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

Residual Stresses in Layered Manufacturing

Layered Manufacturing processes accumulate residual stresses during materialbuildup. These stresses may cause part warping and layer delamination. This paper presents work done on investigating residual stress accumulation andp(i,rt distortion of Layered Manufactured artifacts. A simple analyticaLmodel was developed and used to determine how the number of layers and the layer thickness influences part warping. Resllits show that thin layers produce lower part deflection as compared with depositing fewer and thicker layers. In addition to the analytical work, a finite element model wasdeveloped and used to illvestigate the deposition pattern's influence on. the part deflection. Finite element model and corresponding experimental analysis showed that the geometry of the deposition pattern significantly affects the resulting part distortion. This finite element model was also used to investigate an inter-layer surface defect,. known as the Christmas Thee Step, that is associated with Shape Deposition Manufacturing. Results indicate that the features of this defect are influenced only by the material deposited close. to the part·surface and the particular material deposited. The step is not affected by the deposition pattern.Mechanical Engineerin

Wire mesh design

We present a computational approach for designing wire meshes, i.e., freeform surfaces composed of woven wires arranged in a regular grid. To facilitate shape exploration, we map material properties of wire meshes to the geometric model of Chebyshev nets. This abstraction is exploited to build an efficient optimization scheme. While the theory of Chebyshev nets suggests a highly constrained design space, we show that allowing controlled deviations from the underlying surface provides a rich shape space for design exploration. Our algorithm balances globally coupled material constraints with aesthetic and geometric design objectives that can be specified by the user in an interactive design session. In addition to sculptural art, wire meshes represent an innovative medium for industrial applications including composite materials and architectural façades. We demonstrate the effectiveness of our approach using a variety of digital and physical prototypes with a level of shape complexity unobtainable using previous methods

Powder Deposition and Sintering for a Two-Powder Approach to Solid Freeform Fabrication

A two-powder approach is presented where Fused Deposition modeling (FDM) is used to create a thin shell in the shape of the part to be fabricated. The shell is filled with powder of the part material and surrounded by a support powder that has a high sintering temperature. Upon compressing and sintering the shelVpowder system in a uniaxial hot press, the polymer shell burns out and the support powder compresses the part powder. The part powder consolidates into the desired part while the support material remains in powder form and can be easily removed. This paper presents results ofinitial experimental studies.Mechanical Engineerin

From computer-aided to intelligent machining: Recent advances in computer numerical control machining research

The aim of this paper is to provide an introduction and overview of recent advances in the key technologies and the supporting computerized systems, and to indicate the trend of research and development in the area of computational numerical control machining. Three main themes of recent research in CNC machining are simulation, optimization and automation, which form the key aspects of intelligent manufacturing in the digital and knowledge based manufacturing era. As the information and knowledge carrier, feature is the efficacious way to achieve intelligent manufacturing. From the regular shaped feature to freeform surface feature, the feature technology has been used in manufacturing of complex parts, such as aircraft structural parts. The authors’ latest research in intelligent machining is presented through a new concept of multi-perspective dynamic feature (MpDF), for future discussion and communication with readers of this special issue. The MpDF concept has been implemented and tested in real examples from the aerospace industry, and has the potential to make promising impact on the future research in the new paradigm of intelligent machining. The authors of this paper are the guest editors of this special issue on computational numerical control machining. The guest editors have extensive and complementary experiences in both academia and industry, gained in China, USA and UK

A Review of Layer Based Manufacturing Processes for Metals

The metal layered manufacturing processes have provided industries with a fast method to build functional parts directly from CAD models. This paper compares current metal layered manufacturing technologies from including powder based metal deposition, selective laser sinstering (SLS), wire feed deposition etc. The characteristics of each process, including its industrial applications, advantages/disadvantages, costs etc are discussed. In addition, the comparison between each process in terms of build rate, suitable metal etc. is presented in this paper.Mechanical Engineerin

DeepSketch2Face: A Deep Learning Based Sketching System for 3D Face and Caricature Modeling

Face modeling has been paid much attention in the field of visual computing. There exist many scenarios, including cartoon characters, avatars for social media, 3D face caricatures as well as face-related art and design, where low-cost interactive face modeling is a popular approach especially among amateur users. In this paper, we propose a deep learning based sketching system for 3D face and caricature modeling. This system has a labor-efficient sketching interface, that allows the user to draw freehand imprecise yet expressive 2D lines representing the contours of facial features. A novel CNN based deep regression network is designed for inferring 3D face models from 2D sketches. Our network fuses both CNN and shape based features of the input sketch, and has two independent branches of fully connected layers generating independent subsets of coefficients for a bilinear face representation. Our system also supports gesture based interactions for users to further manipulate initial face models. Both user studies and numerical results indicate that our sketching system can help users create face models quickly and effectively. A significantly expanded face database with diverse identities, expressions and levels of exaggeration is constructed to promote further research and evaluation of face modeling techniques.Comment: 12 pages, 16 figures, to appear in SIGGRAPH 201

The development of a finite elements based springback compensation tool for sheet metal products

Springback is a major problem in the deep drawing process. When the tools are released after the forming stage, the product springs back due to the action of internal stresses. In many cases the shape deviation is too large and springback compensation is needed: the tools of the deep drawing process are changed so, that the product becomes geometrically accurate after springback. In this paper, two different ways of geometric optimization are presented, the smooth displacement adjustment (SDA) method and the surface controlled overbending (SCO) method. Both methods use results from a finite elements deep drawing simulation for the optimization of the tool shape. The methods are demonstrated on an industrial product. The results are satisfactory, but it is shown that both methods still need to be improved and that the FE simulation needs to become more reliable to allow industrial application

Intelligent Freeform Deformation for LED Illumination Optics

In freeform optics, the optimization is limited due to large number of parameters present in it. This limitation was overcome by a technique known as optimization using freeform deformation (OFFD). Though this technique proved to work well, it has left many challenges to the optical designer. These challenges are solved by providing mathematical design techniques. This implementation transformed the OFFD into an intelligent tool replacing the optical designer\u27s efforts during the design process