Design for Additive Manufacturing: A Method to Explore Unexplored Regions of the Design Space

Additive Manufacturing (AM) technologies enable the fabrication of parts and devices that are geometrically complex, have graded material compositions, and can be customized. To take advantage of these capabilities, it is important to assist designers in exploring unexplored regions of design spaces. We present a Design for Additive Manufacturing (DFAM) method that encompasses conceptual design, process selection, later design stages, and design for manufacturing. The method is based on the process-structure-property-behavior model that is common in the materials design literature. A prototype CAD system is presented that embodies the method. Manufacturable ELements (MELs) are proposed as an intermediate representation for supporting the manufacturing related aspects of the method. Examples of cellular materials are used to illustrate the DFAM method.Mechanical Engineerin

Quantifying Dimensional Accuracy of a Mask Projection Micro Stereolithography System

Mask Projection Microstereolithography is capable for fabricating true three-dimensional microparts and hence, holds promise as a potential micro-fabrication process for micro-machine components. In this paper, the Mask Projection Micro-Stereolithography (MPµSLA) system developed at the Rapid Prototyping and Manufacturing Institute at Georgia Institute of Technology is presented. The dimensional accuracy of the system is improved by reducing its process planning errors. To this effect, the MPµSLA process is mathematically modeled. In this paper, the irradiance received by the resin surface is modeled as a function of the imaging system parameters and the pattern displayed on the dynamic mask. The resin used in the system is characterized to experimentally determine its working curve. This work enables us to compute the dimensions of a single layer cured using our system. The analytical model is validated by curing test layers on the system. The model computes layer dimensions within 5% error.Mechanical Engineerin

Process Planning to Build Mask Projection Stereolithography Parts with Accurate Vertical Dimensions

Mask Projection Stereolithography (MPSLA) is a high resolution manufacturing process that builds parts layer by layer in a photopolymer. In this paper, we formulate a process planning method to cure MPSLA parts with accurate vertical dimensions. To this effect, we have formulated and validated the “Layer cure” model that models the thickness of a cured layer as a transient phenomenon, in which, the thickness of the layer being cured increases continuously throughout the duration of exposure. We have shown that for longer durations of exposures, such as those common with MPSLA systems, cure depth varies linearly with exposure. We have also quantified the effect of diffusion of radicals on the cure depth when discrete exposure doses, as opposed to a single continuous exposure dose, are used to cure layers. Using this work, we have formulated and validated the “Print through” model that computes the extra curing that would occur when multiple layers are cured over each other. We have implemented the Print through model to simulate the profile of a down facing surface of a test part and validated the simulation result by building the test part on our MPSLA system.Mechanical Engineerin

On the Use of Angled, Dynamic Laser Beams to Improve Stereolithography Surface Finish

Improved surface finish of Stereolithography (SLA) parts is an important goal for furthering the resolution of the technology. In order to improve the surface finish, a dynamic laser beam with changing angle, beam size, beam shape, and irradiance distribution is proposed. In this paper, an analytical irradiance model of an angled, dynamic laser beam in the SLA process is presented. This model is used to simulate cured shapes of SLA builds. Simulated build shapes are compared to established SLA analytical models and conclusions are drawn on the accuracy of the developed model.Mechanical Engineerin

Use of Parameter Estimation for Stereolithography Surface Finish Improvement

In order to improve Stereolithography (SLA) surface finish, a systematic approach based on estimation of process parameters is needed. In this paper, the exposure on a desired SLA build surface is formulated as a function of process parameters. The deviation of exposure on this surface from the critical exposure, which is the threshold that determines curing in the SLA process, is formulated using least squares minimization. By applying inverse design techniques, SLA process parameters that satisfy this least squares minimization are determined. Application of parameter estimation formulation to important SLA geometries is presented and the results, including surface finish improvement, are discussed.Mechanical Engineerin

Compensation Zone Approach to Avoid Z Errors in Mask Projection Stereolithography Builds

Print-through results in unwanted polymerization occurring beneath a part cured using Mask Projection Stereolithography (MPSLA) and thus creates error in its Z dimension. In this paper, the "Compensation zone approach" is proposed to avoid this error. This approach entails modifying the geometry of the part to be cured. A volume (Compensation zone) is subtracted from underneath the CAD model in order to compensate for the increase in the Z dimension that would occur due to Print-through. Three process variables have been identified: Thickness of Compensation zone, Thickness of every layer and Exposure distribution across every image used to cure a layer. Analytical relations have been formulated between these process variables in order to obtain dimensionally accurate parts. The Compensation zone approach is demonstrated on an example problem.Mechanical Engineerin

Process Planning Based on User Preferences

Typical approaches to adaptive slicing in previous literature have typically used surface finish requirements to control the slicing process. As a result, slice schemes improve the part's surface quality, but do not enable explicit trade-offs between finish and build time. The purpose of this article is to present a process planning method that enables the preferences of the user for surface finish, build time, and accuracy to control how trade-offs are made in a process plan. A multiobjective goal formulation is used by this method to evaluate how well user preferences are met by a process plan. This method consists of three modules, for determining part orientation, for slicing the part, and for determining other parameter values. An example with several scenarios representing different user preferences is provided to illustrate the process planning method.Mechanical Engineerin

High levels of cyclic di-GMP in Klebsiella pneumoniae attenuate virulence in the lung

ABSTRACT The bacterial second messenger bis-(3′-5′)-cyclic dimeric GMP (c-di-GMP) has been shown to influence the expression of virulence factors in certain pathogenic bacteria, but little is known about its activity in the increasingly antibiotic-resistant pathogen Klebsiella pneumoniae . Here, the expression in K. pneumoniae of a heterologous diguanylate cyclase increased the bacterial c-di-GMP concentration and attenuated pathogenesis in murine pneumonia. This attenuation remained evident in mice lacking the c-di-GMP sensor STING, indicating that the high c-di-GMP concentration exerted its influence not on host responses but on bacterial physiology. While serum resistance and capsule expression were unaffected by the increased c-di-GMP concentration, both type 3 and type 1 pili were strongly upregulated. Importantly, attenuation of K. pneumoniae virulence by high c-di-GMP levels was abrogated when type 1 pilus expression was silenced. We conclude that increased type 1 piliation may hamper K. pneumoniae virulence in the respiratory tract and that c-di-GMP signaling represents a potential therapeutic target for antibiotic-resistant K. pneumoniae in this niche. </jats:p

Manufacturing Metallic Parts with Designed Mesostructure via Three-Dimensional Printing of Metal Oxide Powder

Cellular materials, metallic bodies with gaseous voids, are a promising class of materials that offer high strength accompanied by a relatively low mass. In this paper, the authors investigate the use of ThreeDimensional Printing (3DP) to manufacture metallic cellular materials by selectively printing binder into a bed of metal oxide ceramic powder. The resulting green part undergoes a thermal chemical post-process in order to convert it to metal. As a result of their investigation, the authors are able to create cellular materials made of maraging steel that feature wall sizes as small as 400 µm and angled trusses and channels that are 1 mm in diameter.Mechanical Engineerin