Solid Freeform Fabrication Proceedings

Solid Freeform Fabrication Proceedings August 2001 Solid Freeform Fabrication as an important and totally integrated approach to design, materials processing and manufacturing research results related to it is contained in this proceedings of the SFF Symposium held in Austin, Texas on August 6-8, 2001 SFF Topics covered in the Symposium include:

Machine Design Computer Sectioning Reverse Engineering Materials Processing Applications

David L. Bourell, Joseph J. Beaman, Richard H. Crawford, Harris L. Marcus, Kristin L. Wood and Joel W. Barlow, Editors

© 2001 The University of Texas at Austin All rights of reproduction in any form are protected by U.S. Copyright Laws. Permission to copy all or portions of the proceedings contents must be obtained from the authors and The University of Texas at Austin. Library of Congress ISSN 1053-2153

Table of Contents Preface — Organizing/Advisory Committee-

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Page ix xi

Process Development Study on Selective Laser Sintering Components with Electrically Conductive Channels F. P. Y. Ting, I. Gibson, W. L. Cheung, The University of Hong Kong Design and Integration of a Laser-Based Materials Deposition System J. Laeng aka Jamaluddin Abdullah", Frank Lioub, M. N. Mohamad Ibrahim", W. M. Wan Muhammad", aUniversiti Sains Malaysia, bUniversity of Missouri-Rolla Skeleton-based Geometric Reasoning for Adaptive Slicing in a Five-axis Laser Aided Manufacturing Process System Kunnayut Eiamsa-ard, Jun Zhang, F. W. Liou, University of MissouriRolla Surface Roughness Enhancement of Indirect-SLS Metal Parts by Laser Surface Polishing J. A. Ramos, J. Murphy, K. Wood, D. L. Bourell, J. J. Beaman, The University of Texas-Austin SLS Powder Life Study J. Choren, V. Gervasi, T. Herman, S. Kamara, J. Mitchell, Milwaukee School of Engineering High-Speed Curtain Recoating for Stereolithography M. Gilio, J.-P. Kruth, P. Vanherck, Katholieke Universiteit Leuven Effective Cooling Method for Spin Casting Process Yong-Ak Song, Sehyung Park, Yongsin Kwon, Korea Institute of Science and Technology KIST Fabrication of Multi-Layered Carbon Structures Using LCVD Ryan W. Johnson, Scott N. Bondi, Daniel L. Jean, Chad E. Duty, Ming Xuan Jiang, W. Jack Lackey, Georgia Institute of TechnologyHomogeneous Metal Parts by Infiltration Adam M. Lorenz, Emanuel M. Sachs, Samuel M. Allen, Michael J. Cima, Massachusetts Institute of Technology Accuracy Improvement in Rapid Prototyping Machine (FDM-1650) A. Gregorian", B. Elliott, R. Navarro", F. Ochoa", H. Singh", E. Monge", J. Foyos", R. Noorani", B. Fritzb, S. JayantM, aLoyola Marymount University, b Northrop Grumman, C3D Systems —On Some Physical Aspects of Process Control in Direct Selective Laser Sintering of Metals Part I Suman Das, University of Michigan-Ann Arbor On Some Physical Aspects of Process Control in Direct Selective Laser Sintering of Metals Part II Suman Das, University of Michigan-Ann Arbor -

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On Some Physical Aspects of Process Control in Direct Selective Laser Sintering of Metals Part III Suman Das, University of Michigan-Ann Arbor

102

New Way of Process Parameters Optimization in SFF Based on Deposition by Welding Z. Jandric, R. Kovacevic, Southern Methodist University

110

Controlled-Depth Laser Cutting of Aluminum Sheet for Laminated Object Manufacturing Gene Zak, Matthew Shiu, Queen's University

120

Closed Loop Control of 3D Laser Cladding Based on Infrared Sensing D. Hu, H. Mei, G. Tao, R. Kovacevic, Southern Methodist University Research and Development of a Hybrid Rapid Manufacturing Process F. W. Liou, J. Choi, R. G. Landers, V. Janardhan, S. N. Balakrishnan, S. Agarwal, University of Missouri-Rolla Material Movement and Fusion Behavior of TrueForm and TrueForm/SiO2 during Selective Laser Sintering K. M. Fan, W. L. Cheung, I. Gibson, The University of Hong Kong Design of a Micro-Hopper Array for Multi-Material Powder Deposition Suman Das, James Santosa, University of Michigan-Ann Arbor

