Software Testbed for Selective Laser Sintering

Computer software plays an important role in the implementation of Solid Freeform Fabrication (SFF) technologies. This paper describes a software testbed for processing part geometry for a particular SFF technology, selective laser sintering (SLS), that is built around the separation of the slicing and rasterization operations to accommodate geometric information from a variety of sources. The paper also discusses the process control software being developed for a new high-temperat rkstation for SLS of metal powders. This program features a high-resolution data rmat, the ability to interpolate to achieve a desired resolution, and a menu-driven user interface with graphical feedback and process simulation capabilities.Mechanical Engineerin

Systems Issues in Solid Freeform Fabrication

This paper is concerned with the systems aspects of the Solid Freeform Fabrication (SFF) technology, i.e., the issues that deal with getting an external geometric CAD model to automatically control the physical layering fabrication process as directly as possible, regardless ofthe source of the model. The general systems issues are described, the state of systems research is given, and open research questions are posed.Mechanical Engineerin

Freeform Fabrication of Ionomeric Polymer-Metal Composite Actuators

Ionomeric polymer-metal composite (IPMC) actuators are a type of soft electromechanically active material which offers large displacement, rapid motion with only ~1V stimulus. IPMC’s are entering commercial applications in toys (Ashley 2003) and biomedical devices (Soltanpour 2001; Shahinpoor 2002; Shahinpoor, Shahinpoor et al. 2003; Soltanpour and Shahinpoor 2003; Soltanpour and Shahinpoor 2004), but unfortunately they can only actuate by bending, limiting their utility. Freeform fabrication offers a possible means of producing IPMC with novel geometry and/or tightly integrated with mechanisms which can yield linear or more complex motion. We have developed materials and processes which allow us to freeform fabricate complete IPMC actuators and their fabrication substrate which will allow integration within other freeform fabricated devices. We have produced simple IPMC’s using our multiple material freeform fabrication system, and have demonstrated operation in air for more than 40 minutes and 256 bidirectional actuation cycles. The output stress scaled to input power is two orders of magnitude inferior to that of the best reported performance for devices produced in the traditional manner, but only slightly inferior to devices produced in a more similar manner. Possible explanations and paths to improvement are presented. Freeform fabrication of complete electroactive polymer actuators in unusual geometries, with tailored actuation behavior, and integrated with other freeform fabricated active components, will enable advances in biomedical device engineering, biologically inspired robotics, and other fields. This work constitutes the first demonstration of complete, functional, IPMC actuators produced entirely by freeform fabrication.Mechanical Engineerin

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

Direct Extrusion Freeforming of Ceramic Pastes

Microextrusion freeforming of ceramic lattices from high solids ceramic pastes provides multi-scale hierarchical void structures with the advantages of low shrinkage stress and high sintered density. Alumina lattices were directly fabricated using 80-500 Pm diameter filaments. We report here on the implementation of design and fabrication of these scaffolds for band gap materials and micro fluidic devices.Mechanical Engineerin

Multi-Nozzle Biopolymer Deposition for Freeform Fabrication of Tissue Constructs

Advanced freeform fabrication techniques have been recently used for the construction of tissue scaffolds because of the process repeatability and capability of high accuracy in fabrication resolution at the macro and micro scales. Among many applicable tissue scaffolding materials, polymeric materials have unique properties in terms of the biocompatibility and degradation, and have thus been widely utilized in tissue engineering applications. Hydrogels, such as alginate, has been one of the most important polymer scaffolding materials because of its biocompatibility and internal structure similarity to that of the extracellular matrix of many tissues, and its relatively moderate processing. Three-dimensional deposition has been an entreating freeform fabrication method of biopolymer and particularly hydrogel scaffolds because of its readiness to deposit fluids at ambient temperatures. This paper presents a recent development of biopolymer deposition based freeform fabrication for 3-diemnsinal tissue scaffolds. The system configuration of multi-nozzles used in the deposition of sodium alginate solutions and Poly-?- Caprolactone (PCL) are described. Studies on polymer deposition feasibility and structural formability are conducted, and the preliminary results are presented.Mechanical Engineerin

Geometry and Procedure for Benchmarking SFF and Hybrid Fabrication Process Resolution

Since the advent of SFF and RP a number of SFF benchmarking geometries and methodologies have been developed and employed with some similarities but limited standardization. Minimal information has been published in regard to a standard method of measuring the resolution limits or capabilities of SFF and SFF-based hybrid processes. In an effort to benchmark resolution limits of SFF and Hybrid Fabrication processes, several benchmarking geometries were developed to capture the resolution capabilities, specifically hole size and rod size range, of multiple hybrid fabrication path steps and a hybrid path as a whole. These useful geometries are shared with the SFF community and procedures for their use are described in this paper.Mechanical Engineerin

Mobile Paving System (MPS): A New Large Scale Freeform Fabrication Method

In the last decade, significant opportunities for automation have been identified in the area of construction. Soaring labor and material costs have driven multiple research efforts in construction automation. In this paper, we present a novel means for construction automation that involves the fusion of the rapid prototyping, controls and mechatronics technologies. The resultant autonomous construction mechanism has been designed for commercial applications. Mobile Paving System (MPS) is a new freeform fabrication process which is capable of rapidly producing variable profiles such as curbs and sidewalks out of materials like cement and asphalt. Path generation and guidance of the construction operation is controlled by a mobile robot. This article presents an overview of research and development efforts that are aimed at establishing the feasibility and the potential of the process.Mechanical Engineerin

The Characteristics and Applications of Ceramic Laser Fusion and Ceramic Laser Sintering

The aim of present study is to investigate the possible application of the ceramic parts which are fabricated with the process of Ceramic Laser Fusion or Ceramic Laser Sintering. The experimental results reveal: (1) CLF can lead to a reduction in the porosity of the ceramic part but also can induce micro-cracks. Therefore, this process cannot produce a part with the required strength by a post-process of infiltration; (2) CLS is capable of fabricating a ceramic part with high porosity. By adjusting the slurry formulation and varying the scanning energy, the open porosity can be over 90vol% of the total porosity. After a post-process of infiltration, the density can be increased to 95%; therefore, CLS can apply to produce a part with high strength. Because the high open porosity leads to a good permeability, the process of CLS is suitable for the fabrication of ceramic shell mold.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