A Review on Aircraft Manufacturing System Design based on Ergonomic Simulation

3D printing, also known as Additive manufacturing (AM), has emerged as a transformative technology with applications across various industries, including the medical sector. This review paper provides an overview of the current status of AM technology, its challenges, and its application in the medical industry. The paper covers the different types of AM technologies, such as fused deposition modeling, stereolithography, selective laser sintering, digital light processing, binder jetting, and electron beam melting, and their suitability for medical applications. The most commonly used biomedical materials in AM, such as plastic, metal, ceramic, composite, and bio-inks, are also viewed. The challenges of AM technology, such as material selection, accuracy, precision, regulatory compliance, cost and quality control, and standardization, are also discussed. The review also highlights the various applications of AM in the medical sector, including the production of patient-specific surgical guides, prosthetics, orthotics, and implants. Finally, the review highlights the Internet of Medical Things (IoMT) and artificial intelligence (AI) for regulatory frameworks and safety standards for 3D-printed biomedical devices. The review concludes that AM technology can transform the healthcare industry by enabling patients to access more personalized and reasonably priced treatment alternatives. Despite the challenges, integrating AI and IoMT with 3D printing technology is expected to play a vital role in the future of biomedical device applications, leading to further advancements and improvements in patient care. More research is needed to address the challenges and optimize its use for medical applications to utilize AM's potential in the medical industry fully.

This article provides an overview of current approaches to optimizing parameters and processes in additive manufacturing for aerospace metal components. The use of 3D printing technologies such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM) is considered, which enable the creation of parts with complex geometries, reduced mass, and improved operational characteristics. The importance of accurately selecting technological parameters is emphasized, as they directly affect the mechanical properties, durability, and reliability of the produced parts. Special attention is given to issues arising during additive manufacturing, such as material porosity, residual stresses, structural inhomogeneity, and insufficient dimensional accuracy. Methods for their elimination are analyzed, including numerical modeling of thermal processes, topology optimization of structures, and the application of machine learning algorithms for automated print parameter selection. The importance of integrating a comprehensive approach that combines experimental research with digital technologies is emphasized, as it significantly enhances product quality. The article focuses on the future development of additive technologies in the aerospace industry. Specifically, the possibilities of integrating artificial intelligence (AI) into print process management are explored, enabling not only quality control automation but also the prediction of potential defects at early stages of production. Additionally, the development of new metal alloys specifically tailored for 3D printing methods and the standardization of additive parts certification processes are discussed, as these are key factors for the widespread adoption of these technologies in aerospace manufacturing. Thus, the article summarizes the latest research in the field, identifies key problems, and outlines potential solutions. The comprehensive analysis and implementation of modern additive manufacturing optimization methods will improve efficiency, reliability, and cost-effectiveness in aerospace 3D printing applications.

Background: The aerospace industry has been gradually adopting Industry 4.0 technologies, such as the Internet of Things [IoT], big data analytics, and cyber-physical systems, to enhance aircraft maintenance, repair, and overhaul [MRO] operations. These technologies have the potential to improve operational efficiency, reduce costs, and enhance safety in the MRO sector. Objective: This study aims to analyze the current state of Industry 4.0 integration in aircraft maintenance/MRO operations by examining relevant use cases and conducting a patent landscape analysis. The primary objectives are to identify the key players, emerging trends, and technological hotspots in this field, as well as to understand the challenges and opportunities associated with the integration of Industry 4.0 in aircraft MRO. Methods: The research methodology involves a comprehensive literature review to identify and analyze use cases of Industry 4.0 technologies in aircraft manufacturing and MRO operations. A systematic approach was adopted to collect and analyze relevant patent data from various patent databases. The search strategy involved the use of specific keywords related to Industry 4.0 technologies and aircraft MRO. The retrieved patent documents were then subjected to rigorous analysis, including bibliometric analysis, technological categorization, and patent landscape mapping. Results: The patent landscape analysis revealed a steadily increasing trend in patent filings related to Industry 4.0 technologies in aircraft MRO. The major players in this field were identified, and their patent portfolios were analyzed. The analysis of use cases also highlighted that key technological areas, such as 3-D printing and digital twin technology, are attracting significant attention from aircraft industry stakeholders. Conclusion: The analysis of patent landscapes in the field of aircraft maintenance, repair, and overhaul [MRO] provides valuable insights into the current state, emerging trends, and future directions within the industry. These insights are crucial for industry stakeholders, researchers, and policymakers to make informed decisions regarding technology adoption, investment strategies, and regulatory frameworks. In conclusion, the examination of patent landscapes serves as a foundational tool for enhancing transparency, standardization, and reproducibility in research, enabling stakeholders to navigate the complex landscape of Industry 4.0 in aircraft MRO effectively.

