Designing for Feature Preservation and Build Improvement in Fused Deposition Manufacture

1999 ◽  
Author(s):  
Vikram R. Jamalabad ◽  
Charles J. Gasdaska ◽  
Jeffrey A. Chard
Keyword(s):  
Tool Path ◽  
Solid Freeform Fabrication ◽  
Post Processing ◽  
Metal Part ◽  
Binder Removal ◽  
Freeform Fabrication ◽  
Fused Deposition ◽  
Feature Preservation ◽  
Toolpath Generation ◽  
Extract Information

Abstract A common problem facing designers utilizing Solid Freeform Fabrication techniques is the divergence between expected designs and obtained components. The causes range from processing issues (warpage and shrinkage) to discretization issues (reduction of 3-D components to 2-D or 1-D tool path plans). This problem is further compounded when post-processing issues (binder removal and sintering) are added on for applications like ceramic and metal part manufacture. Utilizing the build procedure to ensure that the part is built as expected is useful in reducing the time to manufacture. In addition, the preservation of features and resolution of feature conflict can be addressed. In this paper we specifically look at the toolpath generation procedures for Fused Deposition to extract information regarding the loss or alteration in original features. Further, we use this information to preserve, alter or resolve features. Due to the build procedures, the problems are inherently 2-dimensional in nature.

Characterization of Permeability for Solid Freeform Fabricated Porous Structures

1999 ◽  
Author(s):  
Merve Erdal ◽  
Levent Ertoz ◽  
Selçuk Güçeri
Keyword(s):  
Solid Freeform Fabrication ◽  
Pore Geometry ◽  
Fluid Viscosity ◽  
Porous Structures ◽  
Permeability Measurement ◽  
Porous Flow ◽  
Freeform Fabrication ◽  
Fused Deposition ◽  
Order Of Magnitude

Abstract Fused deposition based solid freeform fabrication technique allows manufacturing of potential functional preforms for subsequent Resin Transfer Molding. In this study, the transport property (permeability) of solid freeform fabricated porous preform geometries are investigated. Specifically the effect of pore geometry and network on the permeability is sought. Wet (saturated) permeability experiments were performed for various pore geometries with different viscosity liquids. For all fluids and preform structures investigated in this study, the porous flow exhibited Darcian behavior. The permeability is affected by changes in order of magnitude of fluid viscosity, the effect considerably significant in low porosity preforms. Current work concentrates on dry permeability measurement and development of numerical permeability models for ordered pore geometries (as produced through SFF) that will be compared with experimental results.

Solid Freeform Fabrication of Silicon Nitride Ceramics

1998 ◽  
Vol 542 ◽  
Author(s):  
C. J. Gasdaska ◽  
R. Clancy ◽  
V. Jamalabad ◽  
D. Dalfonzo
Keyword(s):  
Thermal Expansion ◽  
Silicon Nitride ◽  
Solid Freeform Fabrication ◽  
Freeform Fabrication ◽  
Fused Deposition ◽  
Thermal Expansion Coefficients ◽  
Processed Material ◽  
Nitride Ceramics ◽  
Internal Cavities ◽  
Expansion Coefficients

AbstractSilicon nitride ceramics have been prepared using the fused deposition (FD) process in a Stratasys 1650 modeler. Two types of silicon nitride have been prepared: GS44 and AS800. AS800 is processed and used at higher temperatures than GS44. The strength of machined surfaces of either type of silicon nitride prepared using FD is comparable to conventionally processed material. Using standard build conditions strengths for as-built and as-sintered surfaces are approximately 50% lower. The additive nature of solid freeform processes also allows multi-material combinations to be deposited which result in enhanced performance. For example, combinations of silicon nitride based materials with different thermal expansion coefficients have been prepared which demonstrate strength increases > 20%. In addition, components containing complicated internal cavities may also be fabricated.

Direct 3D Layer Metal Deposition and Toolpath Generation

2008 ◽  
Author(s):  
Jianzhong Ruan ◽  
Lie Tang ◽  
Todd E. Sparks ◽  
Robert G. Landers ◽  
Frank Liou
Keyword(s):  
Solid Freeform Fabrication ◽  
Deposition Method ◽  
Single Track ◽  
Uniform Thickness ◽  
Post Processing ◽  
Freeform Fabrication ◽  
Manufacturing Efficiency ◽  
Layer Deposition ◽  
Staircase Effect ◽  
Parallel Layer

Multi-axis slicing for solid freeform fabrication (SFF) manufacturing process can yield non-uniform thickness layers, or 3-D layers. Using the traditional parallel layer construction approach to build such a layer leads to a staircase which requires machining or other post processing to form the desired shape. This paper presents a direct 3-D layer deposition approach. This approach uses an empirical model to predict the layer thickness based on experimental data. The toolpath between layers is not parallel; instead, it follows the final shape of the designed geometry and the distance between the toolpath in the adjacent layers varies at different locations. Directly depositing a 3-D layer not only eliminates the staircase effect, but also improves the manufacturing efficiency by shortening the deposition and machining times. A single track deposition experiment has demonstrated these advantages. Thus, it is a beneficial addition to the traditional parallel deposition method.

