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Additive Manufacturing Of Composites For Sensing And Harsh Environments Application, Md Sahid Hassan

Open Access Theses & Dissertations

Composite materials are made by combining two or more materials, such as fibers and resins to create a material system that has improved mechanical and physical properties compared to its individual components. The use of 3D printing technology in composite manufacturing allows for the creation of complex and custom shapes with precise control over the placement of the materials. This makes it possible to create composite parts with enhanced performance characteristics and reduced weight. The work presented in this dissertation lies in the design and development of highly flexible impact propagation sensor through material extrusion 3D printing technique. By using …

Analyzing The Effects Of Ultrafast Laser Processing On Mechanical Properties Of 3d-Printed Pla Parts, Darshan Pramodbhai Yadav

Theses and Dissertations

Recent advances in additive manufacturing technologies have already led to wide-scale adoption of 3D-printed parts in various industries. The expansion in choice of materials that can be processed, particularly using Fused Deposition Modeling (FDM), and the steady advancements in dimensional accuracy control have extended the range of applications far beyond rapid prototyping. However, additive manufacturing still has considerable limitations compared to traditional and subtractive manufacturing processes. This work addresses limitations associated with the as-deposited surface roughness of 3D-printed parts. The effects of roughness-induced stress concentrations were studied on ultimate tensile strength and fatigue life. The samples were manufactured using a …

Damage Detection With An Integrated Smart Composite Using A Magnetostriction-Based Nondestructive Evaluation Method: Integrating Machine Learning For Prediction, Christopher Nelon

All Dissertations

The development of composite materials for structural components necessitates methods for evaluating and characterizing their damage states after encountering loading conditions. Laminates fabricated from carbon fiber reinforced polymers (CFRPs) are lightweight alternatives to metallic plates; thus, their usage has increased in performance industries such as aerospace and automotive. Additive manufacturing (AM) has experienced a similar growth as composite material inclusion because of its advantages over traditional manufacturing methods. Fabrication with composite laminates and additive manufacturing, specifically fused filament fabrication (fused deposition modeling), requires material to be placed layer-by-layer. If adjacent plies/layers lose adhesion during fabrication or operational usage, the strength …

Northrop Grumman Collaboration Project, Nikkia Psomas-Sheridan, Santiago Robles, Ben Elkayam, Benjamin Ulfhake

Mechanical Engineering

The Northrop Grumman Collaboration Project (NGCP) is a collaborative club project sponsored by Northrop Grumman for the students of Cal Poly San Luis Obispo (CPSLO) and Cal Poly Pomona (CPP) to create a fleet of vehicles to aid in the simulated rescue of stranded hiker. The CPSLO club is responsible for delivering an autonomous flight vehicle that can suppress a fire and retrieve a payload. Mechanical Design Team of the CPSLO team was responsible for the design of the frame, electronics housing, and payload and fire suppression systems.

Engineered Material Systems For Mimicking Tissue And Disease, Margrethe Ruding

McKelvey School of Engineering Theses & Dissertations

This thesis comprises two studies involving design and application of soft material systems. The goal of the first study was to design, fabricate, and characterize hydrogel lattice structures with consistent, controllable, anisotropic mechanical properties. Lattices, based on four types of unit cells (cubic, diamond, vintile, and Weaire-Phelan), were printed using stereolithography (SLA) of polyethylene glycol diacrylate (PEGDA). In order to create structural anisotropy in the lattices, unit cell design files were scaled in one direction by a factor of two in each layer and then printed. The mechanical properties of the scaled lattices were measured in shear and compression and …

Nasa Student Launch Payload Deployment, Kallysta Ray

All Undergraduate Projects

For the NASA Student Launch Competition, a deployment system was created to deploy the payload of the rocket. To accomplish this the deployment system was designed, analyzed, manufactured, and tested to meet the requirements from the NASA Competition. The requirements included deployment of the payload as well as staying within 4 pounds. The project requirements were researched and each of the proposed components had analyses completed. The analyses included weight calculations, stress, and deflection analyses using statics, mechanics of materials, and dynamics. There were many discussions throughout the project between the teammates to ensure all components of the payload and …

