Information exchange standards for design,tolerancing and Additive Manufacturing: a research review

Nowadays, the implementation of digital thread for Additive Manufacturing (AM) and product data management system strongly depends on specified file formats and used interoperability standards in order to integrate geometric dimensioning and tolerancing (GD&T) information directly in the 3D CAD model. The consideration of geometric deviations and variations is a key issue for design and tolerancing, inspection and management of manufacturing part information in AM through product and manufacturing information (PMI). PMI has been used to describe GD&T and non-geometric data, such as surface texture, surface finishing requirements, material specifications, process data, and other annotations, based on ISO standards. Standards play an important role in enabling the interoperability and efficiency of AM systems through the development of AM standard formats. This paper reviews current challenges of geometric and tolerancing model and formats for AM processes, which largely impede the advancement of AM technologies. Two criteria to enhance AM geometric and tolerancing model and standards are presented in this paper: GD&T management and compliance with PMI. STL, AMF and STEP formats are discussed on their characteristics of product definition and manufacturing specification for AM. The review presented here highlights that STEP standard can be a good basis for future research work to integrate and standardise material information, geometric and tolerancing model, and process planning for AM. Finally, new specifications of STEP-AM format are proposed in this work.     

Off-line view planning for the inspection of mechanical parts

3D optical scanning systems are used more and more for quality control purposes. The effective utilization of such systems needs an efficient virtual planning of the product acquisition viewpoints. Literature shows how 3D CAD product models can be used as reference in order to manage the verification process and as a basis for the computation of the optimal viewpoints. However, in the mechanical field, a variety of inspection tasks is experienced by engineers involved in the quality control process: GD&T verification, production phases control such as sheet metal cutting, evaluation of aesthetic appearance of parts, global shape deformation measurement and specific point deviations assessment. This leads to the necessity of flexible view planning approaches which adapt to the specificity of the required inspection task. The present work targets the development of a comprehensive view planning approach in which several algorithmic options are triggered by the product features to be inspected. Algorithms have been implemented in a prototypal software system which has been experimented as an off-line application to provide inputs to a multi-axis degree of freedom robot arm mounting an optical 3D scanner. Two test cases from die casting and automotive fields are presented. They show the computation of acquisition poses in a suitable sequence and efficiency in the obtained results.     

Design and development of a novel body scanning system for healthcare applications

This paper presents a novel instant 3D whole body scanner for healthcare applications. It is based on photogrammetry, a digital technology which allows to reconstruct the surface of objects starting from multiple pictures. The motivation behind this work is the development of minimally invasive procedures for instant data acquisitions of anatomical structure. The scanner provides several features of interests in 3D body scanning technologies for the healthcare domains: (i) instant capture of human body models; (ii) magnitude of accuracy in the order of 1 mm; (iii) simplicity of use; (iv) possibility to scan using different settings; (v) possibility to reconstruct the texture. The system is built upon a modular and distributed architecture. In this paper we highlight its key concepts and the methodology which has led to the current product. We illustrate its potential through one of the most promising 3D scanning healthcare applications: the data acquisition and processing of human body models for the digital manufacturing process of prostheses and orthoses. We validate the overall system in terms of conformity with the the initial requirements.     

The process of designing a rotating platform artificial knee prosthesis with posterior stabilizers by finite element analysis

The purpose of this paper is to design a rotating platform knee prosthesis with posterior stabilizers. This design is based on reverse engineering and interactive acquisition and reconstruction of 3D models combined with the finite element method. A 3D geometric model of a healthy knee joint was created from an anatomical knee model by using an active acquisition system based on a 3D scanner. This healthy model comprises a portion of the long bones (femur, tibia and fibula), as well as the transverse ligament, medial collateral ligament, posterior cruciate ligament, anterior cruciate ligament, medial meniscus and cartilage. The digital model that was obtained was repaired and converted to an engineering drawing format by use of CATIA© software. Also, based on the foregoing format, a rotating platform knee prosthesis was designed and assembled by this software. Once the healthy and artificial models were repaired, the Mentat Marc© software was used to develop the healthy and artificial knee FE models. From the anthropometry of the human body, a combination of loads and positions were obtained by use of 3D Static Strength Prediction software. The normal stresses, Von Mises stresses and all relative displacements of the healthy and artificial knee FE model were determined. The Von Mises stresses on both the cortical and the trabecular bone of the artificial and healthy knee FE model were analyzed and compared. The prosthesis was designed for the knee of a male patient of height and body weight of 190 cm and 120 kg, respectively.     

