ALF: Additive Layer Flexomer manufacturing

在数字化添加剂层制造流程中生产的复杂金属和聚合物基板将采用新的增值数字化添加剂层Flexmer工艺流程，以提高当前设备的性能，并实现全新的高附加值产品和子组件。通过计算机控制的6轴机械臂和多轴工件夹持器精确操纵沉积源和衬底，将在附加制造的复杂几何零件上一层又一层地建立复合材料、多材料弹性结构。最初的重点将是弹性结构，它在增强骨整合的同时提供强大的抗菌功能。后续的应用将是航天领域的新世界部件&航空航天、半导体设备、传感器和仪器仪表。由全氟弹性体开发的柔性体材料将在数字化制造流程中的不同阶段使用高质量的分析工具进行调整。我们将使用旋转剪切流变仪和拉伸剪切流变仪对流体进行表征，以建立将Flexmer流体中的颗粒类型和浓度与逐层沉积质量相关联的知识。使用Instron剥离测试设备将评估添加剂层Flexmer材料与添加剂层基材‘改良表面’的结合强度。表面改性将使用自动微细磨料喷粉和高能激光处理进行评估。学术研究小组将评估两种类型的逐层沉积头，以实现高精度的三维结构沉积。首先，将优化微环切割法，以定义宽度为0.1 mm的弹性体细线，并优化微喷射，以产生直径0.2 mm的点。研究的目的是帮助建立英国拥有的数字化制造技术，在高附加值附加层组件上无缝地生产先进的附加层弹性体结构。工作流程的设计将允许来自不同行业的客户以既定的格式提交作业文件，与工作流程接口以确定弹性添加剂层结构的类型和位置，并承诺免费向工作流程供应添加剂层基材或购买先进高价值部件的全流程制造。全球医疗器械制造商寻求用于人类和兽医的下一代解剖匹配的功能植入物，将成为新的数字化添加剂制造工作流程的直接商业受益者。最终的受益者将是接受植入物的患者，植入后并发症大大减少。

Complex metal and polymer substrates produced in a digitised additive layer manufacturing workflow will be subjected to a new value adding digititised additive layer Flexomer process flow to improve the performance of current devices and enable entirely new high value products and sub-components. Composite, multi material elastomeric structures will be built up layer by layer on additively manufactured complex geometrical parts by accurate manipulation of deposition sources and substrates with computer controlled 6 axis robot arms and multi-axis work piece holders. Initial focus will be elastomeric structures which enhance osseointegration whilst providing potent antimicrobial function. Follow on applications will be new world components in space & aerospace, semiconductor equipment, sensors and instrumentation.... Flexomer materials developed from perfluoroelastomer will be tuned at their different stages in the digitised manufacturing workflow using high quality analytical tools. Fluids will be characterised using both rotational and extensional shear rheometry to build up the knowledge which relates particulate type and concentration in Flexomer fluids to the quality of the layer-by-layer deposition.Bond strengths of the additive layer Flexomer materials to the 'modified surface ' of additive layer substrates will be assessed using Instron peel testing equipment. Surface modification will be assessed using automated microabrasive powder blasting and high energy laser processing. The academic research team will assess two types of layer by layer deposition heads for highly accurate deposition of three dimensional structures. Firstly microsyringing will be optimised to define build Flexomer lines a fine as 0.1mm wide and microjetting will be optimised to create dots of 0.2mm diameter The aim of the research will be to help establish a UK owned digitised manufacturing technology which produces advanced additive layer elastomeric structures on high value additive layer components seamlessly. The design of the workflow will allow customer from different sectors to submit job files in established formats, interface with the workflow to determine type and location of the elastomeric additive layer structures, and commit to either free issue supply of additive layer substrates to the workflow or purchase full workflow manufacturing of advanced high value components.Global medical devices manufacturers pursuing next generation anatomically matched functional implants for human and veterinary will be the immediate commercial beneficiaries of the new digitised additive manufacturing workflow. The ultimate beneficiary will be the patients receiving implants with much reduced post implant complications.