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About this Abstract
Meeting 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Symposium 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Presentation Title Quantifying Machine-Induced Error in a Custom Binder Jet Platform for Radio Frequency Additive Manufacturing
Author(s) Matthew L. McCoy, Keenan Vaughn, Carolyn Conner Seepersad, Christopher J. Saldaņa
On-Site Speaker (Planned) Matthew L. McCoy
Abstract Scope Radio Frequency Additive Manufacturing (RFAM) enables volumetric sintering of doped polymer powders using RF radiation, offering rapid build times and uniform heating. However, part accuracy depends critically on the precision of the mechanical system, sintering mechanics, and process control. This work introduces a methodology to quantify machine-induced errors in a custom binder jet platform developed to study RFAM, while also introducing concepts to improve the printing process to achieve ideal parts. We model error sources from X-axis ball screw gantries, Z-axis piston actuation, recoater blade variation, and printhead droplet placement. Using a laser interferometer and calibration geometries, we experimentally validate each contribution. These are integrated into an error stack model and evaluated. This framework provides a path toward machine-agnostic error correction and establishes a foundation for high-precision RFAM process development, allowing machine errors to be decoupled from the process physics.
Proceedings Inclusion? Planned: Post-meeting proceedings

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Microstructure-Driven Fracture Behavior and Thermo-Mechanical Analysis of Large Area Additive Manufactured Short Fiber Composites
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Photoelastic Visualization of Residual Stresses in PLA After Interlayer Shot Peening During Fused Filament Fabrication
Physics-Aware AI for Born-Qualified Additive Manufacturing: Toward Real-Time, In-Situ Part Qualification
Physics-Guided Thermal History Control to Improve Part Quality in Laser Powder Bed Fusion Additive Manufacturing
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Pore Behavior in Melt Pool Properties Based on Ti-6Al-4V and SS316L Powders in Directed Energy Deposition (DED) Processes
Porosity Reduction in Large-Format Additive Manufacturing of Fiber-Reinforced Composites via Elongational Screw Design
Porous Membranes for Controlled Release Profiles using Stereolithography and Phase Separation
Post-Build CT Segmentation and Alignment with L-PBF In-Situ Monitoring Signatures
Powder Bed Interaction with Higher Translation Speed Electron Beams Path for the Area Printing
Powder Dispersion For Removal of Unsintered Powder After Selective Laser Flash Sintering
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Powder Particle Impact Behavior in Laser, Powder-Blown Directed Energy
Predicting LPBF Ti-6Al-4V Microstructure via Multi-Modal In-Situ Process Monitoring
Predicting Melt Pool Dimensions from Local Thermal Environment Through a Modified Rosenthal Solution
Predicting the Solidified Microstructure in Laser Powder Bed Fusion (LPBF) of Inconel 718 using Physics-Based Modeling and In-situ Sensor Data
Prediction of Failure in Additively Manufactured Metallic Components
Predictive Modeling of Particle Loading for Functional Grading in Reactive Extrusion Additive Manufacturing
Predictive Qualification of Laser Powder Bed Fusion: Leveraging Multi-Modal In-Situ Monitoring and Real-Time Control for Part Qualification
Printing Cryomilled Copper Chips by Blue Laser Directed Energy Deposition (DED)
Process-Aware Topology Optimization for Mitigating Residual Stress and Distortion in Laser Powder Bed Fusion
Process Development and Thermal Monitoring in Electron Beam Additive Manufacturing of Tungsten
Process Mapping for Single-Track Laser Wire Additive Manufacturing of AZ31 Magnesium Alloy
Producing Stochastic Metal Foam on Desktop FFF 3D Printers using Viscous Thread Printing
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Quantifying Machine-Induced Error in a Custom Binder Jet Platform for Radio Frequency Additive Manufacturing
Quantifying the Dynamic Properties of 3D Printed Polymers and Polymer Composites Via Ultrasonics
Radiative Property Characterization of Porous Medium Using Liquid-Based Advanced Micro-Additive Manufacturing Technique
Rapid and Non-Contact Density Measurement for Powder-Based AM Via Flash Thermography
Rapid Direct-Write Printing of Metallic Nanostructures Via In-Flight Plasma Reduction
Real-Time Closed-Loop Control for Precision Liquid Metal Jetting
Real-Time Implementability Evaluation of FPGA-Based Trackwise Model Predictive Control for Laser Powder Bed Fusion
