Process Development
Direct Laser Fabrication of a Gas Turbine Engine Component -Microstructure and Properties (Part I and 11) 1
Suman Das, Timothy P. Fuesting, Gregory Danyo, Lawrence E. Brown, Joseph J. Beaman, David L. Bourell and Kathleen Sargent
Geometry Processing for SLS/HIP 19
Ravi Venkataramani, Suman Das and Joseph J. Beaman
Surface Finishing of Selective Laser Sintering Parts with Robot 27
Dongping Shi and Ian Gibson
Laser Polishing of Silica Rods 37
Hongyun Wang, David Bourell and Joseph J. Beaman
Enhanced Controlling of the SLS Process During a Build 47
Alexandre L. Papadatos, Kenneth Stanley Jr., Said Ahzi and Frank W.Paul
Process Control of 3D Welding as a Droplet-Based Rapid Prototyping Technique 57
R. Kovacevic and H. Beardsley
Study of Ejection Forces in the AIMtm Process 65
Neil Hopkinson and Phil Dickens
Thermal Behavior of Parts Made by Direct Metal Laser Sintering 79
N.P. Karapatis, Y. Guidoux, P.E. Gygax and R. Glardon
Thermal Behavior in the LENS Process 89
M.L. Griffith, M.E. Schlienger, L.D. Harwell, M.S. Oliver, M.D. Baldwin, M.T. Ensz, J.E. Smugeresky, M. Essien, J. Brooks, C.V. Robino, W.H. Hofmeister, M.J. Wert and D.V. Nelson
Prototyping Large-Sized Objects Using Freeform Thick Layers of Plastic Foam 97
A.F. Lennings, J.J. Broek, I. Horváth, A. de Smit and J.S.M. Vergeest, K.P. Karunakaran, P. Vivekananda Shanmuganathan, Sabine Roth-Koch and Kai Uwe Koch
Direct Rapid Prototyping of Tools 105 Real Time Video Microscopy for the Fused Deposition Method 113
Evan Bossett, Lorna Rivera, Dan Qui, Ryan McCuiston, Noshir Langrana, Sriram Rangarajan, Natesan Venkataraman, Stephen Danforth and Ahmad Safari
Bevel Cutting Methods and Cutting Trajectory Control for Steel Laminations Used in Tooling 123
Daniel F. Walczyk
Designing Conformal Cooling Channels for Tooling 131
Xiaorong Xu, Emanuel Sachs, Samuel Allen and Michael Cima
Investigation of Short Pulse Nd:YAG Laser Interaction with Stainless Steel Powder Beds 147
W. O'Neill, C.J. Sutcliff R. Morgan and K.K.B. Hun
EFAB: Batch Production of Functional, Fully-Dense Metal Parts with Micron-Scale Features 161
Adam Cohen, Gang Zhang, Fan-Gang Tseng, Florian Mansfeld, Uri Frodis and Peter Will
Powder Deposition and Sintering for a Two-Powder Approach to Solid Freeform Fabrication 169
Ashok V Kumar
Effective Mechanisms of Multiple LED Photographic Curing 177
Kai Loose, Toshiki Niino and Takeo Nakagawa
Rapid Freezing Prototyping with Water 185
Wei Zhang, Ming C. Leu, Zhiming Ji and Yongnian Yan
Reducing the Surface Deviation of Stereolithography Using an Alternative Build Strategy 193
P.E. Reeves and R.C. Cobb
Sacrificial Materials for the Fabrication of Complex Geometries With Lens 205
E. Schlienger, M. Griffith, M. Oliver, J. A. Romero, J. Smugeresky
Rapid Prototyping Based on 2D Photographic Images 211
Jianguo Wang, Y.S. Wong, Jerry Fuh, H.T. Loh, ZhaoHui Du, GuoDong Hong and YongNian Yan
Art to Engineering: Pervasive RP Activities at Arizona State University 221
Anshuman Razdan, Mark R. Henderson and Dan Collins
Solid Freeform Fabrication Research in Engineering Education 229
R. S. Crockett and V. R. Gervasi
Computational Modeling
Parametric Based Controller for Rapid Prototyping Applications 236
Georges Fadel and Ravi Ganti
Process Planning and Automation for Additive-Subtractive Solid Freeform Fabrication 245
J. Miguel Pinilla, Ju-Hsien Kao and Fritz B. Prinz
Modeling and Designing Components with Locally Controlled Composition 259
Todd R. Jackson, Nicholas M. Patrikalakis, Emanuel M. Sachs, Michael J. Cima
Domain Decomposition and Space Filling Curves in Toolpath Planning and Generation 267
M. Bertoldi, M. A. Yardimci, C. M. Pistor and S. I. Guceri
Reverse Engineering Trimmed NURB Surfaces From Laser Scanned Data 277
Ben Steinberg, Anshuman Razdan and Gerald Farin
Stereometric Design for Desk-Top SFF Fabrication 285
Zbigniew M. Bzymek, Scott Theis, Tariq Manzur, Chandra Roychaudhuri, Lianchao Sun and Leon L. Shaw
