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Relevant bibliographies by topics / Solid Freeform Fabrication (SFF)

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Academic literature on the topic 'Solid Freeform Fabrication (SFF)'

Author: Grafiati

Published: 4 June 2021

Last updated: 4 February 2022

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Journal articles on the topic "Solid Freeform Fabrication (SFF)"

1

Arni, Ramakrishna, and S. K. Gupta. "Manufacturability Analysis of Flatness Tolerances in Solid Freeform Fabrication." Journal of Mechanical Design 123, no. 1 (September 1, 1999): 148–56. http://dx.doi.org/10.1115/1.1326439.

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Increasingly, Solid Freeform Fabrication (SFF) processes are being considered for creating functional parts. In such applications, SFF can either be used for creating tooling (i.e., patterns for casting, low volume molds, etc.) or directly creating the functional part itself. In order to create defect free functional parts, it is extremely important to fabricate the parts within allowable dimensional and geometric tolerances. This paper describes a systematic approach to analyzing manufacturability of parts produced using SFF processes with flatness tolerance requirements on the planar faces of the part. Our research is expected to help SFF designers and process providers in the following ways. By evaluating design tolerances against a given process capability, it will help designers in eliminating manufacturing problems and selecting the right SFF process for the given design. It will help process providers in selecting a build direction that can meet all design tolerance requirements.

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Pinilla, Jose Miguel, Ju-Hsien Kao, and Fritz Prinz. "Compact graph representation for Solid Freeform Fabrication (SFF)." Journal of Manufacturing Systems 19, no. 5 (January 2001): 341–54. http://dx.doi.org/10.1016/s0278-6125(01)89006-3.

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Kakisawa, Hideki, Kazumi Minagawa, Keisuke Ida, Katsuhiro Maekawa, and Kohmei Halada. "Dense P/M Component Produced by Solid Freeform Fabrication (SFF)." MATERIALS TRANSACTIONS 46, no. 12 (2005): 2574–81. http://dx.doi.org/10.2320/matertrans.46.2574.

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Rogers, Bill, Gordon W. Bosker, Richard H. Crawford, Mario C. Faustini, Richard R. Neptune, Gail Walden, and Andrew J. Gitter. "Advanced Trans-Tibial Socket Fabrication Using Selective Laser Sintering." Prosthetics and Orthotics International 31, no. 1 (March 2007): 88–100. http://dx.doi.org/10.1080/03093640600983923.

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There have been a variety of efforts demonstrating the use of solid freeform fabrication (SFF) for prosthetic socket fabrication though there has been little effort in leveraging the strengths of the technology. SFF encompasses a class of technologies that can create three dimensional objects directly from a geometric database without specific tooling or human intervention. A real strength of SFF is that cost of fabrication is related to the volume of the part, not the part's complexity. For prosthetic socket fabrication this means that a sophisticated socket can be fabricated at essentially the same cost as a simple socket. Adding new features to a socket design becomes a function of software. The work at The University of Texas Health Science Center at San Antonio (UTHSCSA) and University of Texas at Austin (UTA) has concentrated on developing advanced sockets that incorporate structural features to increase comfort as well as built in fixtures to accommodate industry standard hardware. Selective laser sintering (SLS) was chosen as the SFF technology to use for socket fabrication as it was capable of fabricating sockets using materials appropriate for prosthetics. This paper details the development of SLS prosthetic socket fabrication techniques at UTHSCSA/UTA over a six-year period.

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Wu, Quan, Xiang Lin Zhang, and Meng Jun Li. "Research on Microwave Sintering Process for High Strength HA Porous Scaffold." Advanced Materials Research 239-242 (May 2011): 2515–19. http://dx.doi.org/10.4028/www.scientific.net/amr.239-242.2515.

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This paper investigated solid freeform fabrication(SFF) and microwave sintering processes of high strength HA porous scaffold. A newly developed SFF method called motor assisted micro-syringe freeform fabrication system was introduced to construct HA scaffolds. Sintering conditions that influenced the phases, microstructure and mechanical strength of scaffolds were discussed. Study of microstructure images and strength test results showed that densification and grain size were found to play an important role in determining the mechanical properties of sintered porous scaffolds, and microwave sintering process could get a sintered scaffold with small grain size and uniform structure more rapidly at lower sintering temperature than that of the conventional sintering. The fabricated HA scaffolds with controlled architecture (interconnected macro pore of 200-400μm, micro pore of 1-10μm within the rods) and improved mechanical properties (45.2MPa, 56.2% porosity ) may find potential applications in bone tissue engineering.

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KIM, DONG SOO, SUNG WOO BAE, and KYUNG HYUN CHOI. "APPLICATION AND PERFORMANCE EVALUATION FOR THE DMS SYSTEM IN THE SLS PROCESS." International Journal of Modern Physics B 22, no. 09n11 (April 30, 2008): 1833–38. http://dx.doi.org/10.1142/s0217979208047493.

