Category Archives: News

Additive Camp 2017

As mentioned under “Recent Events” we conducted our 3rd additive manufacturing summer camp for rising juniors and seniors in high school during the week of June 11, 2017. Sid Collins, a rising Sophomore in mechanical engineering here at State, was the lead camp counselor this year under the tutelage of Dr. Ola Harrysson. Working with Sid was our own Matt White, who has managed all of our polymer printers for the past two years. The theme of this year’s camp was similar to our previous camps. The goal was to provide campers with the tools and opportunity to optimize the design of a GE jet engine mounting bracket. The goal was achieved, and we here at CAMAL were once again amazed at how quickly students learned how to utilize sophisticated CAD software and other design tools.

Helping throughout the week were visitors from the New York City College of Technology. Lead by Dr. Angran Xiao, three upperclass students first learned and then helped teach campers about the finer points of 3D printing using a variety of polymer technologies. Pictured below from left to right are CityTech students Jordan Derrick, Joyce Tam, and Gamal Mansour; they were welcome additions to our camp staff.

Jordan Derrick, Joyce Tam, and Gamal Mansour

We encountered a few technical challenges along the way, and as usual it was a mad dash to the finish to get everything completed we wanted to get done but all’s well that ends well. Pictures are worth much more than words here:

The team with the strongest bracket!

Prizes and bracket back ups

 

Sid Collins leads campers

Back to the roots, again!

Friday, April 21, 2017, I (Steve Walker) attended the Grand Opening of the brand new Christopher Guy Showroom located right smack dab in the middle of downtown High Point, NC, between the IHFC building (a truly massive structure) and the Showtime building on South Hamilton Street. It’s a beautiful building, inside and out, and is the first newly built showroom space in High Point in more than 10 years.

I was there on behalf of the University, at Chancellor Woodson’s request. I brought along the lovely and talented Portia for good measure; we like selfie’s.

Governor Roy Cooper was there for the ribbon cutting, and made a nice talk in support of Christopher Guy and the furniture industry. Christopher Guy Harrison, the company founder, can be seen behind Governor Cooper, the second man from the right, below. It was a good event, well attended.

Truly beautiful furniture, but I don’t think it’s in the price range for state employees…even the Governor!

Engineering Open House, 2017

Saturday, March 18, was our annual Engineering Open House from 9 AM to 1:30 PM. All departments throughout the College of Engineering participate (I think). The event usually starts on Centennial Campus, after which visitors make their way over to us on the North Campus. We were ready with bells on, so to speak, with all of the CAMAL staff in attendance along with Phd student Chris Ledford.

There’s no denying the cold and rainy weather was a factor…photo’s above are indicative of average attendance! Those that did attend, however, received a lot of attention.

Wait till next year…

Back to the roots…

Last week offered a rare opportunity to reconnect with the furniture industry, one of North Carolina’s core industries for a long time, at the Stiles Manufacturing Solutions Seminar in their Greensboro facility. The folks at Stiles do a terrific job of showcasing their various technology solutions. The ones I (Steve Walker) was particularly interested in related to the latest in panel/flat sanding, or wide belt sanding as it used to be called. All attendees were given excellent demonstrations of equipment from Heeseman and Buttfering, two of the biggest names in wood sanding for a long time. A few photos, below:

  

Stiles also had some first rate moulder demos. Moulders are 4 sided feed through shaping equipment which have been essential productivity tools in volume wood working for a long, long time. Controls are dramatically more sophisticated and easier to use, and safety features are built in and foolproof in many outstanding ways, but the technology of moulders hasn’t really changed in my entire career. You still have to have good tooling properly set. See below:

It was a good day for all in attendance. Many thanks to the folks at Stiles for having me.

Welcome Dr. Chris Rock

Dr. Chris Rock, a PhD material scientist that spent the past 20 years working in the metals manufacturing industry, has joined the staff of CAMAL as an assistant research professor. Chris has been working closely with all of us at CAMAL for the past two years as the chief collaborator on behalf of CAMAL member ATI Specialty Materials, and has a metallurgical background that is perfect for our many research opportunities in the area of additive metals manufacturing.

All of us at CAMAL are delighted to have Chris join us; nothing but good things keep happening at the Center for Additive Manufacturing and Logistics.

Center members pay us a visit

Thursday, Dec. 8, the CAMAL faculty and staff were pleased to be able to host our second CAMAL membership advisory board meeting of the year. Our membership was well represented, either in person or via a Webex connection, and the meeting went off smoothly.

