Solid Freeform Fabrication Proceedings

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Aug 2, 2004 - European Assessment of SFF. Overview of the WTEC Additive/Subtractive Manufacturing Study of. European Research. David W. Rosen ...
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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 —

-



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 -

-

493

On the Use of Angled, Dynamic Laser Beams to Improve Stereolithography Surface Finish Benay Sager, David W. Rosen, Georgia Institute of Technology

-

500



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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