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A Solid Freeform Fabrication (SFF) system using Selective Laser Sintering (SLS) is currently recognized as a leading process and SLS extends the applications to machinery and automobiles due to the various materials employed. Especially, accuracy and processing time are very important factors when the desired shape is fabricated with Selective Laser Sintering (SLS), one of Solid Freeform Fabrication (SFF) system. In the convectional SLS process, laser spot size is fixed during laser exposing on the sliced figure. Therefore, it is difficult to accuracy and rapidly fabricates the desired shape. In this paper, to deal with those problems a SFF system having ability of changing spot size is developed. The system provides high accuracy and optimal processing time. Specifically, a variable beam expander is employed to adjust spot size for different figures on a sliced shape. Therefore, design and performance estimation of the SFF system employing a variable beam expander are achieved and the mechanism will be addressed to measure the real spot size generated from the variable beam expander. Also, the reduction of total processing time is an important issue in SFF system. A digital mirror system (DMS) is a system which scans the laser beam with different spot size. The spot size is selected based on the slicing section to decrease and accuracy of the process time and improve the processing efficiency. In this study, the optimal scan path generation for DMS will be addressed, and this development will improve the whole processing efficiency and accuracy through the scan efficiency by considering the existing scan path algorithm and heat energy distribution.

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Heard, David W., Julien Boselli, Raynald Gauvin, and Mathieu Brochu. "Solid Freeform Fabrication of Al-Li 2199 via Controlled-Short-Circuit-MIG Welding." Advanced Materials Research 409 (November 2011): 843–48. http://dx.doi.org/10.4028/www.scientific.net/amr.409.843.

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Aluminum-lithium (Al-Li) alloys are of interest to the aerospace and aeronautical industries as rising fuel costs and increasing environmental restrictions are promoting reductions in vehicle weight. However, Al-Li alloys suffer from several issues during fusion welding processes including solute segregation and depletion. Solid freeform fabrication (SFF) of materials is a repair or rapid prototyping process, in which the deposited feedstock is built-up via a layering process to the required geometry. Recent developments have led to the investigation of SFF processes via Gas Metal Arc Welding (GMAW) capable of producing functional metallic components. A SFF process via GMAW would be instrumental in reducing costs associated with the production and repair of Al-Li components. Furthermore the newly developed Controlled-Short-Circuit-MIG (CSC-MIG) process provides the ability to control the weld parameters with a high degree of accuracy, thus enabling the optimization of the solidification parameters required to avoid solute depletion and segregation within an Al-Li alloy. The objective of this study is to develop the welding parameters required to avoid lithium depletion and segregation. In the present study weldments were produced via CSC-MIG process, using Al-Li 2199 sheet samples as the filler material. The residual lithium concentration within the weldments was then determined via Atomic Absorption (AA) and X-ray Photoelectron Spectroscopy (XPS). The microstructure was analyzed using High Resolution Scanning Electron Microscopy (HR-SEM). Finally the mechanical properties of welded samples were determined through the application of hardness and tensile testing.

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Chin, R. K., J. L. Beuth, and C. H. Amon. "Successive Deposition of Metals in Solid Freeform Fabrication Processes, Part 2: Thermomechanical Models of Adjacent Droplets." Journal of Manufacturing Science and Engineering 123, no. 4 (May 1, 2000): 632–38. http://dx.doi.org/10.1115/1.1380200.

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Residual stress-induced tolerance losses are a principal barrier for using Solid Freeform Fabrication (SFF) processes to create functional parts out of engineering materials. In Part 1 of this paper, problems of successively deposited layers and droplets deposited in a column are considered for SFF processes. Models of these problems are used to detail thermal and mechanical interactions between existing and newly deposited material as well as their effects on final residual stress distributions on sub-layer (droplet) and multi-layer scales. In the current study, sub-layer interactions are further considered using models of droplets deposited adjacent to one another. As in Part 1, models are applied to a particular SFF process; however, insights and conclusions are relevant to numerous similar SFF processes. Simulations of separated and connected droplets deposited onto a large substrate indicate very limited thermal interactions between adjacently deposited droplets. However, mechanical interactions between droplets can be significant, which is consistent with the directionality of warping observed in experiments. Results from deposition of droplets on a thin substrate demonstrate the importance of process-induced substrate preheating in reducing residual stresses.

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Lim, K. K., P. Cheang, and M. Chandrasekaran. "Studies on Porous Titanium Alloy Implant Manufactured by Three Dimensional Solid Freeform Fabrication System." Advanced Materials Research 29-30 (November 2007): 107–10. http://dx.doi.org/10.4028/www.scientific.net/amr.29-30.107.

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Titanium (Ti) alloys have emerged to become valuable biomaterials for biomedical and orthopedic applications due to their high strength to weight ratio, excellent biocompatibility and corrosion resistance. In this study, the authors utilized Solid Freeform Fabrication (SFF), also commonly known as a rapid prototyping technology to investigate a new porous three-dimensional (3D) Ti alloy implant. Elemental powders for producing a Ti-Al-Fe-Zr alloy were mechanically alloyed and blended with water soluble binder material. The blended powders were manufactured by Three Dimensional Printer (3DP), followed by debinding and sintering in an inert environment. The effects of process parameters on structural and geometrical requirements were assessed. Results from these investigations demonstrated that Ti alloys are promising biomaterials for near net shape fabrication of porous 3D implants, which retained their interconnected pore network. As an illustration, complex geometries of porous 3D Ti alloy specimens were manufactured as a demonstration of 3D SFF System.

