Εργαστήριο Μηχανολογίας Ακριβείας και Αντίστροφης...

3d modelling and manufacturing research activities at the TEI of Crete

Petousis Markos

Dr. Mechanical Engineer

Technological Education Institute of Crete, Mechanical Engineering Department


IntroductionIntroduction

The CNC Machining and Prototyping Laboratory of the Mechanical Engineering Department was The CNC Machining and Prototyping Laboratory of the Mechanical Engineering Department was established in 2008 by the TEI of Crete in partnership with European and private funding.established in 2008 by the TEI of Crete in partnership with European and private funding.

Laboratory cover an area of 500 m2.Laboratory cover an area of 500 m2.

Its equipment are the most recent in their field, acquired in 2008.Its equipment are the most recent in their field, acquired in 2008.

It has a facility with 30 computer stations to design and develop products.It has a facility with 30 computer stations to design and develop products.


IntroductionIntroduction

In brief the research technology areas that can be supported In brief the research technology areas that can be supported are:are:

Design and development of new products.Design and development of new products.

Support any activities in the “3d scanning – 3d modelling Support any activities in the “3d scanning – 3d modelling – 3d printing – rapid tool making” processes chain.– 3d printing – rapid tool making” processes chain.

High precision mechanical processes.High precision mechanical processes.

Most of the potential users of this lab’s services fall into one of Most of the potential users of this lab’s services fall into one of these categories:these categories:

Medical engineering.Medical engineering.

Industries.Industries.

Research and development projects.Research and development projects.

This work is focusing on the research activities and This work is focusing on the research activities and achievements of the laboratory, which are in three, interacting achievements of the laboratory, which are in three, interacting with each other, areas.with each other, areas.


Laboratory Research AreasLaboratory Research Areas

Three dimensional geometric modellingThree dimensional geometric modelling

Support for digital data production.Support for digital data production.

Conformity of three dimensional design models to the Conformity of three dimensional design models to the requirements of international standards (ISO, EN, DIN, etc.).requirements of international standards (ISO, EN, DIN, etc.).

Application of geometric, functional and aesthetic limitations.Application of geometric, functional and aesthetic limitations.

Software tools for computer aided activities: CAD, CAM.Software tools for computer aided activities: CAD, CAM.

Advanced numerical techniques (CAE) to simulate the Advanced numerical techniques (CAE) to simulate the functional behaviour of parts with the finite element analyses functional behaviour of parts with the finite element analyses (FEA) method.(FEA) method.

Document and protect the intellectual work arising from such Document and protect the intellectual work arising from such research and development activities.research and development activities.



Reverse EngineeringReverse Engineering

Design and manufacture an identical, similar or completely Design and manufacture an identical, similar or completely different prototype.different prototype.

The geometry of an existing physical item is scanned by a The geometry of an existing physical item is scanned by a laser scanner creating a cloud of points in space.laser scanner creating a cloud of points in space.

This cloud of points is transformed into a digital file and then This cloud of points is transformed into a digital file and then is processed with a CAD programme.is processed with a CAD programme.

The digital geometric model can be downloaded to the 3d The digital geometric model can be downloaded to the 3d printer to make an identical copy of the original.printer to make an identical copy of the original.

The prototype that the 3d printer makes is a fully functional The prototype that the 3d printer makes is a fully functional prototype.prototype.

It can be used for casting, therefore producing products in It can be used for casting, therefore producing products in small quantities.small quantities.



LeptomechanicsLeptomechanics

Numeric control is the basis of many modern engineering Numeric control is the basis of many modern engineering processes and machinery.processes and machinery.

A program code replaces the individual manual processes A program code replaces the individual manual processes done by the operator.done by the operator.

AdvantagesAdvantages: Greatest accuracy possible and ability to : Greatest accuracy possible and ability to continuously produce the same items.continuously produce the same items.

A CNC milling machine can produce:A CNC milling machine can produce:

Flat surfaces, product outlines, inlets, grooves, hollow Flat surfaces, product outlines, inlets, grooves, hollow surfaces, threads, gears, helical surfaces, freeform surfaces, threads, gears, helical surfaces, freeform surfaces, among others.surfaces, among others.

These capabilities make milling machines ideal for the making These capabilities make milling machines ideal for the making of parts, customized machinery, tools, moulding casts.of parts, customized machinery, tools, moulding casts.

A CNC lathe can produce:A CNC lathe can produce:

Axisymmetric objects, flat and hollow surfaces, grooves, Axisymmetric objects, flat and hollow surfaces, grooves, holes, conical surfaces, threads and other geometries.holes, conical surfaces, threads and other geometries.


Laboratory Research Projects and ActivitiesLaboratory Research Projects and Activities

3d geometric modelling 3d geometric modelling reverse engineeringreverse engineering

3d geometric modelling 3d geometric modelling leptomechanics leptomechanics

Development and manufacturing of mechanisms for research Development and manufacturing of mechanisms for research projects. Most of the parts are manufactured in house.projects. Most of the parts are manufactured in house.

Most of the parts nowadays in the laboratory are 3d printed.Most of the parts nowadays in the laboratory are 3d printed.

This is because of the ease of use of the technology, which This is because of the ease of use of the technology, which doesn’t require codes programming, specialized tools and doesn’t require codes programming, specialized tools and significant technical knowledge, to build a part.significant technical knowledge, to build a part.

