Reverse Engineering Techniques PDF

EL PT N Dr. Amandeep Singh Imagineering Laboratory IIT Kanpur ▪ Reverse engineering ▪ The Reverse Engineering process EL ▪ Reverse engineering industries ▪ Purpose of Reverse Engineering PT ▪ Methodology and stages...

EL PT N Dr. Amandeep Singh Imagineering Laboratory IIT Kanpur ▪ Reverse engineering ▪ The Reverse Engineering process EL ▪ Reverse engineering industries ▪ Purpose of Reverse Engineering PT ▪ Methodology and stages in Reverse Engineering ▪ Reverse Engineering in AM N ▪ Example and Case study ▪ Different scanners ▪ Reverse engineering extracts design blueprints from man- made objects. EL ▪ The idea undoubtedly dates back to the industrial revolution, before computers or current technologies. ▪ It PT investigates created artefacts, while scientific inquiry investigates natural phenomena. N ▪ Reverse engineering traditionally included dismantling shrink- wrapped objects to learn their design. EL ▪ Secrets were employed to build similar or better products. ▪ Reverse engineering was formerly a popular hobby (even if it PT wasn't called that). N N PT EL 1. Digitization of the object/ Data Capturing (using CMM, scanners etc.) EL 2. Processing of measured data PT 3. Creation of CAD model. N 4. Prototype. Source: indiacadworks udaipurcadatc  EL a. b. c. CAD model generation using laser scanner: PT (a) wooden pattern, (b) cloud of points, and (c) 3D CAD model N Source: Fabricated Model Energyinvestmentcasting.com Contact Scanners: CMM Based. Soft materials can’t be EL scanned accurately. 1 Comparatively slow process. Noncontact Scanners: PT Uses lasers, optics and CCD sensors to capture data points. N Shiny surfaces and surfaces 2 parallel to light axis can’t be scanned accurately. Source: cncstep.com afmhelp.com  1. Portable CMM Classification: Portable CMM’s Laser Trackers EL Total Stations PT Digital Photogrammetry N 2. Laser Tracker 3. Total Station Source: geminibps.com Contact Methods: Use sensing devices with mechanical arms, CMM and CNC m/c to digitize a surface. EL Data collection techniques: i. point to point sensing with touch-trigger probes PT installed on CMM or articulated mechanical arm to gather co-ordinate points of a surface. N ii. analogue sensing with scanning probes installed on CMM or CNC m/c. Point Processing Importing the point cloud data. Reducing the noise in the data collected. EL Reducing the number of points. PT A wide range of commercial software are required. The output is a clean, merged, point cloud data set in the N most convenient format.  Point-to-point sensing equipment EL PT N 1. 2. Zenith 3 CNC CMM Source: aberlink.com  Analogue sensing equipment EL PT N 1. SP25M scanning probes 2. Roland DGA Corp. MDX-20 scanning from Renishaw Inc. and milling machine using Roland Active Piezo Sensor for 3D scanning 1. Source: reinshaw.com 2. Source: fablab.uchile Advantages of contact mode High accuracy. Low costs. EL Ability to measure deep slots and pockets. PT Insensitivity to colour or transparency. N  2D cross sectional images and point clouds are captured projecting energy sources (light, sound, or magnetic field) on an object. EL Then, either the transmitted or the reflected energy is observed. PT The geometrical data are calculated by using triangulation, time-of-flight, wave interference information, and image N processing algorithms. The classifications of non-contact RE hardware are based on the sensor technologies or data acquisition techniques employed.  EL PT N RE Hardware Classification-non contact methods  No physical contact. Fast digitizing of substantial volumes. EL Good accuracy and resolution for common applications. PT Ability to detect colours. Ability to scan highly detailed objects, where mechanical N touch probes may be too large to accomplish the task. ▪ When reverse engineering a mechanical product, you start by examining its measurements and qualities. EL ▪ CMM, CT, laser and structured light digitizers are 3D scanning technologies. PT N ▪ CAD drawings are digital two-dimensional and three- dimensional representations of the product's design. EL ▪ Digital models reveal design intent and guide reverse- engineering. engineering. ▪ Technicians PT ▪ Obsolescence of older computer parts often requires reverse reverse engineer a PCB by identifying its N components. ▪ The reverse-engineering team will photograph the board from the front and rear before disassembly. ▪ The team measures capacitors and resistors as they remove them. This helps the team grasp the design's engineering. It EL also shows how the PCB's components interact together. ▪ First, they lay out a fresh board and then install the components PT in the same order. Once constructed, the board is tested for functionality. The team will digitize test results for future study. N 1. Legacy Parts Replacement EL 2. Parts Service or Repair 3. Failure Analysis 4. 5. PT Parts Improvement Diagnostics and Problem-Solving N 1. Legacy Parts Replacement EL ▪ Legacy parts replacement requires inspecting and replicating parts of larger machinery to keep them running. PT ▪ If the machine is old, some parts may no longer be made because the OEM is out of business. N Source: all3dp.com 1. Legacy Parts Replacement EL ▪ Reverse engineering uses a 3D scanner to reproduce a damaged part's design. ▪ Depending on the component's size and complexity, PT reverse engineering could cost more than a newer model. N Source: Additivex.com 2. Parts Service or Repair EL ▪ If you need to fix or service a legacy part or a component that the OEM no longer supports, it helps to know how the product works. PT ▪ With this information, the repair can be done correctly and quickly. N 3. Failure Analysis EL ▪ Failure analysis is a way to figure out what went wrong with something. If a machine breaks down, you might have to take it apart or look at the design files to figure out what went wrong. PT ▪ Once you know this, you can fix or improve the product so that it works again as it should. N 4. Parts Improvement EL ▪ Parts can also be made better with the help of reverse engineering. ▪ If you can't find a replacement or alternative part, you can PT get the part reverse-engineered to make a copy of the original design. N 5. Diagnostics and Problem-Solving EL ▪ Reverse engineering can also be used to figure out what's wrong with an industrial process and fix it. ▪ In a ‘manufacturing system’ identifying the problem PT causing element is hard. Through reverse engineering, by knowing the working you can easily identify the faulty element. N 1. Design of a new component EL ▪ The design of a new part comes from an existing physical real part. 2. Reproduction of an existing component 3. PT ▪ Reverse engineering allows you to reproduce components with no data, designs and details. Recovery of a damaged or broken component N ▪ A reconstructed CAD model would precisely compare damage of worn out parts with the true part surface.  Scanned Data Data Compatible End Input Data EL Capture Processing Software Applications Format PT N For an ideal scanning process, the scanning procedure has been divided into five key steps: EL 1. Acquisition 2. Alignment 3. Mesh Generation PT N 4. Post Processing 5. Simplification 1. Acquisition The acquisition is the first fundamental step in which the acquired image is created in the software as a set of points. These points define a 3D representation of the part of the EL object that has been framed and hit by the light pattern generated by the projector. PT N Source: creaform3d.com 2. Alignment Alignment is the work phase, where, it is possible to bring to the same reference system (align) the Range Images (i.e. images acquired by using the scanner at different lengths EL from the object) acquired previously. a) Manual Alignment: The process is manually helped by the PT identification of three corresponding points between the two acquisitions taken into account. N b) Global Alignment: Beside the manual alignment, that works with the identification of three corresponding points, another alignment tool called 'global alignment' is also available. 