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Meeting 2021 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2021)
Symposium Special Session
Presentation Title Characterizing the Internal Morphology of Transition Regions in Large-scale Extrusion Deposition Additive Manufacturing
Author(s) James C. Brackett, Zaky Hussein, Elijah Charles, Tyler Smith, Ahmed Hassen, Seokpum Kim, Vlastimil Kunc, Chad Duty
On-Site Speaker (Planned) James C. Brackett
Abstract Scope A dual-hopper feed system that was developed for the Big Area Additive Manufacturing (BAAM) system allows for transitioning between different materials while maintaining continuous deposition. This technique creates a step-change in material feedstock by rocking the pellet feeding system to alternate which hopper is currently supplying material, allowing for multi-material construction. The step-change in feedstock material produces a transition region that is characterized by a compositional gradient and blended internal morphology. Initial cross-sectional imaging of the transition region revealed a non-homogenous blend of materials with distinct domains of each material, likely due to incomplete mixing within the screw. This study used a carbon fiber reinforced acrylonitrile butadiene styrene (CF-ABS) and an unfilled ABS to characterize the internal structure and to correlate it to mechanical performance by tracking microhardness across cross-sections of the transition region. Blending capability of the conventional printing hardware was also compared to that of a static-mixing nozzle.
Proceedings Inclusion? Definite: Post-meeting proceedings

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

3D Printing of Structural Battery Composites with Continuous Carbon Fibers
A Comparative Study of Extrusion Deposition of Long and Continuous Carbon Fiber Reinforced Composites for Large-scale Additive Manufacturing
A Dislocation Density Based Constitutive Model for the Design of Additively Manufactured (AM) Metals and Alloys
A Multi Robot Coordinated-motion Approach to Large Scale Deposition Systems – MedUSA
Abrasive Flow Machining of Additively Manufactured Titanium: Thin Walls and Internal Channels
Acoustic Signatures in Metal Laser-powder Bed Fusion
Adaptive Voxelization for Computed Axial Lithography
Additive Manufacturing of a Carbon Fiber Reinforced Thermoset Resin via Reactive Extrusion Additive Manufacturing (REAM)
Additive Manufacturing of Carbon Fiber Reinforced Polymer Composite via Reactive Extrusion
Additive Manufacturing of Neat and Carbon Fiber Reinforced PAEK Polymers
An Investigation on the Definition and Qualification of Form on Lattice Structures
Analysis of Fiber Orientation and Concentration in Large Scale Polymer Composite Deposition of Carbon Fiber-reinforced Thermoplastics
Analyzing Remelting Conditions Based on In-Situ Melt Pool Data Fusion for Overhang Building in Powder Bed Fusion Process
Autoencoder-based Anomaly Detection for Laser Powder Bed Fusion
Automated Anomaly Detection of Laser-based Additive Manufacturing Using Melt Pool Sparse Representation and Unsupervised Learning
Automated Detection of Part Quality during Two Photon Lithography via Deep Learning
Automated Process Planning for a 5-axis Hybrid Manufacturing System
Autonomous Multimodal Manufacturing Optimization
Bayesian Process Optimization for Additively Manufactured Nitinol
Characterizing the Internal Morphology of Transition Regions in Large-scale Extrusion Deposition Additive Manufacturing
Collision-free Solution for Multi-axis Hybrid Additive Manufacturing
Composition-processing-properties Relationships for In Situ Reinforced Ti-B4C-BN Composites via Directed Energy Deposition
Conformal Multifunctional Composite Fabrication via Conductive Direct Ink-write and Sacrificial Additively Manufactured Tooling
Correlating Large-scale AM Print Parameters to Fiber Length and Mechanical Performance of Reinforced Polymer Composites
Correlating the Effect of Part Geometry and Support Structure on Thermal History in Laser Powder Bed Fusion
Data Acquisition in Wire-arc Additive Manufacturing: The Road to Digital Twin
Deep Learning Assisted Approach to Monitoring Anomalies of 3D-bioprinting Process
Defining Robotic Torch Parameters for Non-gravity Aligned (NGA) Metal Additive Manufacturing Using CAD to Part Framework
Design and Manufacture of Continuous Fiber-Reinforced 3D Printed Unmanned Aerial Vehicle Wing
Detecting Defects Caused by Optical Lens and Focus-related Aberrations in Laser Powder Bed Fusion
Development of a Laser Hot Wire Additive Manufacturing Process
Development of Bimetallic Casting for Wear Performance through Infiltration of Additively Manufactured Metal Lattice Structures
Dopant Patterning for Volumetric Sintering via RF Heating
Droplet Diagnostics in Droplet-on-Demand Liquid Metal Jetting Using Heterogenous Sensing
Effect of Composition and Phase Diagram Features on Printability and Microstructure in Laser Powder Bed Fusion: Development and Comparison of Processing Maps Across Alloy Systems
Effect of Surface Texture on Deformation Behavior during Shot Peening of Electron Beam Melted (EBM) Ti-6Al-4V
Effective Registration of Engineered Lattice Geometry: A Comparative Study of Measurement Methodologies
Effectiveness of Shielding Gas in Wire-arc Additive Process
Effects of In-Situ Mechanical and Chemical Polishing on Surface Topography of Additively Manufactured Fiber-Reinforced Polymers
Empirical and simulated x-ray computed tomography probability of detection analysis for additive manufacturing and calibrated defect artifact development
Evaluation of Liquid Doping Methods for Use in Laser Powder Bed Fusion