Additive manufacturing (AM or 3D printing) holds the potential to revolutionize the ceramic industry by offering fresh avenues for manufacturing complicated ceramic components directly from digital models without the need for costly tooling. This advancement can lead to decreased production costs and lead times, while also enhancing design flexibility and tolerance for imperfections. Thus, there is an increasing interest in utilizing AM techniques to produce advanced ceramic components and explore their wide-ranging applications. This special issue consists of several articles from renowned groups worldwide, presenting their insights and recent progress in AM of advanced ceramic materials and applications. These articles discuss advances across various topics including novel materials, innovative techniques, and emerging applications, which broaden the understanding of the capabilities, challenges, future perspectives and implementation of AM of advanced ceramic materials. The collections in this special issue have attracted review and research articles addressing diverse aspects of the AM-fabricated advanced ceramic materials and applications. Fiume et al. (fmats.2023.1242480) discussed the vat-photopolymerization of ceramic materials and explored the state-of-the-art of the applications in advanced multidisciplinary fields including biomedicine, energy, environment, space and aerospace, with a special focus on current trends and project-specific requirements. Pan et al. (fmats.2020.00054) formed high-resolution, defect-free alumina ceramics using stereolithography-based 3D printing technology, which provides a rapid and cost-effective manner to produce ceramic cores used in astronautics engineering and material engineering fields related to high-temperature environments. Yan et al. (fmats.2023.1239692) introduced a hybrid approach methodology that combines experimental rheology with Finite Element simulations to determine the printability of ceramic-polymer ink formulations which aids in optimizing low-temperature extrusion 3D printing of novel inks for bone tissue engineering. Heise et al. (2024.1441812) presented the design and use of an inline mid-infrared optical coherence tomography (MIR-OCT) system combined with deep learning for classification and in-process feedback as a versatile tool for at-line and inline quality control in lithography-based ceramic manufacturing. This special issue has a strong focus on AM-fabricated advanced ceramic materials and their applications. The exceptional dimensional/chemical stability over a wide temperature range, along with high corrosion resistance and lower density in comparison to metal-based components, have made ceramic materials highly intriguing for space and aerospace applications, thus have becoming a fascinating research area. Fiume et al. (fmats.2023.1242480) summarized relevant outcomes and final considerations of various classes of AM-fabricated advanced ceramics used in space and aerospace industry, including both oxide- and non-oxide ceramics and ceramic composites. Pan et al. (fmats.2020.00054) discussed the influence of high-temperature sintering conditions on microstructure and properties of 3D-printed alumina ceramics and obtained high-performance intricate alumina ceramic cores essential for crafting high-temperature hollow turbine blades. Tissue engineering applications are another subfield where AM of bioceramics finds tremendous potential. Fiume et al. (fmats.2023.1242480) highlighted how the scientific community is devoting considerable efforts to the transfer of stereolithography-based 3D printing technology of bioceramic materials into clinical practice in various fields of application, such as orthopedics and dentistry. Yan et al. (fmats.2023.1239692) established a framework for streamlining the design of inks for extrusion 3D printing of ceramic-polymer scaffolds for bone tissue engineering. They evaluated the compressive properties of printed hydroxyapatite-polycaprolactone scaffolds and characterized the effects of ceramic content and component ratio ratio on the hyperelasticity observed in response to compressive deformations.In recent years, artificial intelligence (AI) has emerged as one of the most active subfields of AM. This is also reflected in AM of advanced ceramic materials. AI has been suggested in AM of ceramics for classification between accurately 3D-printed and ceramics specimens with failures at the micron scale. Specifically, deep learning methods involving convolutional neural networks or residual neural networks that have enabled easy training and model generation for image data are chosen. Deep learning plays a crucial role in advancing AM by enabling more efficient processes, better quality control, and innovative material and design solutions. Heise et al. (2024.1441812) highlighted the potential of MIR-OCT coupled with AI-based identification methods for inline process monitoring and quality control in additive ceramic manufacturing machinery. They integrated the OCT measurement head in a 3D ceramic printer that enables direct layer growth monitoring, geometry verification, and real-time defect development monitoring, providing immediate user alerts when misprints are produced. Such monitoring enhances production efficiency by promptly detecting potential defects, reducing the time and cost commitments, and minimizing resource consumption.As mentioned earlier, AM of advanced ceramic materials and its applications constitute a vibrant and rapidly evolving field. While the contents of this special issue may encompass just a fraction of the outstanding research efforts in progress, our aspiration is to offer fellow researchers a glimpse into the dynamic and swiftly evolving landscape of this field.

