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Procedia Manufacturing 00 (2018) 000–000
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Procedia Manufacturing 00 (2018) 000–000 www.elsevier.com/locate/procedia
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Procedia Manufacturing 32 (2019) 22–28

Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia

The
The 12th
12th International
International Conference
Conference Interdisciplinarity
Interdisciplinarity in
in Engineering
Engineering

CAD
CAD CAMCAM System
System for for Manufacturing
Manufacturing Innovative
Innovative Hybrid
Hybrid Design
Design
Using
Manufacturing Engineering Society 3D Printing
International
Using 3D PrintingConference 2017, MESIC 2017, 28-30 June
2017, Vigo (Pontevedra), Spain
a a b c
Tadeusz
Tadeusz Mikolajczyk
Mikolajczyka*,*, Tomasz
Tomasz Malinowski
Malinowski a, Liviu Moldovanb, Hu Fuwenc,
, Liviu Moldovan , Hu Fuwen ,
Costing models for Tomasz
capacity
Tomasz optimization
Paczkowski
Paczkowski
a
in Industry
a, Ileana Ciobanu
, Ileana Ciobanu
d
d 4.0: Trade-off
between a
used
UTP University
a capacity
of Science and
and Technology, 7 Prof.operational efficiency
S. Kaliskiego, 85-809 Bydgoszcz, Poland
UTP University of Science and Technology, 7 Prof. S. Kaliskiego, 85-809 Bydgoszcz, Poland
b
“Petru Maior” University, 1 Nicolae Iorga street, 540088 Tirgu Mures, Romania
b
c “Petru Maior” University, 1 Nicolae Iorga street, 540088 Tirgu Mures, Romania
c NorthChina University of Technology, 5 Jinyuanzhuang Road, Shijingshan District,100144 Beijing, China
d A. Santana , P. Afonso , A. Zanin , R. Wernke
North China University a
of Technology, a,*
5 Jinyuanzhuang b
Road, Shijingshan b Beijing, China
District,100144
d Elias University Hospital, 17 Marasti Blvd. 011461 Bucharest, Romania
Elias University Hospital, 17 Marasti Blvd. 011461 Bucharest, Romania
a
University of Minho, 4800-058 Guimarães, Portugal
b
Unochapecó, 89809-000 Chapecó, SC, Brazil
Abstract
Abstract
Additive manufacturing, commonly referred to as 3D printing, or layer manufacturing is a very dynamically developing direction
Additive manufacturing, commonly referred to as 3D printing, or layer manufacturing is a very dynamically developing direction
Abstract
in the development of manufacturing technology. The article presents considerations on the possibilities of using 3D printing
in the development of manufacturing technology. The article presents considerations on the possibilities of using 3D printing
technology for the production of prototypes of innovative solutions. The special advantage of using 3D printing relies in its
Under theproduce
technology
ability to concept
for of "Industry
the production
directly 4.0",CAD
of prototypes
based on the production
of innovativeprocesses
model, whose
solutions.will
The be pushed
special
file is the source to beofincreasingly
advantage
of information for generatinginterconnected,
using 3D printing relies in its
the incremental
ability to produce
information based directly
on a based
real timeonbasis
the CAD
and, model, whose much
necessarily, file is more
the source of information
efficient. In this for generating
context, capacitythe incremental
optimization
control file.
control
goes file. the traditional aim of capacity maximization, contributing also for organization’s profitability and value.
beyond
The article presents an example of 3D printing using the FDM method, in order to produce a special element of a hybrid structure
The article
Indeed, presents
lean an exampleand
management of 3Dcontinuous
printing using the FDM method,
improvement in order to produce capacity
approaches a special element of a hybrid structure
using ready-made metal elements. It was pointed out that the use of 3D printingsuggest
makes it possible tooptimization instead
finish the elements. of
It has
using ready-made metal elements. It was pointed out that the use of 3D printing makes it possible to finish the elements. It has
maximization.
been pointed outThe thatstudy of capacity
the specific featuresoptimization andwere
of 3D printing costing modelswith
developed is an
CAM important
softwareresearch
based ontopic
CADthat deserves
model, which
been pointed out that the specific features of 3D printing were developed with CAM software based on CAD model, which
contributions from bothofthethis
adapts to the capabilities practical
technique. andGeomagic
theoreticalas perspectives.
CAD software This paperaspresents
and Sli3R and discusses
CAM software a mathematical
are the usual choices. An
adapts to the capabilities of this technique. Geomagic as CAD software and Sli3R as CAM software are the usual choices. An
examplefor
model of capacity
3D printedmanagement
part for special hybrid
based ondesign, madecosting
different using metallic
models normal
(ABC elements
and is presented.
TDABC). A generic model has been
example of 3D printed part for special hybrid design, made using metallic normal elements is presented.
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
© 2019
2018 The Authors.
value. trade-offPublished
capacityby Elsevier Ltd. vs operational efficiency is highlighted and it is shown that capacity
© 2018TheThe Authors. Published bymaximization
Elsevier Ltd.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
optimization
This is an openmight
accesshide operational
article inefficiency.
under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
© 2017 The
Selection Authors.
and Published
peer-review underby Elsevier B.V.
responsibility of the 12th International Conference Interdisciplinarity in Engineering.
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference
Keywords: CAD; CAM; 3D printer; FDM method; Innovative design
2017.
Keywords: CAD; CAM; 3D printer; FDM method; Innovative design

Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency

1. Introduction
* Corresponding author. Tel.: +48-52-340-8736; fax: +48-52-340-8245.
* The
Corresponding
cost author.
of idle Tel.: +48-52-340-8736;
capacity fax: information
is a fundamental +48-52-340-8245.
for companies and their management of extreme importance
E-mail address: tami@utp.edu.pl
E-mail address: tami@utp.edu.pl
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
in several©ways:
2351-9789 tons
2018 The of production,
Authors. available
Published by Elsevier Ltd.hours of manufacturing, etc. The management of the idle capacity
2351-9789 © 2018 The Authors. Published by Elsevier Ltd.
This is anAfonso.
* Paulo open access
Tel.:article under
+351 253 510the761;
CC BY-NC-ND
+351 253license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an open access article under the CCfax:
BY-NC-ND 604 741
license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection
E-mail and peer-review
address: under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
psafonso@dps.uminho.pt
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
2351-9789 © under
2019responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
Ltd.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Selection and peer-review under responsibility of the 12th International Conference Interdisciplinarity in Engineering.
10.1016/j.promfg.2019.02.178
 Tadeusz Mikolajczyk et al. / Procedia Manufacturing 32 (2019) 22–28 23
2 T. Mikolajczyk, T. Malinowski, L.Moldovan,.F. Hu, T.Paczkowski / Procedia Manufacturing 00 (2018) 000–000

1. Introduction

In the production of complex shapes, especially in metal, the CAD-CAM system [1,2,3] is used extensively. The
new trend in the development of manufacturing technology is incremental shaping, commonly referred to as 3D
printing [4,5,6]. These techniques develop very dynamically. Nowadays, many varieties of this manufacturing
technique have been created that enable the most common materials to be shaped (methods: SLS [4], FDM [5.6]
Various techniques of incremental forming of metal alloys are developed [7] as well as tools [9] mainly used for
plastics processing [10] The use of FDM technology is particularly widespread, which is implemented using 3 D
printers in both Cartesian [11] and parallel configurations - delta 3D printers [12].
3D printing due to the possibility of manufacturing based on the CAD module is particularly convenient for the
production of innovative solutions [13]. The most important stage in the production of the prototype is the
development of an appropriate CAD solid model. Recently, hybrid manufacturing (HM) combines different
manufacturing processes mechanisms of additive and subtractive processes has gained significant attentions [14].
The paper presents the innovative hybrid design of the fastening system using metal elements complemented [15]
with a component made using 3D printing technology.

Nomenclature

Nt Nozzle temperature - oC
Tt Table temperature - oC
Dn Nozzle diameter - mm
h Layer thickness - mm
f Filling - %
No Number of outlines
Nl Number of lower layers
Nu Number of upper layers

2. Methods and materials

2.1. CAD CAM system for 3D printing

3D printing process is convenient for CAD (Computer Aided Manufacturing) - CAM (Computer Aided
Manufacturing) system. Today's CAD programs offer a wide range of designing possibilities. For construction, what
possibilities do we have? Traditional CAD CAM system for cutting method is difficult, needs programming
intervention in organizing the sequence of shaping and finishing processing with different performance and
precision [1-3] . In the CAM system for the layer manufacturing process the situation is much simpler compared
with traditional subtractive technology. In Fig. 1 was presented the CAD-CAM system used in presented example
to prepare the design and G-code for it produce using 3D printer. In this case, as CAD software Geomagic was used
[16]. As CAM component, the popular software Sli3R was used [17].

