Engineering Commons^™

3d Printing For Scale-Model Testing: Design, Build And Measurement Of Four Hulls, Thomas Klodenski

Electronic Theses and Dissertations

Recent advances in 3D printing and 3D scanning are poised to improve the state of the art of hydrodynamic scale-model testing. These tools improve the accuracy of the as-built scale model and have a direct influence over the predicted full-scale performance and the confidence level of the designer’s computer simulation.

This thesis explores the subject of accuracy through the development of four 3D printed floating wave energy converter hulls produced with 3D printing. Conceptual and detail design, construction, and measurement techniques are discussed. Financial data is explored as well as time requirements. The ability to use 3D printing to rapidly …

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 …

Modeling And Validations Of Control Parameters For Material Extrusion-Based Additive Manufacturing Of Thixotropic Aluminum Alloys., Lars Herhold

Electronic Theses and Dissertations

Additive Manufacturing (AM) with metals has been accomplished mainly through powder bed fusion processes. Initial experiments and simulations using Material Extrusion Additive Manufacturing (MEAM) have been performed by various researchers especially using low melting alloys. Recently Stratasys Inc. submitted a patent application for the use of their Material Extrusion technology also called Fused Deposition Modeling (FDM) where they describe the process using thixotropic semi-solid alloys. Currently this process using semi-solid, engineering type alloys such as A356 or THIXALLOY 540 aluminum have not been researched to evaluate the control parameters. This research combines the in-depth knowledge of applying thixotropic semi-solid aluminum …

Feasibility Of Using 3d Printed Molds For Thermoforming Thermoplastic Composites, Sunil Bhandari

Electronic Theses and Dissertations

This thesis presents a novel combined experimental and numerical mechanics approach for characterizing 3D printed thermoplastic materials by the fused deposition modeling process for thermoforming thermoplastic composites. The implications of this work are:

1. a methodology for model-based performance evaluation of 3D printed structural parts, and
2. an improved design of 3D printed molds for composites manufacturing, which has potential for material innovations and scaled-up applications in additive manufacturing.

The thesis formulates basic criteria for selection of thermoplastic polymer used for the 3D printed mold based on forming temperatures. The thesis creates a lattice and shell finite element model of the 3D …