After conducting a bit of necessary Center business, the board was able to hear and see a series of presentations on some of the various activities we’ve been pursuing for the calendar year which is about to end. Dr. Tim Horn lead the way with an overall research summary, while PhD student Chris Ledford gave an excellent talk detailing CAMAL’s significant accomplishment of designing, manufacturing, and installing a “small” build chamber for our Arcam S12.  PhD student Hengfeng Gu gave a detailed presentation on some of the varied particle size distribution studies we’ve been conducting. Overall, it should have become clear to the CAMAL members that the Center has been a busy and productive place for the past year.

After providing valued guidance on how we might direct some of our research activities for next year, the CAMAL members received the $2 tour of our ever growing and improving labs. It was obvious to all that 2016 was a very good year at CAMAL, and the best is yet to come.

Hengfeng Gu goes to Texas!

hengfend-sff-2016-poster

Hengfeng Gu made two excellent presentations at the Solid Freeform & Fabrication Conference in August.  One was a poster presentation, the other a paper.

The name of his poster was “Influence of powder feedstock properties on process parameters for electron beam melting across alloys” This project is funded by America Makes and NSF.

The primary goals for this project are:

  • Develop a powder characterization protocol for metallic powders used in AM process.
  • Investigate the influence of particle size distribution of Ti6Al4V powders on the required process parameters in EBM.
  • Apply powder characterization and as-built part analysis framework for Inconel 625 & 718 powder systems in EBM.

Hengfeng’s paper presentation was “Effect of Powder Recycling on Mechanical Properties of ATI 718 (TM) in Laser Powder Bed Additive Manufacturing”. The content is based on the ATI 718 powder recyclability project, abstracted below:

The research is investigating whether the nickel super-alloy 718 reused powders would influence the mechanical properties of the as-built part in SLM process after 10 fabrication operations.  Micro-hardness, tensile and density of the specimens from as-built solids were compared. No significant difference was found.

Hengfeng’s presentation was an NSF Student Award Winner. Congratulations to Hengfeng on a job well done.

SFF in Austin, TX; Zaynab Mahbooba does a great job!

Zaynab Mahbooba, who’s been working here at CAMAL as a graduate student for a few years now , just passed her PhD qualifying exam in Material Science. Congratulations to Zaynab on that significant achievement, although it came as no surprise to us that she did.

Zaynab attended the Solid Freeform & Fabrication Conference held annually in Austin TX back in August, and made an outstanding presentation on her current research, titled:

Fabrication of Fe-based Build Metallic Glass via Direct Metal Laser Sintering

The abstract, below, gives a good indication of what Zaynab’s been doing of late.

“Bulk metallic glasses are among the strongest engineering materials known today.  Fe-based BMGs are of increasing research interest due to their superior mechanical, magnetic and chemical properties, and low manufacturing cost.  Existing manufacturing techniques limit thickness and geometry of BMGs.  This work examines the use of direct metal laser sintering to produce an Fe-based BMG.  Alloys fabricated using the EOSINT M 280 exceed the critical casting thickness of Fe-based BMGs.  Despite decreasing quench effect with increasing build thickness, XRD, SEM and DSC analysis confirm that a fully amorphous structure was maintained throughout the build. Opportunities for novel and unique applications of metallic glass are now achievable through process optimization of existing AM processes.”

Zaynab represented all of us, and herself, very well.

 

Additive Camp Days Three and Four…

As anticipated Wednesday was a busy one for the campers. Two big activities took place: #1 was actually using the mold they had created on Tuesday, using the 3D printed item they had created on Monday, to replicated the 3D printed item. See below:

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The results, available Thursday morning, were pretty good. Several results were outstanding. No matter the result, it’s fair to say the campers now have a sense of what goes on in the mold making process, and if you think about it they’ve built a foundation for understanding how casting works.

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#2 was getting started on the process of optimizing the GE Bracket. Dr. Tim Horn lead the way, along with a great deal of help from our many camp counselors, including:

  • Mahaleigh King
  • Tyler Scheviak
  • Charles Melvin
  • Taylor Wilt
  • Logan Freebourn

The campers have done a great job, it would appear, although the proof will be in the pudding, so to speak. That proof will be shown on Friday, when each 4 person team of campers gets their bracket broken. Last one unbroken wins!

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Prepared by Steve Walker

 

Additive Camp Day Two…

Day Two of camp was mold making day, with a little bit of 3D scanning and a little bit of materials science thrown in. Dr. Harrysson started the day off with an overview of how an effective rapid prototyping process works utilizing 3D technology. This was followed by Dr. Harvey West giving campers some basics on material science as it relates to the world of additive. Understanding and advancing the development of materials that can be used in additive manufacturing is a critical part of making 3D printing more important and useful to all of us.