Design of Fused-Deposition ABS Components for Stiffness and Strength

2000 ◽  
Author(s):  
José F. Rodríguez ◽  
James P. Thomas ◽  
John E. Renaud
Keyword(s):  
Mechanical Performance ◽  
Solid Freeform Fabrication ◽  
Acrylonitrile Butadiene Styrene ◽  
Freeform Fabrication ◽  
Fused Deposition ◽  
Load Carrying ◽  
Volume Production ◽  
Approximate Minimization ◽  
High Degree ◽  
Functional Components

Abstract The high degree of automation of Solid Freeform Fabrication (SFF) processing and its ability to create geometrically complex parts to precise dimensions provide it with a unique potential for low volume production of rapid tooling and functional components. A factor of significant importance in the above applications is the capability of producing components with adequate mechanical performance (e.g., stiffness and strength). This paper introduces a strategy for the optimizing the design of Fused-Deposition Acrylonitrile-Butadiene-Styrene (FD-ABS) components for stiffness and strength. In this strategy, a mathematical model of the structural system is linked to an approximate minimization algorithm to find the settings of select manufacturing parameters which optimize the mechanical performance of the component. The methodology is demonstrated by maximizing the load carrying capacity of a two-section cantilevered FD-ABS beam.

Processing of Novel Electroceramic Components by SFF Techniques

1998 ◽  
Vol 542 ◽  
Author(s):  
A. Safari ◽  
S. C. Danforth ◽  
A. L. Kholkin ◽  
I. A. Cornejo ◽  
F. Mohammadi ◽  
...  
Keyword(s):  
Computer Aided Design ◽  
Composite Structures ◽  
Volume Fraction ◽  
Solid Freeform Fabrication ◽  
Side Lobe ◽  
Electromechanical Properties ◽  
Freeform Fabrication ◽  
Fused Deposition ◽  
Fused Deposition Of Ceramics ◽  
Aided Design

AbstractNovel piezoelectric ceramic and ceramic/polymer composite structures were fabricated by solid freeform fabrication (SFF) for sensor and actuator applications. SFF techniques including fused deposition of ceramics (FDC) and Sanders prototyping (SP) were utilized to fabricate a variety of complex structures directly from a computer aided design (CAD) file. Novel composite structures including volume fraction gradients (VFG) and staggered rods, as well as actuator designs such as tubes, spirals and telescopes were made using the flexibility provided by the above processes. VFG composites were made by SP technique with the ceramic content decreasing from the center towards the edges. This resulted in a reduction of side lobe intensity in the acoustic beam pattern. The FDC technique was used to manufacture high authority actuators utilizing novel designs for the amplification of strain under applied electric field. The design, fabrication and electromechanical properties of these composite and actuator structures are discussed in this paper.

scholarly journals Main 3D Manufacturing Techniques for Customized Bone Substitutes. A Systematic Review

Materials ◽  
2021 ◽  
Vol 14 (10) ◽  
pp. 2524
Author(s):  
Javier Montero ◽  
Alicia Becerro ◽  
Beatriz Pardal-Peláez ◽  
Norberto Quispe-López ◽  
Juan-Francisco Blanco ◽  
...  
Keyword(s):  
Bone Regeneration ◽  
Fused Deposition Modeling ◽  
Solid Freeform Fabrication ◽  
Bone Substitutes ◽  
Cochrane Library ◽  
3D Scaffold ◽  
Hand Search ◽  
Freeform Fabrication ◽  
Fused Deposition ◽  
Bone Scaffolds

Clinicians should be aware of the main methods and materials to face the challenge of bone shortage by manufacturing customized grafts, in order to repair defects. This study aims to carry out a bibliographic review of the existing methods to manufacture customized bone scaffolds through 3D technology and to identify their current situation based on the published papers. A literature search was carried out using “3D scaffold”, “bone regeneration”, “robocasting” and “3D printing” as descriptors. This search strategy was performed on PubMed (MEDLINE), Scopus and Cochrane Library, but also by hand search in relevant journals and throughout the selected papers. All the papers focusing on techniques for manufacturing customized bone scaffolds were reviewed. The 62 articles identified described 14 techniques (4 subtraction + 10 addition techniques). Scaffold fabrication techniques can be also be classified according to the time at which they are developed, into Conventional techniques and Solid Freeform Fabrication techniques. The conventional techniques are unable to control the architecture of the pore and the pore interconnection. However, current Solid Freeform Fabrication techniques allow individualizing and generating complex geometries of porosity. To conclude, currently SLA (Stereolithography), Robocasting and FDM (Fused deposition modeling) are promising options in customized bone regeneration.

