2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026): Hardware Modification
Program Organizers: David Leigh, University of Texas at Austin
Monday 1:30 PM
August 3, 2026
Room: Zlotnick Ballroom 5
Location: AT&T Center
1:30 PM
Decoupling Resolution and Throughput in Material Extrusion Additive Manufacturing: Jochen Mueller1; 1Johns Hopkins University
Material extrusion additive manufacturing remains constrained by a persistent coupling between geometric resolution and deposition throughput: smaller features typically require disproportionate reductions in flow rate, build volume, or process robustness. This abstract frames the resolution–throughput conflict as a system-level process-development problem rather than a limitation of any single subsystem. In this work, we analyze how materials rheology, flow dynamics, thermal or curing kinetics, toolpath planning, machine architecture, sensing, and closed-loop control jointly determine printable feature size and volumetric productivity. Strategies for relaxing the tradeoff are organized into three mechanistic domains: software and control methods that redistribute material or modulate deposition in real time, hardware architectures that alter nozzle-scale flow or parallelize deposition, and hybrid processes that combine extrusion with complementary patterning or consolidation mechanisms. This framework identifies design principles for fabricators whose resolution and throughput can be tuned with greater independence.
1:50 PM
Intellectual Property Protection in Distributed Intelligent Additive Manufacturing via Surrogate STL Generation and G-code Reconstruction: Syed Ziaul Bin Bashar1; Jesus Diaz1; Anusha Vangala2; Roopa Vishwanathan1; Chaitanya Mahajan1; Satyajayant Misra1; 1New Mexico State University; 2National Institute of Technology Warangal (NIT-W)
This paper presents a lightweight framework for Distributed Intelligent Additive Manufacturing (DIAM) to reduce the risks associated with STL file sharing across distributed print environments while preserving manufacturability. Instead of transmitting the original design, the owner generates a protected surrogate STL by inserting a controllable number of artificial layers along the build direction using a Trimesh-based preprocessing pipeline. The modified STL is then encrypted and sent to the service provider for slicing. After slicing, a companion execution module processes the generated G-code, identifies the inserted layer regions, removes the artificial layers, and reconstructs the final production toolpath for printing. In this workflow, the original STL is never disclosed outside the owner’s environment. Experimental results show that the method preserves printability while reducing direct access to the native design. Although partial reverse reconstruction from the final toolpath remains possible, the recovered geometry loses fine-detail fidelity relative to the original STL model.
2:10 PM
Beam Focus and Parametric Process Mapping for Diode Laser Additive Manufacturing: Ahmet KUS1; Zaher Alshehri1; Kamran MUMTAZ1; 1The University of Sheffield
Diode Area Melting (DAM) is an emerging variant of Laser Powder Bed Fusion (LPBF) that employs a multi-laser array, offering a novel approach to metal additive manufacturing. This study investigates the use of low-wavelength (~450 nm) blue diode lasers in a multi-laser configuration. While conventional parameters such as scanning speed and hatch spacing remain critical, this work highlights the often-overlooked influence of focal length on process performance. The system utilises individual 3.5 W lasers, delivering a combined power of approximately 30 W over a 0.045 mm˛ irradiation area (around 700 W/mm˛). Due to the relatively low power per diode, precise focusing and minimisation of spot size are essential for effective energy delivery. Experimental results on Ti-6Al-4V demonstrate that a slight defocus of 0.1 mm can reduce part density by approximately 3%, underscoring the sensitivity of the process to focal adjustment.