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Hu, D., H. Mei, and R. Kovacevic. "Improving solid freeform fabrication by laser-based additive manufacturing." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 9 (September 1, 2002): 1253–64. http://dx.doi.org/10.1243/095440502760291808.

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Solid freeform fabrication (SFF) methods for metal part building, such as three-dimensional laser cladding, are generally less stable and less repeatable than other rapid prototyping methods. A large number of parameters govern the three-dimensional laser cladding process. These parameters are sensitive to the environmental variations, and they also influence each other. This paper introduces the research work in Research Center for Advanced Manufacturing (RCAM) to improve the performance of its developed three-dimensional laser cladding process: laser-based additive manufacturing (LBAM). Metal powder delivery real-time sensing is studied to achieve a further controllable powder delivery that is the key technology to build a composite material or alloy with a functionally gradient distribution. An opto-electronic sensor is designed to sense the powder delivery rate in real time. The experimental results show that the sensor's output voltage has a good linear relationship with the powder delivery rate. A closed-loop control system is also built for heat input control in the LBAM process, based on infrared image sensing. A camera with a high frame rate (up to 800frame/s) is installed coaxially to the top of the laser—nozzle set-up. A full view of the infrared images of the molten pool can be acquired with a short nozzle—substrate distance in different scanning directions, eliminating the image noise from the metal powder. The closed-loop control results show a great improvement in the geometrical accuracy of the built feature.

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Dissertations / Theses on the topic "Solid Freeform Fabrication (SFF)"

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Boivie, Klas. "On the Manufacturing of SFF Based Tooling and Development of SLS Steel Material." Doctoral thesis, KTH, Production Engineering, 2004. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-3814.

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Rice, Christopher S. (Christopher Scott). "Solid freeform fabrication using semi-solid processing." Thesis, Massachusetts Institute of Technology, 1995. http://hdl.handle.net/1721.1/32166.

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Sachlos, Eleftheherios. "Tissue engineering with solid freeform fabrication." Thesis, University of Oxford, 2004. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.418645.

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Park, Seok-min. "Advanced data exchange for solid freeform fabrication /." Full text (PDF) from UMI/Dissertation Abstracts International, 2000. http://wwwlib.umi.com/cr/utexas/fullcit?p3004352.

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Dutta, Anirban. "Study and enhancement of electrophotographic solid freeform fabrication." [Gainesville, Fla.]: University of Florida, 2002. http://purl.fcla.edu/fcla/etd/UFE0000527.

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Souvignier, Chad William. "Solid freeform fabrication of highly loaded composite materials." Diss., The University of Arizona, 2000. http://hdl.handle.net/10150/284190.

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Composites are known for their unique blend of modulus, strength, and toughness. This study focuses on two types of composites; organic-inorganic hybrids and the mineralization of highly swollen polymer gels. Both of these composite systems mimic the biological process of composite formation, known as biomineralization. Biomineralization allows for the control of the precipitating phase through an interaction with the organic matrix. This allows higher volume fractions of inorganic material than can be achieved by many traditional processing techniques. Solid freeform fabrication is a processing method that builds materials by the sequential addition of thin layers. As long as the material can easily be converted from a liquid to a solid, it should be amenable for this processing technique. Freeform fabrication has three distinctions from traditional processing techniques that may enable the formation of composite materials with improved mechanical properties. These are the sequential addition of layers, which allows a layer by layer influence of chemistry, the ability to form complex geometries, and finally, extrusion freeform fabrication has been shown to align fibers due to the extrusion of the slurry through a needle. Cracking and shrinkage still play a major role in forming solid parts. The use of an open mesh structure in combination with proper materials selection allowed the formation of highly loaded composite materials without cracking. The modulus values of these materials ranged from 0.1 GPa to 6.0 GPa. The mechanical properties of these materials were modeled.

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Nace, John G. (John Gregory) 1955. "A surface texture modeling system for solid freeform fabrication." Thesis, Massachusetts Institute of Technology, 1997. http://hdl.handle.net/1721.1/43605.