After lunch it was time to start making molds. See below:

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Above, in the steamer, are various parts the campers had designed on Monday which were then printed on our 3D Systems Projet printer overnight. The support materials used in the Projet come off very easily in the steamer. Once cleaned the parts are ready to be used in the mold making process. In the other photo is an example of how the campers positioned their part in the container used to make a mold.

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Mix up the urethane, pressurize away the bubbles, and then pour. The end result is 20 molds. Wednesday they’ll be carefully dissected, and hopefully will be able to be used to make copies of their designs.

Wednesday will be primarily focused on getting the teams together to start working on their competition project. A busy day ahead.

Prepared by Steve Walker

Additive Camp 2016 is off and running!

Our second additive manufacturing camp for high school juniors and seniors got off to a hot (as in 98°) start on Sunday, June 12, with orientation and a nice dinner in the Tally Student Center ballroom. Monday morning things got down to business.

Dr. Ola Harrysson, the camp leader and co-director of CAMAL, gave campers an overall view of how 3D printing has developed over the years; nobody knows how that’s occurred better than he does. That was followed by a detailed look at the CAD related “slicing” process that is a fundamental part of how 3D models are turned in to usable information for 3D equipment. Freshly minted Dr. Harshad Srinivasan was the leader of that segment. Then it was off to Tally for lunch.

Right after lunch campers got right into learning Solidworks®, the 3D modeling software we and many others use to start the design process. ISE undergrad student Logan Freebourn led the session, aided by newly NCSU graduated Charles Melvin, NCSU undergrads Tyler Shiviak and Taylor Wilt. All involved did a great job; each camper produced a design in Solidworks® which was then sent to our 3D Systems Projet© printer for overnight printing. See campers in action, below:

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Camp’s off and running. We’ll see what the finished products look like tomorrow.

Prepared by Steve Walker

CAMAL at the Vet School Open House

We are proud of our partnerships with all parts of the University, but 1st among equals (by a lot!) is the relationship we have with the College of Veterinary Medicine (CVM).  This past Saturday (April 23) was CVM’s open house, and it was very well attended. It was also very well supported by many of the CAMAL students that work closely with the CVM.

They do a much better job of photo documenting their excellent events than we (I) do. Check out the pdf below to see some of Saturday’s activities:

CMI Open House 2016

CAMAL owes a permanent THANK YOU to the entire CVM, but especially to Dr. Denis Marcellin-Little, our constant friend and guide through so many learning experiences.

President Spelling’s First Stop was…

We were fortunate enough to be UNC Pesident Spelling’s first stop on her April 20, 2016 visit to N.C. State. I think she was rightfully impressed. Check out the links below:

http://www.twcnews.com/nc/triangle-sandhills/news/2016/04/20/unc-president-margaret-spellings-tours-nc-state.html

http://www.newsobserver.com/news/local/education/article72952347.html

http://wncn.com/2016/04/20/spellings-who-has-faced-protesters-lately-has-a-quiet-visit-to-n-c-state/

Visitors today, April 11, 2016

We had visitors today from the Office of Naval Research, who were touring the entire NCSU campus under the guidance of Matt Peterson, the university’s Director of Federal Research Affairs.  Chancellor Woodson took the time to welcome the group; we were the first stop of the day, which got everyone’s day off to a good start.

Chancellor with ONR   Rusty with ONRTim with ONR

 

Our Q-10 is here!

Today, April 6, 2016, was delivery day for our brand new Arcam Q-10. It was delivered to our Daniels Hall home promptly at 8 AM, and was delicately brought into the lab. We’re still waiting for a few doodads to arrive (they’re in town) before we put it into its spot in the new metals room, but all looks to be good. She’s a beauty, in an Arcam sort of way.
q10 three                   q10                    q10 five

Our 530 hour build on the EOS INT M280

Friday, Oct. 30, 2015 was a special day for us here at CAMAL. That was the day we finished a 530 hour long build on our EOS INT M280 creating a very large piece of solid inconel. 530 hours is by far the longest continuous run we have ever had; it’s the longest we’ve heard of, too. That’s a lot of powder, and a lot of argon gas as well.

Enjoy the commemoration video below, filmed by our Matt White with a big sound assist from multiple Grammy® winning mix engineer Miles Walker.

Student research; an update.