A Process Planning Method and Data Format for Achieving Tolerances in Stereolithography 293
Charity M. Lynn, Aaron West and David W. Rosen
Dimensional Issues in Stereolithography 303
David L. Winmill, David M. Hoopes and Suresh S. Jayanthi
Variable Thickness Ruled Edge Slice Generation and Three-Dimensional Graphical Error Visualization 311
Peter B. Chamberlain, Mark D. Van Roosendaal and Charles L. Thomas
Topology Driven Improvement of FDC Build Parameters 319
Vikram R. Jamalabad, Jeffrey A. Chard, Charles Gasdaska and Richard B. Clancy
A Visual Tool to Improve Layered Manufacturing Part Quality 327
Gautham Kattethota and Mark Henderson
Machine Design, Control and Performance of Automated Computer-Aided Manufacturing of Laminated Engineering Materials 335
Brian B. Mathewson, Ravi Hebbar, Sangeun Choi, Wyatt S. Newman, James D. Cawley and Arthur H. Heuer
Build Time Estimations for Large Scale Modelling 343
G. Mensing and I. Gibson
Reverse Engineering of Polymeric Solid Models Using Refractive Index Matching (RIM) 351
Jon Christensen and Amit Bandyopadhyay
Software Development for Laser Engineered Net Shaping 359
M.T. Ensz, M.L. Griffith and L.D. Harwell
Physical Modeling
Measurement and Modeling Of Residual Stress-Induced Warping in Direct Metal Deposition Processes 367
N.W. Klingbeil, J.L. Beuth, R.K. Chin and C.H. Amon
FDM Systems and Local Adaptive Slicing 375
Justin Tyberg and Jan Helge Bøhn
Virtual Design and Fabrication in Layered Manufacturing 383
Kathryn B. Higgins and Noshir A. Langrana
Influence of Rheology on Deposition Behavior of Ceramic Pastes in Direct Fabrication Systems 391
Bruce H. King, Sherry L. Morissette, Hugh Denham, Joseph Cesarano III and Duane Dimos
A Theoretical Model for Optimization of SALD Parameters 399
Zbigniew M. Bzymek, Leon L. Shaw and Wojciech Marks
Simulation of Laminated Object Manufacturing (LOM) with Variation of Process Parameters 407
Lawrance Flach, Michelle A. Jacobs, Donald A. Klosterman and Richard P. Chartoff
Dimensional Variability Analysis in Post-Processing of Rapid Tooling 417
Wanlong Wang, James G. Conley and Henry W. Stoll
Shell Cracking in Investment Casting with Laser Stereolithography Patterns 427
W. L. Yao and Ming C. Leu
2-D Wavelet Analysis of Solid Objects: Applications in Layered Manufacturing 435
Mark D. Van Roosendaal, Peter Chamberlain and Charles L. Thomas
Materials
Strength of the DTM Rapidsteel 1.0 Material 443
T.D. Stewart, K.W. Dalgarno, T.H.C. Childs and J. Perkins
Direct Injection Molding Tooling Inserts from the SLS Process with Copper Polyamide 451
Christian Nelson, Jason Kepler, Rick Booth and Phillip Conner
Rapid Steel Tooling via Solid Freeform Fabrication 461
Timothy J. Weaver, Julian A. Thomas, Sundar V. Atre and Randall M. German
Processing of Titanium Net Shapes by SLS/HIP 469
Suman Das, Martin Wohlert, Joseph J. Beaman and David L. Bourell
Feasibility of Fabricating Metal Parts from 17-4PH Stainless Steel Powder 479
Guohua Wu, Noshir Langrana, Sriram Rangarajan, Rajendra Sadangi, Ahmad Safari and Stephen C. Danforth
Industrial Use of Direct Metal Laser Sintering 487
Olli Nyrhila, Juha Kotila, Jan-Erik Lind and Tatu Syvanen
3D Welding and Milling for Direct Prototyping of Metallic Parts 495
Yong-Ak Song, Sehyung Park, Kyunghyun Hwang, Doosun Choi and Haeseong Jee
Materials Issues in Laminated Object Manufacturing of Powder-Based Systems 503
J. D. Cawley, Z. Liu, J. Mou and A.H. Heuer
Issues Associated with the Development of a Water Soluble Support Material for Use in Extrusion Freeforming & Fused Deposition Modelling 511
John L. Lombardi, Gregory J. Artz, Dragan Popovich, Ranji Vaidyanathan and Sajiv Boggavarapu
Thermal-Expansion and Fracture Toughness Properties of Parts made from Liquid Crystal Stereolithography Resins 519
J.S. Ullett, T. Benson-Tolle, J.W. Schultz and R.P. Chartoff