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Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1997.
Includes bibliographical references (leaves 83-84).
Solid Freeform Fabrication, SFF, is a set of manufacturing processes that fabricates parts as a bonded stack of individual layers. The Three Dimensional Printing process, 3DPTM process, is an SFF technology developed at MIT. It builds layers by ink jet printing binder onto the surface of a bed of powder. The bed of powder is lowered and fresh powder is spread onto the bed. As subsequent cross sections of the part are printed, the part exists, submerged in the powder bed. Access to the individual layers as they are fabricated gives access to the interior structure of the part. This approach allows the part to have high geometric complexity. In this work a designer centric Computer Aided Design system is proposed to allow the interactive creation of functional surface texture on mechanical parts. This system is structured to behave like a VLSI CAD system, which offers substantial process capabilities. The requirements for a Mechanical CAD, MCAD, system to behave like VLSI CAD are determined to be: 1. That the informational model of the unit cell of texture be separable into distinct logical subsets.2. That manipulations on either subset not violate the logical consistency of the other subset. This thesis shows that geometric dimensions and tolerances carry the essential information of the model of a unit cell of functional texture. A variety of Unit Cell editors are evaluated according to their ability to meet the desired system criteria. A tool, Swiss Solid Geometry, SSG, for the design of unit cells of functional texture is developed, that fulfills requirement #1. SSG is an approach to MCAD modeling that combines geometric primitives in the manner of Constructive Solid Geometry, however the primitives of SSG, are different. They consist of simple objects such as lines, but includes the spatial envelope around them of a fixed offset. Also, they are used to represent both positive and negative regions of space. The placement of the individual replications is established by a mesh, that covers the intended 3D surface region. A meshing algorithm is developed that regularizes the mesh by directly utilizing the dimensional tolerances specified in the process of Unit Cell design. The geometric dimensions are instantiated as standalone geometric entities that push and pull on the nodes of the mesh in order to bring their length into dimensional tolerance. This method fulfills requirement #2, and it is implemented into a CAM software called Vari 4. The modularity of the CAM software, Vari 4, is described in detail.
by John G. Nace.
S.M.

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Yarkinoglu, Onur. "Computer Aided Manufacturing (cam) Data Generation For Solid Freeform Fabrication." Master's thesis, METU, 2007. http://etd.lib.metu.edu.tr/upload/12608834/index.pdf.

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Rapid prototyping (RP) is a set of fabrication technologies that are used to produce accurate parts directly from computer aided drawing (CAD) data. These technologies are unique in a way that they use an additive fabrication approach in which a three dimensional (3D) object is directly produced. In this thesis study, a RP application with a modular architecture is designed and implemented to satisfy the possible requirements of future rapid prototyping studies. After a functional classification, the developed RP software is divided into View, RP and Slice Modules. In the RP module, the process parameter selection and optimal build orientation determination steps are carried out. In the Slice Module, slicing and tool path generation steps are performed. View Module is used to visualize the inputs and outputs of the RP software. To provide 3D visualization support for View Module, a fully independent, open for development, high level 3D modeling environment and graphics library called Graphics Framework is developed. The resulting RP application is benchmarked with the RP software packages in the market according to their memory usage and process time. As a result of this benchmark, it is observed that the developed RP software has presented an equivalent performance with the other commercial RP applications and has proved its success.

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Fay, James Edward. "Electrostatic analysis of and improvements to electrophotographic solid freeform fabrication." [Gainesville, Fla.] : University of Florida, 2003. http://purl.fcla.edu/fcla/etd/UFE0001397.

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Chen, Tiebing. "Analysis and modeling of direct selective laser sintering of two-component metal powders." Diss., Columbia, Mo. : University of Missouri-Columbia, 2005. http://hdl.handle.net/10355/5818.

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Thesis (Ph.D.)--University of Missouri-Columbia, 2005.
The entire dissertation/thesis text is included in the research.pdf file; the official abstract appears in the short.pdf file (which also appears in the research.pdf); a non-technical general description, or public abstract, appears in the public.pdf file. Title from title screen of research.pdf file viewed on (November 15, 2006) Vita. Includes bibliographical references.

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Books on the topic "Solid Freeform Fabrication (SFF)"

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Solid Freeform Fabrication Symposium (6th 1995 Austin, Texas). Solid Freeform Fabrication Proceedings, September 1995. Edited by Marcus Harris L. Austin, Tex: University of Texas at Austin, 1995.

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Solid, Freeform Fabrication Symposium (8th 1997 Austin Texas). Solid Freeform Fabrication Proceedings, September 1997. Austin, TX: University of Texas at Austin, 1997.

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Beaman, Joseph J., Joel W. Barlow, David L. Bourell, Richard H. Crawford, Harris L. Marcus, and Kevin P. McAlea. Solid Freeform Fabrication: A New Direction in Manufacturing. Boston, MA: Springer US, 1997. http://dx.doi.org/10.1007/978-1-4615-6327-3.

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Johnson, Jerome L. Principles of computer automated fabrication. Irvine, CA: Palatino Press, 1994.

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Solid Freeform Fabrication Symposium (14th 2003 University of Texas at Austin). Selected papers from the 14th Annual Solid Freeform Fabrication Symposium, University of Texas, Austin, Texas, 4-6 August 2003. Edited by Bourell David Lee, Campbell, R. I. (R. Ian), and ebrary Inc. Bradford, West Yorkshire, England: Emerald Group Pub., 2004.

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Kai, Chua Chee. Rapid prototyping: Principles & applications in manufacturing. New York: J. Wiley, 1997.

