A Framework for Thermal Spray Shape Deposition: The MD* System

This paper present.s t.he framework for a solid-freeform-fabrication syst.em based on thermal spray shape deposition t.o build mult.i-mat.erial st.ruct.ures by incremen tal build-up of t.hin cross-sect.ional layers. The basis of theMD* System (recursively, Mask and Deposit.) is to spray each layer using disposable masks to shape each layer. A thermal spray approach has the potential to build dense parts with desirable mechanical properties. Metal. ceramic, plastic, laminate, and composite structures can be deposited. Since l11asking enables selective deposition wit.hin a layer, complet.e assemblies composed of different mat.erials can be creat.ed in a single process. For example, int.egrated electronic/mechanical structures are feasible.