3. Mesh Generation Once a sufficient number of range images has been acquired and aligned in order to create a 3D model as complete as possible, the next step is to generate a triangular Mesh. EL The Mesh generation converts a set of 3D points (Range Image) to a data constituted by a set of triangles or quadilaterals (Mesh). PT The Mesh is the first useful data that can be elaborated and exported in the available formats. N Source: https://docs.mcneel.com/rhino/7/help/en-us/commands/quadremesh.htm 3. Mesh Generation a) Adaptive Size (0-100) EL PT N Source: https://docs.mcneel.com/rhino/7/help/en-us/commands/quadremesh.htm 3. Mesh Generation b) Detect Hard Edges EL PT N Source: https://docs.mcneel.com/rhino/7/help/en-us/commands/quadremesh.htm 3. Mesh Generation c) Use Surface Edges EL PT N Source: https://docs.mcneel.com/rhino/7/help/en-us/commands/quadremesh.htm 4. Post Processing Post Processing is every operation that involves the enhancement and finishing of a mesh. Its purpose is to prepare a complete and flawless 3D model ready to be EL exported. a) Make Manifold: Solve topological issues PT b) Detect and repair intersection: Solve issues due to intersection of triangles c) Fill Holes: Fill missing data N 5. Simplification Under this process, are gathered all the steps made on the mesh that (tend to) simplify the data. EL Reduce noise on mesh: Reducing noise, imperfections from the surface.Works like a digital sandpaper Mesh Decimation: PT N Reduction of the number of mesh triangles. This operation can be done forcing a tolerance that guarantees that the decimated 3D model does not differ more than this value from the original model. ▪ Model of a physical product that needs to be redesigned or used as a starting point for a new product. EL ▪ Scan the physical model to get the points cloud. Scanners that touch or don't touch the object being scanned can be used. PT ▪ When processing the points cloud, the points cloud may be combined if the part was scanned in more than one place. The noise and outlines are gone. If there are too many points, it should be possible to pick some of them. N  ▪ Object is scanned using the 3D scanner in three different orientations EL PT N Ullah, AMM Sharif, and Akihiko Kubo. "Geometric modeling and 3D printing using recursively generated point cloud." Mathematical and Computational Applications 24.3 (2019): 83.  ▪ How does it work? EL PT N Basic point cloud of the body Solid CAD model constructed using the basic point cloud Ullah, AMM Sharif, and Akihiko Kubo. "Geometric modeling and 3D printing using recursively generated point cloud." Mathematical and Computational Applications 24.3 (2019): 83.  ▪ Solid CAD modeling EL of the ewer spout. a) Basic point cloud of the spout b) c) Point cloud of the spout injected into the solid CAD model Reference planes PT N and ellipses to construct spout d) Result of spout construction e) Solid CAD model with a hollow inside Ullah, AMM Sharif, and Akihiko Kubo. "Geometric modeling and 3D printing using recursively generated point cloud." Mathematical and Computational Applications 24.3 (2019): 83.  ▪ Solid CAD modeling of the ewer handle EL a) Point cloud of the handle b) Point cloud of the handle injected into the solid CAD model c) Reference plane and ellipse to construct the handle d) Result of handle construction PT N Ullah, AMM Sharif, and Akihiko Kubo. "Geometric modeling and 3D printing using recursively generated point cloud." Mathematical and Computational Applications 24.3 (2019): 83.  ▪ Generating surfaces from point cloud data EL ▪ Triangulation model obtained from the 3D scan point cloud data set. a) Front view b) Side view c) Top view d) Bottom view PT N Ullah, AMM Sharif, and Akihiko Kubo. "Geometric modeling and 3D printing using recursively generated point cloud." Mathematical and Computational Applications 24.3 (2019): 83.  EL PT N (a) Rendered solid CAD model; (b) triangulation model (c) 3D printed model Ullah, AMM Sharif, and Akihiko Kubo. "Geometric modeling and 3D printing using recursively generated point cloud." Mathematical and Computational Applications 24.3 (2019): 83.  ▪ A worn-out impeller is reconstructed with the reverse engineering approach. EL ▪ The impeller was placed on the scanner's rotating table. ▪ Each surface was scanned separately, and patches were made for each. ▪ The Roland Modela 4 player was used to save the surfaces and patches in the.stl format. That file was put into Rapidform software, PT Physical model N ▪ which used the.stl file format to make a solid body. ▪ The recreated 3D Solid model of the impeller was subsequently used for finite element analysis Saurabh, Jain, et al. "An integrated reverse engineering and rapid prototyping approach towards reconstruction of damaged impeller." International Journal of Industrial and Systems Engineering 23.4 (2016): 393-404. Solid model  EL ANSYS generated meshed impeller model PT Loading and boundary conditions for the rotor using ANSYS N Saurabh, Jain, et al. "An integrated reverse engineering and rapid prototyping approach towards reconstruction of damaged Deformation of impeller under static loading impeller." International Journal of Industrial and Systems Engineering 23.4 (2016): 393-404. ▪ LASER 3D SCANNERS EL ▪ The best things about laser 3D scanners are how accurate and clear they are and how affordable they are. ▪ Also, these machines can catch moving targets, and light has no effect on how well they work. ▪ Limitations PT ▪ Laser trigonometry triangulation technology can only work within a few meters. N ▪ The target's accuracy is affected if its surface is shiny or see-through. ▪ Lasers can hurt the eyes, so you can't use them on people or animals. ▪ Most 3D laser scanners stay in one place. ▪ LASER 3D SCANNERS EL PT N Source: 3dprint.com ▪ STRUCTURED LIGHT 3D SCANNERS ▪ Structured light 3D scanners use light instead of a laser. EL ▪ So, if you want to scan people or pets, they are a much safer choice. ▪ Structured light scanners are very accurate, just like laser scanners. ▪ Limitations PT ▪ Structured light scanners work best when the object being N scanned is still. ▪ Light can easily mess up the process of getting data. ▪ Structured light 3D scanners that are used for 3D printing aren't the best for use outside. ▪ STRUCTURED LIGHT 3D SCANNERS EL PT N Source: 3dnatives.com ▪ OTHER TECHNOLOGIES Time-of-flight EL ▪ The laser pulse technology is used in 3D scanners. ▪ They use lasers to accurately scan a 3D object in the same way that laser scanners do, but the technology is very different. PT ▪ It works because the exact speed of the laser light is known. ▪ The system then measures how long it takes for the laser to N reach an object and bounce back to its sensor. ▪ OTHER TECHNOLOGIES EL ▪ Phase-shift systems are used in another kind of time-of- flight 3D scanner. This method works the same way as laser pulse technology, but the power of the laser beam is also changed. PT ▪ The phase of the laser that goes out and comes back to the sensor is compared by the scanner. This makes it more N accurate than a laser pulse 3D scanner, but it makes it less adaptable for scanning at a long distance.  