Aug 2, 2004 - European Assessment of SFF. Overview of the WTEC Additive/Subtractive Manufacturing Study of. European Research. David W. Rosen ...
TECHNISCHE INFORMATIONSBIBLIOTHEK UNIVERSITATSBOUOTHEK HANNOVER
Solid Freeform Fabrication Proceedings August 2004 Solid Freeform Fabrication as an important and totally integrated approach to design, materials processing and manufacturing research results related to it is contained in this proceedings of the SFF Symposium held in Austin, Texas on August 2-4, 2004 SFF Topics covered in the Symposium include:
Process Development Modeling Applications Materials
David L. Bourell, Richard H. Crawford, Joseph J. Beaman, Kristin L. Wood, and Harris L. Marcus, Editors
© 2004 The University of Texas at Austin All rights of reproduction in any form are protected by U.S. Copyright Laws. Permission to copy all or portions of the proceedings contents must be obtained from the authors and The University of Texas at Austin. Library of Congress ISSN 1053-2153
TIB/UB Hannover 126 466 084
Table of Contents Page Preface
— ix
Organizing/Advisory Committee
xi
European Assessment of SFF Overview of the WTEC Additive/Subtractive Manufacturing Study of European Research David W. Rosen, Georgia Institute of Technology Rapid Manufacturing Research Group Richard Hague, Phill Dickens, Loughborough University —
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—
1 11
Solid Freeform Fabrication and the Interface with Direct Write K. G. Watkins, University of Liverpool -
14
Research on Layer Manufacturing Techniques at Fraunhofer C. Ader, M. Brosemerh, C. Freyef, H. Frickeb, D. Hennigsh, F. Klocke'', V. Kuhned, W. Meiners", C. Over", H. Pleteitb, S. Stuhrmann, I. Wirthb, T. Wirtz", K. Wissenbach", aFraunhofer Instititue for Laser Technology ILT, b Fraunhofer Institute for Manufacturing and Advanced Materials IFAM, c Fraunhofer Institute for Production Technology IPT, dModelltechnik Rapid Prototyping GmbH -
26
The Reality of Functionally Graded Material Products G. E. Knoppers, J. W. Gunnink, J. van den Hout, W. P. van Vliet, TNO Industrial Technology —
-
38
Binding Mechanisms in Selective Laser Sintering and Selective Laser Melting J. P. Kruth, P. Mercelis, L. Froyen, Marleen Rombouts, University of Leuven (K.U.Leuven) — — -
44'
Materials Creep Behaviour of Polyamide in Selective Laser Sintering Eef Moeskops, Nico Kamperman, Bart van de Vorst, Rik Knoppers, TNO Industrial Technology— — — -
-
60
An Investigation of LENS®-Deposited Medical-Grade CoCrMo Alloys Brent Stacker", Carson Esplinh, Daniel Justinb, aUtah State University, b MedicineLodge, Inc. — --
68
Advances in the Production of Infiltrated Aluminium Parts Using Selective Laser Sintering T. B. Sercombe, G. B. Schaffer, The University of Queensland—
80
—
Effects of Process Variables and Size Scale on Solidification Microstructure in Laser-Based Solid Freeform Fabrication of Ti-6A14V N. W. Klingbeil", S. Bontha", C J. Brown", D. R. Gaddam", P. A. Kobryn, H. L. Frase/, J. W. Sears'1, aWright State University, bAir Force Research Laboratory, cThe Ohio State University, dSouth Dakota School of Mines and Technology — -
92
A Design of Experiments Approach Defining the Relationships Between Processing and Microstructure for Ti-6A1-4V T. A. Wallace, K. S. Bey, K. M. B. Taminger, R. A. Hafley, NASA Langley Research Center — — -
104
Influence of Laser Processing Parameters on the Corrosion Behavior in 316L Stainless Steel Laser Powder Depositions Eswar R. Yarrapareddy, Alan J. Anderson, James W. Sears, South Dakota School of Mines and Technology -
116
Strain Analysis of Initial Stage Sintering of 316L SS Three Dimensionally Printed (3DP™) Components Scott Johnston", Dustin Frame", Rhonda Anderson" , Duane Stortf, a University of Washington-Seattle, bConcurrent Technologies Corporation
129
The Effects of Pre-Alloyed Steels Powder Compositions on Build Quality in Direct Metal Laser Re-Melting 5. P. Akhtar, C. S. Wright, M. Youseffi, University of Bradford —-
141
Scaling Effects in Laser-Based Additive Manufacturing Processes Andrew J. Birnbaum", Jack L. Beuth", James W. Searsb, aCarnegie Mellon University, bSouth Dakota School of Mines and Technology —
