) was used for process simulation of large-scale robotic AM. The important steps of the simulation are presented, and the challenges related to the modeling are recognized and discussed in detail. The numerical results showed reasonable agreement with the temperature data measured by an infrared camera. While in small-scale extrusion AM, the cooling time to the glassy state is less than 1 s, in large-scale AM, the cooling time is around two orders of magnitudes longer. © 2022 by the authors

  • 3.
    Bonham, Euan
    et al.
    University of Strathclyde, UK.
    McMaster, Kerr
    University of Strathclyde, UK.
    Thomson, Emma
    University of Strathclyde, UK.
    Panarotto, Massimo
    Chalmers University of Technology,, Sweden.
    Müller, Jakob
    Chalmers University of Technology,, Sweden.
    Isaksson, Ola
    Chalmers University of Technology,, Sweden.
    Johansson, Emil
    RISE Research Institutes of Sweden, Materials and Production, Manufacturing Processes.
    Designing and integrating a digital thread system for customized additive manufacturing in multi-partner kayak production2020In: Systems, ISSN 2079-8954, Vol. 8, no 4, article id 43Article in journal (Refereed)
    Abstract [en]

    Additive manufacturing (AM) opens the vision of decentralised and individualised manufacturing, as a tailored product can be manufactured in proximity to the customers with minimal physical infrastructure required. Consequently, the digital infrastructure and systems solution becomes substantially more complex. There is always a need to design the entire digital system so that different partners (or stakeholders) access correct and relevant information and even support design iterations despite the heterogenous digital environments involved. This paper describes how the design and integration of a digital thread for AM can be approached. A system supporting a digital thread for AM kayak production has been designed and integrated in collaboration with a kayak manufacturer and a professional collaborative product lifecycle management (PLM) software and service provider. From the demonstrated system functionality, three key lessons learnt are clarified: (1) The need for developing a process model of the physical and digital flow in the early stages, (2) the separation between the data to be shared and the processing of data to perform each parties’ task, and (3) the development of an ad-hoc digital application for the involvement of new stakeholders in the AM digital flow, such as final users. The application of the digital thread system was demonstrated through a test of the overall concept by manufacturing a functional and individually customised kayak, printed remotely using AM (composed of a biocomposite containing 20% wood-based fibre). © 2020 by the authors. 

  • 4.
    Johansson, Emil
    et al.
    RISE - Research Institutes of Sweden (2017-2019), Materials and Production, IVF.
    Lidström, Oscar
    RISE - Research Institutes of Sweden (2017-2019), Materials and Production, IVF.
    Lyckfeldt, Ola
    RISE - Research Institutes of Sweden (2017-2019), Materials and Production, IVF.
    Adolfsson, Erik
    RISE - Research Institutes of Sweden (2017-2019), Materials and Production, IVF.
    Jan, Johansson
    RISE - Research Institutes of Sweden (2017-2019), Materials and Production, IVF.
    Influence of Resin Composition on the Defect Formation in Alumina Manufactured by Stereolithography2017In: Materials, E-ISSN 1996-1944, Vol. 10, no 2, article id 138Article in journal (Refereed)
    Abstract [en]

    Stereolithography (SL) is a technique allowing additive manufacturing of complex ceramic parts by selective photopolymerization of a photocurable suspension containing photocurable monomer, photoinitiator, and a ceramic powder. The manufactured three-dimensional object is cleaned and converted into a dense ceramic part by thermal debinding of the polymer network and subsequent sintering. The debinding is the most critical and time-consuming step, and often the source of cracks. In this study, photocurable alumina suspensions have been developed, and the influence of resin composition on defect formation has been investigated. The suspensions were characterized in terms of rheology and curing behaviour, and cross-sections of sintered specimens manufactured by SL were evaluated by SEM. It was found that the addition of a non-reactive component to the photocurable resin reduced polymerization shrinkage and altered the thermal decomposition of the polymer matrix, which led to a reduction in both delamination and intra-laminar cracks. Using a non-reactive component that decomposed rather than evaporated led to less residual porosity.

    Download full text (pdf)
    materials-10-00138.pdf
  • 5.
    Walander, Magnus
    et al.
    Chalmers University of Technology, Sweden.
    Nygren, Andreas
    Chalmers University of Technology, Sweden.
    Sjöblom, Jonas
    Chalmers University of Technology, Sweden.
    Johansson, Emil
    RISE Research Institutes of Sweden, Materials and Production, Manufacturing Processes.
    Creaser, Derek
    Chalmers University of Technology, Sweden.
    Edvardsson, Jonas
    Johnson Matthey, Sweden.
    Tamm, Stefanie
    Johnson Matthey, Sweden.
    Lundberg, Björn
    Volvo Cars Corporation, Sweden.
    Use of 3D-printed mixers in laboratory reactor design for modelling of heterogeneous catalytic converters2021In: Chemical Engineering and Processing, ISSN 0255-2701, E-ISSN 1873-3204, Vol. 164, article id 108325Article in journal (Refereed)
    Abstract [en]

    A method for identifying radial concentration maldistribution in synthetic catalyst activity test (SCAT) benches, is presented, where spatially resolved concentration measurements are not available. The developed methodology was successfully tested for an injection-based SCAT. To resolve the radial concentration maldistribution a static mixer was designed, 3D-printed and inserted upstream the test sample. The methodology could also prove the effectiveness of the mixer, which did not only resolve the concentration maldistribution but also avoided causing reaction disturbances. The resulting increased axial dispersion from the turbulence created by the static mixer was evaluated using a 3D CFD model in Ansys Fluent 19. The axial dispersion of the injection-based SCAT bench was compared to a premixed SCAT bench through classical Aris-Taylor calculations. The results from the axial dispersion calculations show that the injection-based design with the use of a static mixer is far superior to the premixed design – both with regards to pulse broadening but also time delay. This is highly desirable for modelling studies towards zero emission exhaust aftertreatment. © 2021 The Authors

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