freeform fabrication: current research in the usa
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Freeform Fabrication: Current Research in the USA. J.J. Beaman and Dave Bourell University of Texas at Austin Laboratory for Freeform Fabrication. Introduction to WTEC. World Technology Evaluation Center (WTEC), Inc. 2809 Boston St., #441 Baltimore, MD 21224 October 2003. WTEC Mission. - PowerPoint PPT PresentationTRANSCRIPT
Freeform Fabrication: Current Research in the USA
J.J. Beaman and Dave BourellUniversity of Texas at Austin
Laboratory for Freeform Fabrication
Introduction to WTEC
World Technology Evaluation Center (WTEC), Inc.
2809 Boston St., #441
Baltimore, MD 21224
October 2003
WTEC Mission• Look for good ideas abroad
(technology transfer)• Identify opportunities for cooperation• Compare U.S. R&D with related
international activities (benchmarking)• Provide information useful for planning
future U.S. R&D activities
Key WTEC Principles
• Open sources and open dissemination (http://www.wtec.org)
• Mutually beneficial exchange of ideas among hosts and WTEC visiting delegations
• Review of drafts by hosts and WTEC prior to public dissemination; proprietary considerations honored
WTEC Assessments Since 1989
• Electronics (11 fields assessed) • Materials (9)• Computer Science (5)• Telecommunications (3)• Biotechnology (3)• Energy (4)• Others (14)
Full text reports posted at http://www.wtec.org
• Biosensing (Schultz, Mrksich et al.) – NIH, NSF, NASA, ARO, USDA
• Benign Manufacturing (Gutowski) – NSF, DOE
• Tissue Engineering (McIntire) – NSF, NIH, FDA, NIST, DARPA, NASA (Academic Press book)
• Spin Electronics (von Molnar) –
NSF, DARPA, OSD, NIST, ONR (Kluwer book)
Recently Completed WTEC Projects
Current WTEC Projects
• Additive/Subtractive Hybrid Manufacturing (Beaman) – NSF, DARPA, ONR, NIST
• OR Applied to Healthcare (Sainfort) – NSF, AHRQ (In Europe Nov. 1)
• Staff Support, National Nanotechnology Initiative & Tissue Engineering Interagency Working Group
Consumer Goods25%
Motor Vehicles23%
Medical10%
Business Machines
10%
Other9%
Aerospace9%
Gov/Military7%
Academic Institutions
7%
Applications of Freeform Fab. (Wohlers Report 2002)
World Freeform Fabrication2002
•10,000 FFF Machines Worldwide
•40% of all Machines in USA, 14% in Japan (3rd China, 4th Germany)
•1482 Machines Sold (1299 in 2001)
•RP Market (Products, Part/Equipment Sales, Service Bureaus)
$485 Million
•28 Original Equipment Manufacturers (11 in 1993)
•Average Cost of FFF Part = $150 ($1000 in 1993)
Source: Wohler’s Report 2003
Empirical Similitude Method: Non-Linear Dimensional AnalysisLaboratory for Freeform Fabrication
Proposal Submitted to NSF/DMI
• ESM is a process where prediction can be achieved for a system that has non-linear parameters or response variables.
• Instead of a direct mapping between a model and product, two intermediate specimens (model and product specimens) are used to capture the geometric and material property differences.
• The product of the two matrices describing the material and property variations define the product performance.
• The evaluation is hence empirical compared to the traditional similitude method, where the prediction is purely dimensional in nature.
xp = S' xm
= F' xps
S
Model SpecimenProduct Specimen
Model Product
S'
F F'
xms xps = S xms
xm = F xms
Excessive surface melting removes the original roughness but induces frozen ripples caused by surface tension gradient in the liquid.
Results indicate that Laser Polishing is a rapid and promising
finishing technique for indirect-SLS metal
parts.
ONR N00014-00-1-0334, “Surface Engineering for Solid Freeform Fabrication Processes”
Surface Shallow Melting (SSM)
Surface Over Melt (SOM)
Melting of surface apexes reduces roughness Ra values by spreading of the melt over surface valleys driven by capillary pressure.
Laser Induced Surface Polishing
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
0.5 1.5 2.5 3.5 4.5
Traveling Speed (mm/s)
Ra(
m m)
NSF Grant Number: DMI- 0200283Direct Write of Novel Optical Components
•Research Objectives: •Significant Results:
•Approach
•Graphic:
•Broader Impact:
The development of a novel manufacturing process for the direct-write of sol-gel thin films for optical components.
Silica-based thin films were deposited on silicon, quartz, and borosilicate wafers. Samples were scanned using infrared and ultraviolet lasers.
Characterization of samples was done using multiple angle ellipsometry, atomic force microscopy, and scanning electron microscopy.
To rapidly prototype optical components on standard materials.
Achieve function integration in single wafers.
Initial characterization of fluence levels (power and scan velocity) required to produce smooth tracks.
Initial test with IR laser
Scanned with UV laser at high pulse rate
LENS™ is a Means of Directly Fabricating and Repairing Parts
Design BuildPart
Parts are built line by line,layer by layer
Direct metaldeposition
Nd YAG Laser Powder Nozzles
Substrate Motion
Focus PointMolten Pool
Clint Atwood, Sandia Natl Labs
Nylon-6 Tissue Engineering Scaffolds
Suman Das, University of Michigan
Volumetric Bone micro-CT Data
Scaled Replica (SLS)
Pre-Operative Planning and Surgical Rehearsal
Denis Cormier, North Carolina State University
RTV Molded Parts Using CT Scan Data (SLA)
Additive/Subtractive Manufacturing
Jyoti Mazumder, University of MichiganH13 Tool Steel
Direct Metal Deposition
Negative CTE Specimen
H13 tool steel with copper chill block and conformal coating
Laser Drilled Hole in AI-SIC Composite
Conclusions•US Research in Additive/Subtractive Manufacturing is diverse and advanced
•US Research in Additive/Subtractive Manufacturing represents only a piece of the total picture worldwide
•Exchange of Research Progress with Prominent European Additive/Subtractive Manufacturing Sites will:
advance the technology
enhance our understanding
improve research productivity