The versatility, precision, and ability to create complex geometries afforded by Additive Manufacturing (AM) make it a valuable tool for product designers, engineers, and manufacturers. While AM offers several advantages, the lack of recognized product definition and design standards is a significant barrier to widespread adoption. Product definition practices like Model-Based Definition (MBD) make forming a standardized hub for information about an AM process easier.
PolyJet manufacturing, an AM process, has various materials and unique capabilities and would benefit significantly from MBD. To enable the use of MBD, Design for AM (DfAM) guidelines for PolyJet must be formed for communicating design intent and manufacturing requirements. Great strides have been made in forming DfAM guidelines for PolyJet. However, no comprehensive metrology studies have been done to characterize the multi-material printing capabilities unique to PolyJet.
Three metrology test parts are designed to characterize the PolyJet process and its post-processes. Parts #1 and #2 evaluate the performance of single-material vs. multi-material parts, feature resolution, and geometric accuracy. Test part #3 characterizes the survivability of features in the post-processing stage. All parts are evaluated across different feature sizes and build orientations for a robust understanding of the PolyJet process. The results are compiled into graphs, color-coded charts, and data analysis that guide future designers to avoid unnecessary re-design and part failure.Mechanical Engineerin