Radio-Controlled Baja Car, Jaxx Brown

All Undergraduate Projects

The Central Washington University RC Baja competition tests students’ skills in engineering in a matter of ability to design, construct and test an RC car. The objective of this senior project is to manufacture efficient suspension and steering systems for an RC vehicle and compete at the end of the school year against other students’ vehicles. Two races will be conducted during the competition, the RC vehicle will compete in a slalom-and-sprint and a Baja. Using more than one manufacturing method and material was expected of students to create the steering and suspension systems. Through CAD software and 3D printers …

Anisotropic Material Behavior Of 3d Printed Fiber Composites, Jordan Garcia

Theses and Dissertations--Mechanical Engineering

Literature has shown that 3D printed composites may have highly anisotropic mechanical properties due to variation in microstructure as a result of filament deposition process. Laminate composite theory, which is already used for composite products, has been proposed as an effective method for quantifying these mechanical characteristics. Starting with the analysis of comparing the printing orientation of premanufactured carbon fiber reinforced filament, the mechanical properties of 3D printed objects were examined. The mechanical properties changed not only as a result of machine choice, but how the sample is oriented along the printing bed. The analysis continued with looking at the …

Northrop Grumman Collaboration Project, Nikkia Rae Psomas-Sheridan, Santiago Robles, Ben Elkayam, Benjamin Ulfhake

Mechanical Engineering

The Northrop Grumman Collaboration Project (NGCP) is a collaborative club project sponsored by Northrop Grumman for the students of Cal Poly San Luis Obispo (CPSLO) and Cal Poly Pomona (CPP) to create a fleet of vehicles to aid in the simulated rescue of stranded hiker. The CPSLO club is responsible for delivering an autonomous flight vehicle that can suppress a fire and retrieve a payload. Mechanical Design Team of the CPSLO team was responsible for the design of the frame, electronics housing, and payload and fire suppression systems.

Effect Of Size And Shape Parameters On Microstructure Of Additively Manufactured Inconel 718, Showmik Ahsan

Browse all Theses and Dissertations

Additive Manufacturing (AM) methods are promising in applications where complex part geometries, exotic materials and small lot sizes are required. Aerospace manufacturing stands to use AM methods extensively in the future, and frequently requires temperature- and corrosion-resistant alloy materials such as Inconel 718. However, the microstructural evolution of Inconel 718 during additive manufacturing is poorly understood and depends on part size and shape. We studied the microstructure of Inconel 718 parts manufactured by Laser Powder Bed Fusion in order to further elucidate these dependencies. Microstructural analysis, SEM imaging, EBSD scans and Microhardness testing were performed.

Fabrication Of Solar Absorber Tube With Internal Fin Structure With In718 And Effect Of Boron With In718 For Solar Absorber Tube Using Selective Laser Melting 3d Printing Technology, Naznin Nuria Afrin

Theses and Dissertations

This research aimed to fabricate Solar Absorber Tubes for Solar-Thermal Power Plant with internal fin structures using Selective Laser Melting (SLM) technology. In this study, we investigated the effect of B with IN718 in 3D printing using SLM for solar absorber tubes. The objective was to study the material-process-properties relationship with goal to identify and validate the optimal parameters for the SLM process. Material selected for this study was IN718 with 0.5% and 1% B particle mixed using a V-shape mixing machine. The flowability test was conducted using the Angle of Repose (AOR) method. 3D printed samples …

Bongoties Tying Machine Design, Zachary Stednitz, Tori Bornino, Jackson Mclaughlin, Shea Charkowsky

Mechanical Engineering

BongoTies are a reusable tool for cable management or general fastening, consisting of a strong rubber band attached to a bamboo pin. BongoTies is a company founded by our sponsor Tim Petros that sells its product on a variety of popular shopping sites, such as Amazon and eBay. Currently, the assembly process is to hand-tie the rubber band to the pin for every BongoTie. This is too slow to keep up with demand, requires a skilled worker with good dexterity, and can cause pain or injury if the rubber band snaps back onto the worker’s fingers. In this senior project …

