About this Abstract |
| Meeting |
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Symposium
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2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Presentation Title |
Decoupling Additive Manufacturing Tolerance from Nondestructive Evaluation Ultrasonic Resolution Using 3D-Printed Lithophanes |
| Author(s) |
Kenneth Shen, Harshith Adepu, Michael Sealy, Luz D. Sotelo |
| On-Site Speaker (Planned) |
Kenneth Shen |
| Abstract Scope |
Ultrasonic testing is critical for evaluating sub-surface features, yet its effectiveness in additive manufacturing (AM) is often obscured by high printing tolerance errors. This study proposes a framework to isolate manufacturing noise from ultrasonic sensing performance using 3D-printed lithophanes of famous artworks as controlled geometric benchmarks. To quantify lithophane sample difficulty, a Brushstroke Complexity Index (BCI) is developed, utilizing a weighted average of stroke shape, skeleton curvature, and size variability. To decouple error sources, two Structural Similarity Index Measure (SSIM) metrics are calculated to establish a manufacturing error baseline and compare UT reconstructions to physical samples respectively. By analyzing the delta between these two metrics across a broad range of BCI values, the study successfully isolates the capability of UT to detect fine, sub-micron variations independently of printing errors. This methodology provides a definitive standard for characterizing the practical resolution limits of nondestructive evaluation on complex, non-ideal surface geometries. |
| Proceedings Inclusion? |
Undecided |