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146 155

Materials SALDVI of SiC into Metal and Ceramic Powders James E. Crocker, Haoyan Wei, Leon L. Shaw, Harris L. Marcus, University of Connecticut-Storrs Spot Joining of Si3N4 and SIC Ceramics using Selective Area Laser Deposition (SALD) Technique Ibrahim M. Ghayad", Erik Geissb, James E. Crocker*, Harris L. Marcusb, "Central Metallurgical Research and Development Institute, bUniversity of Connecticut-Storrs Robocasting of Photonic Band Gap Structures James E. Smayab, Joseph Cesarano lit, Shawn Y. Linb, John N. Stuecker1*, Jennifer A. Lewis", "University of Illinois-Urbana-Champaign, bSandia National Laboratory-NM Mechanical Properties of Laser-Deposited Ti-6A1-4V P. A. Kobryn, S. L. Semiatin, Air Force Research Laboratory Composite Modeling and Analysis of FDM Prototypes for Design and Fabrication of Functionally Graded Parts LongmeiLi, Q. Sun, C. Bellehumeur, P. Gu, University of Calgary Microstructure Evaluation for Laser Densification of Dental Porcelains Xiaoxuan Li", Jiwen Wang", Alvin Augustine", Leon L. Shaw", Harris L. Marcus", Thomas B. Cameronb, "University of Connecticut-Storrs, b Degussa-Ney Dental Inc. Freeform Fabrication of Ti3SiC2 Structures D. J. Dcosta, W. Sun, T. EI-Raghy, Drexel University Slurry-Based 3DP and Fine Ceramic Components M. J. Cima, M. Oliveira, H. R. Wang, E. Sachs, R. Holman, Massachusetts Institute of Technology

163

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175 179 187

195 203

216

Fused Deposition of Ceramics (FDC) and Composites Seyi Onagoruwa, Susmita Bose, Amit Bandyopadhyay, Washington State University -

224

Solidification Modeling and Microstructural Characterization of Alloy IN718 Deposited by Laser Engineered Net Shaping J. N. DuPonf, J. G. Nawrocki", M. L. Griffithb, aLehigh University, "Sandia National Laboratory-NM

232

Experimental Study of Selective Laser Sintering of Parmax® Jagan R. Rajan", Kristin L. Wood", Nick Malkovichb, "University of TexasAustin, Mississippi Polymers Technologies Inc. — Effects of Aging on Epoxy-Based Rapid Tooling Materials Xavier Ottemer, Jonathan S. Colton, Georgia Institute of Technology— Limits of Loose Metal Powder Density in the Sinterstation Klas Boivie, The Royal Institute of Technology Direct Metal Laser Re-Melting (DMLR) of 316L Stainless Steel Powder Part 1: Analysis of Thin Wall Structures Rhys Morgan, Adam Papworth, Chris Sutcliffe, Pete Fox, Bill O'Neill, University of Liverpool Direct Metal Laser Re-Melting of 316L Stainless Steel Powder Part 2: Analysis of Cubic Primitives Rhys Morgan, Adam Papworth, Chris Sutcliffe, Pete Fox, Bill O'Neill, University of Liverpool

242 256 264

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Modeling A Study of Functional Testing with SFF Parts Alan J. Dutson, Kristin L. Wood, Joseph J. Beaman, Richard H. Crawford, David L. Bourell, University of Texas-Austin STL-based Finish Machining of Rapid Manufacturing Parts and Tools Xiuzhi Qu, Brent E. Stucker, University of Rhode Island A System Approach in Extrusion-Based Multi-Material CAD Cheng-Tiao Hsieh, Noshir A. Langrana, Rutgers-The State University of New Jersey Maximum Visibility Building Direction for Layered Manufacturing of Jewel Rings Y. Y. Young, K. M. Yu, C. K. Kwong, The Hong Kong Polytechnic University Thermal and Stress Modeling of Laser Fabrication of Multiple Material Components K. Dai, L. Shaw, University of Connecticut-Storrs Manufacturing of Instrumented Prototypes Moss Shimek, Nachiket Patwardhan, Kristin L. Wood, Joseph Beaman, Richard Crawford, University of Texas-Austin Compensation of Non-Linear Shrinkage of Polymer Materials in Selective Laser Sintering K. Manetsberger", J. Shen", J. Muellers'1, aDaimlerChrysler Research Center, bDornier Research

