Interest in additive manufacturing, commonly referred to as 3D printing, is rapidly growing both in theory and practice. Engineers and engineering firms are increasingly turning to 3D printing to create prototypes of products before proceeding with full-scale production. In academic environments, professors, researchers, and students are leveraging the capabilities of 3D printing to enhance project outcomes. This newly revised handbook is specifically tailored to focus on product design within the defense industry, a sector that significantly influences a wide range of other industries.
Additive Manufacturing Handbook: Product Development for the Defense Industry, Second Edition covers the impact and potential of 3D printing in enhancing defense capabilities through updated and detailed case examples. It provides a comprehensive and research-driven overview of 3D printing, with new chapters that fit within the systems engineering framework of product development. This new edition demonstrates how 3D printing technology can improve supply chains, ultimately leading to increased military responsiveness. Readers will find insightful examples and detailed chapters on the innovative process of military product prototyping. Also covered is a variety of topics including environmental issues, manufacturing design, challenges related to learning and forgetting, and applications of military biomedical technology.
The content has been fully revised to meet the demands of businesses, industries, and government entities.
Interest in additive manufacturing, commonly referred to as 3D printing, is rapidly growing both in theory and practice. This newly revised handbook is specifically tailored to focus on product design within the defense industry, a sector that significantly influences a wide range of other industries.
Section I: General Introduction.
1. From Traditional Manufacturing to
Additive Manufacturing.
2. Basic Guide to 3D Printing.
3. Project Management
for Additive Manufacturing.
4. 3D-Printing Impacts on Systems Engineering in
Defense Industry.
5. Systems Engineering in 3D Printing Design.
6. Additive
Manufacturing Software Tools.
7. Additive Manufacturing R&D .
8. Operational
and Regulatory Gaps.
9. Additive Manufacturing Implications for Military
Ethics.10. Additive Manufacturing Technologies Trends.
11. A New Global
Approach to Design for Additive Manufacturing.
12. Methodological Framework
for Design for Additive Manufacturing . Section II: Research & Development.
13. Development and Implementation of Metals Additive Manufacturing.
14.
Selective Laser Melting (SLM) of Ni-based Superalloys: A Mechanics of
Materials Review.
15. Powder Bed Fusion Technology.
16. Additive
Manufacturing of Titanium Alloys.
17. Ultrasonic Additive Manufacturing.
18.
Printing Components for Reciprocating Engine Applications.
19. Developing
Practical Additive Manufacturing Design Methods.
20. Optical Diagnostics for
Real-Time Monitoring and Feedback.
21. 3D Printed Structures for Nano-Scale
Research.
22. Additive Manufacturing at the Micron Scale.
23. Computer
Modeling of Sol-Gel Thin Film Deposition Using Finite Element Analysis.
24.
Additive Manufacturing Review.
25. Mechanical Property Optimization of Fused
Deposition Modeled Polylactic Acid Components via Design of Experiments.
26.
Powder-Bed Fusion Additive Manufacturing.
27. Calculation of Laser Absorption
by Metal Powders in Additive Manufacturing.
28. Accuracy and Surface
Roughness.
29. Surface Roughness of Electron Beam Melting Ti-6Al-4v Effect on
Ultrasonic Testing.
30. Dynamic Failure Properties of Stainless Steel in
Additive Manufactured.
31. Fatigue Life of Selective Laser Melted and Hot
Isostatically Pressed Ti-6Al-4v Absent of Surface Machining.
32. Impact
Response of Titanium.
33. Laser Powder Bed Fusion Additive Manufacturing.
34.
Measurement Science for Additive Manufacturing Processes.
35. Denudation of
Metal Powder Layers.
36. TensionCompression Fatigue of an Oxide/Oxide
Ceramic Composite at Elevated Temperature.
37. Effects of Steam Environment
on Fatigue Behavior. Section III: Applications.
38. 3DEJI Systems Model for
3D-Printed Product Integration.
39. 3D Printing Case Example at ORNL.
40. 3D
Printing Implications for STEM Education.
41. Additive Manufacturing in USAF
Civil Engineer Operations.
42. Additive Manufacturing in Systems Engineering
Spiral Process Model.
43. Additive Manufacturing in Ordnance Disposal
Training.
44. Aircraft Wing Design Utilizing Additive Manufacturing.
45.
Additive Manufacturing Application for Warhead Topology Optimization.
46.
Direct Metal Laser Sintering Revolution.
47. Information Storage on Additive
Manufactured Parts.
48. Education and Research of Additive Manufacturing at
the US Air Force Institute of Technology.
49. Comprehensive Analysis and
Evaluation of the Potential and Characterization of Recycled Polymers for FMD
3D Printing Applications.
50. Learning Curve Modeling for Additive
Manufacturing.
51. Lattice Optimized Actively Cooled Additive Manufactured
Nose Cone Design and Evaluation.
Adedeji B. Badiru is Dean Emeritus at the Graduate School of Engineering and Management, Air Force Institute of Technology (AFIT), Wright-Patterson Air Force Base, Ohio, UAS USA. He is a registered professional engineer (PE), a fellow of the Institute of Industrial & Systems Engineers (IISE), a fellow of the Nigerian Academy of Engineering, and a certified project management professional (PMP). Dr. Badiru has a PhD in industrial engineering from the University of Central Florida, Orlando, Florida, and is the author of several books and technical journal articles. His areas of interest include manufacturing systems, technology transfer, project management, mathematical modelling, simulation, economic analysis, learning curve analysis, quality engineering, and productivity improvement.
Carl R. Hartfield is an Associate Professor of Aerospace Engineering and Director of the Center for Space Research and Assurance, in the Department of Aeronautics and Astronautics at the Air Force Institute of Technology (AFIT) Wright- Patterson Air Force Base, AFB Ohio, USA. He is a life Senior member of the American Institute of Aeronautics and Astronautics (AIAA), an associate member of the American Society of Civil Engineers (ASCE), and a member of the AIAA Small Satellites Technical Committee. Dr. Hartsfield is the author of several journal articles in the subject areas of propulsion, spacecraft thermal management and additive manufacturing.
David Liu is an aerospace engineer and program manager with the United States Air Force (USAF). He previously served as a Materiel Leader in the Weapons Directorate, Air Force Lifecycle Management Center (AFLCMC) at Eglin Air Force Base, (AFB), Florida, USA. Dr. Liu also serves as an adjunct assistant professor of aerospace engineering at the Air Force Institute of Technology (AFIT), Wright-Patterson Air Force Base AFB, Ohio, USA. He is a Senior Member of the American Institute of Aeronautics and Astronautics (AIAA) and was the Technical Chair of the Survivability Technical Committee. Dr. Liu is the author of several technical journal articles about aircraft survivability, ballistic effects, propulsion, and additive manufacturing.
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