In 3d printing the build time is related mainly on the part size In 3d printing the build time is related mainly on the part size and not on its complexity.and not on its complexity.

For these reasons it has been used for the build of very small For these reasons it has been used for the build of very small to very large parts.to very large parts.

CNC only for metal parts.CNC only for metal parts.



Functional mechanisms: Robotic HandFunctional mechanisms: Robotic Hand

All the mechanical parts in the fingers and the palm are 3d All the mechanical parts in the fingers and the palm are 3d printed.printed.

The major challenge of this project, was to design parts that The major challenge of this project, was to design parts that can be assembled and have size as closed as possible to the can be assembled and have size as closed as possible to the real thing and on the same time have adequate shape to host real thing and on the same time have adequate shape to host the robotic hand mechanism and adequate strength to support the robotic hand mechanism and adequate strength to support the developed on the hand operating loads.the developed on the hand operating loads.

This challenge is the most common in 3d printing projects.This challenge is the most common in 3d printing projects.



Functional mechanisms: Steward PlatformFunctional mechanisms: Steward Platform

Vehicle and flight simulators.Vehicle and flight simulators.

Functional mechanisms: Robotic boatFunctional mechanisms: Robotic boat

Employing a propulsion system based on the locomotion mechanisms of sea organisms such as Employing a propulsion system based on the locomotion mechanisms of sea organisms such as cuttlefish and rays.cuttlefish and rays.

The advantage of such a propulsion system is its remarkable maneuverability.The advantage of such a propulsion system is its remarkable maneuverability.

Such systems are employed mainly in unmanned underwater vehicles.Such systems are employed mainly in unmanned underwater vehicles.

The most complex parts of this mechanism were built with the 3d printing technology saving time The most complex parts of this mechanism were built with the 3d printing technology saving time and cost.and cost.

The designers had the ability to experimentally test different design solutions a few hours after the The designers had the ability to experimentally test different design solutions a few hours after the geometrical model of each design solutions was completed.geometrical model of each design solutions was completed.



Biomechanics: modelling and simulation of human joints in the Biomechanics: modelling and simulation of human joints in the computercomputer

Study kinematics and mechanical behaviour with the Finite Study kinematics and mechanical behaviour with the Finite Elements Analysis method. Elements Analysis method.

Intact human knee joint model.Intact human knee joint model.

ACL deficient human knee joint model.ACL deficient human knee joint model.

Reconstructed human knee joint model with a device Reconstructed human knee joint model with a device developed and patented by the laboratory researchers.developed and patented by the laboratory researchers.

This FEA model is now experimentally verified.This FEA model is now experimentally verified.



Biomechanics: 3d printed human modelsBiomechanics: 3d printed human models

Doctors involved in each project can acquire information, not Doctors involved in each project can acquire information, not been able to validate with the geometric models in the been able to validate with the geometric models in the computer.computer.



Biomechanics: Human face anatomyBiomechanics: Human face anatomy

For the development of the 3d geometric model, patients are For the development of the 3d geometric model, patients are scanned with the laboratory 3d laser non contact scanner.scanned with the laboratory 3d laser non contact scanner.

Scanned data are converted to a geometric model in the Scanned data are converted to a geometric model in the computer and then in suitable 3d printing model.computer and then in suitable 3d printing model.

The 3d printing models are employed by the Plastic Surgeon The 3d printing models are employed by the Plastic Surgeon for the evaluation of each surgical case and the design of the for the evaluation of each surgical case and the design of the required surgical procedure.required surgical procedure.


Discussion - ConclusionsDiscussion - Conclusions

Laboratory research activities are in different technological areas, but all have the same focus and Laboratory research activities are in different technological areas, but all have the same focus and content; developing parts and devices, study their behavior, manufacture them and acquire content; developing parts and devices, study their behavior, manufacture them and acquire information for them no other method can provide.information for them no other method can provide.

Laboratory research activities usually support greater technology areas, but can also be the main Laboratory research activities usually support greater technology areas, but can also be the main result on each research project.result on each research project.

3d modelling has been extended far beyond the idea of modelling in a drafting software tool.3d modelling has been extended far beyond the idea of modelling in a drafting software tool.

3d scanning technology provides geometries impossible to model with conventional modelling 3d scanning technology provides geometries impossible to model with conventional modelling methods.methods.

Software tools nowadays are available for different modelling applications and can support almost Software tools nowadays are available for different modelling applications and can support almost any type of modelling project.any type of modelling project.

Customized parts and products development is always required, as well as taking into account Customized parts and products development is always required, as well as taking into account specialized requirements, parameters, issues and technology.specialized requirements, parameters, issues and technology.

Each area has different parameters to be considered. Each area has different parameters to be considered.

In any type of project the only common parameter is the development of the 3d geometry, which is In any type of project the only common parameter is the development of the 3d geometry, which is the most important parameter for a project to succeed.the most important parameter for a project to succeed.


Thank you!

Markos Petousis

Dr. Mechanical Engineer

TEI of Crete, Mechanical Engineering Department

Estavromenos, 71 004, Heraklion Crete, Greece

tel: +30 2810 379227

E-mail: [email protected]

Εργαστήριο Μηχανολογίας Ακριβείας και Αντίστροφης...

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