Layered Manufacturing of Thin-Walled Parts

2000 ◽  
Author(s):  
Sara McMains ◽  
Jordan Smith ◽  
Jianlin Wang ◽  
Carlo Séquin
Keyword(s):  
Voronoi Diagram ◽  
Efficient Algorithm ◽  
Fused Deposition Modeling ◽  
Layered Manufacturing ◽  
Exterior Wall ◽  
Uniform Thickness ◽  
Fused Deposition ◽  
Material Usage ◽  
Deposition Modeling ◽  
Thin Walled

Abstract We describe a new algorithm we have developed for making partially hollow layered parts with thin, dense walls of approximately uniform thickness, for faster build times and reduced material usage. We have implemented our algorithm on a fused deposition modeling (FDM) machine, using separate build volumes for a loosely filled interior and a thin, solid, exterior wall. The build volumes are derived as simple boolean combinations of slice contours and their offsets. We make use of an efficient algorithm for computing the Voronoi diagram of a general polygon as part of the process of creating offset contours. Our algorithm guarantees that the surface of the final part will be dense while still allowing an efficient build.

Thin-Wall Calculation for Layered Manufacturing

2003 ◽  
Vol 3 (3) ◽  
pp. 210-218 ◽  
Author(s):  
Sara McMains ◽  
Jordan Smith ◽  
Carlo Se´quin
Keyword(s):  
Fused Deposition Modeling ◽  
Layered Manufacturing ◽  
Thin Wall ◽  
Winding Number ◽  
Exterior Wall ◽  
High Quality ◽  
Exterior Surface ◽  
Fused Deposition ◽  
Material Usage ◽  
Deposition Modeling

We describe a new algorithm for making partially hollow layered parts with thin, dense walls of approximately uniform thickness, for faster build times and reduced material usage. We have implemented our algorithm and tested its output on a fused deposition modeling (FDM) machine, using separate build volumes for a loosely filled interior and a thin, solid, exterior wall. The build volumes are derived as Boolean combinations of slice contours and their offsets. The Booleans are efficiently calculated via OpenGL winding number rules and the offset contours are generated from robustly generated Voronoi diagrams of the slices. Our algorithm guarantees that the exterior surface of the final part will be of high quality with no gaps while still allowing an efficient build.

Liquefier Dynamics in Fused Deposition

2004 ◽  
Vol 126 (2) ◽  
pp. 237-246 ◽  
Author(s):  
Anna Bellini ◽  
Selc¸uk Gu¨c¸eri ◽  
Maurizio Bertoldi
Keyword(s):  
Rapid Prototyping ◽  
Flow Control ◽  
Fused Deposition Modeling ◽  
Control Strategies ◽  
Building Blocks ◽  
Layered Manufacturing ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Deposition Modeling

Layered manufacturing (LM) is an evolution of rapid prototyping (RP) technology whereby a part is built in layers. Fused deposition modeling (FDM) is a particular LM technique in which each section is fabricated through vector style deposition of building blocks, called roads, which are then stacked layer by layer to fabricate the final object. The latest improvements in this technology brought about the possibility of fabricating not only a model but even the finished product. This paper presents the analysis of the liquefier dynamics towards establishing control strategies for flow control during the extrusion phase, which is necessary to achieve the mentioned objective.

Relation between Surface Roughness and Overlap Interval in Fused Deposition Modeling

2011 ◽  
Vol 264-265 ◽  
pp. 1625-1630 ◽  
Author(s):  
Dae Keon Ahn ◽  
Jin Hwe Kweon ◽  
Jin Ho Choi ◽  
Seok Hee Lee
Keyword(s):  
Surface Roughness ◽  
Manufacturing Process ◽  
Fused Deposition Modeling ◽  
Layered Manufacturing ◽  
Fused Deposition ◽  
Complex Shapes ◽  
Deposition Modeling ◽  
High Level ◽  
Surface Angle

Rapid prototyping (RP) can efficiently fabricate high level models with complex shapes. Hence the RP has been widely applied in various industrial fields. However, as the technology is inherently performed by layered manufacturing process, the surface quality of the RP part is not satisfactory to use general industrial purpose. This is the reason that surface roughness problem has been key issue in RP. In this paper, relation between surface roughness and overlap interval is investigated based on a surface roughness formulation in fused deposition modeling (FDM). Additionally, effects of surface angle and filament shape are analyzed and discussed to predict surface roughness distribution by the overlap interval variation.

Investigating the Impacts of Heterogeneous Infills on Structural Strength of 3D Printed Parts

2019 ◽  
Vol 799 ◽  
pp. 276-281
Author(s):  
Ramisha Sajjad ◽  
Sajid Ullah Butt ◽  
Khalid Mahmood ◽  
Hasan Aftab Saeed
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Weight Ratio ◽  
3D Cad ◽  
Fused Deposition ◽  
Material Usage ◽  
Rectangular Pattern ◽  
Build Time ◽  
Deposition Modeling

Additive Manufacturing is a manufacturing process based on layers for making three dimensional scaled physical parts directly from 3D CAD data. Fused Deposition Modeling (FDM) is widely used technology that provides functional prototypes in various thermoplastics. In additive manufacturing, filling patterns are of two types; External and Internal filling patterns. Multiple patterns are developed for both filling categories. In this work, a heterogeneous infill strategy is used by choosing developed patterns in order to improve strength to weight ratio, material usage and build time for parts. A rectilinear pattern combination with triangular and rectangular pattern has been chosen for 3D printing. The tensile testing is performed on the printed specimens to calculate the strength to weight ratio. By comparing the obtained results, a strategy based on maximum strength to weight ratio, minimum material usage and reduced build time is recommended for FDM technology.

Biodegradable 3D Printed Polymer Microneedles for Transdermal Drug Delivery

2018 ◽  
Author(s):  
Michael A. Luzuriaga ◽  
Danielle R. Berry ◽  
John C. Reagan ◽  
Ronald A. Smaldone ◽  
Jeremiah J. Gassensmith
Keyword(s):  
Drug Delivery ◽  
3D Printing ◽  
Transdermal Drug Delivery ◽  
Fused Deposition Modeling ◽  
Fused Deposition ◽  
Modeling Software ◽  
Deposition Modeling ◽  
3D Printed ◽  
Microfabrication Technique ◽  
Mechanical Strengths

Biodegradable polymer microneedle (MN) arrays are an emerging class of transdermal drug delivery devices that promise a painless and sanitary alternative to syringes; however, prototyping bespoke needle architectures is expensive and requires production of new master templates. Here, we present a new microfabrication technique for MNs using fused deposition modeling (FDM) 3D printing using polylactic acid, an FDA approved, renewable, biodegradable, thermoplastic material. We show how this natural degradability can be exploited to overcome a key challenge of FDM 3D printing, in particular the low resolution of these printers. We improved the feature size of the printed parts significantly by developing a post fabrication chemical etching protocol, which allowed us to access tip sizes as small as 1 μm. With 3D modeling software, various MN shapes were designed and printed rapidly with custom needle density, length, and shape. Scanning electron microscopy confirmed that our method resulted in needle tip sizes in the range of 1 – 55 µm, which could successfully penetrate and break off into porcine skin. We have also shown that these MNs have comparable mechanical strengths to currently fabricated MNs and we further demonstrated how the swellability of PLA can be exploited to load small molecule drugs and how its degradability in skin can release those small molecules over time.

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