START

CAD CAM G-Code control

„.stl” file
Geomagic Sli3R file

Design 3D print process STOP

dimensions parameters

Fig. 1. The principle of CAD CAM system for 3D printing used in presented case software
24 Tadeusz Mikolajczyk et al. / Procedia Manufacturing 32 (2019) 22–28
T. Mikolajczyk, T. Malinowski, L. Moldovan, F. Hu, T. Paczkowski Procedia Manufacturing 00 (2018) 000–000 3

As output of CAD it was used a .stl file, which present the surface of the developed design (Fig. 1). This file was
used as input of CAM part of the system.
For 3D printing, the generating of the G code is defined automatically using this data for the Sli3R software [17]:
 Location of the facility during printing
 Location of support zones for the main product
 Volume filling
 Number of outlines
 Number of lower layers
 Number of upper layers
 Nozzle diameter
 Nozzle temperature
 Print speed
 Thickness of the layer
 Material
An important feature of the 3D printing process is that the production takes place in one cycle in contrast to
subtractive technology.

2.2. The clamping system idea

As part of the development of an original mobile robot, designed for didactic tasks [18], it was decided to equip
it with a solar panel for charging robot’s batteries [19]. The construction of the robot is based on the use of elements
of a universal rack system using 25 mm pipes and various types of connectors [15]. The basic feature of the solar
panel fixing system (Fig. 2) is placing it in a position perpendicular to the stream of sunlight to increase efficiency.
The solution uses the 12 V solar module, model AMS-10 with dimensions 330x290 mm and 10 W of power.
This required the use of appropriate adjustable joints (Fig. 2). The elements selected for the construction of joints
are presented in Fig.3 (Fig. 3). These elements have 1 degree of freedom, and in addition to the sockets for pipes Ø
25 mm you can use an additional 2 degrees of freedom. In connection we obtain 3 DOF. The element used as
gripper is presented in Fig. 4 (it will be some cut on the left side). The task of our work is to develop the special part
which will be connecting the elements from Fig. 3 and Fig. 4 to achieve a device providing the possibility to control
the position of the solar panel and its clamping.

Joint Joint

Fig. 2. Solar module (panel) with original manual control of the vertical position [19]

Axis of the
solar panel
rotation device

Fig. 3. Elements used for the design of solar joints with 3DOF [15] Fig. 4. Element used as gripper [15]
 Tadeusz Mikolajczyk et al. / Procedia Manufacturing 32 (2019) 22–28 25
4 T. Mikolajczyk, T. Malinowski, L.Moldovan,.F. Hu, T.Paczkowski / Procedia Manufacturing 00 (2018) 000–000

2.3. 3D printer

For 3D printing of the original design, a Delta type 3D printer, produced in Poland, was used (Fig. 5).

Fig. 5. The 3D printer (Delta) used in this work

3. CAD design of robots clamping system

The elements shown in Fig. 3 and Fig. 4 were used to build the fastening system, by making an additional
connecting element. The virtual model of the solution developed in the Geomagic software was based on the
dimensions of the hole - both parts (Fig. 2 and fig. 2) and is shown in Fig. 6.

Fig. 6. Geomagic CAD model of the special element developed

26 Tadeusz Mikolajczyk et al. / Procedia Manufacturing 32 (2019) 22–28
T. Mikolajczyk, T. Malinowski, L. Moldovan, F. Hu, T. Paczkowski Procedia Manufacturing 00 (2018) 000–000 5

The cylindrical part of the servo is used for adjusting the angle, the flat part fixes the gripping part. Of course, the
gripping part can also be made as a printed element. To increase the accuracy of machining external surfaces, it was
decided to make this element from two parts. This element, thanks to the cylindrical grip, allows the tilt angle to be
adjusted, providing the vertical position of the solar module (Fig. 2), in order to obtain optimal direction to Sun.
Attaching the gripper in the appropriate position provides the bolt of the element.

4. Produced hybrid design

For printing of the parts presented in Fig. 5, the Delta kind 3D printer was used (Fig. 6).
The print control file was developed with Slic3R software using produced by Geomagic .stl file [17] (Fig. 7)
using the parameters shown in table 1. The designed parts were printed using PLA material (Fig. 8). The
manufacturing process was carried in short time (t=40 min).

