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Binder Removal from Ceramic Stereolithography Green Bodies: A Neutron Imaging and Thermal Analysis Study

March 16, 2023

Author(s)

Eoin McAleer, M Alazzawi, C Hwang, Jacob LaManna, David Jacobson, R.A. Haber, E. Koray Akdogan

Stereolithography of ceramics remains one of the most powerful additive manufacturing routes for the creation of intricate ceramic parts. Despites its strength as a forming tool, ceramic stereolithography requires a challenging debinding stage due to the

Synergistic Fire Resistance of Nanobrick-wall Coated 3D Printed Photopolymer Lattices

March 16, 2023

Author(s)

Thomas Kolibaba, Callie Higgins, Zack Buck, Dash Weeks, Jason Killgore

Photopolymer additive manufacturing has become the subject of widespread interest in recent years due to its capacity to enable fabrication of difficult geometries that are impossible to build with traditional modes of manufacturing. The flammability of

Solidification modes during additive manufacturing of steel revealed by high-speed X-ray diffraction

March 1, 2023

Author(s)

Hans-Henrik Konig, Niklas Hollander Pettersson, A Durga, Steven Van Petegem, Daniel Grolimund, Qilin Guo, Chihpin Chuang, lianyi Chen, Christos Oikonomou, Fan Zhang, Greta Lindwall

Solidification during fusion-based additive manufacturing (AM) is characterized by high solidification velocities and high thermal gradients, two factors that control the solidification mode of AM metals and alloys. Using two synchrotron-based, in situ

Digital Twin-Based Cyber-Attack Detection Framework for Cyber-Physical Manufacturing Systems

February 23, 2023

Author(s)

Efe Balta, Michael Pease, James Moyne, Kira Barton, Dawn Tilbury

Smart manufacturing (SM) systems utilize run-time data to improve productivity via intelligent decision-making and analysis mechanisms on both machine and system levels. The increased adoption of cyber-physical systems in SM leads to the comprehensive

Additive manufacturing titanium powder oxygen variation within a single powder bed due to differences in powder size and oxygen content

January 31, 2023

Author(s)

Nicholas Derimow, Elisabeth Mansfield, Jason Holm, Nik Hrabe

Thermogravimetric analysis of Ti-6Al-4V powders (virgin Grade 5 and a once used Grade 23) was conducted up to 800 C in an industrial grade Ar environment. A standard starting particle size distribution (PSD) for electron beam powder-bed fusion (PBF-EB)

Sustainable Additive Manufacturing of Polyelectrolyte Photopolymer Complexes

January 29, 2023

Author(s)

Thomas Kolibaba, Jason Killgore, Callie Higgins

Polyelectrolyte complexes (PECs), assemblies of oppositely charged polymers with powerful properties and wide-ranging applications, are currently not melt-processable via any conventional means and have been limited commercially to applications only as

Sensitivity of acoustic nonlinearity and loss to residual porosity in additively manufactured aluminum

January 21, 2023

Author(s)

Ward L. Johnson, Jake Benzing, Orion Kafka, Newell Moser, Derek Harris, Jeremy Iten, Nik Hrabe

Acoustic nonlinearity and loss are found to be positively correlated with porosity at industrially relevant levels of less than half a percent in commercially pure aluminum produced by laser powder bed fusion (L-PBF) with several different power levels

Characterizing light engine uniformity and its influence on LCD-based vat photopolymerization printing

December 27, 2022

Author(s)

Benjamin Caplins, Callie Higgins, Thomas Kolibaba, Uwe Arp, C Cameron Miller, Dianne L. Poster, Clarence Zarobila, Yuqin Zong, Jason Killgore

Vat photopolymerization (VP) is a rapidly growing category of additive manufacturing. As VP methods mature the expectation is that the quality of printed parts will be highly reproducible. At present, detailed characterization of the light engines used in

On the Fidelity of the Scaling Laws for Melt Pool Depth Analysis During Laser Powder Bed Fusion

December 27, 2022

Author(s)

Mehdi Naderi, Jordan Weaver, David Deisenroth, Nagaraja Iyyer, Raymond McCauley

In additive manufacturing, the part quality is highly dependent on process parameters. The morphology of the melt pool (depth and width) is highly affected by process parameter selection. Available scaling laws more or less overestimate or underestimate

Protecting Additive Manufacturing Information when Encryption is Insufficient

December 1, 2022

Author(s)

Joshua Lubell

Recent research shows how a side-channel attack on a material extrusion-based 3D printing process can bypass encryption-based defenses to obtain proprietary design information. This result has critical implications for outsourced additive manufacturing (AM

In-Process Data Integration for Laser Powder Bed Fusion Additive Manufacturing

November 11, 2022

Author(s)

Milica Perisic, Yan Lu, Albert T. Jones

Additive manufacturing (AM) is a powerful technology that can create complex metallic parts and has the potential to improve the economic bottom line for various industries. However, due to process instabilities, and the resulting material defects that

SPATIAL-TEMPORAL MODELING USING DEEP LEARNING FOR REAL-TIME MONITORING OF ADDITIVE MANUFACTURING

November 11, 2022

Author(s)

Jaehyuk Kim, Yan Lu, Zhuo Yang, Hyunwoong Ko, Dongmin Shin, Yosep Oh

Real-time monitoring for Additive Manufacturing (AM) processes can greatly benefit from spatial-temporal modeling using deep learning. However, existing, deep-learning approaches in AM are case-dependent, and therefore not robust to changes of control

STEP-NC COMPLIANT DATA REPRESENTATIONS FOR POWDER BED FUSION IN ADDITIVE MANUFACTURING

November 11, 2022

Author(s)

Fahad Milaat, Paul Witherell, Martin Hardwick, Ho Yeung, Vincenzo Ferrero, Laetitia Monnier, Matthew Brown

Powder bed fusion (PBF) is an additive manufacturing (AM) technology that uses powerful beams to fuse powder material into layers of scanned patterns, thus producing parts with great geometric complexity. For PBF, process parameters, environmental control

Using Coaxial Melt Pool Monitoring Images to Estimate Cooling Rate for Powder Bed Fusion Additive Manufacturing

November 11, 2022

Author(s)

Zhuo Yang, Brandon Lane, Yan Lu, Ho Yeung, Jaehyuk Kim, Yande Ndiaye, Sundar Krishnamurty

Cooling rate is a decisive index to characterize melt pool solidification and determine local microstructure formation in metal powder bed fusion processes. Traditional methods to estimate the cooling rate include in-situ temperature measurement and

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