Researchers at North Carolina State University have developed a technique that allows users of 3D printing technologies to conduct automated quality control of metal machine parts during the finishing process. This technique enables users to identify potential flaws without having to remove the parts from the manufacturing equipment, saving time and making production more efficient. The integration of 3D printing, automated machining, laser scanning, and touch-sensitive measurement technologies with related software creates a largely automated system that produces metal machine components meeting critical tolerances.
The process involves pulling up a software file with the measurements of the desired part, which is then 3D printed with metal support structures. The printed part is mounted in a finishing device using the support structure, where lasers scan the part to establish its dimensions. A software program uses these dimensions and the desired critical tolerances to guide the finishing device in polishing out any irregularities in the part. The finishing device manipulates the orientation of the part so it can be measured by a touch-sensitive robotic probe to ensure the dimensions are within the necessary parameters.
In a test comparing the new technique to conventional methods, researchers were able to finish a machine part in 133 minutes using the new approach, compared to 200 minutes using conventional techniques. This time-saving potential could be crucial in professional settings where time is money, or in emergency response contexts where efficiency could be a matter of life and death. While the current focus is on machine parts with circles or cylinders, such as pistons, the approach could be adapted for parts with other features. The hardware used in the technique is commercially available, making it readily applicable for adoption in manufacturing operations.
The researchers received support from the U.S. Army Research Office for this work, under grant number W911NF1910055. The project opens the door for more efficient and automated quality control processes in manufacturing metal machine parts using 3D printing technologies. By streamlining the finishing process and reducing the time needed for measurements and adjustments, this technique has the potential to improve overall production efficiency and reduce costs associated with manufacturing critical machine components on demand. The researchers are open to working with partners interested in implementing this technique in their operations and believe it could be put into use almost immediately due to the availability of necessary hardware and software outlined in the paper.
Overall, this research presents a significant advancement in quality control and finishing processes for metal machine parts manufactured using additive manufacturing technologies. The combination of 3D printing, automated machining, laser scanning, and touch-sensitive measurement technologies, along with related software, creates an automated system that can produce parts meeting critical tolerances without the need for manual handling or repeated measurements. This new technique could revolutionize the way metal machine parts are produced and finished, leading to faster turnaround times, improved production efficiency, and cost savings for manufacturers. The potential applications of this approach extend beyond circles or cylinders, making it a versatile and adaptable solution for a wide range of machine parts.
