Process Development
Finishing of SLS-Parts for Rapid Manufacturing (RM) – A Comprehensive Approach 1
M. Schmid, C. Simon and G.N. Levy
Surface Contour Measurement Using a Short Range Laser Displacement Sensor 11
Yangsheng Li and Lijue Xue
Ceramic Joining by Gas Phase Pulsed Laser Processing 22
C.M. Weiss, M. Aindow and H. Marcus
Fabrication of Nanoimprinting Molds with Acrylic Polymer by Two-Photon Polymerization 29
Wande Zhang, Li-Hsin Han and Shaochen Chen
A Hybrid Rapid Pattern Manufacturing System for Sand Castings 35
Matthew C. Frank, Frank E. Peters, Xiaoming Luo, Fanqi Meng and Joseph Petrzelka
Optimizing the Quality of Parts Manufactured by the Automated Plasma Cutting Process Using Response Surface Methodology 47
B. Asiabanpour, D.T. Vejandla, C. Novoa, J. Jimenez and R. Fischer
Reduction of Complex Objects into Manufacturable Elements Using the Shell-Slice Approach 61
Vito Gervasi and Douglas Cook
Fab @ Home Model 2: Towards Ubiquitous Personal Fabrication Devices 70
Jeffrey I. Lipton, Daniel Cohen, Michael Heinz, Maxim Lobovsky, Warren Parad, Garrett Bernstein, Tianyou Li, Justin Quartiere, Kamaal Washington, Abdul-Aziz Umaur, Rian Masanoff, Justin Granstein, JordanWhitney and Hod Lipson
Calibrating Large-area Mask Projection Stereolithography for Its Accuracy and Resolution Improvements 82
Chi Zhou and Yong Chen
Fully Recyclable Multi-Material Printing 98
Jonathan D. Hiller and Hod Lipson
Design and Construction of a 6-DoF Fabrication Platform 107
James Grossman, Warren Parad and Hod Lipson
Integrating UC and FDM to Create a Support Materials Deposition System 115
M.L. Swank, B.E. Stucker, F.R. Medina and R.B. Wicker
Integration & Process Planning for Combined Ultrasonic Consolidation and Direct Write 129
Ludwing A. Hernandez and Brent Stucker
Development of a Melt Pool Tracking Vision System for Laser Deposition 148
Todd Sparks, Lie Tang and Frank Liou
Characterization of Shrinkage and Stresses in Large Area Maskless Photopolymerization 155
Kiran Kambly, Dajun Yuan, Peng Shao and Suman Das
Experimental Determination of Optimum Parameters for Stainless Steel 316L Annealed Ultrasonic Consolidation 166
R. Gonzalez and B. Stucker
Investigation on Occurrence of Elevated Edges in Selective Laser Melting 180
Evren Yasa, Jan Deckers, Tom Craeghs, Mohsen Badrossamay and Jean-Pierre Kruth
Effect of Powder Compaction in Plastic Laser Sintering Fabrication 193
Toshiki Niino and Kazuki Sato
Development of Extrusion-on-Demand for Ceramic Freeze-Form Extrusion Fabrication 206
Thomas Oakes, Parimal Kulkarni, Robert G. Landers and Ming C. Leu
Increase of Heat Transfer to Reduce Build Time in Rapid Freeze Prototyping 219
Ming C. Leu, Sriram P. Isanaka and Von L. Richards
Investigation of Support Materials for Use in Ultrasonic Consolidation 231
M.L. Swank and B.E. Stucker
Modeling
Sustainability Study in Selective Laser Sintering – An Energy Perspective 257
Rameshwar Sreenivasan and David L. Bourell
STL 2.0: A Proposal for a Universal Multi-Material Additive Manufacturing File Format 266
Jonathan D. Hiller and Hod Lipson
Design Automation for Multi-Material Printing 279
Jonathan D. Hiller and Hod Lipson
Advanced Process Planning for Subtractive Rapid Prototyping 288
Joseph E. Petrzelka and Matthew C. Frank
Digital Data Processing Strategies for Large Area Maskless Photopolymerization 299
Anirudh Rudraraju and Suman Das
Examination of the Powder Spreading Effect in Electron Beam Melting (EBM) 308
C. Eschey, S. Lutzmann and M.F. Zaeh
Effect of Free-Edges on Melt Pool Geometry and Solidification Microstructure in Beam-Based Fabrication of Thin-Wall Structures 320
Joy E. Davis, Nathan W. Klingbeil and Srinkanth Bontha
Materials
