Engineering Commons^™

Design, Fabrication, And Testing Of A 3d Printer Based Microfluidic System, Carlton A. Mcmullen

Graduate Theses and Dissertations

A pneumatically actuated PDMS based microfluidic devices were designed and fabricated by soft-lithography. Two types of molds were fabricated out of different material for this experiment. The first mold, (device 1), was fabricated from a sheet of Polymethyl methacrylate (PMMA) material, similar to Plexiglas. The device features were micro-engraved onto the face of the material. The second mold, (device 2), was fabricated from the use of fused deposition modeling (FDM) 3D printing. The pumping efficiency of the PDMS devices was analyzed through the characterization of the micro-pumps flowrate with respect to the pumps driving pressure and the actuation frequency. Tested …

Printed And Structurally Integrated Electronics For Air Force Applications, Daniel Berrigan, Benjamin Leever, Michael Durstock

Composites at Lake Louise (CALL 2015)

Both printed and flexible electronic systems promise to integrate functional devices into new form factors (e.g., structures or clothing) and environments. Of particular interest are the mechanically harsh environmental conditions to which military systems are sometimes exposed, which can be quite severe (i.e., upward of 100,000 G peak acceleration within 0.1 ms), and commercial off-the-shelf components are not designed to maintain functionality under such rugged conditions. The overarching aim of this project is to leverage the unique ability of additive manufacturing to digitally control materials properties in three dimensions to create multifunctional systems whose structure is ruggedized for mechanically these …

A Study Of Digital Rf Phase Shifters Fabricated With Additive Manufacturing, Yaniel Vega

USF Tampa Graduate Theses and Dissertations

Digital RF phase shifters fabricated using additive manufacturing processes are presented and studied. The purpose is to explain the performance differences between phase shifters fabricated using additive manufacturing and those fabricated with conventional subtractive techniques. All phase shifters are designed to operate at a center frequency of 2.45 GHz with a 100 MHz bandwidth. The 1-bit 45° switched line phase shifters have an average insertion loss of 1.3 dB and a 220 mm² footprint, while the 1-bit 180° high-pass low-pass phase shifters have an insertion loss 1.56 dB and a 180 mm² footprint. The 4-bit high-pass low-pass, switched …

A Study Of Direct Digital Manufactured Rf/Microwave Packaging, John W.I. Stratton

USF Tampa Graduate Theses and Dissertations

Various facets of direct digital manufactured (DDM) microwave packages are studied. The rippled surface inherent in fused deposition modeling (FDM) fabricated geometries is modeled in Ansoft HFSS, and its effect on the performance of microstrip transmission lines is assessed via simulation and measurement. The thermal response of DDM microstrip transmission lines is analyzed over a range of RF input powers, and linearity is confirmed over that range.

Two IC packages are embedded into DDM printed circuit boards, and their performance is analyzed. The first is a low power RF switch, and the second is an RF front end device that …

Factors Affecting Dimensional Precision Of Consumer 3d Printing, David D. Hernandez

International Journal of Aviation, Aeronautics, and Aerospace

This paper investigates the factors affecting dimensional precision of consumer-grade 3D printing, attempting to isolate and mitigate sources of error. The focus is on creating engineering prototypes of, tooling for, or finalized instances of mechanical devices. A specific fused deposition modeling printer – the Ultimaker 2 – is analyzed in terms of meeting precise physical dimensions, consistent shapes, and predictable surface finish. Extensive trial and error resulted in removal of several sources of bias, with square test articles exhibiting a lower-than-anticipated mean percentage error of -0.387% (SD = 0.559), a value comparable to other modern manufacturing techniques. A full …

Nanoenhanced Additive Manufacturing: Additive Introduction Onto Halloysite Nanotubes And Into 3d Printing Filament For Tailored Material Characteristics, James Connor Nicholson

Doctoral Dissertations

With the rapid advancement of additive manufacturing technologies in recent years on both the microscale and the macroscale, research must be done to test the limits of currently available technologies. On the microscale, halloysite nanotubes have proven to be a viable platform for reinforcement of polymers and time release of loaded chemicals, as well as a substrate material for the deposition of nanoparticles. The range of materials are limited due to polarity conflicts, and often lead to wet chemical processes that use more toxic alternatives. Three-dimensional (3D) printing and macroscale additive manufacturing techniques can be used to generate custom structures, …

The Use Of Low-Cost ‘Balloonsats’ For Stem Education With 3d Printing, Jeremy Straub, Josh Berk, John Nordlie, Ronald Marsh

Jeremy Straub

A new technology, known as 3D printing, allows the rap-id fabrication of plastic structures of virtually any config-uration. These structures are light-weight, dura-ble and inexpensive. This paper considers the utility of utilizing 3D printing to create enclosures for ‘BalloonSats’ – small, low-cost spacecraft analog which can be utilized by students to understand space engi-neering, conduct near-space science (e.g., physics, bio-logical and other experiments) and touch the edge of space.