151
Transient Changes in Melt Pool Size in Laser Additive Manufacturing Processes Pruk Aggarangsf, Jack L. Beuth", David D. Gillb, aCarnegie Mellon University, bSandia National Laboratories-NM —
163
Materials Design - Towards a Functionally Graded Electrical Conductor 5. Satapathy, K. Hsieh, C. Persad, Institute for Advanced Technology at UT-Austin -
175
Fabrication of X-Graded H13 and Cu Powder Mix Using High Power Pulsed Nd:YAG Laser V. E. Beal", P. Erasenthiran1', N. Hopkinsonb, P. Dickensb, C. H. Ahrens", a Universidade Federal de Santa Catarina, bLoughborough University
187
Experimental Investigation of Laser Metal Deposition of Functionally Graded Copper and Steel Vinay Kadekar, Sashikanth Prakash, Frank Liou, University of MissouriRolla
-—198
Solidification Morphology Analysis of SLM of Cu Powder Jorge A. Ramos Grez", David L. Bourelt, aPontificia Universidad Catolica de Chile, bThe University of Texas at Austin -
203
Direct Laser Sintering of Borosilicate Glass F. Klocke, A. McClung, C. Ader, Fraunhofer Institute for Production Technology —
— 214
An Initial Assessment of Infiltration Material Selection for Selective Laser Sintered Preforms Stacia L. Barrow, David Bourell, Scott Evans, The University of Texas at Austin — -
220
Rapid Manufacturing of Silicon Carbide Composites R. S. Evans, D. L. Bourell, J. J. Beaman, M. 1. Campbell, The University of Texas at Austin -
228
Preliminary Study for Transparentization of SLS Parts by Resin Infiltration T. Niino", H. Yamada", S. Sekib, aThe University of Tokyo, bASPECT, Inc.
236
Fabrication of PEM Fuel Cell Bipolar Plates by Indirect SLS Ssuwei Chen, David L. Bourell, Kristin L. Wood, The University of Texas at Austin -
244
Advanced Laminated Object Manufacturing (LOM) of SiSiC Ceramics L. Weisensel, N. Travitzky, P. Greil, The University of ErlangenNuremberg -
—
257
Prospect of Making Ceramic Shell Mold by Ceramic Laser Fusion H. H. Tang", H. C. Yen", S. M. Sub, Z Y. Linb, National Taipei University of Technology, institute of Manufacturing Technology -
268
Process Errors and Aspects for Higher Resolution in Conventional Stereolithography Carsten Tille, Caesar Research Center
281
Novel Implementations of Plasma Spraying for Fabricating Components Made of a Multiphase Perfect Material Feng Wang", Ke-Zhang Chen", Xin-An Feng , aThe University of Hong Kong, bDalian University of Technology — —
293
Process Development Metal Laminated Tooling - A Quick and Flexible Tooling Concept Thomas Himmer", Anja Techet, Steffen Nowotnyb, Eckhard Beyerbc, a Fraunhofer USA, Inc., bFraunhofer IWS, cUniversity of Technology at Dresden High Speed Sintering - Early Research into a New Rapid Manufacturing Process Neil Hopkinson, Poonjolai Erasenthiran, Loughborough University
in
304
—
312
Laser-Assisted Photothermal Imprinting of Nanocomposite Y. Lu, D. B. Shao, S. C. Chen, The University of Texas at Austin
321
Continuous Ink-Jet Printing Electronic Components Using Novel Conductive Inks Junfeng Mei, Michael Lovell, Marlin Mickle, Steve Heston, University of Pittsburgh -
334
Exploring Vacuum Casting Techniques for Micron and Submicron Features M. Denouaf, P. Mognot, B. Lepioufle", aBiomis-SATIE, bIRCCyN
346
Micro Thin Film Sensor Embedding in Metal Structures for Rapid Production of Miniature Smart Metal Tooling Xudong Cheng, Patrick Schwieso, Hongseok Choi, Arindom Datta, Xiaochun Li, University of Wisconsin-Madison -
358
Extracting Product Performance by Embedding Sensors in SFF Prototypes Rahul Rai, Matthew Campbell, Kristin Wood, University of Texas at
Austin —
366
Application of Machine Learning Methods to the Open-Loop Control of a Freeform Fabrication System Evan Malone, Oliver Purwin, Cornell University— -
377
Simulation of the Process Step Polymer Removal in Indirect Metal Laser Sintering M. Seefried, M. F. Zaeh, M. Meindl, Technische Universitaet Muenchen
389
Full-Densification of SLS Parts by Re-Melting T. Niino, H. Yamada, The University of Tokyo
400
An Investigation into the Effect of the Shell on SALM Processed Parts A. K. Egodawatta", D. K. Harrison0, A. K. M. De Silva", G. Haritosb, a Glasgow Caledonian University, bSoftnet Consultancy Ltd.
