Computer Aspects of Solid Freeform Fabrication: Geometry, Process Control, and Design

Solid Freefonn Fabrication (SFF) is a class of manufacturing technologies aimed at the production of mechanical components without part-specific tooling or process planning. Originally used for creating modelsfor visualization, many industrial users of SFF technologies are realizing the greater potentialofSFF as legitimate manufacturing processes for producing patterns and, in some cases, functional.parts. Thus, SFF is becoming an important aspect of the product realization process in these industries. Solid Freefonn Fabrication arose from the dream of "push-button" prototyping, in which solid reproductions of three-dimensional geometric models are created automatically under computer control. Perhaps more than any other class of manufacturing technologies, computer software development has been an integral part of the emergence of SFF. As SFF technologies evolve toward the ability to create functional parts, computer issues gain more importance. This paper discusses three aspects of software design for SFF: processing of geometric data, global and local control of SFF processes, and computer-based analysis and design for SFF manufacturing. The discussion of geometric processing issues focuses on accuracy and completeness of input models, and the algorithms required to process such models. The interplay between the physics of SFF processing and the desired output geometry is discussed in terms of the development of model-based control algorithms for SFF. These two areas, geometric processing and control, are necessary for the practical implementation of any SFF technology. However, for SFF to realize its potential as an alternative for manufacturing functional parts, engineers must be provided with analysis and design tools for predicting mechanical properties, ensuring dimensional accuracy, choosing appropriate materials, selecting process parameter values, etc. For each of these three different but related areas of software design, the state-of-theart is assessed, contemporary research is summarized, and future needs are outlined.Mechanical Engineerin

Multi-function based modeling of 3D heterogeneous wound scaffolds for improved wound healing

This paper presents a new multi-function based modeling of 3D heterogeneous porous wound scaffolds to improve wound healing process for complex deep acute or chronic wounds. An imaging-based approach is developed to extract 3D wound geometry and recognize wound features. Linear healing fashion of the wound margin towards the wound center is mimicked. Blending process is thus applied to the extracted geometry to partition the scaffold into a number of uniformly gradient healing regions. Computer models of 3D engineered porous wound scaffolds are then developed for solid freeform modeling and fabrication. Spatial variation over biomaterial and loaded bio-molecule concentration is developed based on wound healing requirements. Release of bio-molecules over the uniform healing regions is controlled by varying their amount and entrapping biomaterial concentration. Thus, localized controlled release is developed to improve wound healing. A prototype multi-syringe single nozzle deposition system is used to fabricate a sample scaffold. Proposed methodology is implemented and illustrative examples are presented in this paper

Product Focused Freeform Fabrication Education

Presented in this paper is our experience of teaching freeform fabrication to students at the Missouri University of Science and Technology, and to high school students and teachers. The emphasis of the curriculum is exposing students to rapid product development technologies with the goal of creating awareness to emerging career opportunities in CAD/CAM. Starting from solid modeling, principles of freeform fabrication, to applications of rapid prototyping and manufacturing in industry sponsored product development projects, students can learn in-depth freeform fabrication technologies. Interactive course content with hands-on experience for product development is the key towards the success of the program.Mechanical Engineerin

Hybrid Prototypes to Assist Modeling Automotive Seats

The development of new modular seats is an important issue in the automotive industry. However, is very time consuming and costly. Virtual models and hybrid prototypes could accelerate the car seats development process. The hybrid prototypes are mainly manufactured by rapid prototyping with multi materials. The objective of this paper is to establish a methodology to develop innovative lightweight multi-functional, modular car seats to be used in Multi-Purpose Vehicles (MPV), by means of FEA simulation and rapid prototyping additive/subtractive technologies utilizing multi materials. A case study is presented to validate the developed methodology. The manufactured hybrid prototype’s reproduces the main functionalities of the MPV modular seat, namely its three key positions: normal, stored and table.Mechanical Engineerin

Direct Laser Fabrication of a Gas Turbine Engine Component - Microstructure and Properties - Part I

This paper presents the development of a new technique for the production of abrasive turbine blade tips by direct laser processing. This superalloy cermet component is an integral part of the low pressure turbine sealing system in a demonstrator engine. Direct laser fabrication of this component fiom a bed a loose powder results in significant cost savings and improved performance over the currently employed production technique. The technology has been demonstrated by fabricating a prototype lot of 100 blade tips, which will be subjected to an engine test. This is the first instance of a direct fabrication method applied to the production of functional engine hardware. This research was funded by the United States Air Force contract F33615-94- C-2424 titled "Affordable Turbine Blade Tips".Mechanical Engineerin