Electrochemical Infiltration of Laser Sintered Preforms with Metals 332
Abhishek Goel and David Bourell
Comparison of Density of Stainless Steel 316L Parts Produced with Selective Laser Melting Using Different Powder Grades 342
A.B. Spierings and G. Levy
Further Exploration of Multi-Material Fabrication Capabilities of Ultrasonic Consolidation Technique 354
J.O. Obielodan and B.E. Stucker
Effect of Build Parameters and Build Geometries on Residual Microstructures and Mechanical Properties of Ti-6Al-4V Components Built by Electron Beam Melting (EBM) 374
L.E. Murr, S.M. Gaytan, F. Medina, E. Martinez, D.H. Hernandez, L. Martinez, M.I. Lopez, R.B. Wicker and S. Collins
The Effects of Specimen Dimensions on the Mechanical Behavior of EBM Produced Ti6Al4V Alloys 398
R.S. Kircher, A.M. Christensen and K.W. Wurth
Effects of Post Processing Heat Treatments on the Bond Quality and Medical Strength of Ti/Al 3003 Dual-Materials Fabricated Using Ultrasonic Consolidation 406
J.O. Obielodan and B.E. Stucker
Electron Beam Melted (EBM) Co-Cr-Mo Alloy for Orthopaedic Implant Applications 428
R.S. Kircher, A.M. Christensen and K.W. Wurth
Indirect Selective Laser Sintered Fully Ferrous Components-Infiltration Modeling, Manufacturing and Evaluation of Mechanical Properties 437
Phani Vallabhajosyula and David L. Bourell
Synthesizing of Functionally Graded Surface Composites by Laser Powder Deposition Process for Slurry Erosion Applications 446
Ehsan Foroozmehr, Rouzbeh Sarrafi, Syed Hamid and Radovan Kovacevic
Functionally Graded Materials by Laser Metal Deposition 454
Syamala R. Pulugurtha, Joseph Newkirk, Frank Liou and Hsin-Nan Chou
Evaluation of Direct Diode Laser Deposited Stainless Steel 316L on 4340 Steel Substrate for Aircraft Landing Gear Application 470
Tien Fu, Todd E. Sparks, Frank Liou, Joseph Newkirk, Zhiqiang Fan,Syamala R. Pulugurtha, Jianzhong Ruan and Hsin-Nan Chou
New Material Systems for 3D Ceramic Printing 477
Grant Marchelli, Mark Ganter and Duane Storti
Fabricating Superhydrophobic Surfaces with Solid Freeform Fabrication Tools 488
Alan M. Lyons, John Mullins, Mark Barahman, Itay Erlich and Todd Salamon
Laser Printed Elastomeric Parts and Their Properties 498
D.I. Wimpenny, S. Banerjee and J. Jones
New Polymerization-Mixture Formulation for Jetting: An Approach to Production of Polyamide 6 Parts 507
K. Khodabakhshi, M. Gilbert, P. Dickens, R. Hague and S. Fathi
Powder Pre-Conditioning for the LS Process 519
C.E. Majewski, P.M. Horsford and N. Hopkinson
Flammability and Thermal Properties of Polyamide 11-Alumina Nanocomposites 529
S.C. Lao, J.H. Koo, T.J. Moon, B. Hadisujoto, W. Yong, L. Pilato and G. Wissler
Processing and Properties of Carbon Black-Filled Electrically Conductive Nylon-12 Nanocomposites Produced by Selective Laser Sintering 538
S. Athreya, K. Kalaitzidou and S. Das
Photopolymer Solidification for Inclined Laser Exposure Conditions 547
Young Hyun Kim, Jong Seon Lim, In Hwan Lee and Ho-Chan Kim
Functional Micro/Macro Fabrication Combining Multiple Additive Fabrication Technologies: Design and Development of an Improved Micro-Vane Phacoemulsifier used in Cataract Surgery 553
Jae-Won Choi, Masaki Yamashita, Jun Sakakibara, Yuichi Kaji, Tetsuro Oshika and Ryan B. Wicker
Applications
Fused Deposition Modeling of Polymethylmethacrylate for Use in Patient-Specific Reconstructive Surgery 569
David Espalin, Karina Arcaute, David Rodriguez, Frank Medina, Matthew Posner and Ryan Wicker
A Study of Variable Stiffness Alginate Printing for Medical Applications 584
Adaleena Mookerjee, Daniel L. Cohen, David H. Peng, Lawrence J.Bonassar and Hod Lipson
Investigation and Design of an Actively Actuated Lower-Leg Prosthetic Socket 595
J. Montgomery, M. Vaughan and R. Crawford