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Fai, Leong Kah, and Lim Chu Sing, eds. Rapid prototyping: Principles and applications. 2nd ed. New Jersey: World Scientific, 2003.

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Fai, Leong Kah, and Lim Chu Sing, eds. Rapid prototyping: Principles and applications. 3rd ed. New Jersey: World Scientific, 2010.

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Binnard, Michael. Design by composition for rapid prototyping. Boston: Kluwer Academic, 1999.

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Rapid prototyping technology: Selection and application. New York: Marcel Dekker, 2001.

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Book chapters on the topic "Solid Freeform Fabrication (SFF)"

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Beaman, Joseph J., Joel W. Barlow, David L. Bourell, Richard H. Crawford, Harris L. Marcus, and Kevin P. McAlea. "Polymers in Solid Freeform Fabrication." In Solid Freeform Fabrication: A New Direction in Manufacturing, 85–119. Boston, MA: Springer US, 1997. http://dx.doi.org/10.1007/978-1-4615-6327-3_4.

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Hanan, Jay C., James E. Smay, Francesco DeCarlo, and Yong Chu. "Microtomography of Solid Freeform Fabrication." In Ceramic Transactions Series, 95–104. Hoboken, NJ, USA: John Wiley & Sons, Inc., 2011. http://dx.doi.org/10.1002/9781118144114.ch10.

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Murr, Lawrence E. "Rapid Prototyping Technologies: Solid Freeform Fabrication." In Handbook of Materials Structures, Properties, Processing and Performance, 639–52. Cham: Springer International Publishing, 2015. http://dx.doi.org/10.1007/978-3-319-01815-7_37.

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Beaman, Joseph J., Joel W. Barlow, David L. Bourell, Richard H. Crawford, Harris L. Marcus, and Kevin P. McAlea. "Solid Freeform Fabrication Using Gas Phase Precursors." In Solid Freeform Fabrication: A New Direction in Manufacturing, 279–90. Boston, MA: Springer US, 1997. http://dx.doi.org/10.1007/978-1-4615-6327-3_8.

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Beaman, Joseph J., Joel W. Barlow, David L. Bourell, Richard H. Crawford, Harris L. Marcus, and Kevin P. McAlea. "Indirect Fabrication of Metals and Ceramics." In Solid Freeform Fabrication: A New Direction in Manufacturing, 121–65. Boston, MA: Springer US, 1997. http://dx.doi.org/10.1007/978-1-4615-6327-3_5.

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Horii, T., M. Ishikawa, Soshu Kirihara, Yoshinari Miyamoto, and Nobu Yamanaka. "Development of Freeform Fabrication of Metals by Three Diminsional Micro-Welding." In Solid State Phenomena, 189–94. Stafa: Trans Tech Publications Ltd., 2007. http://dx.doi.org/10.4028/3-908451-33-7.189.

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Beaman, Joseph J., Joel W. Barlow, David L. Bourell, Richard H. Crawford, Harris L. Marcus, and Kevin P. McAlea. "Direct SLS Fabrication of Metals and Ceramics." In Solid Freeform Fabrication: A New Direction in Manufacturing, 245–78. Boston, MA: Springer US, 1997. http://dx.doi.org/10.1007/978-1-4615-6327-3_7.

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Beaman, Joseph J., Joel W. Barlow, David L. Bourell, Richard H. Crawford, Harris L. Marcus, and Kevin P. McAlea. "Introduction." In Solid Freeform Fabrication: A New Direction in Manufacturing, 1–21. Boston, MA: Springer US, 1997. http://dx.doi.org/10.1007/978-1-4615-6327-3_1.

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Beaman, Joseph J., Joel W. Barlow, David L. Bourell, Richard H. Crawford, Harris L. Marcus, and Kevin P. McAlea. "Process Methods." In Solid Freeform Fabrication: A New Direction in Manufacturing, 23–49. Boston, MA: Springer US, 1997. http://dx.doi.org/10.1007/978-1-4615-6327-3_2.

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Beaman, Joseph J., Joel W. Barlow, David L. Bourell, Richard H. Crawford, Harris L. Marcus, and Kevin P. McAlea. "Information Processing." In Solid Freeform Fabrication: A New Direction in Manufacturing, 51–84. Boston, MA: Springer US, 1997. http://dx.doi.org/10.1007/978-1-4615-6327-3_3.

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Conference papers on the topic "Solid Freeform Fabrication (SFF)"

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Arni, R. K., and S. K. Gupta. "Manufacturability Analysis for Solid Freeform Fabrication." In ASME 1999 Design Engineering Technical Conferences. American Society of Mechanical Engineers, 1999. http://dx.doi.org/10.1115/detc99/dfm-8903.

