Layered Manufacturing Material Issues for SDM of Polymers and Ceramics

Shape Deposition Manufacturing (SDM) is a solid freeform fabrication process which enables the manufacture of structural parts from engineering materials. This paper discusses the requirements and constraints for SDM part and sacrificial support materials, including chemical and physical compatibility, mutual adhesion, low shrinkage, machinability, and support material removability. Polymers and ceramics processed by SDM include polyurethanes, epoxies, polyurethane foams, photocurable acrylics, and green alumina ceramics. SDM compatible support materials include waxes, water-soluble polyacrylate soldermasks, and water-soluble thermoplastics. This paper details the selection of SDM part and support material combinations for the fabrication of polymer prototypes and polymer molds for ceramic prototyPes.