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Multi-material Ceramic-Based Components – Additive Manufacturing of Black-and-white Zirconia Components by Thermoplastic 3D-Printing (CerAM - T3DP)
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System Performance and Process Capability in Additive Manufacturing: Quality Control for Polymer Jetting.

Razvan Udroiu1, Ion Cristian Braga1

  • 1Department of Manufacturing Engineering, Transilvania University of Brasov, 29 Eroilor Boulevard, 500036 Brasov , Romania.

Polymers
|June 10, 2020
PubMed
Summary

This study introduces a statistical quality control method for polymer additive manufacturing (AM). Polymer jetting (PolyJet) technology demonstrates high system and process capability for mass production, meeting stringent ISO tolerance grades.

Keywords:
additive manufacturingmachine capabilitymaterial jettingpolymerprocess capabilityqualitystatistical process controltolerance gradevariability

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Technology
  • Statistical Quality Control

Background:

  • Polymer-based additive manufacturing (AM) is gaining traction for mass production, necessitating robust standardization and quality assessment methods.
  • Existing methodologies for system and process capability analysis in AM require enhancement for effective production management.
  • Statistical quality tools offer a framework for evaluating and ensuring the consistency of AM processes.

Purpose of the Study:

  • To propose a novel methodology for system and process capability analysis in polymer additive manufacturing.
  • To evaluate the capabilities of the polymer jetting (PolyJet) technology for mass production applications.
  • To assess the suitability of PolyJet for achieving specific geometric tolerances required in industrial settings.

Main Methods:

  • Manufacturing of a large sample of circular specimens using photopolymer resins and PolyJet technology.
  • Employing Gage repeatability and reproducibility (Gage R&R) to quantify measurement system variability.
  • Conducting machine and process capability analyses against defined tolerance limits, adhering to statistical process control requirements.

Main Results:

  • The EDEN 350 system and PolyJet process achieved capability indices exceeding 1.67 within a 0.22 mm tolerance interval.
  • PolyJet technology, with its 0.016 mm resin droplet deposition, enables high-volume, rapid manufacturing.
  • Achieved tolerances align with ISO 286 IT9 for radial and IT10 for Z-axis linear dimensions, validated by microscopy.

Conclusions:

  • The proposed statistical methodology effectively assesses system and process capabilities in polymer AM.
  • PolyJet technology is suitable for mass production, delivering high precision and conforming to international standards.
  • This approach facilitates the reliable implementation of polymer AM in industrial mass production environments.