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Methods, strategies and applications for direct hybrid additive manufacture of embedded sensors
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Griffiths, Elliott R. (2022) Methods, strategies and applications for direct hybrid additive manufacture of embedded sensors. PhD thesis, University of Warwick.
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Official URL: http://webcat.warwick.ac.uk/record=b391350
Abstract
With the drive towards Industry 4.0, the demand for a higher level of automated data capture is increasing. Elevating the quantity and quality of data collected allows for: real time monitoring of processes, purely digital workflows, deeper understanding of processes (particularly, in manufacturing) and stronger links between the digital and physical worlds. In order to achieve the level of data capture required, both an increased quantity of sensors will be required as well as manufacturing methods to automatically integrate these systems in a wide array of increasingly customised components. Additive manufacturing technology lends itself to this application.
The body of work enclosed explores methods, strategies, and applications for hybrid additive manufacturing to enable direct write embedding of sensor systems. This can be achieved through a combination of differing materials, or multiple processes to enable materials and manufacturing methods to coexist to create a single component with functionality beyond its structural form.
Multi-material fused deposition modelling was identified as a strong candidate for direct writing sensor structures within components, owing to the bottom-up build process and the capability to print conductive composite thermoplastics – explored in Chapter 2 - alongside structural ones. This allowed for a purely digital workflow to be developed, allowing a computer aided engineering model to be manipulated in real time using a physical object with embedded tactile sensors in Chapter 3. In addition, material selection can be tailored to match the contextual requirements of the use case at a localised level.
An interdigital dielectric sensor design proposed in Chapter 4 and improved in Chapter 5 through a more refined material selection demonstrates the concept of a localised approach to material selection enabled by hybrid additive manufacturing processes. The sensor enabled real time monitoring of a curing epoxy matrix in the carbon fibre reinforced polymer manufacturing process.
Item Type: | Thesis (PhD) | ||||
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Subjects: | T Technology > TA Engineering (General). Civil engineering (General) T Technology > TS Manufactures |
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Library of Congress Subject Headings (LCSH): | Detectors -- Data processing, Additive manufacturing, Three-dimensional printing, Real-time data processing, Industry 4.0 | ||||
Official Date: | April 2022 | ||||
Dates: |
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Institution: | University of Warwick | ||||
Theses Department: | School of Engineering | ||||
Thesis Type: | PhD | ||||
Publication Status: | Unpublished | ||||
Supervisor(s)/Advisor: | Leigh, Simon J. | ||||
Sponsors: | Engineering and Physical Sciences Research Council | ||||
Format of File: | |||||
Extent: | xxxvi, 279 pages : colour illustrations | ||||
Language: | eng |
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