2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024): Design and Predictive Modeling for AM
Program Organizers: Joseph Beaman, University of Texas at Austin
Tuesday 1:30 PM
August 13, 2024
Room: 615 AB
Location: Hilton Austin
Session Chair: Zhenghui Sha, University of Texas at Austin
1:30 PM
Predictive Modeling of Clay Drying Process in Ceramic 3D Printing: Subodh Subedi1; Krishnan Suresh1; 1University of Wisconsin Madison
Ceramic 3D printing is unique, involving material extrusion of soft wet clay over slicer defined paths to create a layer-wise part. Unlike fused deposition modeling (FDM), where molten filament solidifies out of extruder, in ceramic 3D printing, a slurry of clay is extruded out of nozzle that begins losing moisture due to exothermic reaction. Diffusion of moisture within printed part and to the surrounding causes drying of part. However, this process of drying is influenced by geometry, print parameters and constituent materials, often leading to non-uniform drying and defects such as delamination, voids, and cracks. This paper presents a numerical model for predicting time-dependent moisture in a ceramic 3D printed part. Physical experiments are used to measure moisture content at different instances of time for geometries with varying complexities. Results of physical experiments are incorporated in the numerical models to predict moisture in part at different times of passive drying.
1:50 PM
Conceptual Design for 4D Additive Manufacturing: David Rosen1; 1Agency for Science, Technology and Research
4D additive manufacturing (4DAM) refers to the capability of parts to change shape in response to an external stimulus after 3D printing; that is, time is the 4th dimension. The shape memory effect or design residual stresses can cause such shape change. Of interest in this work is the application of AM to fabricate complex shaped devices and integral device architectures that enable significant device simplification and part count reduction. Key to taking advantage of 4DAM is the ability to systematically design devices that demonstrate desired shape changes while being manufacturable with existing materials. In this talk, I briefly survey the 4DAM field, present some state-of-the-art devices, and outline new approaches for systematic engineering design of 4DAM devices. A series of morphing and deployable device designs are demonstrated using both simple components and origami constructs.
2:10 PM
Enhancing the Mechanical Properties of Additively Manufactured Carbon Nanotube Integrated Components: A Simulation-based Approach: Mushfig Mahmudov1; Ismail Fidan1; Mohammad Alshaikh1; Shamil Gudavasov1; Vivekanand Naikwadi1; Elijah Hudson1; 1Tennesse Tech University
Additive Manufacturing (AM) is becoming an attractive production technology due to its ability to produce complex shapes. However, its strengths aren't as good as traditional techniques yet. To address this, nanofillers like carbon nanotubes (CNT) are being introduced in AM processes. CNTs have strong mechanical characteristics that could improve the parts printed of polymers. To explore the mechanical properties of 3D-printed parts when incorporating CNTs, Material Designer was used to incorporate CNT filler at varying percentages into PLA, ABS, and PETG matrices, and the strength analysis was carried out using Static Structural within Ansys software. It appears from preliminary results that 0.5%, 1%, and 2% additions of CNT increase material strength if we consider the strain relatively close to pure material. However, a 2% addition might lead to CNT agglomeration with adverse effects in the actual experiment. Experimental validation will be carried out to substantiate these observations.
2:30 PM Cancelled
Harnessing the Synergy of Reverse Engineering and 3D Printing for Effective Reconstruction and Replacement of an Obsolete Damaged Spare Part: A Comparative Analysis of Dimensional Geometry: Zahra Pourfarash1; Binoy Debnath1; Shivakumar Raman1; 1University of Oklahoma
The progressive integration of reverse engineering and 3D printing technologies has revolutionized the realm of spare part reconstruction. In this study, we aimed to explore the efficacy of this synergy through a comparative analysis of dimensional geometry. Initially, employing Laser Scanning and Coordinate Measuring Machine (CMM), we captured the intricate geometry of an obsolete damaged part. Subsequently, CAD models are generated for post-scanning reconstruction for both scanning methods. Leveraging Fused Deposition Modeling (FDM), we fabricated parts based on the CAD models from both scanning methods. Through precise dimensional measurements, we rigorously compare the accuracy of the printed parts with the original. This research underscores the potential of reverse engineering and 3D printing in industrial applications, particularly in spare part reconstruction. Our findings provide valuable insights into enhancing efficiency and accuracy in the replacement of damaged components.
2:50 PM
ODBP: Portable Post-Processing and Visualization of Abaqus FEA ODBs in Python 3: Clark Hensley1; J. Betts1; Chuyen Nguyen1; Matthew Priddy1; 1Mississippi State University
ODBP is an open-source, Python 3 based post-processing tool for manipulating Abaqus output database (.odb) data. Abaqus is a popular commercial Finite Element (FE) solver used to simulate and model additive manufacturing (AM). Abaqus stores the results of its simulations in the proprietary .odb file format. ODBP uses the Hierarchical Data Format (.hdf5) file format to efficiently store .odb data in a portable, accessible format. ODBP also uses Polyscope, a lightweight, robust three-dimensional visualization tool to emulate Abaqus’ three-dimensional volume-mesh plotting and improve on these capabilities, more easily viewing subsets of the dataset, such as only the melted section during deposition. ODBP’s open-source, portable nature has established a framework that can be used by collaborators across fields from machine learning to computational fluid dynamics. Currently ODBP is being leveraged to compare thermal AM FE simulations to experimental measurements from a pyrometer.
3:10 PM
Design Inputs for Fused Filament Fabricated Non-pneumatic Tires: Manuel Sardinha1; Marco Leite1; Tânia Ramos2; M. Fátima Vaz1; Luís Reis1; 1IDMEC, Instituto Superior Técnico, Universidade de Lisboa; 2CEGIST, Instituto Superior Técnico, Universidade Lisboa
Airless or non-pneumatic tires (NPTs) can operate without internal fluidic pressure, offering a promising low-maintenance and environmentally friendly alternative to their pneumatic counterparts. These new tires concepts open a wide range of design possibilities, which has resulted in a diverse array of proposed solutions. Existing NPT concepts in literature often pursue intricate functional designs that can be challenging to manufacture. Taking advantage of the design freedom offered by additive manufacturing technologies, techniques such as fused filament fabrication (FFF) have recently been used to produce NPTs for diverse applications. In this study, the authors explore NPTs design features within the context of FFF tires made with thermoplastic elastomers, with a focus on bicycle-sized wheels. Following an analysis of the current state-of-the-art of FFF NPTs, the authors propose a processing workflow that helps identify how process-related parameters and design methodologies might interact with different stages of the tire development process.Above all, the authors believe that the early consideration of manufacturing constraints and design for additive manufacturing inputs allows a faster prioritization of initial design proposals. This analysis aims to elucidate suitable design decisions for developing NPTs using FFF and accelerate the study and adoption of these newly proposed products.