A regular event for the CAMAL group is our Friday morning student research meetings. Each Friday at 10 AM all undergraduate and graduate students working on additive related research gather to discuss and review current activities, as well as review research taking place in other parts of the country (and world). We have students involved from just about all of the engineering disciplines, including materials science, computer science/electrical engineering, mechanical engineering, bio medical engineering, the Vet School, and of course ISE.  CAMAL faculty and affiliated faculty are regularly in attendance.

The meetings have a normal format of one student presenting on his/her current research, while another student will present a review of external research related to additive. We also have guest speakers from time to time. Meetings are an hour long; time goes by very quickly (for the non presenters, anyway).

Our latest meeting was a presentation by Austin Isaac on his recently completed internship with American Precision (a part of 3D Systems) in Tulsa, OK. Austin is nearly finished with his Masters program in IMSEI, and worked on various additive processes during his 6 month stay, including brand new technology from 3D Systems company Layerwise. While Austin may not be a fan of Greater Tulsa, he had an excellent working experience (lots and lots of work). Below is Austin presenting:

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The previous week, Harshad Srinivasn provided all involved with an update on what we refer to as the Hybrid Project.  In a nutshell, the Hybrid Project is an America Makes funded research activity we are working on to find a better way to turn near net shaped parts coming from an additive process into the net shape, to tight tolerance, parts required in aerospace, defense, and medical device manufacturing industries. Harshad is making the presentation; also actively involved in the project is phd student Carter Keogh, pictured with Harshad in the lab with their constant companion, our HAAS VF 3ssyt multi axis machining center, being used and adapted as part of the research activities.

Harshad and Carter               Harshad presenting (1)

Lots of good things happening at CAMAL…

 

IDB to visit, again.

The Institute for Defense and Business (IDB) will be here on Tuesday, Sept. 22, 2015 for an all day seminar covering Concurrent Design for Sustainability (by Dr. Paul Cohen), Managing Life Cycle Uncertainty (by Dr. Russell King), and Additive Manufacturing Technology and Trends (by Dr. Ola Harrysson). A tour of the CAMAL facilities will be included, naturally.

The day spent with us is part of a week long Life Cycle Leadership Program that IDB has been putting on for several years for its member companies. We have valued our association with the IDB from the very beginning, and always look forward to their day long visits. It’s a great opportunity for program participants to see where the state of the art is in additive manufacturing, and a great opportunity for us to interact with people that have their feet firmly on the ground when it comes to solving real world problems and meeting real world challenges.

This time around we will be introducing our visitors to the new and dramatically improved Talley Student Center. It’s a fabulous venue; a near match for The Hunt Library!  A few pictures tell a part of the Talley story:

talley             talley 3         talley 4

 

These few shots and the home page photo give a hint at how Talley looks now. The meeting rooms are wonderful, too. Talley should be a destination point for any visit to N.C. State in the future.

A new compressor, thanks to Ingersoll Rand

During the first week of the new school year we were busy getting our newest piece of donated equipment ready for installation.  A 15 horsepower, custom designed compressor from Ingersoll Rand will give us the extra air we need to power our new machining equipment.  While greatly appreciated, getting the compressor ready for installation was not without its challenges.

New Compressor 2                       New Compressor

Above left is the compressor safely on the floor. Above right is Tim Horn oh so carefully hoisting the unit off the pallets that had not fared so well in transit. We would never have made it without the special hoist from Dan Leonard’s lab affectionately known as the “Elmer” gantry. Even then it was exciting. You might be able to tell from the photos that the compressor gives a new meaning to the term top heavy.

All’s well that ends well. Our latest addition is now where it is needed, ready to blow hard on demand. Many thanks to the fine folks at Ingersoll Rand that made this all possible.

CAMAL Camp Grand Finale (Friday, June 26)

CAMAL campers had a wide range of additive and rapid prototyping experiences over the course of the week, but the last few days were directed towards their team competition for the best GE engine bracket design. The Campers challenge was to create a version of this titanium GE bracket, used to mount jet engines;

IMG_0739

that was stronger and lighter. For the sake of cost and time, we converted the above to a resin based 3D printed and scaled version, seen below:

FullSizeRender (1)

As always, click or tap to enlarge the photos.

The student versions were printed within the same machine (our Stratasys Objet 350) and the same build as the GE Bracket above. Every effort was made to be sure we were comparing apples to apples, in a polymers sort of way.

