fab 4 - august 2007 university of southern california sff processes b. khoshnevis

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

SFF Processes

B. Khoshnevis

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Application Areas

Small batch actual production of parts or assemblies

Prototyping of products to test functionality, fit for assembly, marketability, and other factors

Mold, die, and other tool making for other manufacturing processes such as casting, extrusion, etc.

Solid imaging of 3D data in domains such as mathematics, chemistry, medicine, etc.

Sculpturing and other forms of art work.

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Advantages

Possibility of unattended operation Significant reduction in product design cycle Ability to produce parts with unlimited

geometrical complexity Radically new possibility of designing the

internal structure of parts Possibility of wasteless and environmentally

sound fabrication

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Commercialized RP Technologies

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Selective Inhibition Sintering (SIS)

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

The working of sintering inhibitor

Sintered powder

Sintered powder

Particles treated with sintering inhibitor

Break-away surface

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Preliminary experiment

Built in one afternoon with an electric heater filament and a light dimmer.

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Preliminary Results

Sintered layer Holes due to inhibitor

Printed inhibitor Separated sections

Single-layer experiments with polystyrene powder

Inhibitors:

- Cooking oil

- Water+alcohol

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

The Alpha Machine

Drive electronicsUse of a halogen lamp heater

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Sintering by Nichrome Pivoting Heater

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

The Alpha Machine

Desk top size

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Driver software

Interface

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Sample Parts

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

2.5 D Parts

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

3D parts

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Moldless Powder Metallurgy (MPM)

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

The MPM-Metal machine

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Elementary parts

Simple copper part made with ceramic inhibitor

Copper Part with complex geometry and sharp edges

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Scaling up

From Fabrication to Construction

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

CCContour Crafting

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Flow analysis for nozzle design

Comparison of flow patterns with simulation result and actual process.

Side views with a square orifice (top pictures), and side views with an elliptical orifice (bottom pictures)

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

3D ceramic parts

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Ceramic and Plastic parts

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Application in building construction

Cavities made with CC and filled with concrete.

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Imbedding Reinforcement

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Co-extrusion of outer and filler materials A 6DOF Nozzle Assembly

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Conventional Structures

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Adobe structures

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Multiple mobile robotics approach

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

CC – The Sass Method

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

IT issues

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Lunar construction – From Earth to Moon

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Deployable CC

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

NASA Trials

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Nozzle for corrugated internal structure

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Nozzle for corrugated internal structure

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Adjustable width nozzle

UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007

Imbedding sensors and IT components

Conductive concrete may be used to power densely imbedded sensors and actuators.