Fast and accurate mesh registration applied to in-line dimensional inspection processes

Dimensional inspection is a critical step in product manufacturing processes where final assemblers require very tight tolerance levels. New measurement tools such as 3D scanners are becoming a very good alternative to inspect parts where the whole surface needs to be analysed. This process involves registering input data from the scanner with a reference geometry in order to measure dimensional deviations. However it has high computing requirements due to the amount of points that are sampled from the surface of the part being inspected that makes it not suitable for in-line inspection processes. In this paper a fast and robust method is proposed to register 3D meshes with reference geometries for dimensional inspection purposes. It implements the standard metrology alignment pipeline based on geometrical reference features obtained from the reference mesh. Experiments on both real and synthetic data analyses the accuracy and robustness of the method, and compares its efficiency with commercially available software. The method has been validated in an industrial manufacturing environment demonstrating its effectiveness under real conditions.     

Comparison of coronary stenosis quantitation results from on-line digital and digitized cine film images

To examine the effects of digital image acquisition mode and subtraction techniques on the results of coronary stenosis quantitation, 100 discrete lesions from 45 patients undergoing routine diagnostic angiography were analyzed in each of 3 image types: direct on-line digital, electrocardiogram-gated digital subtraction and digitized cine film images. For the geometric measurements (minimal lumen diameter and percent diameter stenosis) correlation coefficients for 2-way comparisons among the image types ranged from 0.90 to 0.96. Linear regression slopes ranged from 0.93 to 1.00, with intercepts from 0.03 to 0.07 mm for minimal diameter and -0.5 to 4.4% for percent diameter stenosis. For the videodensitometric percent area stenosis data, the correlation coefficients ranged from 0.80 to 0.89, with linear regression slopes from 0.84 to 0.89 and intercepts from 8.3 to 12.8%. Thus, the results of quantitative geometric measurements of coronary stenosis severity were not strongly affected by image acquisition mode (on-line versus cine film digitization) or by electrocardiogram-gated digital subtraction, while densitometric data correlated less well when on-line digital and digitized cine film acquisition methodology were compared.     

Statistical Analysis and Optimisation of Data for the Design and Evaluation of the Shear Spinning Process

This work proposes a research method that is a scheme that can be universally applied in problems based on the selection of optimal parameters for metal forming processes. For this purpose, statistical data optimisation methods were used. The research was based on the analysis of the shear spinning tests performed in industrial conditions. The process of shear spinning was conducted on the components made of Inconel 625 nickel superalloy. It was necessary to select the appropriate experimental plan, which, by minimising the number of trials, allowed one to draw conclusions on the influence of process parameters on the final quality of the product and was the starting point for their optimisation. The orthogonal design 2III3−1 is the only design for three factors at two levels, providing non-trivial and statistically significant information on the main effects and interactions for the four samples. The samples were analysed for shape and dimensions using an Atos Core 200 3D scanner. Three-dimensional scanning data allowed the influence of the technological parameters of the process on quality indicators, and thus on the subsequent optimisation of the process, to be determined. The methods used proved to be effective in the design, evaluation and verification of the process.     

Digital signal and image processing in echocardiography

Digital signal and image processing techniques are acquiring an increasingly important role in the generation and analysis of cardiac images. This is particularly true of 2D echocardiography, in which image acquisition, manipulation, and storage within the echocardiograph, as well as quantitative analysis systems, depend upon digital techniques. The increasing role of computers in echocardiography it essential that echocardiographers and technologists understand the basic principles of digital techniques applied to echocardiographic instrumentation and data analysis. In this article, we have discussed digital techniques as applied to image generation (digital scan conversion, preprocessing, and postprocessing) as well as to the analysis of image data (computer-assisted border detection, 3D reconstruction, tissue characterization, and contrast echocardiography); a general introduction to off-line analysis systems was also given. Experience with other cardiac imaging methods indicates that digital techniques will likely play a dominant role in the future of echocardiographic imaging.     