Rapid Prototyping of Functional Three-Dimensional Microsolenoids and Electromagnets by High-Pressure Laser Chemical Vapor Deposition 529
J. Maxwell, K. Larsson, M. Boman, P. Hooge, Kirk Williams and P. Coane
Gas-Phase Selective Area Laser Deposition (SALD) Joining of SiC Tubes with SiC Filler Material 537
S. Harrison and H. L. Marcus
Preparation and Properties of In-Situ Devices Using the SALD and SALDVI Techniques 543
James E. Crocker, Lianchao Sun, Leon L. Shaw and Harris L. Marcus
Temperature Dependent Optical Properties of Polymers as a Basis for Laser Process Modeling 549
Bernd Keller, Rolf Pfeifer, Wei-Nien Su and Peter Eyerer
Mechanical Characterization of Parts Processed via Fused Deposition 557
M. Bertoldi, M.A. Yardimci, C.M. Pistor, S.I. Guceri and G. Sala
Material Strength in Polymer Shape Deposition Manufacturing 567
J.W. Kietzman and F. B. Prinz
Rapid Prototyping of Titanium Nitride Using Three-Dimensional Laser Chemical Vapor Deposition 575
James Maxwell, Jubin Shah, Terry Webster and Jason Mock
Ceramic Materials
Si/SiC-Ceramic-Low Process Shrinkage-High Temperature Material for the Laser Sinter Process 581
Peter Stierlen, Peter Schanz and Peter Eyerer
Mechanical Behavior of Robocast Alumina 589
Hugh B. Denham, Joe Cesarano III, Bruce H. King and Paul Calvert
Titanium Casting Molds via Selective Laser Sintering 597
Nicole Harlan, David Bourell and Joe Beaman
Selective Laser Sintering of Zirconium Silicate 605
F. Klocke and H. Wirtz
Development of a Binder Formulation for Fused Deposition of Ceramics 613
Thomas F. McNulty, Ivan Cornejo, Farhad Mohammadi, Stephen C. Danforth and Ahmad Safari
Materials for Biomedical Applications 621
N.K. Vail, L.D. Swain, W.C. Fox, T.B. Aufdemorte, G. Lee and J.W. Barlow
Processing of Bioceramic Implants via Fused Deposition Process 629
Susmita Bose, Marisol Avila and Amit Bandyopadhyay
Automated Fabrication of Nonresorbable Bone Implants Using Laminated Object Manufacturing (LOM) 637
Cheri Steidle, Don Klosteman, Nora Osborne, George Graves, Richard Chartoff
Generation of Porous Structures Using Fused Deposition 639
M. Bertoldi, M.A. Yardimci, C.M. Pistor, S.I. Guceri and S.C. Danforth
A Study on Weight Loss Rate Controlled Binder Removal from Parts Produced by FDC 651
Senol Pekin; John Bukowski and Avigdor Zangvil
Binder Formulation in EVA-wax System for Fused Deposition of Ceramics 661
Senol Pekin, Avigdor Zangvil and William Ellingson
Curved Layer LOM of Ceramics and Composites 671
Donald A. Klosterman, Richard P. Chartoff, Nora R. Osborne, George A. Graves, Allan Lightman, Gyoowan Han, Akos Bezeredi, Stan Rodrigues, Sung Pak, Gary Kalmanovich, Leon Dodin and Song Tu
Multiple Materials
Virtual Simulation for Multi-material LM Process 681
Dan Qiu, Noshir A. Langrana, Stephen C. Danforth, Ahmad Safari and Mohson Jafari
Features in Layered Manufacturing of Heterogeneous Objects 689
Xiaoping Qian and Debasish Dutta
Recent Developments in Robocasting of Ceramics and Multimaterial Deposition 697
Joseph Cesarano III, Bruce H. King and Hugh B. Denham
Functionally Optimized Ceramic Structures 705
C. Gasdaskaa, R. Clancya, M. Ortiz, V. Jamalabad, Anil Virkar and Dragan Popovitch
Fabrication of Curved Ceramic/Polymer Composite Transducers for Ultrasonic Imaging Applications by Fused Deposition of Ceramics 713
G. M. Lous, I. A. Cornejo, T. F. McNulty, A. Safari and S. C. Danforth
Automated Fabrication of Complex Molded Parts Using Mold SDM 721
A.G. Cooper, S. Kang, J.W. Kietzman, F. B. Prinz, J.L. Lombardi and L. Weiss
Composites With Gradient Properties from Solid Freeform Fabrication 729
V. R. Gervasi and R. S. Crockett
Properties of a High Temperature Liquid Crystal Stereolithography Resin 737
R. P. Chartoff, J. W. Schultz, J. Bhatt and J. S. Ullett
Net Shape Fabrication of SiC and SiC/SiC Components Using Laminated Object Manufacturing (LOM) 745
Don Klosterman, Richard Chartoff, Nora Osborne, George Graves, Allan Lightman and Akos Bezeredi