Friday arrived, and so did the parents to see what the CAMAL Campers had accomplished in one surprisingly short week.  Everyone piled into Harvey West’s testing lab, where Harvey had devised a system to test each of the Camper designs on our ATS Series 1620 20,000 lb. capacity universal testing machine. Harvey tested each design to failure, including the original GE design.  The results:

  • Using a formula to compare the strength to weight ratio of each design, every single one of the Camper design’s was better than the GE Bracket!
  • One design, the result of amazing creativity, ingenuity, and the practical application of real engineering tools, beat the GE Bracket not only in a strength to weight ratio comparison, but also beat the GE Bracket in real terms. That means it took more weight to break it than it did the GE Bracket!

And the winner was (drum roll, please…) the bracket in the Universal machine, left below.

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After the competition, tours, food and fun ensued. The winning prize was a Tervis Tumbler for each member of the winning team, seen above right.

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We enjoyed our very first Additive Camp. We hope it won’t be our last.

 

CAMAL Camp Day 5 (Thursday)

The Thursday schedule to finish up the last full day of CAMAL camp was:

  • Learn about how testing is done with Harvey West, and learn some tricks of the trade in the world of microscopy.
  • Finish up any last minute stuff the campers were working on in their various projects.
  • Prepare a presentation (each team) describing the steps taken to come up with the final team design of the improved GE bracket.
  • Deliver the presentation.

IMG_0721           IMG_0998             IMG_0722

Click or tap to enlarge all photos.

Above left is our Thomas Martin showing Campers the results of their 3D printing efforts; center is a camper presentation; right is Ola Harrysson showing the inner workings of our Arcam S12, the very first EBM machine Arcam ever made.

Note the blue in the center photo. Tim Horn taught Campers how to use finite element analysis in designing their brackets. They took to the very complex engineering tool like fish to water; it was amazing. Did it make a difference in their final bracket design? We’d find that out on Friday, when parents came to town to witness the best GE bracket competition themselves.

CAMAL Camp Day Four (Wednesday)

GE Children (1)                GE Children (2)

Wednesday was the day to put the Campers newly acquired Solidworks skills into actual practice by making their own version of the so called GE bracket. The GE bracket, seen above as the big grey part in the picture on the right, was part of a national design competition a few years ago. Our campers scanned the GE bracket then used Solidworks to come up with their very own, somewhat smaller scaled, versions. Above in both photos are their versions, printed on our Objet Connex 350 printer. Click on either picture to enlarge. It’s amazing how quickly the Campers are catching on.

Wednesday also included the completion of the mold making process. Photos not yet available for that one, but they will soon come!

Thursday will be a learning activity involving testing and microscopy, lead by our very own Harvey West. Breaking of stuff will be involved! That’s always fun.

CAMAL Camp Day Three (Tuesday)

campers mixing          campers mixing 4          campers mixing 3

Tuesday was a full day for CAMAL Campers. With their previously printed items in hand, the Campers were now ready to make a mold, which will allow them to make many copies of whatever they printed using a wide range of mold able materials. Think chocolate. Above left Dr. Harrysson is giving campers the basics. Above center and right shows the high tech process of mixing the mold base. Remember to click on photos for a bigger view.

After all the mixing was completed (times 20) the campers simply placed their printed part into the mix, where it will sit overnight. Wednesday will lead to the next step in the process, which will be using the molds to make a copy of whatever the campers have printed.

Mold making took place in shifts. While one half made molds, the other half continued their dazzling growth in using Solidworks. Dr. Tim Horn, building on campers previous scanning experience on Monday, showed everyone how to use Solidworks to turn the scanned information into usable, 3D printable, information. In other words, how to reverse engineer using scanning and 3D printing. See Tim below:

Tim with campers 2 (1)

Tuesday afternoon was fully consumed by a tour of Fineline/Protolabs. The folks at Fineline could not have been any more hospitable, and their facility is amazing. They can really do a lot of terrific things there.

It was a good day.

CAMAL Camp Day Two (Monday)

Monday is the day things really start for campers. Right off the bat Monday Morning Dr. Harrysson and Dr. Horn got the amazingly quick learning campers up and running on Solidworks, the CAD system we start everything off with here. None of the campers had ever used Solidworks before, but fearless and bright leads to rapid success. After each student completed a design for a key chain, the next lesson was in scanning technology. Phd candidate Harshad Srinivasan was the scanning leader; see him in action below. Don’t forget you can click on any picture for a larger view.

Campers with Harshad (2)          Campers with Harshad (1)

The Campers then had their work 3D printed, most of which happened overnight. Their printed design was waiting for them Tuesday morning. See some examples below:

Precious print               Precious print2                 Precious print 3

Tuesday’s challenge? To turn the above into molds that can be used to make lots of key chains. Also on tap for Tuesday is a tour of Fineline/ProtoLabs, one of the very best on demand rapid prototype businesses that exist anywhere.