Additive manufacturing of cementitious composites: Materials, methods, potentials, and challenges

Additive manufacturing in the aerospace and automotive industries: Recent trends and role in achieving sustainable development goals

Additive manufacturing (AM), or 3D printing, has attracted substantial attention in the aerospace sector due to its potential for complex part manufacturing, reduced material waste, and greater design freedom. The integration of robot-assisted systems with additive manufacturing (AM) techniques has demonstrated the potential to enhance efficiency, precision, and scalability. This review paper seeks to investigate recent advancements in robot-assisted AM for aerospace applications, emphasizing their impact on the industry and discussing future possibilities. The concept of robot-assisted additive manufacturing has been addressed and its advantages over traditional methods are highlighted. A complete examination of contemporary research and breakthroughs in this sector is offered, covering wire arcing additive manufacturing, laser metal deposition, and the extrusion of composite materials. The hardware implementation, printing material utilization, and printing path planning methods are investigated for the AM of metallic and fiber-reinforced composite materials. The challenges connected with robot-assisted AM, including system calibration, accuracy, and adaptability to complicated geometries, have been studied as well. Overall, the insights presented will be beneficial for researchers, engineers, and industry professionals working in aerospace manufacturing, paving the path for the next generation of robot-assisted AM techniques.

Exploring the integration of digital twin and additive manufacturing technologies

Lean manufacturing is an approach to enhancing productivity through lean thinking. The success of the lean manufacturing application is influenced by various factors, one of them is the organizational culture. This study aims to explore lean manufacturing and organizational culture in an Indonesian aircraft manufacturer. Ninety workers in three production divisions (i.e., Detailed Part Manufacturing/DPM, Component Assembly/CA, Final Assyline & Delivery Center/FAL & DC) in the aircraft manufacture are involved in this study voluntarily by filling out a set of questionnaire. Lean manufacturing performance is observed using Lean Manufacturing Benchmark, whereas organizational culture is evaluated using the Organizational Culture Assessment Instrument. The result shows that lean performance for DPM is 57%, CA is 61%, FAL & DC is 59%. All divisions have no dominant culture. However, the increased of lean performance is along with the increased hierarchy and clan culture, and the decreased of market and adhocracy culture. Implications of the results are discussed.

Design for Additive Manufacturing (DfAM) encompasses two primary strategies: adapting traditional designs for 3D printing and developing designs specifically optimized for additive manufacturing. The latter emphasizes consolidating assemblies and reducing weight, leveraging complex geometries and negative space through advanced techniques such as generative design and topology optimization. Critical considerations in the design phase include printing methods, material selection, support structures, and post-processing requirements. DfAM offers significant advantages over conventional subtractive manufacturing, including enhanced complexity, customization, and optimization, with transformative applications in aerospace, medical devices, and automotive industries. This review focuses on the automotive sector, systematically examining DfAM’s potential to redefine vehicle design, production processes, and industry standards. By conducting a comprehensive analysis of the existing literature and case studies, this research identifies gaps in the integration of additive manufacturing into broader manufacturing frameworks. The study contributes to the literature by providing insights into how 3D printing is currently reshaping automotive production by offering a forward-looking perspective on its future implications for the industry.

3D printing application in biomedical - a review

Additive manufacturing (AM) has revolutionized the manufacturing industry by offering flexibility, customization, and rapid prototyping capabilities. Complex geometries and low volume parts can be produced via AM in much lower lead time and cost compared to traditional manufacturing methods. However, ensuring the quality and reliability of AM parts remains a significant challenge due to variations in material properties and process parameters. Traditional material property analysis methods, that require experimental testing and computational modeling, are often costly and time-consuming and often not applicable to the complex geometries of AM components. These challenges are further magnified when repetitive sampling is required. To address these challenges, this paper presents a novel approach that combines experimental findings with Finite Element Modeling (FEM) to construct a digital twin (DT) model of AM parts. The DT model will serve as a virtual representation along with real-time monitoring, simulation, and optimization capabilities. Numerical simulations are conducted to correlate the resonance frequency of parts at different process conditions with their material characteristics, represented as RF Z-score values. Hence, the results suggest that such an approach provides manufacturers with cost-effective and efficient means of analyzing material properties and optimizing AM processes. Moreover, by leveraging digital twin technology, manufacturers can achieve greater process control and quality assurance in additive manufacturing. The findings of this study contribute to advancing the understanding and implementation of digital twin technology in AM; therefore, paving the way for enhanced productivity and reliability in additive manufacturing processes.