It is also often lawful to reverse-engineer a product or process as long as it is obtained legitimately. EL If the product is patented, it doesn't necessarily need to be reverse-engineered, as patents require a public disclosure of invention. PT The fundamental use of Reverse Engineering is to get the feel of the product, in terms of dimensional accuracy. N Justifying RE: The fundamental use of Reverse Engineering is to get the feel of the product, in terms of dimensional accuracy. EL In other words, the reverse engineering process in itself is not concerned with creating a copy or changing the artifact in some way. PT N ▪ What is Reverse engineering? ▪ Explain the Reverse Engineering process. EL ▪ Differentiate between the contact and non-contact scanners ▪ Industrial application of the Reverse Engineering. PT ▪ State the purpose of Reverse Engineering. ▪ Methodology and stages in Reverse Engineering. N N PT EL N PT EL  EL PT N Dr. Amandeep Singh Imagineering Laboratory IIT Kanpur ▪ CAD softwares EL ▪ Demonstration on CAD PT N ▪ AutoCAD EL ▪ Fusion 360 ▪ Solidworks ▪ CATIA ▪ Inventor ▪ Creo Parametric PT N ▪ FreeCAD ▪ Ansys Spaceclaim Feature Solidworks Fusion 360 EL Parametric Assembly-Oriented Multi-Component Part System Feature Complex PT Advancement Professionals Customizable Interfaces Entirely Cloud-based For Remote Teams N Usage & More Traditionally Much More Versatile Program Applications Used By Professionals Source: https://roboticsandautomationnews.co m/ Cont. Feature Solidworks Fusion 360 EL Support online materials A Number Of Free Official and learning Training Materials From resources Autodesk Final Thoughts PT Robust Simulation Packages And 3D Modeling Tools Very Intuitive Assembly Interface, Being Versatile And Friendly Enough For Different N Applications ▪ COMSOL MULTIPHYSICS EL ▪ MATLAB ▪ ANSYS ▪ Fusion 360 ▪ Inventor ▪ Solidworks PT N Source: https://www.mechanical360.net/ N PT EL  EL PT N Dr. Amandeep Singh Imagineering Laboratory IIT Kanpur ▪ Non Destructive Testing EL ▪ Contact Methods ▪ Ultrasonic Testing ▪ Eddy Current Testing ▪ Magnetic Testing ▪ Penetrant Testing ▪ Acoustic Testing ▪ Non-Contact Methods PT N ▪ Radiography Testing ▪ Thermographic Testing ▪ Visual Inspection ▪ X-Ray Computed Tomography ▪ Nondestructive testing (NDT) is the practice of looking for flaws or differences in a EL ▪ material, ▪ component, or ▪ assembly normally. PT without damaging the part's or system's capacity to function ▪ It’s inspecting, testing, or evaluating materials, components or N assemblies for discontinuities, or differences in characteristics without destroying the serviceability of the part or system. ▪ In other words, when the inspection or test is completed the part can still be used. ▪ Modern nondestructive tests are being utilised in manufacturing, fabrication, and in-service inspections to EL guarantee product integrity and dependability, ▪ to regulate manufacturing processes, ▪ to cut costs, and PT ▪ to keep output levels uniform. ▪ In-service NDT inspections are used to make sure that the products being used continue to have the integrity required to N ensure their usefulness and the safety of the general public. Test method names often refer to the type of penetrating medium or the equipment used to perform that test. EL NDT Contact Methods Ultrasonic Testing Eddy Current Testing Magnetic Testing Penetrant Testing PT N Acoustic Testing Non-Contact Methods Radiography Testing Thermographic Testing Visual Inspection Source: X-Ray Computed Tomography tuv.com N PT EL ▪ This technique is used for the detection of internal and surface defects in sound conducting materials. EL ▪ A short pulse of ultrasound is generated by means of an electric charge applied to a piezoelectric crystal PT ▪ Pulse vibrates for a very short period at a frequency related to the thickness of the crystal. ▪ Frequency range 1 MHz to 6 MHz N  EL PT N Schematic diagram of ultrasonic detection of defects Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4. ▪ Thickness and lengths up to 30 ft can be tested. EL ▪ Position, size, and type of defect can be determined. ▪ Instant test results. ▪ Portable. ▪ Extremely sensitivePT ▪ Capable of being fully automated N ▪ Access to only one side is necessary. ▪ No consumables. ▪ No permanent record available unless one of the more sophisticated test results and data collection systems is used. EL ▪ The operator can decide whether the test piece is defective or not whilst the test is in progress. PT ▪ Indications require interpretation. ▪ Considerable degree of skill necessary to obtain the fullest information from the test. N ▪ Very thin sections can prove difficult ▪ Thickness Measurement EL ▪ Delamination & Inclusions Identification ▪ Flaw detection in welds, castings and connections PT N Source: tmmarin.com ▪ Eddy currents can be produced in any electrically conducting material EL ▪ The alternating magnetic field is normally generated by passing an alternating current through a coil PT ▪ Any change in the material or geometry can be detected by the excitation coil as a change in the coil impedance. ▪ When a crack occurs in the product surface the eddy currents must travel farther around the crack. N  EL PT N Illustration of eddy current testing Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4. ▪ Faster process & little or no surface preparation needed. EL ▪ Easily automated ▪ No contact needed PT ▪ No special operator skills are needed ▪ Extremely compact and portable units are available ▪ No consumables N ▪ Flexibility in the selection of probes and test frequencies ▪ Probe size affects sensitivity EL ▪ For simple geometries ▪ Shallow depth of penetration PT ▪ Generally, tests are restricted to surface breaking conditions N ▪ Cracks & Porosity EL ▪ Defect discontinuities such as ▪ seams ▪ laps ▪ pits ▪ cracks ▪ voids PT N ▪ inclusions ▪ Material thickness measurement Source: Twiglobal.com  ▪ The principle is to generate magnetic flux in the article to be EL examined. ▪ With the flux lines running along the surface at right angles to the suspected defect. ▪ Where the flux lines approach a discontinuity, they will stray out PT N into the air at the mouth of the Principle of Magnetic Particle Inspection crack. Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4. ▪ Faster process EL ▪ Easily automated ▪ Little and no surface preparation PT ▪ Cheap and robust probes ▪ Simplicity of operation and application. ▪ Quantitative. N ▪ Restricted to ferromagnetic materials. EL ▪ Restricted to the surface or near-surface flaws. ▪ Every component needed to be tested twice PT ▪ Diagonal defects are difficult to detect N ▪ Subsurface defects ▪ Checking pipes for crack & Cast and welds EL ▪ Fully automated inspection of drive shafts ▪ Inspection of gear PT Drive shaft with material defect, N Greyscale image of the MT indication Magnetic testing of gear Source: www.ndt.net  ▪ Frequently used for the detection of surface breaking flaws in nonferromagnetic materials. EL PT N Illustration of penetrant testing Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4. ▪ Simplicity of operation EL ▪ Best method for surface breaking cracks in non-ferrous metals. ▪ Suitable for automatic testing, with reservation concerning viewing. PT ▪ Low cost and no sophisticated equipment needed ▪ Quantitative N ▪ Multiple stages in the complete process so difficult to automate EL ▪ Requirescasting conditions like suitable of the light arrangement ▪ Restricted to surface breaking defects only. PT ▪ Surface cleanliness needed. ▪ Decreased sensitivity. N ▪ Uses a considerable number of consumables. ▪ Surface crack, Porosity EL ▪ Crack detection in weld ▪ The forging surface detects like Laps and Bursts can be easily identified by performing a liquid penetrant test. PT N Source: Theconstructor.org ▪ The term acoustic emission refers to the generation of transient waves during the rapid release of energy from localized EL sources within a material. ▪ In an acoustic emission test, an inspector records elastic