— 408
Study on Incorporating Support Material in Rapid Freeze Prototyping Frances D. Bryant, Ming C. Leu, University of Missouri-Rolla
416'
On the Interface'Between LENS® Deposited Stainless Steel 304L Repair Geometry and Cast or Machined Components D. D. Gill, J. E. Smugeresky, M. F. Harris, C. V. Robino, M. L. Griffith, Sandia National Laboratories-NM
428
Characterization of Thin Walled Ti-6A1-4V Components Reduced via Electron Beam Melting Denis Cormier, Harvey West, Ola Harrysson, Kyle Knowlson, North Carolina State University
440
Further Developments in Process Mapping and Modelling in Direct Metal Selective Laser Melting C. Hauser, T. H. C. Childs, M. Badrossamay, University of Leeds
448
IV
Effect of Surface Treatments on Electron Beam Freeform Fabricated Aluminum Structures Karen M. B. Taminger, Robert A. Hafley, David T. Fahringer, Richard E. Martin, NASA Langley Research Center -
460
Compensation for Uneven Surfaces When Building Laser Deposited Structures E. Fearon, K. G. Watkins, University of Liverpool
471
Quantifying Dimensional Accuracy of a Mask Projection Micro Stereolithography System Ameya Limaye, David Rosen, Georgia Institute of Technology
481
Geometry and Procedure for Benchmarking SFF and Hybrid Fabrication Process Resolution Vito R. Gervasi, Adam Schneider, Joshua Rocholl, Milwaukee School of Engineering -
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493
On the Use of Angled, Dynamic Laser Beams to Improve Stereolithography Surface Finish Benay Sager, David W. Rosen, Georgia Institute of Technology
-
500
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512
Numerical and Experimental Analysis of the Powder Flow Streams in the Laser Aided Material Deposition Process Yogesh Thakar, Heng Pan, Frank Liou, University of Missouri-Rolla Modeling of the Metal Powder Flow with Carrier Gas in Coaxial Nozzle for Direct Laser Deposition Process Heng Pan, Frank Liou, University of Missouri-Rolla— -
523
Modeling Converting a CAD Model into a Manufacturing Model for the Components Made of a Multiphase Perfect Material Feng Zhu", Ke-Zhang Chen", Xin-An Fengb,aThe University of Hong Kong, bDalian University of Technology —
-
SFF-Oriented Modeling and Process Planning of Functionally Graded Materials Using a Novel Equal Distance Offset Approach Anping Xu", Leon L. Shawb, aHebei University of Technology, bThe University of Connecticut at Storrs -
532
544
Morphing Based Approach for Process Planning for Fabrication of Geometries and the Control of Material Composition Rajeev Dwivedi, Radovan Kovacevic, Southern Methodist University
-
553
A Combinatorial Parametric Engineering Model for Solid Freeform Fabrication J. C. Boudreaux, NIST/Advanced Technology Program
-
563
The Approach of Complex Insert Packaging Fabrication in Stereolithography Y. Y. Chiu, J. H. Chang, Oriental Institute of Technology
-
-572
Development of Image Processing Tools for Analysis of Laser Deposition Experiments Todd Sparks, University of Missouri-Rolla — Analyzing the Cutting Process of a Heated Flexible Blade in Extruded Polystyrene Foam Bram de Smit, Han J. Broek, Delft University of Technology Study of Ceramic Slurries for Investment Casting with Ice Patterns Qingbin Liu, Ming C. Leu, Harish Jose, Von L. Richards, University of Missouri-Rolla-
584
—
591
— 602
Stereolithography Cure Process Modeling Using Acrylate Resin Yanyan Tang, Clifford L. Henderson, John Muzzy, David W. Rosen, Georgia Institute of Technology
612
Investigation of the Oven Process in Indirect Metal Laser Sintering M. Seefried, M. F. Zaeh, Technische Universitaet Muenchen—
624
Thermal Optimization of Injection Molds Produced by Layered Manufacturing Techniques Eric Boillat, Remy Glardon, Marc Matthey, Ecole Polytechnique Federale de Lausanne -
