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From prototypes to end user products through additive manufacturing

Sampaio, Álvaro M.; Almeida, José Carlos Ferreira; Pontes, A. J.

This paper challenges the notion that Additive Manufacturing (AM) is limited to prototyping by demonstrating its signifcant role in fnal product development. Through its ability to create complex geometries, optimize material usage, and consolidate parts, AM has evolved into an efective strategy for producing functional end-use products. The incorporation of Design for Additive Manufacturing (DfAM) principles e...


Cradle-to-gate life cycle assessment: a comparison of polymer and metal-based p...

Anwar, Talha; Lopes, Ana Carina Ferreira; Silva, Eva C.; Mould, Sacha Trevelyan; Sampaio, Álvaro M.; Pontes, A. J.

Diferent industries are adopting additive manufacturing (AM) technologies to produce complex designs with minimum material wastage. The sustainability assessment of AM technologies is therefore essential to address the current environmental challenges. This research aims to compare the environmental impacts of diferent raw materials used for the production of a robot end-efector with internal conformal channels...


Development and characterization of composite materials with multi-walled carbo...

Lopes, Ana Carina Ferreira; Sampaio, Álvaro M.; Pontes, A. J.

Purpose: With the technological progress, high-performance materials are emerging in the market of additive manufacturing to comply with the advanced requirements demanded for technical applications. In selective laser sintering (SLS), innovative powder materials integrating conductive reinforcements are attracting much interest within academic and industrial communities as promising alternatives to common engi...


Design and development of urban space products by large-scale robotic extrusion...

Santos, Afonso Henrique Freitas Ferreira; Sampaio, Álvaro M.; Costa, Artur José Teixeira; Pontes, A. J.

The production of products in additive manufacturing systems through the extrusion of material using robotic arms requires new paradigms ranging from product design, material selection, material processability, communication with the production system, production control, etc. The development of products through these technologies allows the production of solutions of considerable scale and innovation. These ap...


Design and industrial implementation of a multi-functional part produced by pow...

Lopes, A. C.; Sampaio, Álvaro M.; Fernandes, F.; Vaz, P. M.; Pontes, A. J.

The use of robot end-effectors programmed to perform handling tasks in industrial environments has expanded in several sectors as a consequence of the rapid digital transformation seen in recent years. With such growing demands, additive manufacturing is evolving in the robotics field with more efficient, innovative, and customer-specific solutions owing to its design flexibility. Thus, this work presents a rob...


Design of nozzles for surface mount technologies produced by additive manufactu...

Sampaio, Álvaro M.; Miranda, Ana C.; Pontes, A. J.

The increasing use and production of electronic systems, equipped with multiple PCBs, leads to constant development in manufacturing technologies. A predominant choice in PCB production is Surface Mount Technology (SMT). The most important phase of the SMT process is the pickup and placement step, where nozzles, specific to the electronic component, are responsible to pick components and place them on the PCB. ...


Design and development of an Automatic Optical Inspection (AOI) system support ...

Sampaio, Álvaro M.; Lima, André; Silva, Cátia Samanta Ribeiro; Carneiro, Vítor H.; Fernandes, Fábio; Fernandes, André; Pontes, A. J.

Visual inspection of components, subassemblies and final products is an essential step to ensure the quality control of ready-to-market electronic components. In many manufacturing plants, including Bosch Car Multimedia S.A., typically automated systems for automatic optical inspection (AOI) are implemented at several workstations to perform visual verification and validation in between critical production task...


From transparent to opaque: a route towards multifunctional parts injected with...

Pedroso, Luís D.; Pontes, A. J.; Alves, António; Duarte, F. M.; Carneiro, O. S.

The technological, social and economic development observed in recent decades brought an exponential increase in consumption and inherent new challenges. Recycling is one of the best solutions to minimize the environmental impact of raw materials. However, multi-material components are difficult or even impossible to recycle. The present work focuses on the reduction in the number of different materials used in...


Design optimization of conformal cooling channels for injection molds: 3D trans...

Silva, Hugo Miguel Andrade Lopes Figueiredo; Noversa, João Tiago; Fernandes, Leandro; Rodrigues, Hugo Luís; Pontes, A. J.

This research aims to enhance the design of an injection mold in order to minimize ejection time and increase temperature uniformity by repositioning cooling channels. For 3D transient thermal simulations, the ANSYS finite element method (FEM) program was employed, while the MATLAB program was used for optimization. It was discovered that the method could be used successfully to optimize the design of Conformal...


Development of an open-source injection mold monitoring system

Gomes, Tiago E. P.; Cadete, Mylene S.; Ferreira, Jorge A. F.; Febra, Renato; Silva, João; Noversa, João Tiago Gomes; Pontes, A. J.; Neto, Victor

In the highly competitive injection molding industry, the ability to effectively collect information from various sensors installed in molds and machines is of the utmost relevance, enabling the development of data-based Industry 4.0 algorithms. In this work, an alternative to commercially available monitoring systems used in the industry was developed and tested in the scope of the TOOLING 4G project. The nove...


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