Table 1. Parameters of the 3D printing process used to prepare of G-Code using Slic3R software

Parameters of 3D print Symbol Value

Nozzle temperature Nt 210oC
Table temperature Tt 60oC
Nozzle diameter Dn 0.5 mm
Layer thickness h 0.3 mm
Filling f 50%
Number of outlines No 5
Number of lower layers Nl 4
Number of upper layers y 4

Fig. 7. The model of the special element, developed in Sli3R CAM system based on Geomagic CAD .stl file
 Tadeusz Mikolajczyk et al. / Procedia Manufacturing 32 (2019) 22–28 27
6 T. Mikolajczyk, T. Malinowski, L.Moldovan,.F. Hu, T.Paczkowski / Procedia Manufacturing 00 (2018) 000–000

a b c

Fig. 8. A special element produced from PLA using the FDM 3D printing method: (a) first half, (b) second half, (c) completed detail

The production of a part of a hybrid construction using printed and metal elements is to obtain the appropriate
accuracy of the dimensions of these parts. This is to ensure proper tolerances of the associated surfaces of co-
operating elements.
Due to the complex process of shaping elements by 3D printing to obtain the required dimensions, appropriate
experience of exploitation 3D printer for each material and nozzle diameter is necessary.
The article shows the procedure of adjustment, which was used to obtain the dimensions of the 3D part and
adapted to the hybrid construction.
The output point are the dimensions of the metallic elements of proposed hybrid design. For these dimensions
was elaborated a CAD model of the 3D printed part (Fig. 6). Based on the experience of exploitation used 3D printer
(Fig. 5), the 3D printed element was dimensioned, including practical knowledge for obtaining the actual
dimensions of the printed parts. The dimension presented in Fig. 6 was modified using this knowledge based on type
of dimension (outer or inter). It has been noticed that external dimensions are larger than nominal ones and internal
ones are smaller. Larger errors were found for holes. It is believed that 3D printer with parallel type (Delta type) is
less accurate in the machining especially of holes in comparison with machines with XYZ configuration. Hence the
corrections were used in the adjusted CAD model.
The adequate dimensions of the printing parts (dimensions in the drawing) and the actual size of the printed
surface was shown in Table 2. This parameter was used to prepare .stl model for the generation of the G-Code using
Slic3R software. Measurements of finished elements were carried out using of digital caliper. In the last column, the
difference between practical and pre-determined dimensions is given in column 4. The accuracy of the obtained
product was sufficient to mount the developed gripper structure.

Table 2. Theoretical and practical dimension of 3D printing used to prepare of G-Code using Slic3R software

1. Theoretical dimension 2. Dimension for 3D printing 3. Measurements results 4. Difference (3-1)

mm Type dim mm mm mm

Ø25 Outer Ø25 Ø25,5 +0,5

29 Outer 28,6 29 0
17 Inner 17,4 17 0
31 Outer 31 31,5 +0,5
Ø8 Inner Ø9 Ø7,3 -0,7
Ø5 Inner Ø5,5 Ø5,2 +0,2
14 Inner 14,2 13,8 -0,2
12 Outer 11,8 11,9 -0,1
21 Outer 20,8 21,5 +0,5
28 Tadeusz Mikolajczyk et al. / Procedia Manufacturing 32 (2019) 22–28
T. Mikolajczyk, T. Malinowski, L. Moldovan, F. Hu, T. Paczkowski Procedia Manufacturing 00 (2018) 000–000 7

5. Conclusions

3D printing is an important step in the development of manufacturing techniques particularly suitable for the task
of building prototype and unique solutions. A special feature of 3D printing techniques is the ability to produce, on
the basis of a G-code control file for machining developed directly from the CAD model by generating subsequent
sections of a detail. Combination of the CAD software and of software used to generate the G-code from .stl
developed in CAD for control printing process is a specific of the CAD CAM system additive technology.
Recently, hybrid manufacturing (HM) combines different manufacturing processes mechanism of additive and
subtractive processes has gained significant attentions.
The practical solution of a hybrid construction presented in the article that based on ready-made elements of
the universal metal construction system. Based on the use of these components along with
a specially designed and manufactured using 3D printing technique part, an innovative robot gripper solution has
been created. This design allows the robot's solar panel to be adjustable and can also be used for other tasks in
changed position. In the presented solution, the element has been deliberately divided into two parts to obtain high
element strength (due to the printing direction).
In the hybrid construction, it is necessary to ensure proper dimensional accuracy of the parts produced by 3D
printing. The article uses a modification of the CAD model based on practical knowledge on the dimensional
accuracy of models. It ensured sufficient accuracy of cooperating elements in order to obtain a functional device.

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6yfDL3QIVBN-yCh1upwZhEAQYAiABEgKTh_D_BwE