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Abstract This paper describes a systematic approach to analyzing manufacturability of parts produced using Solid Freeform Fabrication (SFF) processes with flatness, parallelism and perpendicularity tolerance requirements on the planar faces of the part. SFF processes approximate objects using layers, therefore the part being produced exhibits stair-case effect. The extent of this stair-case effect depends on the angle between the build orientation and the face normal. Therefore, different faces whose direction normal is oriented differently with respect to the build direction may exhibit different values of inaccuracies. We use a two step approach to perform the manufacturability analysis. We first analyze each specified tolerance on the part and identify the set of feasible build directions that can be used to satisfy that tolerance. As a second step, we take the intersection of all sets of feasible build directions to identify the set of build directions that can simultaneously satisfy all specified tolerance requirements. If there is at least one build direction that can satisfy all tolerance requirements, then the part is considered manufacturable. Otherwise, the part is considered non-manufacturable. Our research will help SFF designers and process providers in the following ways. By evaluating design tolerances against a given process capability, it will help designers in eliminating manufacturing problems and selecting the right SFF process for the given design. It will help process providers in selecting a build direction that can meet all design tolerance requirements.

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Lao, Wenxin, Mingyang Li, Lorenzo Masia, and Ming Jen Tan. "Approaching Rectangular Extrudate in 3D Printing for Building and Construction by Experimental Iteration of Nozzle Design." In Annual International Solid Freeform Fabrication Symposium. Laboratory for Freeform Fabrication and University of Texas at Austin, 2017. http://dx.doi.org/10.32656/sff.2017.208.

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Zhou, Chi, Yong Chen, and Richard A. Waltz. "Optimized Mask Image Projection for Solid Freeform Fabrication." In ASME 2009 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. ASMEDC, 2009. http://dx.doi.org/10.1115/detc2009-86268.

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Solid freeform fabrication (SFF) processes based on mask image projection have the potential to be fast and inexpensive. More and more research and commercial systems have been developed based on these processes. For the SFF processes, the mask image planning is an important process planning step. In this paper, we present an optimization based method for mask image planning. It is based on a light intensity blending technique called pixel blending. By intelligently controlling pixels’ gray scale values, the SFF processes can achieve a much higher XY resolution and accordingly better part quality. We mathematically define the pixel blending problem and discuss its properties. Based on the formulation, we present several optimization models for solving the problem including a mixed integer programming model, a linear programming model, and a two-stage optimization model. Both simulated and physical experiments for various CAD models are presented to demonstrate the effectiveness and efficiency of our method.

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Khandelwal, Deepesh, and T. Kesavadas. "A Computational Design Framework for a Rapid Solid Freeform Fabrication Process." In ASME 2000 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. American Society of Mechanical Engineers, 2000. http://dx.doi.org/10.1115/detc2000/dac-14269.

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Abstract Solid Freeform Fabrication (SFF) techniques in recent years have shown tremendous promise in reducing the design time of products. This technique enables designers to get three-dimensional physical prototypes from 3D CAD models. Although SFF has gained popularity, the manufacturing time and cost have limited its use to small and medium sized parts. In this paper we have proposed a novel concept for rapidly building SFF parts by inserting prefabricated inserts into the fabricated part. A computational algorithm was developed for determining ideal placement of inserts/cores in the CAD model of the part being prototyped using a heuristic optimization technique called Simulated Annealing. This approach will also allow the designers to build multi-material prototypes using the Rapid Prototyping (RP) technique. By using cheaper pre-fabricates instead of costly photopolymers, the production cost of the SFFs can be reduced. Additionally it will also reduce build time, resulting in efficient machine utilization.

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Storti, Duane, Chad Redl, Mark Ganter, George Turkiyyah, and Tony Woo. "Encapsulated Transmission of Part Specifications for Distributed Solid Freeform Fabrication." In ASME 1999 Design Engineering Technical Conferences. American Society of Mechanical Engineers, 1999. http://dx.doi.org/10.1115/detc99/dac-8600.

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Abstract This paper describes an approach to the transmission of part specifications for distributed solid freeform fabrication. We consider an approach motivated by recent advances in software development associated with object oriented programming style and data encapsulation. Rather than insisting on translation of part specifications to a standard format, we specify a set of public methods necessary for solid freeform fabrication (SFF) or layered manufacturing (LM). By specifying public members and methods that provide fabrication systems with all the information needed to build parts, SFF systems can build parts based on models constructed in any modeling environment for which the methods are available. As an example, we consider a candidate set of methods required by a simple layered fabrication system, and we discuss an implementation of those methods for a modeling format, implicit solid modeling, that has not previously been directly supported by SFF systems. Since for any modeling system, SFF relies on the construction of the layers or slices through the part, we pay particular attention to describing a slicing implementation for implicit solids.

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Malone, Evan, and Hod Lipson. "Multi-Material Freeform Fabrication of Active Systems." In ASME 2008 9th Biennial Conference on Engineering Systems Design and Analysis. ASMEDC, 2008. http://dx.doi.org/10.1115/esda2008-59313.