PT ultrasonic waves traveling through the surface of solid material using one or more sensors. ▪ As an acoustic wave travels on or through the surface of an object any defect it encounters can change that wave N  EL PT N Principle of acoustic emission testing Source: onestopndt.com ▪ It gives you a direct measure of failure mechanisms EL ▪ It is highly sensitive ▪ It provides data immediately PT ▪ It is non-destructive to the material being tested ▪ It allows for a structure to be globally monitored ▪ It can be used in hazardous environments N ▪ It can be done remotely and can detect defects in materials that might be hard to test using other NDT methods ▪ Its usefulness is generally limited to locating a defect, not describing it in detail EL ▪ It cannot detect defects that do not change over time ▪ It can be slow to implement PT ▪ It can be hard to use N ▪ Acoustic emission is commonly used to test for EL ▪ cracking ▪ corrosion ▪ delamination ▪ breakages. PT ▪ Airplane longevity estimation ▪ Bridge inspections N ▪ Concrete corrosion monitoring ▪ Mine wall stability inspections ▪ Pressure vessel inspections ▪ Structural integrity inspections Source: Wikipedia.org ▪ Wind turbine inspections N PT EL ▪ Non Destructive Testing EL ▪ Non-Contact Methods ▪ Radiography Testing ▪ Thermographic Testing PT ▪ Visual Inspection ▪ X-Ray Computed Tomography N  ▪ This technique is suitable for the detection of internal defects within EL the volume of the examined part. ▪ The source of radiation can be either an X-ray tube or a radioactive isotope. ▪ Radiation from X-rays and Gamma rays differentially absorbed by the material through which it passes. PT N Schematic illustration of a typical exposure arrangement for radiography Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4. ▪ Information is presented pictorially. EL ▪ A permanent record is provided which may be viewed at a time and place distant from the test. ▪ Useful for thin sections. PT ▪ Sensitivity declared on each film. ▪ Suitable for any material. N ▪ Generally, an inability to cope with thick sections. EL ▪ Possible health hazard. ▪ Need to direct the beam accurately for two-dimensional defects. exposure compound.PT ▪ Film processing and viewing facilities are necessary, as is an ▪ Not suitable for automation, unless the system incorporates N fluoroscopy with an image intensifier or other electronic aids ▪ Not suitable for surface defects. ▪ No indication of the depth of a defect below the surface  ▪ Detect deep or embedded defects ▪ For detection of porosity, defects in casting, and lack of fusion in welding. EL ▪ For measurement of geometry variation and thickness of the component. PT N Yang, J.; Li, S.; Wang, Z.; Dong, H.; Wang, J.; Tang, S. Using Deep Learning to Detect Defects in Manufacturing: A Comprehensive Survey and Current Challenges. Materials 2020, 13, 5755.  EL PT N Radiographic weld inspections Pipe inspection using digital radiography Source: vidisco.com atslab.com ▪ Detects radiation in the infrared range of the electromagnetic spectrum and produce images of that radiation called EL thermograms. ▪ Performed using an infrared sensor PT N Thermal inspection Source: photonics.com ▪ Large areas can be scanned fast EL ▪ No downtime or production interruptions for testing ▪ Requires no contact with components or machines ▪ Real-time output PT ▪ Easy-to-read visual images ▪ Does not emit any radiation N ▪ Affected by weather conditions EL ▪ Expensive ▪ Infrared technology can’t detect temperature if a component is separated by a non-transparent material such as a glass cover. PT ▪ Penetration is possible only for a few mm’s ▪ Infrared data requires significant expertise and an extensive knowledge base to evaluate imaging results N ▪ Detection of near-surface defects EL ▪ Rolling element bearing fault detection ▪ Electrical Wiring maintenance ▪ Infrared imaging is widely used in industries to detect gas leaks PT N Source: Theconstructor.org ▪ To detect surface defects by naked eye. ▪ Particularly effective in detecting EL macroscopic flaws, such as poor welds, improper surface finish, large cracks, cavities etc. PT ▪ Normally applied without the use of any additional equipment ▪ VT can be improved by using aids such N as a boroscope to improve its effectiveness and scope. Visual inspection Source: indsutriallndt.com  EL PT N Principle of the visual inspection system for monitoring of the powder layer top surface. Craeghs, Tom & Clijsters, Stijn & Yasa, Evren & Kruth, Jean-Pierre. (2011). Online quality control of selective laser melting. 22nd Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2011. ▪ Faster process EL ▪ Applicable at all stages of construction or manufacturing ▪ Modest skills required ▪ Low cost PT N ▪ Lighting requirements EL ▪ Superficial ▪ Only for surface defects PT ▪ High interpretation skills needed ▪ The use of optical aids is often required to monitor AM processes N  ▪ Inspection of newly manufactured components EL ▪ Condition monitoring during service PT N Source: single-peak.com ▪ Examining the critical aero-engine components like: ▪ turbine shafts EL ▪ blades ▪ intermediate casing ▪ oil tank etc. PT N Source: single-peak.com ▪ Computed tomography or CT, refers to a computerized x-ray imaging procedure EL ▪ Works on the principle of ▪ irradiating a sample with a beam of X-rays, PT ▪ measuring the subsequent absorption X-ray image, and ▪ repeatedly acquiring such images as the sample rotates. ▪ The X-ray absorption images represent views of the sample N from many angles, providing internal detail due to the penetration of X-rays.  EL PT N Withers, P.J., Bouman, C., Carmignato, S. et al. X-ray computed tomography. Nat Rev Methods Primers 1, 18 (2021)  EL PT N Schematic of an X-ray microCT scan Du Plessis, Anton, et al. "X-ray microcomputed tomography in additive manufacturing: a review of the current technology and applications." 3D Printing and Additive Manufacturing 5.3 (2018): 227-247. ▪ The CT technique eliminates the superimposition of images of undesired structures completely. EL ▪ Multiplanar reformatted imaging is possible due to multiple contiguous or single helical scans. PT ▪ It provides more detail compared to ultrasonography. ▪ It is quicker, cheaper, and superior to MRI scanning. ▪ Motion artifacts are of less concern in CT scans than in MRI. N ▪ It is time-consuming. EL ▪ It is expensive for routine clinical use. ▪ The operator is exposed to higher radiation. PT ▪ There is a risk of ionizing radiation and iodinated contrast agents. N  1. Porosity and defect analysis 2. Surface roughness or topography EL PT N Transparent view of the porosity Surface roughness/topography analysis of analysis in 3D AM part on a cylindrical geometry Du Plessis, Anton, et al. "X-ray microcomputed tomography in additive manufacturing: a review of the current technology and applications." 3D Printing and Additive Manufacturing 5.3 (2018): 227-247. ▪ How has X-ray computed tomography brought advances to industrial design? EL ▪ How can we improve limitations of visual testing? ▪ How can we increase the scope and utilities of Radiographic testing? PT ▪ How has ultrasonic testing been revolutionary in field of metal additive manufacturing? N ▪ How can we broaden domain of eddy current testing in terms of testing complex geometries? ▪ How can we remove constraints of on surface testing in penetrant testing? EL ▪ How can we bring down costs of thermographic testing? ▪ Why is acoustic testing difficult to use and how can we PT eliminate requirements of extreme sensitivity? ▪ How can we reduce trials of testing in magnetic testing? N N PT EL  EL PT N Dr. Amandeep Singh Imagineering Laboratory IIT Kanpur ▪ Introduction to Sustainability EL ▪ Sustainable impact evaluation ▪ Sustainable design approaches PT ▪ Lean & Green Business Model ▪ Design quality and sustainability ▪ Sustainable design methodology for AM N ▪ Design guidelines and design rules ▪ AM and sustainability in industry 1. The concept of needs, in particular the essential needs EL of the world’s poor, to whom overriding priority should be given. 