2012 International Solid Freeform Fabrication Symposium
Proceedings for the 2012 International Solid Freeform Fabrication Symposium. For more information about the symposium, please see the Solid Freeform Fabrication website .
The Twenty-Third Annual International Solid Freeform Fabrication (SFF) Symposium – An Additive Manufacturing Conference, held at The University of Texas in Austin on August 6-8, 2012, was attended by 170 researchers from 13 countries. A two-morning special session on “Societal Impacts” emphasized the integration of additive manufacturing into culture and society. Terry Wohlers (Wohlers Associates) presented a keynote to start the session. Of special interest were a number of talks from China organized by Professor Wei Sun who currently holds joint appointments at Drexel University and Tsinghua University in Beijing. Other presentations summarized activity in the US and United Kingdom. Brent Stucker (University of Louisville) talked about international trends including standards development. Dr. Ian Gibson from the University of Singapore closed out the session with a 20-year perspective on the development of AM with a personal bent.
This year’s best oral presentation was entitled, “Observation and Numerical Simulation of Melt Pool Dynamic and Beam Powder Interaction During Selective Electron Beam Melting”, authored by Thorsten Scharowsky, Andreas Bauereiβ, Robert F. Singer and Carolin Körner from the Friedrich Alexander Universität Erlangen. 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. Selected from 107 oral presentations, the associated manuscript appears on Page 815. The best poster presentation selected from 18 posters was given by Andrew Johnson, Dr. Guy Bingham and Dr. Candice Majewski from the University of Sheffield and Loughborough University. Titled, “Establishing the Performance Requirements for Stab Resistant Additive Manufactured Body Armour (AMBA)”, the article appears on Page 297 of this Proceedings.
The recipient of the International Outstanding Young Researcher in Freeform and Additive Manufacturing Award was Dr. Christopher Williams, an assistant professor with joint appointments in the Departments of Mechanical Engineering and Engineering Education at Virginia Tech in the United States. Dr. Jean-Pierre Kruth won the International Freeform and Additive Manufacturing Excellence (FAME) Award. He is a professor at the Katholieke Universitaet Leuven in Belgium.
The editors would like to extend a warm “Thank You” to Rosalie Foster for her detailed handling of the logistics of the meeting, 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 participation, 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 additive manufacturing community in organizing the Symposium. We also want to thank the Office of Naval Research (N00014-10-1-0528) and the National Science Foundation (#CMMI-1230744) for supporting this meeting financially. The meeting was co- organized by The University of Connecticut at Storrs, and the Mechanical Engineering Department and the Lab for Freeform Fabrication at The University of Texas at Austin.
Recent Submissions
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Effects of Processing on Microstructure and Mechanical Properties of Ti-6Al-4V Fabricated using Electron Beam Melting (EBM): Orientation and Location
(2012)Electron beam melted (EBM) titanium alloy (Ti-6Al-4V) samples were built and characterized (qualitative prior-β grain size, quantitative α lath thickness, monotonic tensile, Vickers microhardness) to determine the effect ... -
Controlling the Quality of Laser Sintered Parts Along the Process Chain
(University of Texas at Austin, 2012-08-22)The quality of laser sintered parts, in this work, manufactured by polymer laser sintering by using an EOSINT P395 Laser Sintering system, depends on several steps along the process chain. The first step is the ... -
Characterisation of Metal Deposition During Additive Manufacturing of Ti-6Al-4V by Arc-Wire Methods
(University of Texas at Austin, 2012)This study considers the use of the gas tungsten arc (GTA) welding process in conjunction with ‘cold’ wire addition to give layer-wise build-up of thin walled structures, simulating those commonly found in aerospace ... -
Thermography for Monitoring the Selective Laser Melting Process
(University of Texas at Austin, 2012-08-22)A lot of strategies exist to monitor and control additive layer manufacturing processes. Basically one can distinguish between coaxially monitoring the process zone and monitoring the complete layer currently being built. ... -
An Investigation of the Effects of Quantum Dot Nanoparticles on Photopolymer Resin for Use in PolyJet Direct 3D Printing
(University of Texas at Austin, 2012-08-15)The addition of quantum dot (QD) nanoparticles to additive manufacturing (AM) media provides the opportunity to create artifacts with complex geometry that also have unique optical characteristics. However, the addition ... -