Imaging techniques in cardiology: three-dimensional echocardiography

Three-dimensional echocardiography offers new opportunities for clinical cardiology and the solution of scientific questions. Data acquisition is possible using different techniques: (1) Realtime 3D echocardiography with matrix-array transducers is the most promising approach, but is still limited by several difficulties; (2) 3D reconstruction is based on a number of sequentially acquired 2D image planes (like in multiplane TEE), which are put together afterwards. There are 2 ways of data analysis. 1. Morphological analysis. Surface rendering of the endocardial border can create perspectives not achievable with conventional methods such as the "en face" view of atrial septal defects or the atrial view of the mitral valve. Prolapsing leaflets and the spatial relationship can be identified much easier than using 2D methods. In complex congenital heart disease 3D echo may provide better spatial orientation and easier communication with the cardiothoracic surgeons. 2. Quantitative analysis of volumes, masses, and surfaces is only possible after manual contour tracing with several cut planes generated from the 3D data set. This procedure is time consuming and limits the use in clinical routine, even though validation studies demonstrated that 3D echo determination of masses and volumes is superior to one- or two-dimensional techniques which are based on geometric assumptions. Furthermore, quantitative 3D analysis has a unique pre- and postinterventional diagnostic potential. FUTURE PERSPECTIVES: Combination with color Doppler data may lead to a more precise quantitation of valve regurgitations. Improvements of hard- and software will allow faster acquisition, reconstruction, and quantitative analysis. Assessment of regional myocardial perfusion may be possible in combination with left heart contrast agents. CONCLUSION: 3D echocardiography allows perspectives not achievable conventionally and has a great potential for precise quantitative and reproducible analysis of cardiac morphology which overcomes the limitations of 2D echocardiography.     

Digital signal and image processing in echocardiography. The American Society of Echocardiography

Digital signal and image processing techniques are acquiring an increasingly important role in the generation and analysis of cardiac images. This is particularly true of 2D echocardiography, in which image acquisition, manipulation, and storage within the echocardiograph, as well as quantitative analysis of echocardiographic data by means of "off-line" systems, depend upon digital techniques. The increasing role of computers in echocardiography makes it essential that echocardiographers and technologists understand the basic principles of digital techniques applied to echocardiographic instrumentation and data analysis. In this article, we have discussed digital techniques as applied to image generation (digital scan conversion, preprocessing, and postprocessing) as well as to the analysis of image data (computer-assisted border detection, 3D reconstruction, tissue characterization, and contrast echocardiography); a general introduction to off-line analysis systems was also given. Experience with other cardiac imaging methods indicates that digital techniques will likely play a dominant role in the future of echocardiographic imaging.     

Accuracy of Digital Impression Taking with Intraoral Scanners and Fabrication of CAD/CAM Posts and Cores in a Fully Digital Workflow

Current intraoral scanners (IOS) enable direct impression taking for computer-aided de-sign/computer-aided manufacturing (CAD/CAM) posts and cores (P+C) with subsequent milling out of monolithic materials. The aim of this in vitro study was to systematically investigate the accuracy of CAD/CAM-P+C in a fully digital workflow, considering different IOS impression methods (Primescan (PRI), Trios4 without (TRI) and with scanpost (TRI+SP)) (Part A), and CAD/CAM milling of zirconium dioxid (ZIR) and resin composite (COM)-P+C (Part B). Five human models were developed in this study. Micro-CT imaging was used as a reference (REF). For Part A, the models were scanned 12 times for each impression method. Then, IOS datasets (n = 180) were superimposed with REF, and scan accuracy was determined using 3D software (GOMInspect). For Part B, one CAD/CAM-P+C (n = 30) was milled for each model, impression method, and material. The triple-scan method was applied using an industrial scanner (ATOS) to determine the accuracy of the fit. Statistical analysis was performed using analysis of variance (ANOVA, p < 0.05). Part A showed for PRI significantly lower accuracy than TRI and TRI+SP (p < 0.05). The data of Part B revealed significantly higher accuracy for ZIR than for COM (p < 0.05). Within the limitations of this study, CAD/CAM-P+C of the ZIR can be recommended for fabrication in a fully digital workflow regarding the accuracy of fit.     