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Current Solid Freeform Fabrication (SFF) technologies can manufacture, directly from digital data, end-use mechanical parts in an increasingly wide variety of engineering materials. However, commercial SFF systems remain costly, complex, proprietary, and are limited to working with one or two proprietary materials during the course of building a part, hindering their broader application and the impact of the technology. The work we present here demonstrates (1) that SFF systems can employ many materials and multiple processes during the course of building a single object, (2) that such systems can produce complete, active, electromechanical devices, rather than only mechanical parts, and (3) that such multi-material SFF systems can be made accessible to, and are of interest to the general public. We have developed a research-oriented, multi-material SFF system and employed it to produce not only mechanical parts, but complete and functional Zn-air batteries, electrical wiring, flexible circuit boards, strain-gages, electromagnets, electroactive polymer actuators, organic-polymer transistors, and electromechanical relays. We have also developed and published the Fab@Home Model 1 open-source, multi-material, freeform fabrication system design. The Fab@Home project has received broad public and media attention, and more than 100 Model 1 machines have been built by individuals around the world.

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Qi, Huan, and Jyotirmoy Mazumder. "Laser Cladding Based Solid Freeform Fabrication and Direct Metal Deposition." In ASME 2006 International Manufacturing Science and Engineering Conference. ASMEDC, 2006. http://dx.doi.org/10.1115/msec2006-21009.

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Three-dimensional additive manufacturing or solid freeform fabrication (SFF) techniques, originated in the rapid fabrication of non-functional physical prototypes in polymers (Rapid Prototyping), have matured to the manufacture of functional prototypes, short-run production products, and now even advanced engineering designs. Laser-based material deposition or laser cladding has been used as a SFF technique, in which a laser beam is used as a precise high-energy thermal source to melt preplaced or pneumatically delivered metal powders and make solidified deposits on a substrate. By using laser cladding techniques, three-dimensional fully dense components can be built line-by-line and layer-by-layer directly from a CAD model with tailored material properties. Laser cladding is essentially a fusion and solidification (thermal) process, which involves complicated interactions between the laser beam, metal powders, the base material (substrate), and processing gases. Maintaining a stable and uniform melt pool during laser cladding is critical to produce dimensional accuracy and material integrity. An effective control of energy (laser power) spatial and temporal distributions in either an open-loop or closed-loop laser cladding process is essential to achieve the high quality results. This paper reviews, from a laser-material interaction point of view, various laser cladding based SFF processes, and particularly the direct metal deposition technique.

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Kumpaty, Subha K., Dawn Garten, Russell Laursen, and Sheku Kamara. "Fluid Flow Applications of Solid Freeform Fabrication: Valves in Single Build." In ASME 2004 Heat Transfer/Fluids Engineering Summer Conference. ASMEDC, 2004. http://dx.doi.org/10.1115/ht-fed2004-56198.

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There is a constant need for custom designed and manufactured valves that are capable of precision flow control. The applications vary, such as medically related fluid situations; a check valve for a feeding tube for example. The fluids under consideration are diverse: air, water and blood, to name a few. Solid freeform fabrication (SFF) has immense potential for creating intricate valve structures without the limitations and numerous machining processes involved in conventional methods of valve assembly. This research demonstrated the usefulness of SFF in novel fluid mechanics applications. The primary goal was the design and fabrication of a functional valve in one build using a stereolithography apparatus. A valve with linear motion was designed that was rapid prototyping compatible and was fabricated using stereolithography under the NSF sponsored REU program in the summer of 2002. The valve was fully functional as a sealed system. Its performance was evaluated and compared to that of a traditional gate valve. Precision flow control and improved sealing were two goals that this research program achieved in summer of 2003. Through proper design, an angle valve has been built that retains the flow and sealing characteristics of a traditional valve, but has the advantages associated with SFF. The highlight of this work was the fact that moving parts, integral O-rings, and threaded connections were all shown to be possible and the entire valve prototyped in a single build using SFF. In addition, a downsized valve, 0.4 inch inside diameter, has been built that will broaden the applications of this technology. The accomplishments of this research will allow functional prototypes of valves to be built and tested using solid freeform fabrication and influence the use of specialty valves in medical and engineering applications.

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Rosen, David, Yong Chen, Jonathan Gerhard, Janet Allen, and Farrokh Mistree. "Design Decision Templates and Their Implementation for Distributed Design and Solid Freeform Fabrication." In ASME 2000 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. American Society of Mechanical Engineers, 2000. http://dx.doi.org/10.1115/detc2000/dac-14293.

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Abstract In this paper, we describe issues arising in distributed design and fabrication, where fabrication of prototypes is performed by Solid Freeform Fabrication (SFF) technologies. The focus is on a design-manufacture collaboration problem, namely the transfer of design information from the design organization to a manufacturing organization. In other research, this has been called the need for a “clean digital interface.” In the context of designing and fabricating a prototype, we explore two factors: the types of design and product information to be transferred from design to manufacturing, and which types of decisions can be made by the manufacturer regarding the prototype. As a representative product design process, we focus on three main activities, including material and SFF process selection, geometric tailoring (detailed design for manufacture modifications), and process planning. Further we investigate three interfaces between design and manufacturing organizations, one interface before each main activity. We demonstrate that a series of design decision templates can be used to transfer design information between the design and manufacturing organizations in support of the main activities. Furthermore, we demonstrate the implementation of these decision templates in a distributed design and fabrication environment called the Rapid Tooling TestBed. An example scenario is explored to illustrate the usage of two of the decision templates. Results show that, for the decision templates utilized, the templates are sufficient to specify design freedom to the manufacturer, enabling the manufacturer to assume more decision-making responsibility during the development of prototypes.