2. The idea of limitations imposed by the state of PT technology and social organization on the environment’s ability to meet present and future needs N  EL PT N Growth of additive manufacturing Wohlers Report (2013) Additive manufacturing and 3D printing state of the industry annual worldwide progress report. ISBN 0-9754429-9-6 ▪ Sustainability enables humans and nature to live in a way that meets the social, economic, and other requirements of present EL and future generations. ▪ It is critical to apply eco-design principles and develop ▪ Additive PT greener products and production processes manufacturing has the capability of producing components with the lowest amount of raw material. N  EL PT N Source: https://www.frontiersin.org ▪ Additive manufacturing is an innovative and environmentally EL friendly approach to make parts. less PT ▪ Consumes less resources and has emissions conventional machining. than N Rogers, Peter P., Kazi F. Jalal, and John A. Boyd. An introduction to sustainable development. Routledge, 2012. ▪ Supply chain efficiency and raw material reduction. EL ▪ Reduced need to mine and process natural ores. ▪ Replacing energy-inefficient and wasteful manufacturing techniques like casting or CNC machining that uses cutting fluids. PT N Source: https://www.frontiersin.org ▪ Ability to design more efficient goods by adding conformal cooling, heating, and gas flow routes, etc. EL ▪ Carbon footprint reduction ▪ Lighter parts in aircraft boost fuel efficiency and minimize carbon emissions. PT N Source: https://www.frontiersin.org Additive manufacturing also presents some sustainability disadvantages. EL ▪ Some techniques require support structures that are removed after each part is made ▪ AM machines need a controlled environment without excessive PT heat and humidity for both machine and raw material ▪ Some machines require pre-heated and air-controlled building chambers N ▪ Some machines also require energy for processing raw materials, such as lasers.  EL PT N Source: Rogers, Peter P., Kazi F. Jalal, and John A. Boyd. An introduction to sustainable development. Routledge, 2012. Eco-design EL ▪ Eco-design incorporates environmental considerations into products to reduce their PT environmental impact. ▪ Eco-design displays itself in real-world applications using low-impact materials throughout N the manufacture. Source: http://www.oree.org/en/eco-design-platform.html ▪ Sustainable design includes economic imperatives, ethics, and other socioeconomic sustainability factors EL ▪ Applies ecological principles as design approaches, striving for ‘triple bottom-line’ solutions. PT N Source: https://www.bth.se/eng 1. Cyclic: Organic, recyclable, compostable materials should be used EL 2. Solar: Solar or renewable energy should be used during manufacture and product use. 3. 4. ecosystems. PT Safe: Manufacture, usage, and disposal should not harm Efficient: The product should consume 90% less material, N energy, and water than a 1990s equivalent. 5. Social: The manufacture and use of a product should not impact on basic human rights or natural justice.  EL PT N Source: https://www.biothinking.com/btintro.htm ▪ The Sustainability Principles include a stronger notion of social sustainability. ▪ In a sustainable society, nature is not subject to systematically EL increasing: ▪ Concentrations of substances extracted from the Earth’s crust ▪ Concentrations of substances produced by society PT ▪ Degradation by physical means N Rogers, Peter P., Kazi F. Jalal, and John A. Boyd. An introduction to sustainable development. Routledge, 2012.  L & GBM Operations EL Lean Green Sustainability PT N  EL PT N Source: Pampanelli, A.B., Found, P. and Bernardes, A.M., 2015. Sustainable manufacturing: The lean and green business model. In Sustainable operations management (pp. 131-161). Springer 1. Define EL 2. Identify 3. Make 4. 5. Let Pursue PT N  L&GBM MODEL PRINCIPLES 1. Identify a stable value stream EL (VS) 2. Identify the environmental impact (E) PT 3. Measure the environmental value streams (EVS) N 4. Improve the environmental value streams (EVS) 5. Continuous Improvement (CI) Source: Pampanelli, A.B., Found, P. and Bernardes, A.M., 2015. Sustainable manufacturing: The lean and green business model. In Sustainable operations management (pp. 131-161). Springer ▪ It is aligned to business strategy (environment is key) EL ▪ It recreates the concept of cleaner production ▪ It improves the use of resources PT ▪ It is an alternative for pollution prevention N ▪ It needs management support EL ▪ It needs resources ▪ It needs implementers PT ▪ It needs experts to direct and guide N LEAN AND GREEN MODEL BENEFITS ▪ Education on Lean tools EL ▪ Standardize process for production ▪ Team building from event PT ▪ Roll out to other sites ▪ Ease Capital approval using ▪ Lean and Green N ▪ Implementation process—time EL ▪ Impact on quality/throughput ▪ Capital expenditure required PT ▪ Time and resources N MASS AND ENERGY FLOW ANALYSIS EL PT N Rogers, Peter P., Kazi F. Jalal, and John A. Boyd. An introduction to sustainable development. Routledge, 2012. ▪ Circular Economy is a sustainable growth paradigm that strives to revolutionise how societies create, manufacture, and consume goods and services. EL ▪ Emerging technologies are transforming global value chains. AI/ML, robotics, IoT, bioelectrochemical engineering, sharing platforms, etc. play a crucial role in enabling circular business models. PT N Source: worldbank.org/content/circular-economy-and-emerging-technologies ▪ Circular Economy business models enhance sustainability by: ▪ increasing efficiencies and reducing waste; EL ▪ driving innovation by allowing new entrants in the markets ▪ increasing information transparency across companies ▪ enabling to shun the traditional materials PT N Source: worldbank.org/content/circular-economy-and-emerging-technologies The five circular business models are: ▪ Circular Supplies EL ▪ Resource Recovery ▪ Product Life Extension ▪ Sharing Platform PT ▪ Product as a Service N Rogers, Peter P., Kazi F. Jalal, and John A. Boyd. An introduction to sustainable development. Routledge, 2012. ▪ Design quality affects a product's longevity from a sustainable product perspective EL ▪ A highly desirable object have long life and less negative impact on the environment PT ▪ A well-designed object is more sustainable and have more value N  ▪ Additive manufacturing of a titanium bottle opener saved 90% of the material compared to CNC machining because of the EL component's intricacy. ▪ It was made of titanium 64 utilizing selective laser melting to remove as much material as feasible while keeping mechanical properties. PT N Additively manufactured titanium bottle opener S.S. Muthu and M.M. Savalani (eds.), Handbook of Sustainability in Additive Manufacturing, Environmental Footprints and Eco-design of Products and Processes ▪ AM provides quantifiable sustainability benefits. Material use is one. EL ▪ After a simple sieving operation, most unmelted powder from metal AM can be reused PT ▪ Compared to normal manufacturing, waste is minimal N General Design Flow EL The whole design workflow can be divided into four stages 1. Functional design 2. Design optimization PT 3. Design refinement 4. Environmental impact evaluation N N PT EL ▪ A functional specification drives this design stage EL ▪ Functional specifications define a product's overall functions and input/output qualities ▪ Designers can summarize the interaction between developed PT items and external agents based on the functional specification ▪ A generic black box model can be used to represent the input functional specification N  ▪ Physical entities can be optimized to reduce environmental impact and improve product performance EL ▪ Multiscale AM-enabled design optimization methods consider the environmental impact model's pre-feedback PT N Rogers, Peter P., Kazi F. Jalal, and John A. Boyd. An introduction to sustainable development. Routledge, 2012.  