Real-Time Prediction of Working Distance in Laser-Wire DED Via Multi-Modal In-Situ Data Fusion Using a CNN Model
Real Time Measurement System for Digital Glass Shaping Processes
Real Time Visualization of Glass Additive Manufacturing Processes
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Repeatability and Reproducibility of Mechanical Properties in HIP-Treated GRX810 Across Multiple LPBF Machines and Build Angles
Review on Atomization of Meals
Rheology-Driven Analysis of Extrusion Forces in Fused Filament Fabrication
Rheology-Informed Mixture Engineering of Aggregates for Extrusion Additive Manufacturing
Rheology Modification and Reinforcement of True Silicone Resins for Vat Photopolymerization
Robotic Subscale Bar-Fed Friction Stir Additive Manufacturing
Robotic Wire Arc DED (Directed Energy Deposition) of 316 l Stainless Steel Preform for Forging Application
Role of Defect Interaction and Multi-Site Damage in Fatigue Life of Additively Manufactured Metals
Sacrificial Preform Design and Parameter Optimization for Thin Walls and Corners in Powder-Blown Hybrid DED
Scalable and Data-Driven Control Strategy for Layer Thickness Consistency in Directed Energy Deposition
Selective Laser Etching of Fused Silica for Complex 3D Geometries
Sequential Element Rejection and Admission (SERA) Method for Topological Design of Cellular Materials
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Silicon Carbide Nanoparticle Filled Nanocomposites Using SLA Resin for Low Thermal Expansion and Enhanced Mechanical Properties
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Thermal Exposure Optimization for Enhanced Interlayer Strength in FFF-Printed ABS: A DOE and Microstructural Investigation
Thermal History Prediction of More Complex Geometries for DED Based on SciML
Thermal Monitoring in AC Selective Laser Flash Sintering of Ceramics Using a Mid-Wave Infrared Photodiode
Toolpath Planning for Multi-Nozzle Concurrent Molten Metal Jetting Process
Top Layer Quality Assurance of Complex Geometries Based on Region of Interest in Additive Manufacturing
Topology and Orientation Optimized-Inspired Toolpath Planning for Continuous Fiber Material Extrusion
Toward Real-Time Finite Element Analysis-Informed Feedback Control of Wire-Arc Directed Energy Deposition via Robot Operating System 2 In-Situ Monitoring System
Towards Parametric Design for Additive Manufacturing of Coral Structures Using a Digital Twin Approach
Towards Scalable and Energy-Efficient Extrusion Additive Manufacturing of Thermoplastic Polymer Composites
Towards the Production of a 3D Part in Selective Laser Additive Manufacturing Acousto-Optic Light Engine (SLAM – ALE)
Train Small, Predict Big: Scalable Thermal Surrogate Modeling for LPBF Using MODAL
Transfer Learning for Process–Microstructure–Property Mapping in Micro Selective Laser Sintering
Transient Liquid Phase Surface Smoothing
Tribo-Mechanical and Corrosion Characteristics of SS316L-IN625 Alloys of Varying Compositions Fabricated by Twin Wire WAAM-TIG
Two-Component Thermoset Polymer Formwork for Concrete Casting
Uncovering Process-Structure Relationships in Directed Energy Deposition of Nickel-Based Alloys on Low-Alloy Steel with Post-Deposition Heat Treatment
Understanding Hardening Behavior Induced by Interlayer Shot Peening in Laser Powder Bed Fusion of 316L Stainless Steel
Understanding Multi-Line Printing and the Effects of Controlled Prewetting on Binder Jetting Print Cohesion
Understanding Sources of Spatial Density Variation in Green Parts Produced by Binder Jetting
Understanding the Effect of Heat Treatment on Mechanical Properties of Additive Manufactured 1.2709 Grade Maraging Steel
Understanding the Feasibility of Using NiTi55 Interlayer for Ti6Al4V-18Ni Maraging Steel Multi-Metal Deposition in L-PBF
Use of In-Situ Thermography to Study Scan Strategy for Laser Foil Printing of Metallic Glass
Using Acoustic Signals For Torch-to-Bead Distance Estimation and Closed-Loop Control in Wire Arc Additive Manufacturing
Using Coaxial Melt Pool Images to Construct In-Process 3D Volume Model in Powder Bed Fusion Additive Manufacturing
Using Machine Learning-Based Process Map to Guide Evaluation of Inconel 625 Mechanical Properties in Laser Foil Printing
Vat Photopolymerization of Na3V2(PO4)3-Based Electrodes for Sodium-Ion Batteries
Vat Photopolymerization of Ultra-Soft Polymer Foams
Volumetric Medical Models: Direct Imaging to Functional 3D Prints
Wire Arc Additive Manufacturing Benefits and Challenges: A Survey
Wire Arc Additive Manufacturing Development for Aluminum 6061 RAM
Wire Arc Additive Manufacturing of a Large Scale, High Aspect Ratio, Multi-Material Part
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