European Assessment of SFF
Overview of the WTEC Additive/Subtractive Manufacturing Study of European Research 1
David W. Rosen
Rapid Manufacturing Research Group 11
Richard Hague and Phill Dickens
Solid Freeform Fabrication and the Interface with Direct Write 14
K. G. Watkins
Research on Layer Manufacturing Techniques at Fraunhofer 26
C. Ader, M. Brosemer, C. Freyer, H. Fricke, D. Hennigs, F. Klocke, V. Kühne, W. Meiners, C. Over, H. Pleteit, S. Stührmann, I. Wirth, T. Wirtz and K. Wissenbach
The Reality of Functionally Graded Material Products 38
G. E. Knoppers, J. W. Gunnink, J. van den Hout and W. P. van Vliet
Binding Mechanisms in Selective Laser Sintering and Selective Laser Melting 44
J. P. Kruth, P. Mercelis, L. Froyen and Marleen Rombouts
Materials
Creep Behaviour of Polyamide in Selective Laser Sintering 60
Eef Moeskops, Nico Kamperman, Bart van de Vorst and Rik Knoppers
An Investigation of LENS®-Deposited Medical-Grade CoCrMo Alloys 68
Brent Stucker, Carson Esplin and Daniel Justin
Advances in the Production of Infiltrated Aluminium Parts Using Selective Laser Sintering 80
T. B. Sercombe and G. B. Schaffer
Effects of Process Variables and Size Scale on Solidification Microstructure in Laser-Based Solid Freeform Fabrication of Ti-6Al-4V 92
N. W. Klingbeil, S. Bontha, C. J. Brown, D. R. Gaddam, P. A. Kobryn, H. L. Fraser and J. W. Sears
A Design of Experiments Approach Defining the Relationships Between Processing and Microstructure for Ti-6Al-4V 104
T. A. Wallace, K. S. Bey, K. M. B. Taminger and R. A. Hafley
Influence of Laser Processing Parameters on the Corrosion Behavior in 316L Stainless Steel Laser Powder Depositions 116
Eswar R. Yarrapareddy, Alan J. Anderson and James W. Sears
Strain Analysis of Initial Stage Sintering of 316L SS Three Dimensionally Printed (3DP™) Components 129
Scott Johnston, Dustin Frame, Rhonda Anderson and Duane Storti
The Effects of Pre-Alloyed Steels Powder Compositions on Build Quality in Direct Metal Laser Re-Melting 141
S. P. Akhtar, C. S. Wright and M. Youseffi
Scaling Effects in Laser-Based Additive Manufacturing Processes 151
Andrew J. Birnbaum, Jack L. Beuth and James W. Sears
Transient Changes in Melt Pool Size in Laser Additive Manufacturing Processes 163
Pruk Aggarangsi, Jack L. Beuth and David D. Gill
Materials Design – Towards a Functionally Graded Electrical Conductor 175
S. Satapathy, K. Hsieh and C. Persad
Fabrication of X-Graded H13 and Cu Powder Mix Using High Power Pulsed Nd:YAG Laser 187
V. E. Beal, P. Erasenthiran, N. Hopkinson, P. Dickens and C. H. Ahrens
Experimental Investigation of Laser Metal Deposition of Functionally Graded Copper and Steel 198
Vinay Kadekar, Sashikanth Prakash and Frank Liou
Solidification Morphology Analysis of SLM of Cu Powder 203
Jorge A. Ramos Grez and David L. Bourell
Direct Laser Sintering of Borosilicate Glass 214
F. Klocke, A. McClung and C. Ader
An Initial Assessment of Infiltration Material Selection for Selective Laser Sintered Preforms 220
Stacia L. Barrow, David Bourell and Scott Evans
Rapid Manufacturing of Silicon Carbide Composites 228
R. S. Evans, D. L. Bourell, J. J. Beaman and M. I. Campbell
Preliminary Study for Transparentization of SLS Parts by Resin Infiltration 236
T. Niino, H. Yamada and S. Seki
Fabrication of PEM Fuel Cell Bipolar Plates by Indirect SLS 244
Ssuwei Chen, David L. Bourell and Kristin L. Wood
Advanced Laminated Object Manufacturing (LOM) of SiSiC Ceramics 257
L. Weisensel, N. Travitzky and P. Greil
Prospect of Making Ceramic Shell Mold by Ceramic Laser Fusion 268
