Proceedings for the 2009 International Solid Freeform Fabrication Symposium. For more information about the symposium, please see the Solid Freeform Fabrication website .

The Twentieth Annual International Solid Freeform Fabrication (SFF) Symposium, held at The University of Texas in Austin on August 3-5, 2009, was attended by 123 national and international researchers from 9 countries. Papers addressed SFF issues in computer software, machine design, materials synthesis and processing, and integrated manufacturing. The diverse domestic and foreign attendees included industrial users, SFF machine manufacturers, university researchers and representatives from the government. The Symposium organizers look forward to its being a continuing forum for technical exchange among the expanding body of researchers involved in SFF.

The Symposium was again organized in a manner to allow the multi-disciplinary nature of the SFF research to be presented coherently, with various sessions emphasizing process development, design tools, modeling and control, process parameter optimization, applications and materials. We believe that documenting the changing state of SFF art as represented by these Proceedings will serve both those presently involved in this fruitful technical area as well as new researchers and users entering the field.

New this year was recognizing outstanding research by a senior and junior researcher. The recipient of the first Freeform and Additive Manufacturing Excellence (FAME) Award was Phill Dickens of Loughborough University. The junior award, the International Outstanding Young Researcher in Freeform and Additive Manufacturing Award, went to Carolyn Seepersad of The University of Texas at Austin. These awards include a framed certificate, a small honorarium and a freeformed trophy.

The awards were presented at a conference banquet Monday evening, August 3. As part of the celebration of the twentieth anniversary of the International Solid Freeform Fabrication Symposium, several special presentations were given. Tom Mueller of Express Pattern described the manufacture of the FAME trophies which were donated by his company. The trophy art was designed by digital artist, Sheba Grossman. She described the artwork and some of the details of its development. Finally, Harris Marcus, the founder of the SFF Symposium, made some remarks about the circumstances surrounding the first SFF Symposium held in 1990.

This year’s best oral presentation was given by Christopher Williams of Virginia Tech University. Selection is based on the overall quality of the paper, the presentation and discussion at the meeting, the significance of the work and the manuscript submitted to the proceedings. The paper title was, “Design and Manufacture of Formula SAE Intake System Using Fused Deposition Modeling and Fiber-Reinforced Composite Materials” by Ryan Ilardo and Christopher B. Williams. Selected from 84 oral presentations, his presentation appears on Page 770 of this Proceedings. The best poster presentation selected from 15 posters was given by David Espalin of The University of Texas at El Paso (co-authored by K. Arcaute, D. Rodriguez, F. Medina, M. Posner, R. Wicker). The paper title was, “Fused Deposition Modeling of Polymethylmethacrylate for Use in Patient-Specific Reconstructive Surgery”, and the paper starts on Page 569.

The editors would like to extend a warm “Thank You” to Rosalie Foster for her detailed handling of the logistics of the meeting and the Proceedings, as well as her excellent performance as registrar and problem solver during the meeting. We would like to thank the Organizing Committee, the session chairs, the attendees for their enthusiastic contributions, and the speakers both for their significant contribution to the meeting and for the relatively prompt delivery of the manuscripts comprising this volume. We look forward to the continued close cooperation of the SFF community in organizing the Symposium. We also want to thank the Office of Naval Research (N00014-09-1-0940) and the National Science Foundation (CMMI-0905636) for supporting this meeting financially. The meeting was co-organized by the University of Connecticut at Storrs, and the Mechanical Engineering Department, Advanced Manufacturing Center, and Laboratory for Freeform Fabrication at The University of Texas at Austin.

Recent Submissions

  • 2009 International Solid Freeform Fabrication Symposium Table of Contents 

    Laboratory for Freeform Fabrication and University of Texas at Austin (2009)
  • Design, Fabrication and Evaluation of Negative Stiffness Elements 

    Kashdan, Lia; Seepersad, Carolyn; Haberman, Michael; Wilson, Preston S. (University of Texas at Austin, 2009-09)
    Recent research has shown that constrained bistable structures can display negative stiffness behavior and provide extremal vibrational and acoustical absorptive capacity. These bistable structures are therefore compelling ...
  • Scaffold Fabrication for Drug Delivery System Using Layered Manufacturing Methods 

    Chu, W.S.; Jung, B.S.; Ahn, H. (University of Texas at Austin, 2009-09-15)
    To fabricate functional shape of drug delivery system (DDS), various processes are used. In this research, based on layered manufacturing, two different processes of 1) replication and 2) direct deposition were used to ...
  • Experimental Characterization of High Viscosity Droplet Ejection 

    Meachum, J. Mark; O'Rourke, Amanda; Yang, Yong; Fedorov, Andrei G.; Degertekin, F. Levent; Rosen, David W. (University of Texas at Austin, 2009-09)
    Additive Manufacturing via Microarray Deposition (AMMD) expands the allowable range of physical properties of printed fluids to include important, high-viscosity production materials (e.g., polyurethane resins). This ...
  • Cellular Structures for Optimal Performance 

    Engelbrecht, Sarah; Folgar, Luis; Rosen, David W.; Schulberger, Gary; Williams, Jim (University of Texas at Austin, 2009-09)
    Cellular material structures, such as honeycombs and lattice structures, enable unprecedented stiffness and strength characteristics, for a given weight. New design and CAD technologies to construct cellular materials ...
  • Customised Layer Deposition for Chemical Reactor Applications 

    Singh, J.; Hauser, C.; Chalker, P.R.; Sutcliffe, C.J. (University of Texas at Austin, 2009-09)
    This paper discusses the development and application of an adaptive slicing algorithm for use with Digital Light Processing (DLP) for the manufacture of micro chemical reactors. Micro reactors have highly complex ...
  • Hydrocolloid Printing: A Novel Platform for Customized Food Production 