Autonomous Material Refill For Swarm 3d Printing, William C. Jones

Mechanical Engineering Undergraduate Honors Theses

3D printing currently offers robust and cheap rapid prototyping solutions. While standard 3D printing remains at the periphery of mass production, the technology serves as a starting point for the development of swarm manufacturing. Since swarm manufacturing is predicated upon autonomy, swarm technology companies such as AMBOTS are seeking to minimize human involvement in the swarm’s functions. At present, the 3D printing swarm consists of the printers, a transporter which can take them between job sites, and the floor tiles which provide power and support the build surfaces. To add to this ecosystem, this project is focused on the design …

The Study Of 3d Micro-Fluid Printing In Aqueous Two-Phase System, Mian Huang

Dissertations and Theses

Aqueous two-phase system (ATPS) is a technology that allows phase separation in an aqueous environment. This technology can be used for the separation, extraction and purification of a variety of biomolecules and thus gained great attention in industry and academia. This thesis is a combination of ATPS, 3D printing, and microfluidics technologies and realizes the printing of biocompatible aqueous structures in another aqueous matrix. The objectives of this thesis include 1) customizing a regular thermal extrusion 3D printer for printing 3D aqueous structures, 2) printing 3D aqueous structure in an aqueous matrix, and 3) studying the stability of the printed …

Recycled Printer Filament, Charlotte Hyland, Troy D. Molinar

Williams Honors College, Honors Research Projects

The purpose of this research is to examine the effects of recycling PLA filament for 3D printing on its material properties. After examining these effects, PLA and carbon fiber additives were mixed with recycled PLA pellets in different ratios to attempt to regain material properties lost in the recycling process. To complete these findings, an experiment was design and executed.

The research found that tensile strength during multiple iterations of recycling remained mostly unaffected, however, the strain degraded exponentially. In the PLA additive study, high ratios of PLA additive were able to increase the strength and strain properties of the …

Thermal And Mechanical Numerical Modeling Of Extrusion-Based 3d Printed Reinforced Polymers For Selecting Manufacturing Process Parameters, Sunil Bhandari

Electronic Theses and Dissertations

Extrusion-based 3D printing of thermoplastic polymer composites manufactures parts that have nonhomogenous, orthotropic, and process-dependent macro-scale material properties. As a part of the dissertation, research works were carried out to: • improve the interlayer mechanical properties and reduce the orthotropy, • use experimentally homogenized orthotropic material properties to numerically model the mechanical behavior of the non-homogenous orthotropic 3D printed parts, • create an efficient numerical thermal model to predict the process-dependent thermal history of the 3D printed part, and • aid the manufacturing process by selecting a suitable set of processing parameters based on a simplified sequentially coupled thermomechanical model. …

Materials And Process Design For Ceramic Fused Filament Fabrication (Cf3) Of Hydroxyapatite., Kavish Sudan

Electronic Theses and Dissertations

Ceramic fused filament fabrication (CF3) enables the fabrication of highly customizable ceramic parts at relatively lower costs compared to other AM technologies. Advanced ceramics, having specific or niche applications, call for a high level of accuracy to meet the performance requirements. For achieving the desired level of accuracy in any manufacturing process, it is important to know the effect of involved parameters at different stages of fabrication. CF3 has been around for a while but there has been a severe lack of literature dealing with understanding the effect of process parameters on the final part properties. In this study, Hydroxyapatite …

3d Printing Technology Applied In Lithium Metal Batteries: From Liquid To Solid., Xuejie Gao

Electronic Thesis and Dissertation Repository

Li-metal batteries are strongly considered to be one of the most promising candidates for high energy density energy storage devices in our modern society. However, the state-of-the-art Limetal batteries are still limited by several challenges including 1) low energy/power density; 2) Li dendrite growth; 3) low coulombic efficiency, and 4) safety concerns within the liquid electrolyte. This thesis mainly focuses on addressing these challenges by using a 3D printing technique to realize high energy/power density Li-metal batteries.