H. H. Tang, H. C. Yen, S. M. Su and Z. Y. Lin
Process Errors and Aspects for Higher Resolution in Conventional Stereolithography 281
Carsten Tille
Novel Implementations of Plasma Spraying for Fabricating Components Made of a Multiphase Perfect Material 293
Feng Wang, Ke-Zhang Chen and Xin-An Feng
Process Development
Metal Laminated Tooling – A Quick and Flexible Tooling Concept 304
Thomas Himmer, Anja Techel, Steffen Nowotny and Eckhard Beyer
High Speed Sintering – Early Research into a New Rapid Manufacturing Process 312
Neil Hopkinson and Poonjolai Erasenthiran
Laser-Assisted Photothermal Imprinting of Nanocomposite 321
Y. Lu, D. B. Shao and S. C. Chen
Continuous Ink-Jet Printing Electronic Components Using Novel Conductive Inks 334
Junfeng Mei, Michael Lovell, Marlin Mickle and Steve Heston
Exploring Vacuum Casting Techniques for Micron and Submicron Features 346
M. Denoual, P. Mognol and B. Lepioufle
Micro Thin Film Sensor Embedding in Metal Structures for Rapid Production of Miniature Smart Metal Tooling 358
Xudong Cheng, Patrick Schwieso, Hongseok Choi, Arindom Datta and Xiaochun Li
Extracting Product Performance by Embedding Sensors in SFF Prototypes 366
Rahul Rai, Matthew Campbell and Kristin Wood
Application of Machine Learning Methods to the Open-Loop Control of a Freeform Fabrication System 377
Evan Malone and Oliver Purwin
Simulation of the Process Step Polymer Removal in Indirect Metal Laser Sintering 389
M. Seefried, M. F. Zaeh and M. Meindl
Full-Densification of SLS Parts by Re-Melting 400
T. Niino and H. Yamada
An Investigation into the Effect of the Shell on SALM Processed Parts 408
A. K. Egodawatta, D. K. Harrison, A. K. M. De Silva and G. Haritos
Study on Incorporating Support Material in Rapid Freeze Prototyping 416
Frances D. Bryant and Ming C. Leu
On the Interface Between LENS® Deposited Stainless Steel 304L Repair Geometry and Cast or Machined Components 428
D. D. Gill, J. E. Smugeresky, M. F. Harris, C. V. Robino and M. L. Griffith
Characterization of Thin Walled Ti-6Al-4V Components Reduced via Electron Beam Melting 440
Denis Cormier, Harvey West, Ola Harrysson and Kyle Knowlson
Further Developments in Process Mapping and Modelling in Direct Metal Selective Laser Melting 448
C. Hauser, T. H. C. Childs and M. Badrossamay
Effect of Surface Treatments on Electron Beam Freeform Fabricated Aluminum Structures 460
Karen M. B. Taminger, Robert A. Hafley, David T. Fahringer and Richard E. Martin
Compensation for Uneven Surfaces When Building Laser Deposited Structures 471
E. Fearon and K. G. Watkins
Quantifying Dimensional Accuracy of a Mask Projection Micro Stereolithography System 481
Ameya Limaye and David Rosen
Geometry and Procedure for Benchmarking SFF and Hybrid Fabrication Process Resolution 493
Vito R. Gervasi, Adam Schneider and Joshua Rocholl
On the Use of Angled, Dynamic Laser Beams to Improve Stereolithography Surface Finish 500
Benay Sager and David W. Rosen
Numerical and Experimental Analysis of the Powder Flow Streams in the Laser Aided Material Deposition Process 512
Yogesh Thakar, Heng Pan and Frank Liou
Modeling of the Metal Powder Flow with Carrier Gas in Coaxial Nozzle for Direct Laser Deposition Process 523
Heng Pan and Frank Liou
Modeling
Converting a CAD Model into a Manufacturing Model for the Components Made of a Multiphase Perfect Material 532
Feng Zhu, Ke-Zhang Chen and Xin-An Feng
SFF-Oriented Modeling and Process Planning of Functionally Graded Materials Using a Novel Equal Distance Offset Approach 544
Anping Xu and Leon L. Shaw