CAMAL Camp Day One

The first ever additive manufacturing summer camp got off to a roaring (hot!) start on Sunday, June 21 as 20 high school juniors and seniors came to the NCSU campus for what is sure to be a learning experience for all concerned. Below left is Susan D’Amico welcoming all campers at Withers Hall, which was followed by an orientation of all the ISE campers in Daniels Hall (below right). Sunday evening was a cookout for all involved; no charcoal needed in the current Raleigh climate. Double click pictures for expanded views.

Sunday Welcom

Campers on Sunday

Chancellor Woodson Visits CAMAL

Monday, March 30, we had visitors; Chancellor Woodson and Dean Louis Martin-Vega stopped by to see our newly updated facilities. It’s safe to say they were impressed; Wow was a term used quite frequently. Note that you can click/tap on all pictures for expanded views.

Dr Harrysson and Chancellor at Objet

 

chancellor woodson with Dr Harrysson

 

 

Dr Harrysson tells the Chancellor how it is

 

 

 

 

Above left Dr. Harrysson shows the Chancellor the finer points of 3D printing on our Objet printer.  Above center Drs. King and Harrysson outline the challenges of metal additive manufacturing, while above right the Chancellor and Dr. Cohen see our ITAR compliant metals printing lab up close.

Thomas teaches the Chancellor

 

chancellor-woodson drives the scanner

 

chancellor woodson with Aiden

 

 

 

 

Above left the Chancellor gets the lowdown on our many personal 3D printers utilizing ABS or PLA materials from Thomas Martin, our student guru in this area. Center, Chancellor Woodson gets to drive our Faro scanning technology after a brief training session from Harshad Srinivasan, Phd candidate in ISE. Right, Aidan Special describes the work he has been doing since becoming part of the CAMAL research team this year.

Tim tells the Chancellor how its made

 

 

 

the Titanium pigskin

 

 

 

 

The best was saved for last: Dr. Tim Horn made a gift for Chancellor Woodson that could only be made here; a lifesize titanium football with the NC State logo on the outside and a surprisingly artistic (and intricate) spiral design on the inside. Chancellor Woodson will soon have it on display in the Chancellor’s box at Carter Finley Stadium.

 

 

 

Let me tell you all a story about a lab named CAMAL…

During the week of Spring Break here at NCSU, the CAMAL lab facilities in Daniels Hall underwent a dramatic change as our brand new, state of the art metal finishing equipment was delivered. Pictures tell the story best.  Be sure to click/tap on photos for clearer and bigger views.

Here’s our “before” picture, with our old faithful Shoda 5 axis CNC router waiting for removal:

Camal lab 8

 

Then out the door it goes…

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Then out the door goes…the door!

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Go here next:

The CAMAL lab story continued…

So we took out the door to enable us to bring in three state of the art pieces of technology. First in was our Cincom L20 Screw Machine from Citizen Machinery.

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Then, the next day (Thursday, March 12) in came the next piece of equipment in our new and soon to be highly developed finishing capability, a haas Multigrind CA 5 axis grinding center.

IMG_0568                                                                                                                              New haas precision grinding machine.

 

Then, last but far from least, in came our new Mazak Integrex i-100ST. This is a 5 axis plus machining center, capable of space age machining tolerances.  We now have the technology to take our 3D printed near net shape parts all the way to extraordinarily precise finished tolerances.

IMG_0601Haas and Mazak

 

 

 

 

 

 

We are going to do some really good things here at CAMAL. The future is very bright!

Amir Milak shines in Undergraduate Research Symposium

Amir 2Amir Milak, an undergraduate researcher here at CAMAL, participated in the Engineering College’s Undergraduate Research Symposium on Nov. 22, 2014, and represented himself and our program very well.  Below is the abstract from his presentation, and below that is a link to the excellent poster he created to represent the work.  Amir, by the way, is graduating from NCSU on December 18, 2014.  That’s in less than 3 weeks!

Abstract:

With the rapid evolution of additive manufacturing in recent years, metal powder bed fusion has shown great potential for various applications ranging from Biomedical to Aerospace. This study will focus on comparing the tensile and material properties of two forms of powder bed fusion using the Titanium alloy system, Ti6Al4V.   The two processes that will be compared are the Electron Beam Melting process (Arcam, EBM) and the Direct Metal Laser Sintering process (EOS M280 Laser, DMLS).   The EBM uses a Tungsten filament to generate electrons which are guided through 3 electro-magnetic coils that focus and deflect the beam across the build area, selectively consolidating the powder.  The build area is under a mid-vacuum and remains at a relatively high temperature (800 Degrees C). The EOS uses a laser energy source, requires finer powder and does not operate at the high temperatures typical to EBM.  We hypothesize that there will be a difference in tensile properties of the two processes.