636
Simulating the Effects of Substrate Pre-Heating on the Final Structure of Steel Parts Built by Laser Powder Deposition L. Costa", R. Vilar", T. Reti, aDEMat, bSzechenyi Istvan University —
643
Applications Development of Nickel-Titanium Graded Composition Components M. S. Domack", J. M. Baughmanb, aNASA Langley Research Center, ^Lockheed Martin Space Operations
655
Ejection Forces and Friction Coefficients from Injection Molding Experiments Using Rapid Tooling Inserts M. E. Kinsella", B. Lilly", B. Carpenterb, K. Coopef, aAir Force Research Laboratory, bThe Ohio State University, CNASA Marshall Space Flight Center—
669
Faster - Better Molds Through RSP Tooling New Research and Advancements James R. Knirsch, RSP Tooling, LLC
681
Freeform Fabrication of Electroactive Polymer Actuators and Electromechanical Devices Evan Malone, Hod Lipson, Cornell University
697
VI
Industrial Freeform Generation of Microtools by Laser Micro Sintering P. Regenfup1, L. Hartwig", S. Klotzer", R. Ebert", Th. Brabantb, T. Petschb, H. Exner", aLaserinstitut Mittelsachsen e. V., b 3D - Micromac AG—
— 709
Direct Freeform Fabrication of Spatially Heterogeneous Living CellImpregnated Implants D. L. Cohen, E. Malone, H. Lipson, L. J. Bonassar, Cornell University
720
Soft and Hard Implant Fabrication Using 3D-Bioplotting™ C. Carvalho, R. Landers, R. Mulhaupt, Freiburg Materials Research Center-
732
Biomimetic Design and Fabrication of Interior Architecture of Tissue Scaffolds Using Solid Freeform Fabrication B. Starly", A. Lau", W. Sun", W. Laub, T. Bradburyh, aDrexel University, b Therics, Inc. -
742
Multiple Material Micro-Fabrication: Extending Stereolithography to Tissue Engineering and Other Novel Applications Ryan Wicker", Francisco Medina", Chris Elkins , aUniveristy of Texas at El Paso, Stanford University -
-
754
Accurate Heart Model for Pacemaker Development in SFF R. S. Crockett", T. Horvath", M. Koch", M. Yangh, aCalifornia Polytechnic State University-San Luis Obispo, bSt. Jude Medical -
765
Orthopedic Surgery Planning Based on the Integration of Reverse Engineering and Rapid Prototyping Dong-Gyu Ahn", Jun-Young Lee", Dong-Yol Yangb, aChosun University, b KAIST -
773
Fabrication of Bone Substitute Material by Rapid Prototyping A. Ott, J. Heinzl, D. Janitza, R. Pelzer, Technische Universitat Miinchen
— 784
Design and Manufacture of an Attachment Fitting for Transtibial Prosthetic Sockets Using Selective Laser Sintering Danny Burhan, Richard Crawford, University of Texas at Austin —
— 794'
Laser Densification of Extruded Dental Porcelain Bodies in MultiMaterial Laser Densification (MMLD) Process Xiaoxuan Lf, Jiwen Wang", Leon L. Shaw", Thomas B. Cameron , a University of Connecticut-Storrs, bDentsply Ceramco Solid Freeform Fabrication of Artificial Human Teeth Jiwen Wang", Leon L. Shaw", Anping Xu , Thomas B. Cameron, a University of Connecticut-Storrs, Hebei University of Technology, c Dentsply Ceramco — Multi-Nozzle Biopolymer Deposition for Freeform Fabrication of Tissue Constructs S. Khalil, J. Nam, A. Darling, W. Sun, Drexel University
Vll
808
-
816
-—
826
Design and Fabrication of Components with Optimized Lattice Microstructures Vito R. Gervasi, Douglas C. Stahl, Milwaukee School of Engineering
838
Panel Discussion on Broader Applications of SFF Harris L. Marcus", Clinton L. Atwood*1, David G. Alexander1, Phill M. Dickens , Kent Firestone1', aUniversity of Connecticut-Storrs, bSandia National Laboratory-NM, cPratt & Whitney, dLoughborough University, e University of Texas at Austin -
845
Author!Attendee List
856
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