Finite Element Modelling of the Fused Filament Fabrication Additive Manufacturing
Fused Filament Fabrication on the Moon
Geometrical Deviations in Additive Manufacturing – Influences on the Manufacturing Accuracy
Heterogenous Sensing and Scientific Machine Learning for In-process Anomaly Detection in Laser Powder Bed Fusion – A Single-track Study
High Resolution, High Conductivity Components by Aerosol Jet Printing and Electrodeposition
Hybrid Laser Powder Bed Fusion of Aluminum Alloy Radio Frequency Resonators
In-situ Detection and Prediction of Porosity in Laser Powder Bed Fusion Using Dual-wavelength Pyrometry
In-situ Flaw Detection in Wire Arc Additive Manufacturing Using an Acoustic Sensor
In-situ Microstructural Transformations in Wire-arc Additively Manufactured Maraging 250-grade Steel
In-situ Thermographic Inspection for Laser Powder Bed Fusion
In-situ Verification of 3D-Printed Electronics Using Deep Convolutional Neural Networks
Influence of Measurement and Sampling Strategy on Analysis of Surface Finish in Laser Powder Bed Fusion Additive Manufacturing of Nickel Superalloy 625
Influence of the Loading Direction on the Mechanical Properties of Additively Manufactured Metals
Integrating a Direct Ink Write and Mask-projection Vat Photopolymerization System to Enable Additive Manufacturing of High Viscosity Photopolymer Resins
Integrating Digital Light Processing with Direct Ink Writing for Hybrid 3D Printing of Functional Structures and Devices
Investigations for the Optimization of Visual and Geometrical Properties of Arburg Plastic Freeforming Components
Laser Powder Bed Fusion of Highly-reinforced Metal Matrix Composites
Layer-wise Certification for Direct Energy Deposition Processes based on Melt Pool Morphology Dynamic Analysis
Location and Orientation Dependency in Surface Roughness of Nickel Super Alloy 625 Parts: Statistical and Distributional Analysis
Locational Dependency of Additively Manufactured Parts: Effects of Surface Roughness on Fatigue Behaviors
Low Density Mechanical Metamaterial Using DLP-based 3D Printing
Machine Learning Enabled Laser Spatter and Flaw Detection in Laser Powder Bed Fusion Processes
Mapping Energy Consumption during Milling of Interlayer Ultrasonic Peened 316 Stainless Steel
Mechanical Behavior of ABS after Interlayer Ultrasonic Peening during Fused Filament Fabrication
Mechanical Interface for Iterative Hybrid Additive/Subtractive Manufacturing
Microstructural Evolutions in Jetting Reinforcement Nanoparticles to Metal Matrix in Laser Powder Bed Fusion
Microstructural Modeling of β to α Transformation Morphologies in Multi-layered Laser Wire Additively Manufactured Ti-6Al-4V Parts
Microstructure and Tensile Test Data Alignment for Additive Manufacturing Data Registration
Modeling Inter-layer Bonding in Additive Manufacturing of Continuous Fiber Reinforced Polymer Composites
Multi-modal In-situ Monitoring Data Analysis for Overhang Features Built with Laser Powder Bed Fusion
New Robotic Work-cell for Hybrid Large-scale Metals Additive and Subtractive Manufacturing
On the Diminishing Returns of Thermal Camera Resolution for PBF Temperature Estimation
Online Geometry Quality Management During Directed Energy Deposition Using Laser Line Scanner
Physics-informed and Hybrid Machine Learning in Additive Manufacturing
Porosity Analysis of Laser Powder Bed Fusion Parts Using the Statistics of Extremes
Powder Features Affecting Structural and Mechanical Properties of Additively Manufactured Inconel 718: A Machine Learning Analysis
Predictions of the Elastic-plastic Compressive Response of Functionally Graded Polymeric Composite Lattices Manufactured by 3D Printing
Predictive Control of Porosity in Laser Powder Bed Fusion
Preparation and Characterization of Laser Direct Deposited Spinel Filaments for Wire-fed Additive Manufacturing of Transparent Ceramics
Printing of Metal Droplet Streams Using Continuous Breakup of a Laser Heated Metal Wire
Process Development for the Selective Laser Melting of Tungsten Carbide-nickel Matrix Composites
Progress in Photopolymer Resin Development for Volumetric Additive Manufacturing
Progress on Residual Stress Measurement (RSM) in Hybrid Additive Manufacturing
Quality Assurance in Biomaterial Aerosol Jet Printing Using Machine Learning
Recent Advances in Laser-wire Directed Energy Deposition: Novel Modes of Thermal Control and Site-specific Melt Pool Size Control
Recycling Carbon Fiber Filled Acrylonitrile-Butadiene-Styrene for Large Format Additive Manufacturing
Selective Doping of Composites Using Piezoelectric Printheads
State of the Art and Technology in Additively Manufactured Polymer Composites
Study of Printing Parameters in Binder Jet Additive Manufacturing of Cobalt Chrome - Tricalcium Phosphate Biocomposite
Surface Improvement of Additively Manufactured Polypropylene Parts
Surface Roughness Variation in Laser Powder Bed Fusion Additive Manufacturing
The Role of Interface in Additively Manufactured Interpenetrating Composites
Thermomechanical Properties of a Glass and Carbon Nanofilled Photopolymer Composite Additively Manufactured via Stereolithography
Towards a Digital Twin: 4D Data Conditioning for Metal Inert Gas Big Area Additive Manufacturing
Ultrasonic Characterization of Frequency Dependence from Interlayer Milling and Peening 316 Stainless Steel during Additive Manufacturing
Understanding Filler Orientation in Material Extrusion Additive Manufacturing of Thermoset Composites
Unsupervised Defect Classification of 2D SEM and 3D X-Ray CT Images from Laser Powder Bed Fusion
Wire Arc Additive Manufacturing of Low Carbon Steel for Casting Applications
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