Research Symposium Poster-Amir

 

Life Cycle Executive Leadership Group Comes to Learn

The Life Cycle Leadership Group (LCLP), from the Institute for Defense and Business (IDB) located in Chapel Hill, came to the Hunt Library and our CAMAL lab facilities on Tuesday, Sept. 16, 2014 for a day long seminar on the world of additive manufacturing and the logistical challenges that exist moving forward.  ISE department head Dr. Paul Cohen, CAMAL co director Dr. Russell King, and research scholar Dr. Ron Aman gave participants a wide ranging and in depth series of presentations on the world of advanced and additive manufacturing as it’s being practiced on a global scale.  The day finished with a tour of our labs by Ron and Harshad Srinivasan, an ISE Phd student working on various additive research projects.

harshad at A2ron with IDB

Harshad, left, showing the finer points of our Arcam AB EBM technology.  Note that while this was happening, Drs. Harvey West and Ola Harrysson were in Sweden at an Arcam users group meeting.  Ron (above, right) is giving the LCEL team a step by step on how we design our varied additive projects.

IDB Group

The entire LCEL group on the steps of Daniels Hall.  They were terrific guests; a good day was had by all.

WNCN Channel 17 Talks with ISE Researchers

You will have to turn up your volume once the video starts

Local News Channel WNCN’s Melanie Sanders stopped by ISE’s Advanced Manufacturing and Logistics Lab and talked with Dr. Ron Aman, Tim Horn, Carter Keough, and Amir Milak about the work they are doing with creating transplantable parts for animals.

The researcher team has designed and streamlined the manufacturing process for many of these type of transplants while Dr. Marcellin-Little, NC State College of Veterinary Medicine, has performed the surgeries. Currently, ISE is the only department in the world that can manufacture these prosthetic limbs in-house.

Advanced Mfg. and Logistics Symposium, October 2013.

The Advanced Manufacturing and Logistics Symposium held at the Radisson RTP on October 17 & 18 was an event which brought together a wide range of the leading experts in the world of 3D printing/additive manufacturing.

Dr. King at AMALThe Symposium got off to a fine start with hosts Dr. Russell King and Dr. Paul Cohen welcoming symposium guests and introducing the Thursday Keynote address by Dr. Anthony Atala, director of the world renowned Wake Forest Institute for Regenerative Medicine (WFIRM). Dr. Atala delivered an outstanding address which touched on the full spectrum of innovation taking place at WFIRM.

AMAL SponsorsBoth days of the Symposium were full of dynamic speakers making excellent presentations. We also were able to enjoy two fine receptions and dinners thanks to our many generous sponsors, listed in the photo on the right. We are especially grateful to the Society of Manufacturing Engineers (SME) who were the lead sponsors of the event. For those that are interested in some of the topics discussed, many of the Symposium presentations can be found at :

https://camal.ncsu.edu/research/ise-symposium-presentations/

Dr. Harrysson Joins Panel Discussion at Hunt Library Along With Dr. Dickey, Adam Rogers and 3D Systems Founder Chuck Hull

Dr. Ola Harryson, Fitts Fellow in Biomedical Manufacturing, recently participated in a panel discussion on 3D printing at N.C. State at the Hunt Library Friday, August 30, at 11 AM.   He along with  Adam Rogers, Dr. Michael Dickey (Chemical and Biomolecular Engineering), and 3D Systems founder Chuck Hull discussed the state of 3D Printing technologies.  You can see the full panel discussion here:

Dr. Dickey and his group recently made headlines with the development of techniques to 3D-Print free-standing metal structures from liquid metal.  See the article “Researchers Build 3-D Structures Out of Liquid Metal” on the NC state news page.

 

 

Dr. Li Yang, Emerald Engineering Outstanding Doctoral Research Award Winner

Li Yang

Dr. Li Yang is the 2012 recipient of the Rapid Prototyping Journal Engineering Outstanding Doctoral Research Award.  The title of his research was “Structural Design, Optimization and Application of 3D Re-entrant Auxetic Structures”.  The work was selected by the Senior Editor of the journal as the winner in the Additive Manufacturing category.