EL PT N General workflow of optimization process S.S. Muthu and M.M. Savalani (eds.), Handbook of Sustainability in Additive Manufacturing, Environmental Footprints and Eco-design of Products and Processes ▪ A design refinement procedure is needed to modify some optimized product design details due to the second design EL stage's coarse or irregular boundaries ▪ Material is eliminated where relative density is below the threshold PT N This general flow can be divided into three main steps EL ▪ Energy and material consumption analysis PT ▪ Life Cycle Inventory ▪ Life Cycle Impact Analysis compilation N Source: https://ecochain.com ▪ LCIA provides additional information to assess life cycle inventory (LCI) results. EL ▪ It help users better understand the environmental significance of natural resource use and environmental releases PT N ▪ Use the advantages that are included in RM processes ▪ Do not build the same parts designed for conventional manufacturing EL processes ▪ Do not consider traditional mechanical design principles PT ▪ Reduce the number of parts in the assembly by intelligent integration of functions N The four stages of the product life cycle: EL 1. Product and process design 2. Material input processing 3. Make-to-order component and product manufacturing PT 4. Closing the loop N Source: https://www.business-to-you.com/product-life-cycle  EL PT N Ford, Simon, and Mélanie Despeisse. "Additive manufacturing and sustainability: an exploratory study of the advantages and challenges." Journal of cleaner Production 137 (2016): 1573-1587. ▪ Material and energy savings in the production of high value products EL ▪ Improved product functionality and efficiency in use ▪ Lower energy intensity and waste avoidance in the manufacturing process PT N Challenges: EL ▪ Educating manufacturers about the potential uses and benefits of AM ▪ Implementation of distributed maintenance system PT ▪ Certification of new components ▪ Capturing and replicating learning in future applications N ▪ Limited and uncertain performance due to low maturity of the technology for large-scale structures ▪ Requirement for standards and regulations Material input processing: EL ▪ Process reactants are non-toxic and can be recycled locally ▪ Localised material recycling PT ▪ Input recycled materials are from larger-scale recycling systems, potentially more efficient than local recycling systems ▪ Diversion of by-product from waste stream N Source: https://ecochain.com Material input processing: EL ▪ Material and process standardization ▪ Process scale-up for new materials PT ▪ Possibility of material contamination ▪ Limited material options ▪ Limited recyclability of product at its end-of-life due to mixed N materials Material input processing: EL PT N Manufacturing: EL ▪ Increased access to digital designs for spare parts ▪ More localised manufacturing PT ▪ Less high-value waste generated ▪ Raised awareness of manufacturing process and its impacts ▪ Improved access to equipment N ▪ Increased equipment utilization ▪ More localized production through proximity of producer to customer Manufacturing: EL PT N Challenges at manufacturing stage: EL ▪ Limited availability of digital designs ▪ Cost of acquiring new digital designs PT ▪ Limited functionality and utility ▪ Reliability and quality of 3D printing process ▪ Encourages materialistic society and consumerism N ▪ Services are currently fragmented and unevenly distributed ▪ Majority of services are lower-end consumer 3D printers End-of-life strategies: EL ▪ Small and simple equipment, quick and easy to use as mobile or small-scale recycling station ▪ In-situ recycling of common waste from everyday products and packaging PT ▪ Improved product utilization ▪ Reduced material consumption N ▪ Designed for longevity ▪ Automated processes, all process steps integrated into one ▪ Remanufacturing and repair of high value components at low cost Challenges: EL ▪ Limits on recyclability of material due to quality loss ▪ Educating consumers about recycling 3D printed material PT ▪ Replication of business model to other sectors ▪ Limited integration of AM with other techniques in design and production N ▪ Required mindset shift for designers and engineers ▪ How do we measure sustainable impact evaluation? ▪ Explain the sustainable design approach. EL ▪ Differentiate between Lean & Green business models. ▪ How is design quality retained in sustainable manufacturing? PT ▪ Elaborate ‘Sustainable design methodology for AM’ ▪ List the design guidelines and rules. N ▪ Write down the characteristics of sustainability in metal additive industry. N PT EL  EL PT N Dr. Amandeep Singh Imagineering Laboratory IIT Kanpur ▪ Optimize for printing EL ▪ Optimize for washing ▪ Optimize for sintering PT ▪ General strategies N  EL Identify Critical Dimensions PT N Maximize Bed Contact Source: https://markforged.com/3d-printers/metal-x  EL Reduce Supports PT N Optimize Your Production Workflow Source: https://markforged.com/3d-printers/metal-x Eliminates Supports Simplify Support Removal EL PT N Source: https://markforged.com/3d-printers/metal-x Shell Out Thick Parts EL PT Wash Bowls Upside Down N Source: https://markforged.com/3d-printers/metal-x Solid triangular infill wash time EL PT N Solid triangular infill dry time Source: https://markforged.com/3d-printers/metal-x Reduce Stress Concentrations EL PT Ensure Features are Well Balanced N Disable Part Rafts Source: https://markforged.com/3d-printers/metal-x Use Pins for Alignment Features EL PT N Separate Printed from Simple Features Source: https://markforged.com/3d-printers/metal-x Isolate Properties with Modular Features EL PT N Source: https://markforged.com/3d-printers/metal-x  EL PT N Source: https://markforged.com/3d-printers/metal-x N PT EL  EL PT N Dr. Amandeep Singh Imagineering Laboratory IIT Kanpur ▪ Potential Hazards of Additive Manufacturing EL ▪ High Energy Density Sources ▪ High Voltage ▪ Chemical Hazards ▪ Power Hazards PT ▪ Safety Analysis Methods N ▪ The safety aspects in additive EL manufacturing are among the most crucial elements that need to be carefully considered. To create a space that is productive for everyone, a safe outlook is crucial. PT ▪ Therefore, it is essential to be aware of the dangers to health and safety prior to an N accident and to take action to reduce or eliminate those risks. Source: Markal.com  EL Hazards in AM High Energy Sources PT High Voltage Chemical Hazards Metal Powders N Laser and electron beams are the two high energy density sources EL most frequently used in additive manufacturing. A) Laser: a) The American National Standards Institute (ANSI) created a PT series of standards called ANSI 2136. b) The Maximum Permissible Exposure (MPE) is the maximum amount of laser radiation to which a person may be exposed. N c) The specifics of different EL standards are displayed without risk or negative biological effects on the skin or eyes. PT d) The list of MPE values for the eye and skin with regard to laser wavelength and likely laser exposure period is N provided in ANSI Z136. Source: Wikipedia.org  Standard General description ANSI Z136.1 Provides direction to industry, military, research and EL Safe use