Topology Optimization and Freeform Fabrication Framework for Developing Prosthetic Feet 607
Nicholas P. Fey, Brian J. South, Carolyn C. Seepersad and Richard R. Neptune
Wafer-Scale, Solid Freeform Fabrication of Fully-Assembled Metal Micro-Mechanisms for Minimally-Invasive Medical Devices 620
A. Cohen, R. Chen, U. Frodis, M. Wu and C. Folk
Design Optimization of a Customized Dental Implant Manufactured via Electron Beam Melting® 631
Gilbert Chahine, Hosein Atharifar, Pauline Smith and Radovan Kovacevic
Effect of Laser Fluence in Laser-Assisted Direct Writing of Human Colon Cell 641
Yafu Lin, Guohui Huang, Yong Huang, Jeremy Tzeng and Douglas Chrisey
Fabrication of Custom Dynamic Pedorthoses for Clubfoot Correction via Additive-Based Technologies 652
Vito Gervasi, Douglas Cook, Robert Rizza, Sheku Kamara and Xue Cheng Liu
Customized Rapid Manufactured Parts: Technology and Case Studies from the Custom-Fit Project 662
J. Jones, C.L. Jones and D.I. Wimpenny
Investigation on Occurrence of Elevated Edges in Selective Laser Melting 673
Evren Yasa, Jan Deckers, Tom Craeghs, Mohsan Badrossamay and Jean-Pierre Kruth
Fuel Cell Development Using Additive Manufacturing Technologies – A Review 686
N.P. Kulkarni, G. Tandra, F.W. Liou, T.E. Sparks and J. Ruan
Design, Fabrication of Testing of Graphite Bipolar Plates for Direct Methanol Fuel Cells 704
Kaushik Alayavalli and David L. Bourell
Brick Printing: Freeform Fabrication of Modular Architectural Elements with Embedded Systems 711
Jeffrey I. Lipton, Daniel Cohen and Hod Lipson
Selective Electron Beam Melting: A New Way to Auxetic Cellular Structures 724
Jan Schwerdtfeger, Peter Heinl, Robert F. Singer and Carolin Körner
Electronics Integration in Conformal Substrates Fabricated with Additive Layered Manufacturing 730
Sylvia Castillo, Dan Muse, Frank Medina, Eric MacDonald and Ryan Wicker
Design of Periodic Cellular Structures for Heat Exchanger Applications 738
Vikas Kumar, Guhaprasanna Manogharan and Denis R. Cormier
Advanced Heat Sinks Enabled by Three-Dimensional Printing 749
Alan Lyons, Shankar Krishnan, John Mullins, Marc Hodes and Domhnaill Hernon
Reprinting the Telegraph: Replicating the Vail Register Using Multi-Materials 3D Printing 761
Matthew Paul Alonso, Evan Malone, Francis C. Moon and Hod Lipson
Design and Manufacture of a Formula SAE Intake System Using Fused Deposition Modeling and Fiber-Reinforced Composite Materials 770
Ryan Ilardo and Christopher B. Williams
Multiple Material Microstereolithography 781
Jae-Won Choi, Eric MacDonald and Ryan Wicker
High Thermal Conductivity Coatings via LENS™ for Thermal Management Applications 793
Félix A. España, Vamsi Krishna Balla, Susmita Bose and Amit Bandyopadhyay
Recent Progress on Scanning Laser Epitaxy: A New Technique for Growing Single Crystal Superalloys 799
Michael Kirka, Rohan Bansal and Suman Das
Hydrocolloid Printing: A Novel Platform for Customized Food Production 807
Daniel L. Cohen, Jeffrey I. Lipton, Meredith Cutler, Deborah Coulter, Anthony Vesco and Hod Lipson
Customized Layer Deposition for Chemical Reactor Applications 819
J. Singh, C. Hauser, P.R. Chalker, C.J. Sutcliffe, A.T. Clare and M. Dunschen
Cellular Structures for Optimal Performance 831
Sarah Engelbrecht, Luis Folgar, David W. Rosen, Gary Schulberger and Jim Williams
Experimental Characterization of High Viscosity Droplet Ejection 843
J. Mark Meacham, Amanda O’Rourke, Yong Yang, Andrei G. Fedorov, F. Levent Degertekin and David W. Rosen
Scaffold Fabrication for Drug Delivery System Using Layered Manufacturing Methods 859
W.S. Chu, B.S. Jung and S.H. Ahn
Design, Fabrication and Evaluation of Negative Stiffness Elements 865
Lia Kashdan, Carolyn Seepersad, Michael Haberman and Preston S. Wilson