Determination of the Actual Stress–Strain Diagram for Undermatching Welded Joint Using DIC and FEM

This paper presents new methodology for determining the actual stress–strain diagram based on analytical equations, in combination with numerical and experimental data. The first step was to use the 3D digital image correlation (DIC) to estimate true stress–strain diagram by replacing common analytical expression for contraction with measured values. Next step was to estimate the stress concentration by using a new methodology, based on recently introduced analytical expressions and numerical verification by the finite element method (FEM), to obtain actual stress–strain diagrams, as named in this paper. The essence of new methodology is to introduce stress concentration factor into the procedure of actual stress evaluation. New methodology is then applied to determine actual stress–strain diagrams for two undermatched welded joints with different rectangular cross-section and groove shapes, made of martensitic steels X10 CrMoVNb 9-1 and Armox 500T. Results indicated that new methodology is a general one, since it is not dependent on welded joint material and geometry.     

Ceramic Biomaterial Pores Stereology Analysis by the Use of Microtomography

The main aim of this study was to analyze microtomographic data to determine the geometric dimensions of a ceramic porous material’s internal structure. Samples of a porous corundum biomaterial were the research material. The samples were prepared by chemical foaming and were measured using an X-ray scanner. In the next stage, 3D images of the samples were generated and analyzed using Thermo Scientific Avizo software. The analysis enabled the isolation of individual pores. Then, the parameters characterizing the pore geometry and the porosity of the samples were calculated. The last part of the research consisted of verifying the developed method by comparing the obtained results with the parameters obtained from the microscopic examinations of the biomaterial. The comparison of the results confirmed the correctness of the developed method. The developed methodology can be used to analyze biomaterial samples to assess the geometric dimensions of biomaterial pores.     

Magnetic resonance imaging based colonography for diagnosis and assessment of diverticulosis and diverticulitis

Background and aims MRI-based colonography is a new minimally invasive imaging modality to assess the colon and abdomen. This new method which is applied mainly for polyp screening could be an integrative approach for colonic diverticulitis assessment. This study evaluated the feasibility of MRI-based colonography to assess diverticulosis or diverticulitis.Patients and methods Fourteen consecutive patients with clinically suspected diverticulitis were examined by MRI colonography on a 1.5-T scanner. All patients underwent abdominal CT as gold standard. N-Butyl-scopalamin was given intravenously to reduce bowel peristalsis. After rectal administration of a T1-positive enema T1- and T2-weighted acquisitions with additional intravenous contrast were obtained. A 3D FLASH sequence was acquired for virtual colonography. The results were compared with CT and biological parameters such as white blood cell count and C-reactive protein.Results Of 56 bowel segments (sigmoid colon, descending colon, transverse colon, ascending colon) in all 14 patients 54 were assessed to have good to fair image quality. Having CT as standard of reference, all sigmoid diverticula were diagnosed based on MRI. Inflammation as judged by CT was identically assessed on MRI. 3D models of the colon revealed further diverticula in the remaining colon; additionally, the 3D models gave a comprehensive image for surgical planning.Conclusion In our preliminary study MRI colonography revealed the same diagnosis as CT in all patients without ionizing radiation. Additionally, 3D-rendered models and virtual colonoscopy can be performed. This comprehensive 3D models could replace presurgical planning barium enema with concurrent assessment of the residual colon.     

Measurement of volumetric mitral and aortic blood flow based on a new freehand three-dimensional colour flow imaging method. An in vivo validation.

