2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024): Other AM Processes and Applications II
Program Organizers: Joseph Beaman, University of Texas at Austin
Tuesday 1:30 PM
August 13, 2024
Room: 404
Location: Hilton Austin
Session Chair: Farzana Tasnim, University of Texas at Austin
1:30 PM
Application of Solid Freeform Fabrication for Using Low-Cost Reconfigurable Items to Develop Actively Steered Mobile Robot Platform to Experiment with Advanced Vision and ML Based Experiments: Rajeev Dwivedi1; Indira Dwivedi2; Bharat Dwivedi2; Rohit Bhupatiraju3; Arihant PAnwar4; 1STEM and Robotics Academy; 2Eastlake HighSchool; 3Allen ISD; 4Frisco ISD
Over the last three years under Robotics for Everyone (R4E) initiative, we have presented multiple design ideas that enable low cost, reconfigurable mobile as well as non-mobile robotic systems. Most of the R4E design was limited to basic experiments in Robot navigation, obstacle avoidance, sensor (proximity, touch, ultrasonic) based environment perception and simple pick and place tasks. In this paper we are presenting a platform that can be used for furthering the learning and experimentation in advanced topics such as vision system and machine learning. The system uses reconfigurable parts combined with 3D printed parts to build an actively steered robot. The system allows usage of cost-effective computational platform such as Raspberry Pi and compatible camera. System can also be expanded to use other advanced computing platforms and sensors such as LIDARs. We discussion 3D printed features to sustain dynamic loads as well as accurately steer the robot.
1:50 PM Cancelled
Study of Sodium Ion based Battery Components based on a High Resolution 3D Printing DLP Technology: Sina Bakhtar Chavari1; Alexis Maurel2; Ana C. Martinez2; Bharat Yelamanchi1; Eric MacDonald2; Carol Ochoa-Putman3; Pedro Cortes1; 1Youngstown State University; 2University of Texas at El Paso; 3Marshall NASA
Additive manufacturing (AM) introduces the creation of three-dimensional batteries where ions can migrate in three axes instead of two axes as seen in conventional batteries. Additionally, AM can enhance the electrochemical performance, and energy density of batteries by producing shape-conformable structures. Nowadays, the AM process of energy storage systems has expanded to outer space applications such as NASA's Artemis mission which aims to address the energy storage requirements on Moon and Mars. The efforts of the present work are primarily focused towards the AM process of various components of batteries including electrodes, and electrolytes using DLP printer. Preliminary work has demonstrated that the incorporation of intricate architectures with precisely controlled porosity, significantly increases the specific charge/discharge capacity and performance due to the improved ion diffusing mechanism. The current presentation will cover the design of several battery configurations, as well as the optimization of their manufacturing and post-thermal processes.
2:10 PM
Investigating the Impact of Decontamination on Recycled Polymer Viability in Additive Manufacturing: Nathaniel Kaill1; Mazher Mohammed1; Richard Bibb2; Shahin Rahimifard1; Bana Quronfuleh1; Zahrina Mardina3; 1Loughborough University; 2Nottingham Trent University; 3University of Leeds
The additive manufacturing sector has recently focused on reducing its impact of climate change. However, when these polymers reach the recycling centre, they may not be in a viable state due to contamination from biological, chemical, or pharmaceutical sources. This necessitate decontamination prior to be reformed into a new device. To ensure continuity with the medical sector the selected procedure follows the same prescribed methodology. First cleaned in an ultrasonic bath with triple detergent, then disinfected with a quaternary disinfectant before being sterilised at 121oC for 30 minutes. This procedure is for decontaminating reusable medical devices and is sufficient for ensuring the reclaimed polymer is suitable for use within the additive manufacturing industry and wider sectors. The work contained within this paper aims to address what effect this procedure has on common polymers and their viability for reuse within the additive manufacturing sector to support a wider circular economy.
2:30 PM
Sustainable Waste Management In Additive Manufacturing: Old And New Strategies To Divert Industrial Waste From Landfills
: Mladenko Kajtaz1; Ryan Blakis1; Chrysoula Pandelidi1; Marcian Lee1; 1RMIT University
Additive manufacturing (AM) typically produces less waste than traditional subtractive methods but still generates significant waste post-production. This waste primarily comes from support structures removal and unprocessed stock materials that have been exposed to the processing conditions but have not become part of the final components. The latter is predominantly the product of powder bed fusion AM techniques such as Multi-jet fusion (MJF). MJF, adhering to a recommended refresh rate of 30%, produces between 15% to 25% of build volume waste per cycle. This paper investigates and presents effective strategies to divert this industrial waste away from landfills. By identifying existing challenges and barriers, the paper provides insights into potential solutions crucial for advancing sustainable practices within the AM industry.
2:50 PM
Aerosol Jet Printing and Characterization of Mechanical Strain Gauges: Jaylene Martinez1; Sofia Pinzon1; Austin Sutton1; John Bernardin1; 1Los Alamos National Laboratory
Aerosol jet printing (AJP) is a type of non-contact direct-ink write technology used for fabrication of micro-electronics. Coupling the geometrical freedom and high-resolution characteristics inherent to the process, AJP can be used to tailor conductive traces for (1) embedded strain and temperature sensors on additive manufactured substrates and (2) advancing research and design of these embedded sensors onto 3D “free form geometries”. Specifically, this project investigated print parameters for (non-nanoparticle) reactive silver ink on polyimide and fused filament fabricated (FFF) substrates. A strain gauge geometry was repeatedly printed using non-nanoparticle ink with two different aerosol jet printers, the Optomec AJ5X and IDS Nanojet. Post print characterization found print parameters influenced material deposition. In addition, pre-print surface cleaning of substrates influenced consistency of printed patterns and reduced variability in resistance values. A smooth surface of FFF polylactic acid substrates is needed to achieve measurable resistance of the AJP geometry.
3:10 PM
Additive Manufacturing Thermoforming: Tyler Smith1; Brittany Rodriguez1; Vlastimil Kunc1; Issac Talabi1; Vipin Kumar1; ryan ogle1; Julian Charron1; Jeremy Malmstead1; Ahmed Hassen1; 1Oak Ridge National Laboratory
Polymer Additive Manufacturing is traditionally used for rapid prototyping, tooling, and end use components. Fiber filled materials are often used to print material to increase part performance. Fibers tend to align during the extrusion process creating highly anisotropic parts. Through system integration, AM technology can be used to print highly aligned re-enforcement grids or patterns on top of thermoforming sheets. These sheets can then be formed over a mold to create higher performance structures and help prevent tearing, thickness variation, and reduce weight of common thermoformed parts. To produce parts of value, properties such as bonding between the printed materials and the thermoforming sheet and tensile properties must be determined. Through a parametric study of various printing conditions, ideal processing parameters can be determined to enable this new integrated process. Process parameters of interest include sheet temperature, printing temperature, and forming temperature.