ALF: Additive Layer Flexomer manufacturing

在数字化增材层制造流程中生产的复杂金属和聚合物基板将接受新的数字化增材层Flexomer工艺流程的增值，以提高当前设备的性能，并实现全新的高价值产品和子组件。复合材料，多材料弹性体结构将通过计算机控制的6轴机械臂和多轴工件夹具精确操纵沉积源和基底，在增材制造的复杂几何零件上逐层构建。最初的重点将是弹性结构，增强骨整合，同时提供有效的抗菌功能。后续应用将是空间和航空航天，半导体设备，传感器和仪器仪表的新世界组件。由全氟弹性体开发的Flexomer材料将在数字化制造工作流程的不同阶段使用高质量的分析工具进行调整。将使用旋转和拉伸剪切流变仪对流体进行表征，以建立将Flexomer流体中的颗粒类型和浓度与逐层沉积质量相关的知识。将使用Instron剥离测试设备评估增材层Flexomer材料与增材层基材“改性表面”的粘合强度。将使用自动微磨料粉末喷砂和高能激光处理评估表面改性。学术研究团队将评估两种类型的逐层沉积头，以实现三维结构的高精度沉积。首先，微喷射将被优化，以定义0.1 mm宽的Flexomer生产线，微喷射将被优化，以创建0.2 mm直径的点。该研究的目的是帮助建立一个英国拥有的数字化制造技术，该技术可以无缝地在高价值的增材层组件上生产先进的增材层弹性体结构。工作流程的设计将允许来自不同部门的客户以既定格式提交作业文件，与工作流程对接以确定弹性体增材层结构的类型和位置，并承诺为工作流程免费提供增材层基材或购买先进高价值组件的完整工作流程制造。全球医疗器械制造商追求下一代解剖学匹配功能人类和兽医植入物将成为新的数字化增材制造工作流程的直接商业受益者。最终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.