Dr. Yang completed his doctoral work in 2011 in Industrial Engineering at North Carolina State University.  His advisors were Dr. Ola Harrysson (Chair) and Denis Cormier (Co-Chair). Presently, Dr. Yang is an assistant professor in the Industrial Engineering Department at the University of Louisville. Prior to this, he worked at B/E Aerospace, Inc. in Everett, Washington as a Certification Engineer.  B/E Aerospace is a leading manufacturer of aircraft passenger cabin interior products for the commercial and business jet aircraft markets.

The Engineering Outstanding Doctoral Research Award includes an award of 1,000 Euros, a certificate and the prospect of an offer of publication of the work in the Rapid Prototyping Journal.

Ron Aman becomes Dr. Ron, PhD.

Today, August 6, 2013, Ron Aman became Dr. Ron Aman, officially.  Ron has been a vital part of the Edward P. Fitts Department of Industrial and Systems Engineering for 10+ years as a student, teacher, lab manager; you name it and Ron’s done it and done it well.

Ron has had an active hand in the development of our additive manufacturing capabilities.  His thesis involved the study of the absorptive qualities of different materials that can be used medically as implants which can be made using additive technologies.

Congratulations to Ron on this significant achievement.

Carter Keough Presents at The NCSU Summer Undergraduate Research Symposium

Carter, Christine, Tim

This summer, Carter Keough (see above with Dr. Grant and Tim Horn) did some excellent work on the project,  “Preliminary Investigation into the Influence of  3D Printing on  Sustainable Manufacturing”.   Carter was sponsored through an NSF Grant awarded to Dr. Christine Grant from Engineering Dean Louis Martin Vegas’ office (Co-PIs Christine Grant, Steven Peretti, Tuere Bowles , Bradley Mehlenbacher, Pamela Martin).

This grant, An ARK on the SEE: Sustainability, Energy & the Environment: Reasearch Experience for Undergraduates  The ARK represents Answers, Research, and Knowledge that will teach students to think globally, train  globally and, practice globally with a focus on waste minimization ,  pollution prevention and  environmentally conscious manufacturing.

Carter and the rest of the undergraduate team have been mentored by Tim Horn, and soon to be PhD (officially August 6) research scholar Ron Aman. You can get a good feel about the work being done here by Carter and friends by viewing her outstanding poster she used to present the results of her work at a recent event at N.C. State’s 12th Annual Summer Undergraduate Research Symposium at the McKimmon Center. Check it out, below:

Symposium Presentation

Carter is a rising senior in the Edward P. Fitts Department of Industrial and Systems Engineering, and has been part of a terrific group of undergraduate students working here since May to help us continue to push the envelope regarding the benefits of 3D printing/additive manufacturing.

We’re all proud of Carter, and glad she’s part of our group.  We’re proud of the whole group, too.  More to come about the rest of them, soon.

Terry Wohlers is coming!

For those attending the Additive Manufacturing Symposium, Oct. 17 and 18, 2013, we are delighted to announce that Terry Wohlers will be our Friday Keynote Speaker. Terry is the leading expert in the world of additive manufacturing, and his annual Wohlers Report, as he accurately states on his website, “offers an unparalleled window into additive manufacturing and 3D printing…”. Learn more about Terry at http://wohlersassociates.com/index.html

Congressman Price Comes for a Visit

ronamandavidpriceisencsu03a-001

We were honored back in May to have a visit from U.S. Rep. David Price, a longtime veteran of the U.S. House of Representatives from the 4th District of North Carolina.  Ron Aman, pictured above with the Congressman, gave Mr. Price a thorough rundown of the many things being done in the world of additive manufacturing at N.C. State.  We’re sure Ron made a good impression; he always does.

Ron, by the way, has successfully completed his Phd. defense.  He is Dr. Ron now!  Congratulations to him!

Welcome to the ISE Lab for Additive Manufacturing

The Edward P. Fitts Department of Industrial and Systems Engineering (ISE) is delighted to welcome the wide world of the Internet to our new web page.  While there is still a lot to do to make this as informative as we would like it to be, we are on our way to using this site as an important source of information regarding the dynamic world of additive manufacturing.  We hope you find our site to be helpful, and come back often to see what’s new.

Additive Manufacturing and Logistics Symposium

In cooperation with the Additive Manufacturing Consortium (AMC) the Edward P. Fitts Department of Industrial and Systems Engineering is pleased to invite all AMC members to join us at North Carolina State University in Raleigh, NC, for the Fall AMC Meeting  .  The meeting will be held on October 16, 2013.  For meeting details, please contact Ed Herderick, AMC Director, at eherderick@ewi.org.

For those attending, you are also cordially invited to attend our Additive Manufacturing Symposium, Oct. 17 and 18, 2013, on the N.C. State Campus and Research Triangle Park.