Royal University of Agriculture Harnessing 3D printing technologies for the manufacture of spare parts for agri machinery Mark O Looney Plant & AgriBiosciences Research Centre (PABC), NUI Galway & International Rice Research Institute (IRRI), Philippines �
Background • Rural-urban migration has seen rural human labor availability decrease. • Agricultural machinery helps farming communities decrease farm drudgery and production losses. • Mechanisation can support farming communities. �
From hand-held tools to mechanisation Source. www.fao.org �
Mechanisation and spare part availability? Source. www.machineservice.com �
What is 3D printing? • Manufacturing process invented in the 1980’s (Rayna and Striukova, 2016). • 3D model that is transformed into a solid object one layer at a time without different forms of machining or treatment (Lipson and Kurman, 2013). • A form of Additive Manufacturing (AM). �
3D printing vs conventional manufacturing A. Computer Numerical Control (CNC milling) = Subtractive manufacturing B. 3D printing = Additive manufacturing Source. www.3dnatives.com �
Additive manufacturing methods Name: Development years: Stereolithography (SL) 1986-Present Fused Deposition Modelling (FDM) 1988-Present Selective Laser Sintering (SLS) 1987-Present 3D Printing 1985-Present Source. De Beer, 2006 �
How does 3D printing work? Source. Campbell et al, 2011 �
3D printing: Step by step process 1. Use CAD software to draw the part �
3D printing: Step by step process 2. Slice the design with Cura software. Save as G code and transfer to SD card. �
3D printing: Step by step process 3. 3D printing process begins �
3D printing: Step by step process 4. Parts are now 3D printed �
Preparatory steps • Unloading and loading of filament. • Calibration of print bed. • Put glue on the print bed for adhesion and removal of 3D object. �
Terminology • Rafts are primarily used to help with warping and bed adhesion, or to create a strong foundation on which to build the upper layers of your part. • Skirts serve a useful purpose because they help prime your extruder and establish a smooth flow of filament. • Brims are often used to hold down the edges of your part, which can prevent warping and help with bed adhesion. Source. www.simplify3d.com �
Support structures • Support structures are used when parts have complex designs or “overhangs”. • Support structures stabilise the build. • Supports often require post processing work to finish the object. • Objects will warp or collapse if support structures aren't used. Source. www.3dhubs.com �
3D printing advantages & issues Advantages Issues 1. Rapid design and 1. High capital prototyping investment 2. Cost effective for small 2. Legal issues and batches Intellectual Property Rights (IPR) 3. Timely provision of parts 3. Always requires a digital design 4. Complexity and design freedom 4. Not all materials can be 3D printed 5. Little to no waste is produced 5. Some larger parts need time �
3D printer comparison Figure 1. RUA Ultimaker 3D printer Figure 2. IRRI XYZ 3D printer Figure 3. NUI Galway Makerbot 3D printer Figure 4. Aurora Labs metal 3D printer �
Materials used for 3D printing Plastic Metal Other Polylactic Acid (PLA) Stainless steel Epoxy Resins Acrylonitrile Titanium Glass Butadiene Styrene (ABS) Nylon Gold Ceramic Silver Chocolate • Various materials can be 3D printed including different compounds of both metal and plastic. • Research into further material compounds is ongoing. �
Metal 3D printing Source. www.all3dp.com �
What can be 3D printed? • In theory, any object that has a 3D digitised design can be 3D printed (Print size will depend on the specification of the 3D printer). • Automotive, aviation and biomedical industries are already using 3D printing. • NASA, Mercedes Benz, German train company Deutsche Bahn, and BMW are using 3D printing. �
SpaceX rocket engine valve • SpaceX 3D printed a Main Oxidizer Valve (MOV) for a Falcon 9 rocket engine. • The valve operated successfully with high pressure liquid oxygen, cryogenic temperatures (circa - 150C) and high vibration. • The MOV was 3D printed in less than 2 days, compared to castings cycle which takes months. Source. www.tesla.com �
Inter operability at NASA • Ratchet designed on earth and “emailed” to International Space Station (ISS) • Proves that geographical distance is not an issue when exchanging part designs and subsequent 3D printing of objects. Source. www.nasa.gov �
3D printed prosthetic hand Source. www.3dprint.com �
3D printing and agriculture • 3D printing has yet to impact agriculture like other industries. • However, 3D printing has been piloted in some countries. • The 3dforagdev program in Malawi is using 3D printing to make hand held tools. • It includes user led innovation of women smallholder farmers. �
Malawi 3dforagdev program Source. www.3dforagdev.org �
Feasibility study in the Philippines • Conducted a feasibility study in 2017 with NUI Galway & IRRI. • Conducted surveys with Agri machinery manufacturers, spare part suppliers and repair shops in the Philippines. • Got their opinion on spare part access and introduced 3D printing technologies. • Results have similar trends to study in Cambodia. �
Inter operability between NUI Galway and IRRI • CAD file successfully emailed from NUI Galway (Ireland) to IRRI (Philippines). • 3 nozzles were successfully 3D printed using ABS material. • Mimicking a value chain between two geographically distanced research partners. Source. Martin Gummert, IRRI �
3D printed machinery parts �
Original CAD drawing of metering device �
Re-drawn metering device on CAD �
Slicing software �
3D printed metering device Source. NUI Galway & IRRI �
Philippines: Waiting time for parts Average Waiting Time for Parts 4.5 4 4 4 3.5 Number of Respondents 3 2.5 2 2 2 1.5 1 0.5 0 0 0 Days Less than 1 1 to 7 7 to 14 14 to 21 Up to 1 month Over 1 month �
Feasibility study in Cambodia • Conducted surveys with 15 agri machinery manufacturers, spare part suppliers and repair shops. • Met with provincial departments and disseminated the concept of 3D printing. • Studies have shown similar trends to the Philippines, there is an issue with access to some spare parts, i.e. waiting periods of 1 to 4 weeks. �
Training program on 3D printing • 34 students have been trained on 3D printing technologies. • Students were also trained in using the RUA Ultimaker 3D printer. • Prototypes were digitally designed and 3D printed by the students. • 8 staff from the agricultural engineering department in Phnom Pehn were also trained on 3D printing. �
Training program Training of students at RUA. Training of staff at the department. �
3D printing service for spare parts? • Aim of this project is to get feedback from agricultural machinery suppliers/manufacturers/repair specialists. • There’s been a proposal for a 3D printing service to be situated in the Philippines. • Various industries including agriculture, could use this service. �
Intellectual Property Rights • Intellectual property is one of the biggest barriers in setting up a 3D printing service. • Agreements will need to be reached: Access to digital designs in return for fees or royalties to the main manufacturer? • Licensing of digital designs will need widespread collaboration between 3D printing service providers and manufacturers of spare parts. �
What can a 3D printing service offer? • Training for educational purposes. • Improved access to prototypes and “on demand” spare parts. • High quality parts. • Price of parts should be competitive but relative when speed to market is considered. �
Conclusion • 3D printing is a relatively new disruptive technology. • 3D printing is being used across a variety of industries. • 3D printing is a simple and straight forward process. • Various materials and compounds can be used for 3D printing spare parts. • However, more research and collaboration needs to be done on 3D printing and it’s benefits for agriculture. �
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