Morphing Based Approach for Process Planning for Fabrication of Geometries and the Control of Material Composition 553
Rajeev Dwivedi and Radovan Kovacevic
A Combinatorial Parametric Engineering Model for Solid Freeform Fabrication 563
J. C. Boudreaux
The Approach of Complex Insert Packaging Fabrication in Stereolithography 572
Y. Y. Chiu and J. H. Chang
Development of Image Processing Tools for Analysis of Laser Deposition Experiments 584
Todd Sparks
Analyzing the Cutting Process of a Heated Flexible Blade in Extruded Polystyrene Foam 591
Bram de Smit and Han J. Broek
Study of Ceramic Slurries for Investment Casting with Ice Patterns 602
Qingbin Liu, Ming C. Leu, Harish Jose and Von L. Richards
Stereolithography Cure Process Modeling Using Acrylate Resin 612
Yanyan Tang, Clifford L. Henderson, John Muzzy and David W. Rosen
Investigation of the Oven Process in Indirect Metal Laser Sintering 624
M. Seefried and M. F. Zaeh
Thermal Optimization of Injection Molds Produced by Layered Manufacturing Techniques 636
Eric Boillat, Rémy Glardon and Marc Matthey
Simulating the Effects of Substrate Pre-Heating on the Final Structure of Steel Parts Built by Laser Powder Deposition 643
L. Costa, R. Vilar and T. Réti
Applications
Development of Nickel-Titanium Graded Composition Components 655
M. S. Domack and J. M. Baughman
Ejection Forces and Friction Coefficients from Injection Molding Experiments Using Rapid Tooling Inserts 669
M. E. Kinsella, B. Lilly, B. Carpenter and K. Cooper
Faster – Better Molds Through RSP Tooling New Research and Advancements 681
James R. Knirsch
Freeform Fabrication of Electroactive Polymer Actuators and Electromechanical Devices 697
Evan Malone and Hod Lipson
Industrial Freeform Generation of Microtools by Laser Micro Sintering 709
P. Regenfuβ, L. Hartwig, S. Klötzer, R. Ebert, Th. Brabant, T. Petsch and H. Exner
Direct Freeform Fabrication of Spatially Heterogeneous Living Cell-Impregnated Implants 720
D. L. Cohen, E. Malone, H. Lipson and L. J. Bonassar
Soft and Hard Implant Fabrication Using 3D-Bioplotting™ 732
C. Carvalho, R. Landers and R. Mülhaupt
Biomimetic Design and Fabrication of Interior Architecture of Tissue Scaffolds Using Solid Freeform Fabrication 742
B. Starly, A. Lau, W. Sun, W. Lau and T. Bradbury
Multiple Material Micro-Fabrication: Extending Stereolithography to Tissue Engineering and Other Novel Applications 754
Ryan Wicker, Francisco Medina and Chris Elkins
Accurate Heart Model for Pacemaker Development in SFF 765
R. S. Crockett, T. Horvath, M. Koch and M. Yang
Orthopedic Surgery Planning Based on the Integration of Reverse Engineering and Rapid Prototyping 773
Dong-Gyu Ahn, Jun-Young Lee and Dong-Yol Yang
Fabrication of Bone Substitute Material by Rapid Prototyping 784
A. Ott, J. Heinzl, D. Janitza and R. Pelzer
Design and Manufacture of an Attachment Fitting for Transtibial Prosthetic Sockets Using Selective Laser Sintering 794
Danny Burhan and Richard Crawford
Laser Densification of Extruded Dental Porcelain Bodies in Multi-Material Laser Densification (MMLD) Process 808
Xiaoxuan Li, Jiwen Wang, Leon L. Shaw and Thomas B. Cameron
Solid Freeform Fabrication of Artificial Human Teeth 816
Jiwen Wang, Leon L. Shaw, Anping Xu and Thomas B. Cameron
Multi-Nozzle Biopolymer Deposition for Freeform Fabrication of Tissue Constructs 826
S. Khalil, J. Nam, A. Darling and W. Sun
Design and Fabrication of Components with Optimized Lattice Microstructures 838
Vito R. Gervasi and Douglas C. Stahl
Panel Discussion on Broader Applications of SFF 845
Harris L. Marcus, Clinton L. Atwood, David G. Alexander, Phill M. Dickens and Kent Firestone