of lasers development (labs), and higher education (universities). ANSI Z136.4 Provides regulation for measurement techniques required Recommended laser for the classification and assessment of optical radiation safety evaluations ANSI Z136.5 Safe use of lasers in educational institutions PT risks. settings. Addresses laser safety concerns in educational institutions N ANSI Z136.9 Intended to protect individuals with laser exposure Safe use of lasers in manufacturing environments. The standard contains manufacturing industries. rules and actions to ensure laser safety in public environment and private ▪ An expert does the NHZ calculation, typically a Laser Safety EL Officer (LSO). ▪ The following relationships are indicative of a dangerous laser: a) For continuous wave laser : PT 𝐿𝑎𝑠𝑒𝑟 𝑂𝑢𝑡𝑝𝑢𝑡 (𝑊) 𝐿𝑖𝑚𝑖𝑡𝑖𝑛𝑔 𝐴𝑝𝑒𝑟𝑡𝑢𝑟𝑒 (𝑐𝑚2 ) > MPE N b) For single pulse lasers: 𝐿𝑎𝑠𝑒𝑟𝐸𝑛𝑒𝑟𝑔𝑦 𝑂𝑢𝑡𝑝𝑢𝑡 (𝐽) > MPE 𝐿𝑖𝑚𝑖𝑡𝑖𝑛𝑔 𝐴𝑝𝑒𝑟𝑡𝑢𝑟𝑒 (𝑐𝑚2 ) A) Ocular effect: Since the capacity of light to enter through ocular EL components in the eye varies with the light's wavelength, the ocular effect of laser exposure is explained with reference to the wavelength of the laser beam. The numerous eye parts are shown in figure. PT N Source: biology.com  EL Optical Wavelength Effect Hazard Band light (100-400 nm) Ultraviolet Light (100-400 nm) Ultraviolet A 315-400 nm Can penetrate the aqueous humour and Cataract absorb on the eye lens Ultraviolet B Ultraviolet C 280-315 nm 100-280 nm PT Can get absorbed on the cornea and aqueous humour. Cannot penetrate to the iris or eye lens Can get absorbed on the cornea and Photokeratitis (welder's flash) and erythema (reddening) - N aqueous humour Cannot penetrate to the iris or eye lens  EL Optical Wavelength Effect Hazard Band light (100-400 nm) Visible light (400-780 nm) Visible light 400-780 nm Highly penetrating and absorbs Irradiance above 10 W cm-2 primarily on the eye retina can result in tissue damage Infrared A Infrared B Infrared C 780 nm-1400 nm 1400 nm-3000 nm 3000 nm-1 mm PT Infrared light (780 nm-1 mm) Similar to visible light Will not enter past the lens Absorbs mainly on the cornea Affects the retina Causes cataract Can result in burning, if N irradiance is high  EL PT N Source: prolite.co.uk B) Skin effects: The laser with different wavelength has a EL different depth of penetration. The depth of penetration of radiation in human skin varies with wavelength: Ultraviolet-B Infrared-A PT Ultraviolet-C Ultraviolet-A Visible Infrared-B Infrared-C N Outer Skin Dermis Tissue Source: prolite.co.uk  EL ▪ Ultraviolet C and Infrared C – Absorbed by the outer and dead skin layers, which can result in burning ▪ Ultraviolet B and Infrared B – Penetrate fairly deeper into the PT living skin tissue ▪ Ultraviolet A and Infrared A – Penetrate even deeper into the skin N ▪ Visible light – Penetrates to the deepest skin layer  Classification of lasers EL Class Type and General Description of laser in the class Class 1 A laser not capable to produce radiation levels which can cause damage. Class 2 A visible laser (wavelength: 400-700 nm) which cannot surpass the maximum Class 3a Class 3b PT permissible exposure for ocular exposure time less than 0.25 s. A laser whose output is less than 5 times the ocular maximum permissible exposure. A laser whose output is more than 5 times the ocular maximum permissible exposure but which: N a) cannot exceed an average radiant power greater than 0.5 W for 0.25 s or longer b) cannot produce radiant energy greater than 0.125 J for exposure times less than 0.25 s Class 4 A laser with output more than the limits for Class 3b lasers  ▪ The penetration results in a different effect on skin, based on the laser intensity. The effect of laser light is presented below: EL Effect Reason Damage Depends on First degree of burn, if Rate of energy absorption exceeds the irradiance >12 W cm-2 Thermal effects heat transfer rate that the tissue can Burning Second degree of burn, if Photochemical effects PT handle in the exposed volume Induced chemical reactions in tissue from the absorption of ultraviolet Burning irradiance > 24 W cm-2 Third degree of burn, if irradiance > 34 W cm² Amount of energy absorbed in a given volume of tissue N radiation Net dose of radiation received and whether the Delayed effects Due to the absorption of ultraviolet Skin Cancer exposure is acute (short radiation which can cause mutation in the period) or chronic (long DNA of living cells period)  EL Control Measures Engineering PT Control Measures Personal Control Measures Administrative Control Measures N  Control What is it? Purpose measure EL Remote The electrical connection Automatically triggers a warning light or interlock between the power supply audible signal every time the laser is connector and an exterior device energized, or automatically turns off the laser, if (pressure switch, light or the sensor at the entryway is triggered PT audible alarm) Beam stop or To stop or weaken the laser To instantly stop laser or when a lower beam attenuator beam at the exit port or irradiance or radiant exposure is desired To somewhere along the beam stop the beam after its useful path path using a mechanical N shutter or other devices Activation A light, a loud alarm, a To make people aware before startup of the warning system distinctive sound from laser laser To remind people to stand away from the auxiliary equipment or an direct laser beam and wear safety goggles oral countdown  EL Control What is it? Purpose measure Remote firing Use of a booth or barrier that Permits firing and observing the laser from a and monitoring interrupts between the laser location without exposure to direct, reflected or control panel and all scattered radiation above the maximum Warning signs/labels PT probable laser beam pathways Cautioning symbols and tags for lasers and laser systems permissible expo- sure limit for the eyes and skin Notify laser hazard in the area Specify the particular rule in effect relative to laser controls N Display the seriousness of hazard present (e.g. class of laser, nominal hazard zone identification) Offer directions for the usage of laser goggles and risk prevention  EL Control measure What is it? Purpose Diffuse reflective material Equipment and components that produce Reduces the hazard to only diffuse reflections personnel Panic button Large red mushroom-shaped knob Enables the instant shutdown of connected to the laser power supply a laser in case of an emergency Entryway controls Beam path control PT Doors and barriers that are interlocked and Stop people from exposure to not interlocked to the laser power supply unsafe levels of the laser zone Use of a mechanically stable, optical table Decrease the nominal hazard Careful placement of optical components to around the laser N confirm that the beam path is clear. Keeping the beam path above or below eye level covers, etc.  