296 304 313

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A Model of Laser-Powder Interaction in Direct Selective Laser Sintering of Metals Suman Das, Haseung Chung, University of Michigan-Ann Arbor Thermal Stresses in Direct Metal Laser Sintering Haiko Pohl", Abdolreza Simchi"b, Munther Issa"c, Hugo Calefi Diasad, "Fraunhofer Institute for Manufacturing and Advanced Materials IFAM, b Sharif University of Technology, cUniversity of Bremen, dUniversidade Federal de Santa Catarina Thermal, Fluid, and Mass Transport Modeling of a Gas-Jet Reagent Delivery System for Laser Chemical Vapor Deposition (LCVD) Chad Duty, Ryan Johnson, Daniel Jean, Scott Bondi, W. Jack Lackey, Georgia Institute of Technology Finite Element Structural Analysis of Prosthesis Sockets for Below-theKnee Amputees Manufactured Using SLS Mario Faustiniac, Mahendra Lokhande", Richard Crawford", William Rogersb, Andrew Gitterb, Gordon Bosket,"University of Texas-Austin, b University of Texas Health Science Center-San Antonio, "National Council of Scientific and Technological Development Modeling of Selective Area Laser Deposition Vapor Infiltration (SALDVI) of Silicon Carbide K. Dai, J. Crocker, L. Shaw, H. Marcus, University of Connecticut-Storrs Computer Integrated Adaptive Slicing and Vision Technologies for High Performance Rapid Prototyping System Jia-Chang Wang, Jun-Ming Wang, Tsung Te Lin, Jeng-Ywan Jeng, National Taiwan University of Science and Technology A Slicing Procedure for 5-Axis layered Manufacturing R. Sundaram, J. Choi, University of Missouri-Rolla Voxel-based Modeling with Multi-resolution Wavelet Transform for Layered Manufacturing Soonkyu Yim, Hae Chang Gea, Rutgers-The State University of New Jersey Rapid Prototyping using Fractal Geometry S. C. Soo, K. M. Yu, The Hong Kong Polytechnic University Melt Pool Size Control in Thin-Walled and Bulky Parts via Process Maps Aditad Vasinonta, Jack L. Beuth, Raymond Ong, Carnegie Mellon University On-line Monitoring of Epoxy Resin Cure using Infrared Spectroscopy F. Fouchal, J. A. G. Knight, P. Dickens, N. Garrington, DeMontfort University

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400 - 408 416 424

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Empirical Modeling and Vision Based Control for Laser Aided Metal Deposition Process Mallikharjuna R. Boddu, Srinivas Musti, Robert G. Landers, Sanjeev Agarwal, Frank W. Liou, University of Missouri-Rolla

452

Control of Laser Cladding for Rapid Prototyping—a Review Mallikharjuna R. Boddu, Robert G. Landers, Frank W. Liou, University of Missouri-Rolla

460

Physical Modeling for Dynamic Control of Melting Process in DirectSLS S. Ahn, J. Murphy, J. Ramos, J. J. Beaman, University of Texas-Austin Software for the Interactive Configuration of RP Based Process Chains Stefan Dreher, Fraunhofer IPK Berlin Simulation of the Electrochemical Machining Process R. Temur, T. Coole, C. Bocking, Buckinghamshire Chilterns University College

468 479 486

Applications Automated Construction using Contour Crafting B. Khoshnevis, H. Kwon, S. Bukkapatnam, University of Southern California

497

Clinical Evaluation of Prosthetic Sockets Manufactured by Selective Laser Sintering Bill Rogers", Andrew Gitter", Gordon Bosker", Mario Faustinib, Mahendra Lokhandeb, Richard Crawfordt, "University of Texas Health Science Center-San Antonio, bUniversity of Texas-Austin

505

Testing of Compliance in a Prosthetic Socket Fabricated Using Selective Laser Sintering Mahendra Lokhande, Richard Crawford, University of Texas-Austin Rapid Prototyping Assisted Design and Development of Inter-Vertebral Implants J. Chiang, M. Lehmicke, D. Dcosta, X. Hu, F. Lin, W. Sun, Drexel University Custom Fabrication of Hard Tissue Reconstructive Frameworks R. V. Nambiar, R. E. Jones, J. R. Gomez, University of Texas-Pan American Powder Delivery in Dental Restoration Rapid Prototyping Process Jiwen Wang", Xiaoxuan Li", Leon L. Shaw", Harris L. Marcus", Thomas B. Cameronb, "The University of Connecticut-Storrs, bDegussa-Ney Dental Inc. Manufacturing of a Heterogeneous Flywheel on a LENS Apparatus Stephane Morvan", Georges Fadet, James Love", Dave Keicher", "Optomec Inc., bClemson University Robocasting Periodic Lattices for Advanced Filtration John N. Stuecker, Joseph Cesarano III, James E. Smay, Sandia National Labs-NM Synthesis of a Compact Tetralattice Heat Exchanger using Solid Freeform Fabrication and Comparison Testing Against a Tube Heat Exchanger James R. Heidrich, Vito Gervasi, Subha Kumpaty, Milwaukee School of Engineering Applications of Solid Freeform Fabrication at the Naval Research Laboratory J. P. Thomas", B. A. Bender0, A. Pique", K. P. Cooper", R. J. Rayne", A. C. Richardsonb, "Naval Research Laboratory, bNational Naval Medical Center

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State of Solid Freeform Fabrication Solid Freeform Fabrication: An Historical Perspective Joseph J. Beaman, University of Texas-Austin Manufacturing by Solid Freeform Fabrication Emanuel Sachs, Massachusetts Institute of Technology Integration of Solid Freeform Fabrication in Design R. Hague", I. Campbelt, P. Dickens", P. Reevesc, "DeMontfort University, b Loughborough University, cEdward Mackenzie Ltd.

619

Laser Fusion Coatings of Functional Parts J. A. Ramos", D. L. Bourell", M. R. Govindarajub, "University of TexasAustin ,bKarta Technologies, Inc.

628

Author!Attendee List--

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584 596

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637