A self-standing high areal energy density cathode for Li-S battery was developed by the 3D printing method in the first part. The optimized …

Modeling The Effect Of In Situ Nozzle-Integrated Compression Rolling On The Mechanical And Fracture Behavior Of Fused Filament Fabrication (Fff) 3d Printed Parts, Momen Mohammad Qasaimeh

Mechanical and Aerospace Engineering Dissertations

Fused filament fabrication (FFF) is one of the most common additive manufacturing/3D printing techniques where continuously extruded semi-molten filaments are deposited in a layer-by-layer manner. The quality of the manufactured part depends on some major factors such as filament-filament contact and adhesion as well as the void fraction. Filament to filament adhesion affects the part strength under transverse load. In our earlier work, we studied the effect of in situ ball rolling on the thermal and mechanical properties of the printed parts. It was found that when printing/rolling parameters are correctly tuned and in situ compression rolling is appropriately applied …

Blds Pressure Belt, Hailey Earnest, Sean Casteel, Benjamin Bons, Biren Rama

Mechanical Engineering

Dr. Westphal has a Boundary Layer Data System (BLDS) that is used to take pressure measurements on the surface of the aircraft. Our team has created a design and manufacturing method for producing the corresponding pressure belt that attaches to Dr. Westphal's system to obtain pressure data.

3d Printing Of Hybrid Architectures Via Core-Shell Material Extrusion Additive Manufacturing, Robert Cody Pack

Doctoral Dissertations

Biological materials often employ hybrid architectures, such as the core-shell motif present in porcupine quills and plant stems, to achieve unique properties and performance. Drawing inspiration from these natural materials, a new method to fabricate lightweight and stiff core-shell architected filaments is reported. Specifically, a core-shell printhead conducive to printing highly loaded fiber-filled inks, as well as a new low-density syntactic foam ink, are utilized to 3D-print core-shell architectures consisting of a syntactic epoxy foam core surrounded by a stiff carbon fiber-reinforced epoxy composite shell. Effective printing of test specimens and structures with controlled geometry, composition, and architecture is demonstrated …

Investigation On Microstructure And Mechanical Properties Of Porous Structures Processed By Laser Powder Bed Fusion, Samarth Ramachandra

Mechanical and Aerospace Engineering Theses

Inconel 718 (i.e., IN718) is a prominent nickel-based, precipitation-hardening superalloy which exhibits exceptionally stable mechanical and corrosion resistant properties, even at temperature range of 650ºC to 700ºC, making it suitable for a wide range of applications such as aerospace, nuclear reactors, tooling, turbines, oil and gas applications. The high toughness and work hardening offered by this superalloy, however, greatly limits the choice of machinability. The presence of low levels of aluminum permits good weldability which further allows the use of laser-based additive manufacturing (AM) to efficiently fabricate IN718 parts without the limitations associated with conventional manufacturing methods. Thanks to AM …

Investigation Of The Microstructural And Mechanical Properties Of Selectively Laser Melted In718 Overhangs Fabricated Without Support Structures, Manjunath Hanumantha

Mechanical and Aerospace Engineering Theses

Additive manufacturing is a new manufacturing technology that allows for extreme design freedom as well as the simultaneous production of many parts with high complexities. IN718 is a high-strength, corrosion-resistant super alloy of nickel and chromium. It is ideal for high-end applications such as rocket nozzles and turbines because it can handle exceptionally high pressure and heat. Because of its high stiffness qualities, conventional manufacturing of complex IN718 geometries is challenging. Various fabrication techniques have been developed, and this study focuses on selective laser melting (SLM) because of its potential to produce near-perfect parts at a low cost when working …

Metallization Process For 3d Printed Electronics: From I3dp Ii To 3d Co-Printing Technology, Junfeng Xiao

Electronic Thesis and Dissertation Repository

3D printing has emerged as a powerful additive manufacturing technique and becomes as a viable alternative to conventional manufacturing processes in an increasing number of applications. Thus, the development of printable materials also continues to expand, while polymers are still the most utilized materials in 3D printing. There is a great advance for developing polymers with versatile mechanical and chemical properties. However, the end-use products are demanding various functions. It is imperative to develop functional 3D printed polymeric materials to achieve enhanced functionalities.

