Aerosol Jet technology is for additive manufacturing of electronic applications
such as fully additive manufactured strain gauges, vibration sensors,
temperature sensors, antennas, and moulded interconnect devices (MIDs).
This project aims to develop a system to
successfully develop sensors using novel multi-material additive manufacturing
and 3D printing technologies for condition monitoring of mechanical components
and develop proactive decision-making algorithms to recommend condition based
The objective of this project is to develop proactive condition monitored mechanical
· Development of sensors using novel multi-material additive
manufacturing and 3D printing technologies
of proactive decision-making software to recommend condition based maintenance
on the customized sensors.
Figure. 1: Failure Modes
and Effect Analysis (FMEA), Finite Element Analysis (FEA), Multilayer
Perceptron Artificial Neural Network and the temperature sensor design were
investigated to develop the customized 3D printed sensors based on failure
mechanisms of components.
To date, strain gauges have been designed and printed,
while the optimal design to improve the sensitivity of single-metal
thermocouple (SMC) was being developed. A customizable multifunctional
sensor design, which can measure both strain and temperature simultaneously, has
been proposed. In addition, measurement of acceleration is possible if sensor
is mounted on a cantilever beam, making it a 3-in-1 sensor. Part of the sensor
is 3D printed allowing its properties to be easily modified.
The key benefits arising from this project are:
Pre-emptive maintenance before the break
down of a component to enable for safe and reliable travel with minimum
Machine Learning algorithms to minimise false alarms and and also provides sharper diagnoses.
- Production of integrated sensors which enables organic condition monitoring capabilities.