Prototyping Large-Sized Objects Using Freeform Thick Layers of Plastic Foam

Current Rapid Prototyping systems are primarily aimed at small-sized objects containing many shape details. In this paper a Rapid Prototyping technology is presented that is aimed at largesized objects having a complex, freeform outer shape. This new technology builds the model out ofthick layers, each having freeform outside faces. The paper will present: an overview of current methods to produce large prototypes, the basics of the new method, the technology used to produce the layers, the toolpath planning and finally the overall system design.Mechanical Engineerin

A Combinatorial Parametric Engineering Model for Solid Freeform Fabrication

Fabricated parts are often represented as compact connected smooth 3-manifolds with boundary, where the boundaries consist of compact smooth 2-manifolds. This class of mathematical structures includes topological spaces with enclosed voids and tunnels. Useful information about these structures are coded into level functions (Morse functions) which map points in the 3-manifold onto their height above a fixed plane. By definition, Morse functions are smooth functions, all of whose critical points are nondegenerate. This information is presented by the Reeb graph construction that develops a topologically informative skeleton of the manifold whose nodes are the critical points of the Morse function and whose edges are associated with the connected components between critical slices. This approach accurately captures the SFF process: using a solid geometric model of the part, defining surface boundaries; selecting a part orientation; forming planar slices, decomposing the solid into a sequence of thin cross-sectional polyhedral layers; and then fabricating the part by producing the polyhedra by additive manufacturing. This note will define a qualitative and combinatorial parametric engineering model of the SFF part design process. The objects under study will be abstract simplicial complexes K with boundary ∂K. Systems of labeled 2-surfaces in K, called slices, will be associated with the cross-sectional polyhedral layers. The labeled slices are mapped into a family of digraph automata, which, unlike cellular automata, are defined not on regular lattices with simple connectivities (cells usually have either 4 or 8 cell neighborhoods) but on unrestricted digraphs whose connectivities are irregular and more complicated.Mechanical Engineerin

Thermal Modeling and Experimental Validation in the LENS™ Process

Several aspects of the thermal behavior of deposited stainless steel 410 (SS410) during the Laser Engineered Net Shaping (LENSTM) process were investigated experimentally and numerically. Thermal images in the molten pool and surrounding area were recorded using a two-wavelength imaging pyrometer system, and analyzed using ThermaVizTM software to obtain the temperature distribution. The molten pool size, temperature gradient, and cooling rate were obtained from the recorded history of temperature profiles. The dynamic shape of the molten pool, including the pool size in both travel direction and depth direction, was investigated and the effect of different process parameters was illustrated. The thermal experiments were performed in a LENSTM 850 machine with a 3kW IPG laser for different process parameters. A three-dimensional finite element model was developed to calculate the temperature distribution in the LENS process as a function of time and process parameters. The modeling results showed good agreement with the experimental data.Mechanical Engineerin

Freeform Bioprinting of Liver Encapsulated in Alginate Hydrogels Tissue Constructs for Pharmacokinetic Study

An in vitro model that can be realistically and inexpensively used to predict human response to various drug administration and toxic chemical exposure is needed. By fabricating a microscale 3D physiological tissue construct consisting of an array of channels and tissue-embedded chambers, one can selectively develop various biomimicking mammalian tissues for a number of pharmaceutical applications, for example, experimental pharmaceutical screening for drug efficacy and toxicity along with apprehending the disposition and metabolic profile of a candidate drug. This paper addresses issues relating to the development and implementation of a bioprinting process for freeform fabrication of a 3D cell-encapsulated hydrogel-based tissue construct, the direct integration onto a microfluidic device for pharmacokinetic study, and the underlying engineering science for the fabrication of a 3D microscale tissue chamber as well as its application in pharmacokinetic study. To this end, a prototype 3D microfluidic tissue chamber embedded with liver cells encapsulated within a hydrogel matrix construct is bioprinted as a physiological in vitro model for pharmacokinetic study. The developed fabrication processes are further validated and parameters optimized by assessing cell viability and liver cell phenotype, in which metabolic and synthetic liver functions are quantitated.Mechanical Engineerin

From 3D Models to 3D Prints: an Overview of the Processing Pipeline

Due to the wide diffusion of 3D printing technologies, geometric algorithms for Additive Manufacturing are being invented at an impressive speed. Each single step, in particular along the Process Planning pipeline, can now count on dozens of methods that prepare the 3D model for fabrication, while analysing and optimizing geometry and machine instructions for various objectives. This report provides a classification of this huge state of the art, and elicits the relation between each single algorithm and a list of desirable objectives during Process Planning. The objectives themselves are listed and discussed, along with possible needs for tradeoffs. Additive Manufacturing technologies are broadly categorized to explicitly relate classes of devices and supported features. Finally, this report offers an analysis of the state of the art while discussing open and challenging problems from both an academic and an industrial perspective.Comment: European Union (EU); Horizon 2020; H2020-FoF-2015; RIA - Research and Innovation action; Grant agreement N. 68044