AIMS: To validate a new three-dimensional (3D) colour flow method used to calculate cardiac output (CO) in aortic and mitral blood flow. METHODS: The transducer was freely tilted transthoracically using a magnetic locating device recording its spatial position. Raw digital ultrasound data were recorded in healthy subjects during 10-20 heartbeats at a high frame rate ranging from 41 to 66 frames/s and analysed off-line with no loss in temporal resolution. Blood flow velocities aligned with the ultrasound beam were integrated across a moving spherical surface to calculate volumetric flow. RESULTS: The range of agreement between the 3D mitral and 3D aortic method was 0.04+/-1.32 l/min (mean+/-2 standard deviations). The range of agreement between 3D aortic flow and the two-dimensional (2D) pulsed wave Doppler method (2DPW) in the left ventricular outflow tract (LVOT) was 0.7+/-1.7 l/min, while the range of agreement between 3D mitral flow and the 2DPW method was 0.88+/-1.64 l/min. CONCLUSION: The 3D methods agreed well. The 3D volumetric flow overestimated the 2DPW method, as expected, and the range of agreement was wide. The common pitfalls in pulsed wave ultrasound methods to calculate CO were avoided, as the 3D method was angle-independent, no assumptions about the velocity profile were made, and a moving sample surface was applied. The acquisition of data was fast and easy and high temporal resolution was achieved.     

A new dynamic three-dimensional digital color doppler method for quantification of pulmonary regurgitation: validation study in an animal model

OBJECTIVES: The purpose of the present study was to validate a newly developed three-dimensional (3D) digital color Doppler method for quantifying pulmonary regurgitation (PR), using an animal model of chronic PR. BACKGROUND: Spectral Doppler methods cannot reliably be used to assess pulmonary regurgitation. METHODS: In eight sheep with surgically created PR, 27 different hemodynamic states were studied. Pulmonary and aortic electromagnetic (EM) probes and meters were used to provide reference right ventricular (RV) forward and pulmonary regurgitant stroke volumes. A multiplane transesophageal probe was placed directly on the RV and aimed at the RV outflow tract. Electrocardiogram-gated and rotational 3D scans were performed for acquiring dynamic 3D digital velocity data. After 3D digital Doppler data were transferred to a computer workstation, the RV forward and pulmonary regurgitant flow volumes were obtained by a program that computes the velocity vectors over a spherical surface perpendicular to the direction of scanning. RESULTS: Pulmonary regurgitant volumes and RV forward stroke volumes computed by the 3D method correlated well with those by the EM method (r = 0.95, mean difference = 0.51 +/- 1.89 ml/beat for the pulmonary regurgitant volume; and r = 0.91, mean difference = -0.22 +/- 3.44 ml/beat for the RV stroke volume). As a result of these measurements, the regurgitant fractions derived by the 3D method agreed well with the reference data (r = 0.94, mean difference = 2.06 +/- 6.11%). CONCLUSIONS: The 3D digital color Doppler technique is a promising method for determining pulmonary regurgitant volumes and regurgitant fractions. It should have an important application in clinical settings.     

Recognition of intrinsic quality properties for automatic geometric inspection

In the last few years the need for methodologies capable of performing an automated geometric inspection has increased. These methodologies often use 3D high-resolution optical digitisers to acquire points from the surface of the object to be inspected. It is expected that, in the near future, geometric inspection will be requiring more and more the use of these instruments. At present geometric inspection is not profiting from all the opportunities attainable by 3D high-resolution optical scanners or from the numerous tools which can be used for processing the point cloud acquired from the inspected product. For some years now, these authors have been working on a new methodology for automatic tolerance inspection working from a 3D model acquired by optical digitisers. In this paper all the information recognisable in a scanned object is organised into a new data structure, called Recognised Geometric Model (RGM). The final aim is to define a representation of the inspected object for the automatic evaluation of the non-idealities pertaining to the form, orientation and location of the non-ideal features of the acquired object. The key concept of the proposed approach is the capability to recognise some intrinsic nominal properties of the acquired model. These properties are assumed as references to evaluate the non-idealities of the inspected object. With this approach the references of geometric inspection are searched for in the inspected object independently of a tolerance specification and of the availability of a 3D nominal representation. The high-level geometric information within RGM depends on the rules used for its identification. The capability to recognise specific categories of nominal references offers the possibility of introducing new tolerances to be specified. The proposed approach has been implemented in original software by means of which a specific test case has been analysed.     