2:30 PM
Influence of Gaussian and Ring Beam Energy Profiles on Melt Pool Morphology in Laser-Based Powder Bed Fusion of GRX-810 and 304 Stainless Steel: Lizbeth Licerio1; Rebecca Herrera1; James Carney1; Kurtis Watanabe1; Colton Katsarelis2; Paul Gradl2; Francisco Medina1; 1UTEP; 2NASA
This study investigates the influence of Gaussian and ring-beam energy profiles on melt pool morphology using single-line-scan experiments on 304 stainless steel and GRX-810 alloy substrates. Quantitative measurements of melt pool width, depth, and bead shape were performed to analyze the effects of beam profile on track formation. The results demonstrated that the conventional Gaussian beam generated deeper, concave-shaped melt pools, consistent with a higher energy concentration at the beam center. In comparison, the ring beam profile produced wider and shallower beads, indicating a more uniform energy distribution.These findings underscore that beam shaping is essential for controlling melt pool geometry and the resulting microstructure during laser-based additive manufacturing. Data from 304 stainless steel were used to develop process parameters, while GRX-810 allowed for validation under more advanced alloy conditions, establishing a basis for optimizing process control across a range of material systems.
2:50 PM
A Hybrid Additive Manufacturing Platform for the Development of Bespoke Mechatronic Devices In-Situ: Matthew Doyle1; Mateusz Gora1; Alexander Brown1; Hitesh Bhardwaj1; Matthew Shuttleworth2; Damian Crosby3; Lutong Li4; Andrew Weightman4; Robert Richardson1; Robert Kay1; 1Leeds University; 2Hydra Manufacturing; 3Czech Technical University in Prague; 4Manchester University
Fully automated end-to-end manufacturing of functional mechatronic devices in situ remains a challenge. Conventional approaches to this ‘factory-in-a-box' problem typically automate subprocesses but do not deliver complete, ready-to-use devices. We address this limitation with a bespoke hybrid manufacturing platform that integrates 3D printing and pick-and-place assembly within a single, digitally driven workflow. The system comprises an automatic tool changer and five interchangeable tools: two fused filament fabrication extruders, a vacuum gripper, a parallel-plate gripper, and an automatic screwdriver. Operating autonomously, these tools combine 3D printing with the manipulation, embedding, and assembly of components. Minimal hardware reconfiguration is required between products, enabling dynamic, low-volume production without the extensive hardware retooling required in conventional manufacturing lines. Two case studies, a quadcopter and a wheeled robot, demonstrate the high-mix capabilities of the platform. We evaluate automation level, manufacturing cost, and production time, confirming the potential of this approach for end-to-end in-situ manufacturing.
3:10 PM Break
3:30 PM
Room-Temperature Precipitation-Induced 3D Printing of PEEK with Tunable Porosity: Harish Gunjal1; Gurminder Singh1; 1IIT Bombay
Processing of high-performance polymers, such as polyether ether ketone (PEEK), remains a challenge in additive manufacturing owing to the high processing temperatures (> 350°C) and thermal degradation. This study presents a novel room-temperature precipitation-induced 3D printing (PI-3DP) approach for fabricating PEEK structures with tunable porosity. PEEK dissolved in 4-chlorophenol was extruded into a nonsolvent bath (water and isopropanol), inducing phase inversion and solidification. The process kinetics were studied through an in-situ phase inversion time study. The porosity and structural properties were systematically controlled by varying the polymer concentration and nonsolvent. The printed structures exhibited dual porosity, micro-to-nano pores via precipitation within the filament, and macro pores via 3D printing. Thermal (Tg = 145.9 ℃ and Tm = 337 ℃) and chemical analyses confirmed the retention of PEEK properties, indicating no degradation. Thus, PI-3DP provides an alternative technique for fabricating high-performance polymers such as PEEK with scalable and tunable properties.
3:50 PM
Effect of a High-Flow Nozzle Design on the Printability of Polymer Feedstock in Material Extrusion Additive Manufacturing: Lucky Bernard1; Chukwuzubelu Ufodike1; Gaius Nzebuka2; Kareem Chaar1; 1Texas A&M University; 2Federal University of Technology, Owerri, Nigeria
The modification of the nozzle flow geometry of an extrusion-based printer to enable high-flow extrusion is presented. The novel nozzle design has a conical exit section, a channel width of 6 mm, and a cross-sectional area 12.5 times that of a standard 0.6 mm nozzle. The dimensional accuracy was evaluated for different nozzle heights, temperatures, and flow percentages. The thickness swell ratio showed a positive correlation with nozzle height and flow rate, and the width swell ratio showed a positive correlation with flow rate but a negative correlation with nozzle height. The swell ratios increased with temperature across all heights and flow percentages. The thickness swell ratio and average build volume decreased with the volume flow rate due to slippage, motor inaccuracies, and flow losses at higher speeds. In conclusion, the nozzle design could increase the flow rate at the same speed, reduce extrusion time, and increase the build rate.