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Shim, Jin-Hyung, Jong Young Kim, Kyung Shin Kang, Jung Kyu Park, Sei Kwang Hahn, and Dong-Woo Cho. "Development of HA-PLGA Scaffold Encapsulating Intact BMP-2 Using Solid Freeform Fabrication Technology." In ASME 2011 International Manufacturing Science and Engineering Conference. ASMEDC, 2011. http://dx.doi.org/10.1115/msec2011-50259.

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Tissue engineering is an interdisciplinary field that focuses on restoring and repairing tissues or organs. Cells, scaffolds, and biomolecules are recognized as three main components of tissue engineering. Solid freeform fabrication (SFF) technology is required to fabricate three-dimensional (3D) porous scaffolds to provide a 3D environment for cellular activity. SFF technology is especially advantageous for achieving a fully interconnected, porous scaffold. Bone morphogenic protein-2 (BMP-2), an important biomolecule, is widely used in bone tissue engineering to enhance bone regeneration activity. However, methods for the direct incorporation of intact BMP-2 within 3D scaffolds are rare. In this work, 3D porous scaffolds with poly(lactic-co-glycolic acid) chemically grafted hyaluronic acid (HA-PLGA), in which intact BMP-2 was directly encapsulated, were successfully fabricated using SFF technology. BMP-2 was previously protected by poly(ethylene glycol) (PEG), and the BMP-2/PEG complex was incorporated in HA-PLGA using an organic solvent. The HAPLGA/PEG/BMP-2 mixture was dissolved in chloroform and deposited via a multi-head deposition system (MHDS), one type of SFF technology, to fabricate a scaffold for tissue engineering. An additional air blower system and suction were installed in the MHDS for the solvent-based fabrication method. An in vitro evaluation of BMP-2 release was conducted, and prolonged release of intact BMP-2, for up to 28 days, was confirmed. After confirmation of advanced proliferation of pre osteoblasts, a superior differentiation effect of the HA-PLGA/PEG/BMP-2 scaffold was validated by measuring high expression levels of bone-specific markers, such as alkaline phosphatase (ALP) and osteocalcin (OC). We show that our solvent-based fabrication is a non-toxic method for restoring cellular activity. Moreover, the HAPLGA/PEG/BMP-2 scaffold was effective for bone regeneration.

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Reports on the topic "Solid Freeform Fabrication (SFF)"

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Frigola, P., L. Faillace, Robert Rimmer, William Clemens, James Henry, Frank Marhauser, Andy Wu, et al. Development of a CW NCRF Photoinjector using Solid Freeform Fabrication (SFF). Office of Scientific and Technical Information (OSTI), October 2010. http://dx.doi.org/10.2172/990209.

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Bourell, D. L., J. J. Beaman, and Jr. Solid Freeform Fabrication Proceedings. Fort Belvoir, VA: Defense Technical Information Center, August 2001. http://dx.doi.org/10.21236/ada400355.

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Kumar, Ashok V. Electrophotographic Solid Freeform Fabrication. Fort Belvoir, VA: Defense Technical Information Center, August 1999. http://dx.doi.org/10.21236/ada367167.

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Bourell, D. L., and Kristin L. Wood. Solid Freeform Fabrication Proceedings. Fort Belvoir, VA: Defense Technical Information Center, August 2003. http://dx.doi.org/10.21236/ada422996.

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Stanley, James H. CT-Assisted Solid Freeform Fabrication. Fort Belvoir, VA: Defense Technical Information Center, August 1996. http://dx.doi.org/10.21236/ada324726.

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Stanley, James H. CT-Assisted Solid Freeform Fabrication. Fort Belvoir, VA: Defense Technical Information Center, May 1997. http://dx.doi.org/10.21236/ada326274.

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Bourell, David L., Joseph J. Beaman, Crawford Jr., Marcus Richard H., Barlow Harris L., and Joel W. Solid Freeform Fabrication Proceedings -1999. Fort Belvoir, VA: Defense Technical Information Center, August 1999. http://dx.doi.org/10.21236/ada377264.

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Calvert, Paul. Smart Materials by Extrusion Solid Freeform Fabrication. Fort Belvoir, VA: Defense Technical Information Center, January 2000. http://dx.doi.org/10.21236/ada376056.

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Marcus, Harris L. Solid Freeform Fabrication from Gas Precursors Using Laser Processing. Fort Belvoir, VA: Defense Technical Information Center, January 2002. http://dx.doi.org/10.21236/ada403015.

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Rice, Chris S. Semi-Solid Metal Freeform Fabrication - Phase I Final Report for Period September 4, 1999--June 14, 2000. Office of Scientific and Technical Information (OSTI), July 2000. http://dx.doi.org/10.2172/769242.

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