A Novel Approach to the Holistic 3D Characterization of Weld Seams—Paving the Way for Deep Learning-Based Process Monitoring

In an industrial environment, the quality assurance of weld seams requires extensive efforts. The most commonly used methods for that are expensive and time-consuming destructive tests, since quality assurance procedures are difficult to integrate into production processes. Beyond that, available test methods allow only the assessment of a very limited set of characteristics. They are either suitable for determining selected geometric features or for locating and evaluating internal seam defects. The presented work describes an evaluation methodology based on microfocus X-ray computed tomography scans (µCT scans) which enable the 3D characterization of weld seams, including internal defects such as cracks and pores. A 3D representation of the weld contour, i.e., the complete geometry of the joint area in the component with all quality-relevant geometric criteria, is an unprecedented novelty. Both the dimensions of the weld seam and internal defects can be revealed, quantified with a resolution down to a few micrometers and precisely assigned to the welded component. On the basis of the methodology developed within the framework of this study, the results of the scans performed on the alloy AA 2219 can be transferred to other aluminum alloys. In this way, the data evaluation framework can be used to obtain extensive reference data for the calibration and validation of inline process monitoring systems employing Deep Learning-based data processing in the scope of subsequent work.     

Tri-Planar Geometric Dimensioning and Tolerancing Characteristics of SS 316L Laser Powder Bed Fusion Process Test Artifacts and Effect of Base Plate Removal

The precision of LPBF manufactured parts is quantified by characterizing the geometric tolerances based on the ISO 1101 standard. However, there are research gaps in the characterization of geometric tolerance of LPBF parts. A literature survey reveals three significant research gaps: (1) systematic design of benchmarks for geometric tolerance characterization with minimum experimentation; (2) holistic geometric tolerance characterization in different orientations and with varying feature sizes; and (3) a comparison of results, with and without the base plate. This research article focuses on addressing these issues by systematically designing a benchmark that can characterize geometric tolerances in three principal planar directions. The designed benchmark was simulated using the finite element method, manufactured using a commercial LPBF process using stainless steel (SS 316L) powder, and the geometric tolerances were characterized. The effect of base plate removal on the geometric tolerances was quantified. Simulation and experimental results were compared to understand tolerance variations using process variations such as base plate removal, orientation, and size. The tolerance zone variations not only validate the need for systematically designed benchmarks, but also for tri-planar characterization. Simulation and experimental result comparisons provide quantitative information about the applicability of numerical simulation for geometric tolerance prediction for the LPBF process.     

Longitudinal study investigating serum metabolites and their association with type 2 diabetes risk in a Korean population

Aim

The lack of longitudinal metabolomics data and the statistical techniques to analyse them has limited the understanding of the metabolite levels related to type 2 diabetes (T2D) onset. Thus, we carried out logistic regression analysis and simultaneously proposed new approaches based on residuals of multiple logistic regression and geometric angle-based clustering for the analysis in T2D onset-specific metabolic changes.

Materials and methods

We used the sixth, seventh and eighth follow-up data from 2013, 2015 and 2017 among the Korea Association REsource (KARE) cohort data. Semi-targeted metabolite analysis was performed using ultraperformance liquid chromatography/triple quadrupole-mass spectrometry systems.

Results

As the results from the multiple logistic regression and a single metabolite in a logistic regression analysis varied dramatically, we recommend using models that consider potential multicollinearity among metabolites. The residual-based approach particularly identified neurotransmitters or related precursors as T2D onset-specific metabolites. By using geometric angle-based pattern clustering studies, ketone bodies and carnitines are observed as disease-onset specific metabolites and separated from others.

Conclusion

To treat patients with early-stage insulin resistance and dyslipidaemia when metabolic disorders are still reversible, our findings may contribute to a greater understanding of how metabolomics could be used in disease intervention strategies during the early stages of T2D.