Design of Fused-Deposition ABS Components for Stiffness and Strength

2003 ◽  
Vol 125 (3) ◽  
pp. 545-551 ◽  
Author(s):  
Jose´ F. Rodrı´guez ◽  
James P. Thomas ◽  
John E. Renaud
Keyword(s):  
Mechanical Performance ◽  
Solid Freeform Fabrication ◽  
Acrylonitrile Butadiene Styrene ◽  
Freeform Fabrication ◽  
Fused Deposition ◽  
Load Carrying ◽  
Volume Production ◽  
Approximate Minimization ◽  
High Degree ◽  
Functional Components

The high degree of automation of Solid Freeform Fabrication (SFF) processing and its ability to create geometrically complex parts to precise dimensions provide it with a unique potential for low volume production of rapid tooling and functional components. A factor of significant importance in the above applications is the capability of producing components with adequate mechanical performance (e.g., stiffness and strength). This paper introduces a strategy for optimizing the design of Fused-Deposition Acrylonitrile-Butadiene-Styrene (FD-ABS; P400) components for stiffness and strength under a given set of loading conditions. In this strategy, a mathematical model of the structural system is linked to an approximate minimization algorithm to find the settings of select manufacturing parameters, which optimize the mechanical performance of the component. The methodology is demonstrated by maximizing the load carrying capacity of a two-section cantilevered FD-ABS beam.

A Study on Reduction of Processing Time and Improvement of Strength by Using Photopolymer Resin in the 3DP Process

2006 ◽  
Vol 326-328 ◽  
pp. 151-154 ◽  
Author(s):  
Won Hee Lee ◽  
Dong Soo Kim ◽  
Jung Su Kim ◽  
Min Cheol Lee
Keyword(s):  
Processing Time ◽  
Solid Freeform Fabrication ◽  
Low Cost ◽  
Three Dimensional ◽  
Post Processing ◽  
Printing Technology ◽  
Freeform Fabrication ◽  
Post Process ◽  
Curing Method ◽  
Fabrication Time

3DP(three dimensional printing) technology is one of SFF(solid freeform fabrication) technologies which have recently come into a spotlight due to its adaptability to various applications. This technology has a great advantage in terms of short fabrication time for a prototype at a low cost, especially when it comes with multi-nozzle inkjet printing technology. However, it has also a disadvantage since it requires additional curing time, after jetting a binder material, and post-processing time in order to increase the mechanical strength of a product. In this study, a novel 3DP process is proposed to overcome slow solidification and elaborate post-process by adopting photo curing method into the conventional 3DP process. Mechanical properties, such as tensile and bending strengths, of specimens fabricated with the proposed 3DP process were measured and compared with those fabricated with the conventional 3DP process. As a result, it is found that mechanical strengths of specimens from the proposed novel 3DP process show three times higher than those from the conventional 3DP process. Besides, the overall fabrication time with the proposed novel 3DP process is about two times faster than that with the conventional 3DP process, because it does not need additional curing and post-processing time.

Process Improvements in Fused Deposition of Ceramics (FDC): Progress Towards Structurally Sound Components

1996 ◽  
Author(s):  
Vikram R. Jamalabad ◽  
Mukesh K. Agarwala ◽  
Noshir A. Langrana ◽  
Stephen C. Danforth
Keyword(s):  
Fused Deposition Modeling ◽  
Solid Freeform Fabrication ◽  
Sintered Ceramic ◽  
Process Improvements ◽  
Freeform Fabrication ◽  
Fused Deposition ◽  
Ceramic Components ◽  
Manufacturing Procedure ◽  
Fused Deposition Of Ceramics ◽  
The Cost

Abstract Fused Deposition of Ceramics (FDC) is a Solid Freeform Fabrication (SFF) technique under development at Rutgers University. This technique is based on Fused Deposition Modeling (FDM)2, a commercially available SFF technology. Freeform fabrication of ceramic and metal parts is a means of significantly lowering the cost of currently expensive components. The feasibility of Fused Deposition of Ceramics (FDC) has been demonstrated in the recent past. Crucial to the viable fabrication of ceramic components is the elimination of defects in the parts. Apart from some of the usual traits of SFF techniques, some distinct features of FD Processing lead to defects in fabricated parts. The focus of this work is to study and improve the build procedure of FDM, thereby reducing the defects that are associated with FD processing. Predictable errors in the FDC/FDM components need to be consistently eliminated to increase the yield of fully dense, defect free, green parts. Changes in the manufacturing procedure and operation of FDC are shown to reduce these errors. Fully dense green components are further processed to obtain defect free fully dense sintered ceramic parts.

Solid freeform fabrication of metal components using fused deposition of metals

2002 ◽  
Vol 23 (1) ◽  
pp. 97-105 ◽  
Author(s):  
Guohua Wu ◽  
Noshir A. Langrana ◽  
Rajendra Sadanji ◽  
Stephen Danforth
Keyword(s):  
Solid Freeform Fabrication ◽  
Freeform Fabrication ◽  
Fused Deposition
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