4:10 PM
In-situ Dynamic Laser Area Heating in 450nm Diode Point Melting: Impacts on Microstructure and Surface Quality of SS316L: S. Can Erman1; Alkim Aydin2; Kamran Mumtaz1; 1University of Sheffield; 2Gazi University
Laser Powder Bed Fusion (LPBF) enables near-net-shape fabrication with refined microstructures and enhanced mechanical properties. However, steep thermal gradients can induce residual stresses, distortion, and warpage. This study introduces in-situ Dynamic Laser Area Heating (DLAH) during low-power Diode Point Melting (DPM) of SS316L to improve thermal control. The system combines a defocused 140 W, 915 nm diode laser with a 35 W, 450 nm DPM laser. In-situ DLAH reduces cooling rates, promoting 20.5% grain coarsening and the formation of ferrite alongside γ-austenite. Surface roughness improves from 14.94 μm to 8.14 μm, while common LPBF defects such as balling, lack of fusion, and spatter are suppressed. The DLAH approach provides enhanced thermal management, enabling controlled microstructural evolution and reduced defect formation in SS316L components.
4:30 PM
Hardware-Constrained DMD Mask Optimization for Uniform Microscale Selective Laser Sintering of Copper Nanoparticle Films: Farzana Tasnim1; David Shui1; Pratik Koirala1; Michael Cullinan1; 1University of Texas at Austin
Microscale selective laser sintering (µ-SLS) of copper nanoparticles suffers from non-uniform densification driven by two simultaneous mechanisms: a hardware-induced optical asymmetry in the Digital Micromirror Device (DMD) projection system and thermally driven edge losses caused by lateral heat dissipation through the glass substrate. Conventional flat-field and binary exposure masks cannot compensate for either effect, resulting in central overheating and under-sintered boundaries. This work presents a multiple-stage computational pipeline that integrates DMD optical field characterization, reduced-order finite-difference thermal modeling, and linear programming optimization to generate spatially tailored inverse-vignette composite masks under 8-bit DMD constraints. Transient finite element simulations validate thermal homogenization predictions prior to physical sintering. Experimental evaluation using spatially resolved four-point probe resistance mapping and SEM characterization demonstrated reduced thermal gradients, improved electrical uniformity, and more consistent microstructural development across sintered features. These results establish a computationally tractable framework for deterministic spatial process control in µ-SLS and advance the adoption of additive manufacturing for semiconductor packaging applications.
4:50 PM
Quantifying Airborne Particulate Dispersion in Binder Jetting : Sam Erickson1; Max Gunn1; Nathan Crane1; 1Brigham Young University
Airborne particulate dispersion and particle accumulation during binder jetting is measured to establish a predictive framework for safety and maintenance. Using custom air-monitoring sensors and passive deposition samples, mass distributions were characterized for powders of varying density. Results indicate that steady-state printing processes contribute >93% of cumulative dispersion, with over 75% of particulates falling within the PM2.5 category (<2.5 μm). A Gaussian elliptical dispersion model was developed to define spatial accumulation rates. The model achieves a strong fit without active air filtration (R˛ = 0.87-0.93), revealing that decay lengths in the recoater travel direction are up to 2.8 times greater than in transverse axes. Evaluation of air filtration showed a 96% reduction in airborne mass concentration. This research provides a framework for real-time monitoring and provides a strategy for assessing safety risks in printing new materials.