    Cohen, Daniel L.; Lipton, Jeffrey I.; Cutler, Meredith; Coulter, Deborah; Vesco, Anthony; Lipson, Hod (University of Texas at Austin, 2009-09-18)
    Solid Freeform Fabrication (SFF) of food has the potential to drastically impact both culinary professionals and laypeople; the technology will fundamentally change the ways we produce and experience food. Several imposing ...
  • Recent Progress on Scanning Laser Epitaxy: A New Technique for Growing Single Crystal Superalloys 

    Kirka, Michael; Bansal, Rohan; Das, Suman (University of Texas at Austin, 2009-09)
    This paper presents recent progress on scanning laser epitaxy, a laser manufacturing technique being developed for achieving single crystal growth in nickel‐based superalloys. Investigations have been performed for ...
  • High Therma 

    España, Félix A.; Balla, Vamsi Krishna; Bose, Susmita; Bandyopadhyay, Amit (University of Texas at Austin, 2009-09-15)
    Surface modification has been used to improve wear resistance, corrosion resistance and thermal barrier properties of metals. However, no significant attempts have been made to improve thermal conductivity by surface ...
  • Multiple Material Microstereolithography 

    Choi, Jae-Won; MacDonald, Eric; Wicker, Ryan (University of Texas at Austin, 2009-09)
    We have previously described the development of a µSL system using a Digital Micromirror Device (DMDTM) for dynamic pattern generation and an ultraviolet (UV) lamp filtered at 365 nm for crosslinking the photoreactive ...
  • Design and Manufacture of a Formula SAE Intake System Using Fused Deposition Modeling and Fiber-Reinforced Composite Materials 

    Ilardo, Ryan; Williams, Christopher B. (University of Texas at Austin, 2009-09)
    In this paper, the authors discuss the design and manufacture of an intake system for a 600cc Formula SAE engine. Specifically, Fused Deposition Modeling is used to create an intake system (consisting of a plenum, plenum ...
  • Reprinting the Telegraph: Replicating the Vail Register using Multi-Materials 3D Printing 

    Alonso, Matthew Paul; Malone, Evan; Moon, Francis C.; Lipson, Hod (University of Texas at Austin, 2009-09)
    Solid Freeform Fabrication is a family of manufacturing processes that create three-dimensional objects by depositing material, layer-by-layer. Traditionally, this technology has been used to fabricate passive parts, but ...
  • Advanced Heat Sinks Enabled by Three-Dimensional Printing 

    Lyons, Alan; Krishnan, Shankar; Mullins, John; Hodes, Marc; Hernon, Domhnaill (University of Texas at Austin, 2009-09-15)
    With the rapid rise in power dissipated by integrated circuits, improved heat sinks designs are needed to decrease the thermal resistance between them and forced air streams. Manufacturing methods such as extrusion, ...
  • Design of Periodic Cellular Structures for Heat Exchanger Applications 

    Kumar, Vikas; Manogharan, Guhaprasanna; Cormier, Denis R. (University of Texas at Austin, 2009-09)
    Powder based metal additive manufacturing processes generally produce parts with a textured surface. Although surface roughness is undesirable in most cases, it can be advantageous for applications such as heat exchangers ...
  • Electronics Integration in Conformal Substrates Fabricated with Additive Layered Manufacturing 

    Castillo, Sylvia; Muse, Dan; Medina, Frank; MacDonald, Eric; Wicker, Ryan (University of Texas at Austin, 2009-09)
    A three-dimensional (3D) accelerometer sensor system with microprocessor control was fabricated using a previously developed integrated layered manufacturing system that combines conductive ink dispensing with stereolithography ...
  • Selective Electron Beam Melting: A new Way to Auxetic Cellular Structures 

    Schwerdtfeger, Jan; Heinl, Peter; Singer, Robert F.; Körner, Carolin (2009-09-18)
    This paper is concerned with the build up and characterisation of well defined auxetic structures from Titanium alloys through Selective Electron Beam Melting (SEBM).The negative Poisson’s ratio of auxetic structures ...
  • Brick Printing: Freeform Fabrication of Modular Architectural Elements with Embedded Systems 

    Lipton, Jeffrey I.; Cohen, Daniel; Lipson, Hod (University of Texas at Austin, 2009-09-15)
    We propose the use of modular, printed bricks to enable the integration of building systems and various processing techniques through the use of scalable printer platforms. This is enabled by a novel material platform ...
  • Process and Properties of Carbon Black-Filled Electrically Conductive Nylon-12 Nanocomposites Produced by Selective Laser Sintering 

    Artreya, S.; Kalaitzidou, K.; Das, S. (University of Texas at Austin, 2009-09)
    Electrically conductive polymer composites are suitable for use in the manufacture of antistatic products and components for electronic interconnects fuel cells and electromagnetic shielding. Selective laser sintering ...
  • Flammability and Thermal Properties of Polyamide 11-Alumina Nanocomposites 

    Lao, S.C.; Koo, J.H.; Moon, T.J.; Hadisujoto, B.; Yong, W.; Pilato, L.; Wissler, G. (University of Texas at Austin, 2009-09)
    Neat polyamides 11 and 12 lack high strength/high heat resistance and flame retardancy. The incorporation of selected nanoparticles is expected to enhance these properties to a level that is desired and required for ...
  • Powder Pre-Conditioning for the LS Process 

    Majewski, C.E.; Horsford, P.M.; Hopkinson, N. (University of Texas at Austin, 2009-09-18)
    It has previously been shown that the use of recycled Nylon-12 powder leads to increased Elongation at Break (EaB) of Laser Sintered (LS) parts, possibly due to elevated powder temperature in the part bed causing increases ...

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