EL Control measure What is it? Purpose Exhaust ventilation Usage of screens, curtains, Eradicates air contaminates window Canopy hoods and created by the laser interaction enclosing hood with the target material Personal Control Measures Protective eyewear PTGoggles, face shields, spectacles and prescription filters or reflective coating Weakens the laser radiation below the level ocu- lar maximum permissible exposure (Continued) N  Control What is it? Purpose EL measure Skin protection Fresh shields, laboratory coats and cotton Safeguards the skin from gloves ultraviolet radiation to prevent skin cancer Security and access PT Administrative control Measures Control over keys to entryway doors Control over keys and passwords for energizing the laser Area monitoring by security personal, cam- eras, etc. Avoid the risk of exposure to laser radiation and authorized entry N Training Training may include the following topics: To ensure that persons are Basics of laser and laser operation aware of the hazards Biological effects of laser radiation associated with the use of the Varieties of threats and control methods laser or the hazards involved Location-specific actions Duties and in working in the laser- responsibilities of personnel controlled area  Control measure What is it? Purpose EL Administrative control Measures Standard operating Step-by-step directions including For operating the laser in a procedures laser-specific common precautions safe and controlled manner and definite guidelines of the laser system Maintenance and Tasks indicated in the operating or For daily upkeep of the service procedures Emergency procedures PT maintenance manual Instantaneous actions during an emergency, like turn of laser, call fire and safety, run in case of fire accident, like To reduce the effects fire, explosion, release of toxic gas, or serious injury to N personnel  EL Electron beam: The various potential hazards during electron beam additive manufacturing arc the following: A. X-Ray generation: PT ▪ When the electron beam collides with a solid or gas, X-rays are produced. The majority of X-rays produced during electron beam additive manufacturing occur when the electron beam N collides with the powder or substrate surface.  EL PT N Source: ehs.usc.edu  EL B) Visible radiation: ▪ The melt pool is produced through the interaction of the electron beam with the PT powder or substrate surface. The melt pool of molten metal in the electron beam additive manufacturing process is what emits the light. The eyesight is N harmed by the direct observation of this light. Source: ehs.lbl.gov C) Vacuum: EL As high vacuum is necessary for electron beam systems to operate smoothly, implosion and the potential risks of flying glass, chemical splatter, and fire can occur. PT N ▪ Electrical shock risk exists when EL exposed to electrical components with a voltage greater than 50V. ▪ During installation, maintenance, internal malfunction. PT modification, or repair, there is a chance that the power supply or components will N ▪ The magnitudes vary depending on the extent of the exposure, but in the worst case, it might result in electrocution death. Source: verywellhealth.com The following are some of the control measures: EL ▪ Ground all the equipment properly. ▪ Insulate and safeguard the electrical terminals. wires. PT ▪ Utilize a barrier mechanism to prevent contact with electrified ▪ Verify sure the electrical warning tags and signals are firmly in N place and clearly visible. ▪ Make sure the "power-up" warning lights are clearly visible.  EL PT N Source: matsusada.com The sources of chemical hazards can be classified as follows: EL A) Compressed gases: ▪ In additive manufacturing systems, a variety of gases with PT varying toxicity and dangers are used. The safety control measures used with compressed gases include the following: N ▪ Separation of personnel and the gas cylinder. ▪ When not in use, the gas cylinder should be stored properly (capped, supported, ventilated enclosure. segregated). ▪ A method for closing the gas line off and purging it after usage. ▪ Proper identification of the cylinder. ▪ Location gas detection The sources of chemical hazards can be classified as follows: B) Fumes and gases EL a) Metal fumes: ▪ Metal fume fever is brought on by the metal vapours (like influenza).PT produced during metal additive manufacturing techniques ▪ The symptoms include a metallic or sweet taste, chills, thirst, N fever, soreness in the chest, exhaustion, gastrointestinal pain, headache, nausea, and vomiting. ▪ It develops after many hours of exposure. ▪ Typically, within 1-3 days of exposure, the symptoms go away completely. b) Exposure to ozone: EL ▪ Ozone is produced when metal additive manufacturing methods are exposed. ▪ Mucus PT secretion, headaches, fatigue, eye and respiratory tract irritation, and inflammation N are all side effects. ▪ Even pulmonary bleeding is possible in high-risk situations. Source: thebiocleanteam.com c) Exposure to nitrogen oxides: EL Nitrogen dioxide fumes ▪ Ozone and nitrogen oxides both have impacts on the respiratory system. ▪ Nitrogen oxide PT inhalation does necessarily cause ozone to become immediately irritated. not N ▪ Some hours after the exposure ends, it could lead to an excessive buildup of fluid in the lung tissues (pulmonary edema). Source: issr.edu.kh C) Hazardous compounds: EL ▪ The basic components used in polymer additive manufacturing techniques are transformed into hazardous by-products. PT ▪ For instance, acrylonitrile is one of the main breakdown products in the production of acrylonitrile butadiene styrene polymer. N ▪ Styrene and I,3-butadiene react at a temperature between 160 and 180° C.  EL Category Potential Hazards Material Extrusion Inhalation exposure to volatile organic compounds, particulate, additives and burns Powder bed fusion Inhalation/dermal exposure to powder, fume, explosion, laser PT exposure Vat photo-polymerisation Inhalation to volatile organic compounds, dermal exposure to resins, soivents, ultraviolet soivents, ultraviolet exposure Material jetting Inhalation to volatile organic compounds, dermal exposure to N resins, exposure to volatile organic com- Binder jetting Inhalation/dermal exposure to powder explosion, inhalation laser, radiation exposure pounds, dermal exposure to binders Sheet lamination Inhalation of fumes, volatile organic compounds, shock, In directed energy hazards based on specialized and binder jetting based additive manufacturing processes, the powder is EL employed as a feedstock material. Some of the major health issues associated with exposure to powder are as follows: discomfort. PT 1. Inhalation: Inhalation may cause upper respiratory tract 2. Consumption: Consuming metal powder might cause N gastrointestinal tract discomfort. 3. Skin contact: Skin-to-skin contact may cause mechanical itchiness or an allergic skin reaction. 4. Eye-contact: Contact with the eyes may irritate. The following description of first aid EL measures are to be followed: 1. Inhalation: ▪ If inhaled, the victim should be air. PT escorted outside to get some fresh ▪ In the absence of a pulse or N respiration, administer cardiopulmonary resuscitation. ▪ Breathing is challenging, oxygen needs to be given. Source: jncasr.ac.in 2. Ingestion: EL ▪ Inducing vomiting is not advised. ▪ After cleaning your mouth, drink a lot of water. ▪ If PT discomfort develops, seek medical attention. N Source: jncasr.ac.in 3. Skin contact: EL ▪ Remove contaminated clothing, shoes and jewellery and wash before reuse. ▪ Wash skin with soap and water for PT several minutes. ▪ Get medical attention, if irritation develops or persists. N Source: seton.com 4. Eye contact: EL ▪ Do not rub the eye. Avoid contaminating unaffected eye. ▪ Make sure to remove any contact PT lenses from the eyes. ▪ Rinse with a gentle stream of water or saline for at least 15 min. N Source: seton.com The various precautions that need to be taken for handling and storage of powder are the following: EL 1. Handling: ▪ During handling, avoid the formation of dust clouds, use personal protection properly when handling powders and 2. PT confirm dust ventilation during handling. Storage precautions: ▪ It should be locked and kept out of reach of children. N ▪ It should be prevented from contacting with incompatible materials, like moisture, flames, etc. ▪ The powder should be kept in the original container in a well-ventilated and fresh place.  Control Measures Engineering Sufficient ventilation should be provided, which includes appropriate EL measures local extraction, to confirm that the defined occupational exposure