Usually, one polymer can meet one specific application. This has considerably limited the capability of 3D printing …

Centrifugal Microfluidic Platform For Solid-Phase-Extraction (Spe) And Fluorescence Detection Applications, Yong Zhang

LSU Doctoral Dissertations

Solid phase extraction (SPE) is a widely used method to separate and concentrate the target molecules in liquid mixture. Traditional SPE has to be conducted in the laboratory with professional equipment and skilled operators. The microfluidic and 3D printing technology have opened up the opportunity in developing miniaturized automatic instruments. The main contribution of this research is to integrate the SPE process on a novel centrifugal platform. Various valves are applied on the platform to help control the aqueous sample and reagents in the cartridge.

First, a centrifugal microfluidic platform was built for automatically detecting trace oil pollution in water. …

Design For Additive Manufacturing, Michael Charonnat, Leonardo Franco-Muñoz, Sam Noble, J.P. Purdom

Mechanical Engineering

This document outlines the critical design details and timeline for the Design for Additive Manufacturing Senior Project sponsored by Solar Turbines, Inc. The scope of this project encompasses the redesign of two of Solar Turbine’s cast parts for metal additive manufacturing in order to minimize lead time, cost, and weight. With the overall objective of performing in-depth analysis exploring affordability & feasibility, this redesign process will aid Solar Turbines in expanding their knowledge of Design for Additive Manufacturing principles and enable them to further incorporate the use of additive manufacturing into their production processes. The first part that the team …

Prosthetic Hand: Structure, Riley Smith, Riley Smith

All Undergraduate Projects

The objective of this project was to design the structure of a prosthetic hand that has articulating fingers and thumb in order to grip various objects. A design was developed that can add to the available options of prosthetics on the market.

In order to create a base hand for the project, the hand was modeled off of rough human hand dimensions. Analyses determined the feasible size of components. Once a base size was found the movement system in both grip and return form were developed and refined. With the parts being modeled in Solidworks and 3D printed, iterations of …

Mechanical Lift Assist Hoist, Jacob Vanblaricom

All Undergraduate Projects

Pneumatic Gripper for Cast Products

By: Jacob VanBlaricom

Mentors: Craig Johnson (craig.johnson@cwu.edu), Kurt Gray (kgray06@northstarcasteel.com ),

Ted Bramble (ted.bramble@cwu.edu) , Travis Lamberte (travis@northstarcasteel.com )

The Team was tasked by NorthStar Casteel to create a device that would allow for easy mobility and manipulation of unfinished cast products. The device is needed to increase manufacturing time and decrease worker strain. In order to do this the team designed a custom gripper to match the castings produced at this facility. The gripper was powered by a pneumatic system due to the speed and reliability in this …

Binder Saturation, Layer Thickness, Drying Time And Their Effects On Dimensional Tolerance And Density Of Cobalt Chrome - Tricalcium Phosphate Biocomposite, John Ruprecht

All Graduate Theses, Dissertations, and Other Capstone Projects

Traditional metals such as stainless steel, titanium and cobalt chrome are used in biomedical applications (implants, scaffolds, etc.) but suffer from issues such as osseointegration and compatibility with existing bone. One way to improve traditional biomaterials is to incorporate ceramics with these metals so that their mechanical properties can be similar to cortical bones. Tricalcium phosphate is such a ceramic with properties such that it can be used in the human body. This research explores the use of the Binder Jetting based additive manufacturing process to create a novel biocomposite made of cobalt chrome and tricalcium phosphate. Experiments were conducted …

Dynamic Testing: An Experimental Approach To Defect Identification In Additive Manufactured Parts, Aimee Allen

Dissertations, Master's Theses and Master's Reports

Today’s additive manufacturing (AM) industry produces specialized parts at low volume or with complex geometries. Traditional testing methods are effective, but costly and time consuming to perform. The AM industry lacks an optimized testing method for identifying internal defects that occur in parts. The evaluation of multiple parts printed on the same build plate for internal defects using various nondestructive (dynamic) testing techniques is presented. From these experiments, perspective was gained on when and how dynamic testing can be used to find defects. Insight gained from these experiments can help the industry in future testing for internal defects.