Before Liberation, even such small items as nails and matches in China were all manufactured by foreigners, as a result, they were called ‘‘foreign nails’’ and ‘‘foreign matches’’. China’s mechanical manufacturing capabilities picked up after the foundation of new China with the aid of the former Soviet Union. From 1960s onwards, the industry was mainly dependent on self-reliance. In 1978 China’s higher education was resumed and universities began to enroll students. As a result of economic reforms and opening up, China’s manufacturing industry began to learn from foreign examples, and launched the first wave of manufacturing for household electrical appliances between 1978 and 1987. During this period mechanical engineering and science also underwent rapid development. Professor Chongxian Gu at Xian Jiaotong University was one of the earliest scholars studying dynamics of machining tools. His research achievements attracted some world-renowned experts’ (for example the famous Professor Tobias) attention and academic exchange with their Chinese partners. Professor Yushan Tan was invited to build the Machine Tool Laser Measurement Laboratory at the University of Birmingham. During the 1980s Hanhe Yang founded the ‘‘Mechanical Control Engineering’’, highly praised by Prof. Shuzi Yang, the academician of Chinese Academy of Engineering. His work was considered as the classic works of mechanical dynamics. Two alumni of Xian Jiaotong University namely Yansun Lu (former chief engineer and Deputy Minister of the Ministry of Mechanical Industry) and Mr. Guobao Zhang, former Deputy Director of National Development and Reform Commission and Director of National Energy Administration. Both men had devoted their entire lives and energy to Chinese manufacturing industry, and earned the accolade of ‘‘Engineers of the Republic’’. The second wave of manufacturing in modern Chinese history is automotive manufacturing (1987–1997). During this period of time, foreign manufacturers came to China in droves, and many privately-owned manufacturers began to sprout up. One must recognize that the astounding success in both waves of manufacturing in China—so successful are they that China is now the world’s largest manufacturing nation—is mainly attributed to China’s large population and cheap rural labor. It is important to note that the State ‘‘985’’ and ‘‘211’’ programs were aimed at developing world-class academic disciplines in key universities. After more than 30 years of development, China’s manufacturing industry has become the largest in the world constituting 19.4 % of the global manufacturing in 2010 (see Fig. 1). It expanded further to 19.8 % in 2011. In many other products China’s production volume also topped the world (see Table 1). Nevertheless at this point, China is only a large manufacturing nation but not a manufacturing power. Aerospace manufacturing is the third wave for China’s manufacturing industry. It represents a high level of manufacturing technology and indeed powers its development. Manufacture of large aircrafts, aircraft engines, rotor blades and turbine disc is an extremely difficult process, especially considering that they require materials such as high-temperature alloy and titanium alloy and that they possess curved surfaces. Nevertheless China’s aerospace industry is beginning to move away from its early days and is moving towards becoming a full-fledged industry. B.-H. Lu (&) School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, People’s Republic of China e-mail: bhlu@mail.xjtu.edu.cn

Chapter 2 - 3D printing and nanotechnology

Science and engineering have been instrumental in advancing the progress of humanity and are the key enablers that are shaping our very present and the future, improving our health and living standards, allowing humanity to leave the planet, walk on the moon, and explore distant stars and galaxies. Additive manufacturing (AM) or 3D printing is the latest technological marvel in manufacturing that is compelling us to think differently about how we design and manufacture parts and components, the location where the parts are being manufactured, the supply chains, environmental impact of manufacturing and sovereign capability. AM is now being perceived as a disruptive technology because of the benefits and opportunities it offers over the long-established traditional manufacturing technologies. It is a relatively young technology, some 30 years since the invention of the first 3D printer, compared to conventional subtractive technologies that have been around for centuries. Mainstream AM has in fact only been around the last 5 to 10 years as both the 3D printing technology and feedstock materials have evolved and become more robust, cheaper, and reliable giving manufacturers the necessary level of confidence to adopt them in serial production. The level of activity in AM is at an all-time high as various stake holders, company executives, investors, researchers, and government agencies try to predict its trajectory. Global organizations of all types are attempting to understand the role they can play in the AM space. This chapter presents an overview of AM and its enormous potential in the advancement of chemical sciences and engineering. In-depth discussion of fundamental and applied aspects of each individual AM technology and how they relate to chemical sciences and engineering are presented in subsequent chapters. To date AM has seen greater adoption by the aerospace, defense, and biomedical industries and to somewhat lesser degree in the chemical manufacturing and processing industries. Introduction of AM practices in this sector can improve the efficiencies of existing chemical processing technologies, allow sophistication of existing processes for manufacturing of new products, improve process economics, and address complex challenges and demands of our modern society such as environmental compatibility, reduction in wastes and emissions and localized production. AM in chemical sciences has enormous potential in process intensification which enables efficient heat and mass transfer, large reduction in the footprint of chemical manufacturing and processing and reduce environmental pollution.KeywordsAdditive manufacturing3D printingRapid prototypingCustomizationChemical manufacturingProcess intensificationEnergy storageReactors