2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024): Other AM Processes and Applications I
Program Organizers: Joseph Beaman, University of Texas at Austin

Tuesday 8:00 AM
August 13, 2024
Room: Salon F
Location: Hilton Austin

Session Chair: David Leigh, University of Texas at Austin

8:00 AM
Adapting Sheet Lamination for Automated Fabrication of Origami-inspired Deployable Mechanisms: Tyler Stevens¹; Garrett Graham¹; Tyler Campbell¹; Nathan Crane¹; ¹Brigham Young University
    Many sheet lamination processes have been explored with varied physical mechanisms and materials but have not found wide use due to limitations such as high levels of waste materials. We consider the application of this technique to the fabrication of origami-inspired devices. Such devices leverage the advantages of sheets including compact storage, excellent in-plane properties, and potential for functionalization, but there is a lack of available techniques for manufacturing origami. This study demonstrates how cutting, bonding, and placing of sheet materials can be used to form complex, origami-inspired geometries that can change shape with time. Mechanisms fabricated with this approach demonstrate versatile functionalities, such as regulating thermal properties and unfolding beyond the confines of the manufacturing footprint. We will present a manufacturing strategy and methods of adapting traditional origami for manufacturing with this method and highlight potential benefits in material usage, low-cost performance, and overcoming build volume limitations.

8:20 AM
Simulation and Estimation of Mechanical Properties of Additively Manufactured Metal Components: Prudhvi Raj Pola¹; Ranji Vaidyanathan¹; Prahalada Rao²; Jack Seiler¹; ¹Oklahoma State University; ²Virginia Tech
    Additive manufacturing offers a promising but challenging way to create complex parts. However, the time-consuming and costly testing and qualification of printed parts hinder its widespread adoption. In our study, we investigate 3D printed metallic parts by correlating grain size with thermal history. Thermal history significantly influences solidification and cooling rates, impacting microstructure and mechanical properties. Using Electron Back-Scattered Diffraction characterization and Ansys Software, we determine grain size to study the microstructure-thermal history relationship and predict local yield stress. This can be used to generate a global stiffness matrix and apply boundary conditions to generate a component lifetime. The above analysis can be confirmed by micro-tensile testing of mini samples from various locations is used to link grain size with localized mechanical behavior. This correlation provides a more accurate understanding of the mechanical behavior of 3D printed metallic parts, aiding in predicting their lifetime and accelerating their simulation and qualification.

8:40 AM
Prospects of Fusion Additively Manufactured Microstructures for Enhancing Hydrogen Embrittlement Resistance: Saket Thapliyal¹; Jiahao Cheng¹; Weicheng Zhong¹; Yukinori Yamamoto¹; Andrzej Nycz¹; ¹Oak Ridge National Laboratory
    Despite their typically low hydrogen embrittlement (HE) susceptibility, hydrogen segregation at certain microstructural sites, such as grain boundaries weakens the boundaries of austenitic stainless steels and leads to their premature failure. In this work, we investigate the implications of unique microstructural attributes of wire arc additive manufacturing (WAAM) processed SS316L for its hydrogen embrittlement resistance. To this end, WAAM processed SS316L is charged with hydrogen. Subsequently, the implications of the microstructural features specific to fusion additively manufactured SS316L for its mechanical behavior in hydrogen rich environments are discussed. A crystal plasticity-coupled hydrogen adsorption diffusion model is used to describe the hydrogen-microstructure interaction of different WAAM fabricated specimens with varying microstructural attributes. Overall, by revealing the mechanistic details of hydrogen-microstructure interaction, this research will facilitate the design of HE resistant materials by additive manufacturing and a subsequent implementation of hydrogen fuel in a CO2 free economy.

9:00 AM
Design of 3D Printed Concrete Structures and Their Resilience to High Energy Blast Loading: Jacob Sneed¹; Phillip Mulligan¹; ¹Missouri University of Science and Technology
     3D-printed concrete has become a major focus in the commercial construction industry as the demand for low-cost infrastructure has increased. The topics of interest have primarily been housing and livable structures. Many nontraditional applications have surfaced as industry and research fields have grown. For example, the Worlds Advanced Savings Project, designed eco-friendly clay-based housing made from local raw earth in a printable material format. One downfall in the current industry is the required amount of post-processing and additional rebar reinforcement. One particular area of interest is the behavior of 3D-printed steel fiber-reinforced cementitious material under high energy impact and blast loading conditions. This study will look at the performance of additively manufactured concrete structures in correlation with the particular structure design and resultant energy dissipation. The performance and energy dissipation characteristics will aim to show the viability and effectiveness of these structures in extreme applications.

9:20 AM
Application of Solid Freeform Fabrication for Manufacturing and Prototyping of a Reconfigurable CubeSat for Ease of Assembly, Testing and Experimentation: Rajeev Dwivedi¹; Indira Dwivedi²; Arun Rebbapragada³; Bharat Dwivedi²; Arka Rebbapragada³; ¹STEM and Robotics Academy; ²Eastlake HighSchool; ³Carrolton-Farmers Branch Independent School District
    Within the educational community, CubeSats have democratized access to space by providing a cost-effective platform to conduct space-based missions and experiments. Hands-on activities help students contextualize classroom learning with actual physical system. We are using a reconfigurable architecture of 1U (100mm X 100mmX100mm) CubeSat to perform multiple experiments in satellite technology. Our experiments range from vision, communication, IMU, solar power storage and distribution, and dynamic loads. We are using Solid Freeform Fabrication to manufacture structural elements that allow (1) ease of assembly and disassembly (2) ease of debugging and (3) mounting various modules for the experiment. The structural elements reduce total assembly time, reconfigure the satellite, attach different modules, route connecting cables and access the internal volume for debugging.