Error Detection in Laser Beam Melting Systems by High Resolution Imaging
(University of Texas at Austin, 2012-08-15)Laser Beam Melting as a member of Additive Manufacturing processes allows the fabrication of three-dimensional metallic parts with almost unlimited geometrical complexity and very good mechanical properties. However, its ... -
Efforts to Reduce Part Bed Thermal Gradients During Laser Sintering Processing
(University of Texas at Austin, 2012-08-15)Part bed surface thermal gradients (x-y plane) are usually present in laser sintering (LS) fabricators. The purpose of this study was to investigate various means to reduce these thermal gradients. Several experiments ... -
Integration of a Thermal Imaging Feedback Control System in Electron Beam Melting
(University of Texas at Austin, 2012-08-15)A thermal imaging system using an infrared (IR) camera was incorporated in the fabrication process of an Arcam A2 Electron Beam Melting system to provide layer-by-layer feedback and ensure quality and defect free products. ... -
Combined Build-Time, Energy Consumption and Cost Estimation for Direct Metal Laser Sintering
(University of Texas at Austin, 2012-08-15)As a single-step process, Additive Manufacturing (AM) affords full measurability with respect to process energy inputs and production cost. However, the parallel character of AM (allowing the contemporaneous production ... -
A Designer's Guide for Dimensioning and Tolerancing SLS Parts
(University of Texas at Austin, 2012)Because additive manufacturing (AM) is a relatively novel industry, with the first commercial machines introduced in the late 1980s, many designers are unaware of the capabilities of AM technologies. Many engineers also ... -
Proposal for a Standardized Test Artifact for Additive Manufacturing Machines and Processes
(University of Texas at Austin, 2012-08-15)Historically, standardized test parts are used to quantitatively evaluate the performance of a machine or process. While several different additive manufacturing (AM) test parts have been developed in the past, there are ... -
First Steps Towards Collaboratively Edited Design for Additive Manufacturing Knowledge
(University of Texas at Austin, 2012-08-18)Despite the broad coverage concerning the technological challenges, little research has been performed on the methods that enable designers to deal with Additive Manufacturing. At present, the challenge is to generate ... -
Examining Variability in the Mechanical Properties of Parts Manufactured via PolyJet Direct 3D Printing
(University of Texas at Austin, 2012-08-15)In Objet’s PolyJet process, part layers are created by selectively inkjetting photopolymers onto a build substrate and then cured with ultraviolet lamps. With an eye towards using PolyJet as a manufacturing process to ... -
Ceramic-Polymer Additive Manufacturing System for Ultrasound Transducers
(University of Texas at Austin, 2012)A modified multi-layer lithography process is used to additively manufacture highresolution netshape ceramic structures by photopolymerizing a ceramic-polymer slurry using structured light patterns. This paper will discuss ... -
Fast Recoating Methods for the Projection-based Stereolithography Process in Micro- and Macro-Scales
(University of Texas at Austin, 2012)The purpose of this paper is to present a recoating method for the development of a direct digital manufacturing (DDM) process that can be an order of magnitude faster than other currently available DDM processes. In the ... -
Fused Deposition Modeling of Metals
(University of Texas at Austin, 2012-08-22)Studies have been conducted to improve previous work performed in developing a Fused Deposition Modeling for metals (FDMm) system used for applications in electronics and fabrication of 3-dimensional metallic structures. ... -
Multi-Material, Multi-Technology FDM System
(University of Texas at Austin, 2012-08-15)A multi-material, multi-technology FDM system was developed and constructed to enable the production of novel thermoplastic parts. Two legacy FDM systems were modified and installed onto a single manufacturing system to ... -
Remanufacture of Turbine Blades by Laser Cladding, Machining and In-Process Scanning in a Single Machine
(University of Texas at Austin, 2012-08-16)Remanufacturing is one of the most efficient ways of recycling worn parts because it consumes only a fraction of the energy, cost, and material required for new parts. Remanufacture of engineering components typically ... -
Observation and Numerical Simulation of Melt Pool Dynamic and Beam Powder Interaction During Selective Electron Beam Melting
(University of Texas at Austin, 2012)Selective electron beam melting (SEBM) is an additive manufacturing method used to produce complex parts in a layer-by-layer process utilizing Ti6Al4V powder. To improve the very good properties of built parts even more ...