The Use Of Additive Manufacturing For Cubesat Design And Testing, Jeremy Straub, Ronald Marsh, Scott Kerlin

Jeremy Straub

In developing a small spacecraft, the integration of numerous systems in a small area is a key challenge. It is easy to overlook how various component parts will integrate or have multiple sub-groups utilize un-filled space without realizing that they are creating a resource conflict. Additionally, the manufacturability of the final design is a key consideration. For all of these reasons, developing low-cost and incremental prototypes is a engineering ‘best practice’ for small spacecraft development.

Three-Dimensional Printing And Scanning Web-Based Job Management System, Stephanie Hollman, Dalyn Limesand, Jeremy Straub, Scott Kerlin

Jeremy Straub

Three-dimensional (3D) printers have gained popularity for use for many different projects. The work presented herein aims to make this process simpler. This poster discusses a system that will allow individuals from all over campus to submit object files for printing, without having to schedule appointments and schedule 3D scanning appointments and retrieve scan results.

An Experimental Study On Passive Dynamic Walking, Philip Andrew Hatzitheodorou

USF Tampa Graduate Theses and Dissertations

In this study, a previously designed passive dynamic walker (PDW) is built out of aluminum and plastic. The aim of the study was to produce an asymmetrical PDW and to compare the results to a computer simulation to validate the mathematical model. It also aimed at identifying the limitations of using additive manufacturing to create components for a PDW as well as gain insights on asymmetric systems.

Beginning with a five mass kneed model, parameters were varied to produce up to a nine mass kneed model solution. The nine mass model allows more variability in added mass locations and separates …

A Web-Based Job Management System For Three-Dimensional Printing And Scanning At The University Of North Dakota, Dalyn Limesand, Stephanie Hollman, Jeremy Straub, Scott Kerlin

Jeremy Straub

Three-dimensional (3D) printers have gained popularity for use for many different projects. The work presented herein aims to make this process simpler. This paper discusses a system that will allow individuals from across campus to submit object files for printing by a 3D printer, without having to schedule appointment and manually operate it.

Logistical requirements dictate some level of human involvement, despite a goal of creating a fully automated system. Involvement areas include converting /preparing submitted files, sending the job to the printer, print tray preparation, and completed object removal. From a user’s perspective, however a seamless experience is anticipated. …

Development Of A Metal-Printing 3d Printer At The University Of North Dakota, Benjamin Kading, Michaela Kegley, Tiana Delzer, Jeremy Straub, Scott Kerlin

Jeremy Straub

Three-dimensional (3D) printing is being used for numerous applications: from consumer hobbies to the development of aircraft parts. However, inexpensive 3D printers have been constrained in material selection to plastic. These printer use the fused deposition modeling (FDM) method of printing, which is a relatively new technology that utilizes computer numerical control (CNC) techniques to deposit melted material at specific places. Other methods, for example, include laser sintering and stereolithography. With 3D printing, layers are stacked upon each other and via this compilation of layers, a 3D object is formed. Currently there are a variety of materials that can be …

Multi-3d System: Advanced Manufacturing Through The Implementation Of Material Handling Robotics, Jose Luis Coronel Jr.

Open Access Theses & Dissertations

Since the rise of additive manufacturing (AM), innovation has been at the forefront. Additive Manufacturing systems that incorporate complex processes are steadily being developed. One example is the Multi3D System, which was designed to integrate the ability to print multi-material parts with that of embedding electronics. To achieve this automated process, the Multi3D incorporates a six-axis robotic arm to transfer a build platform containing a printed part, to various manufacturing stations (two fused deposition modeling (Stratasys, FDM400mc) systems and a computer numerical control router (Techno CNC Router). The robot is a Yaskawa Motoman MH50 chosen for its payload capacity of …

Study Of Materials And Machines For 3d Printed Large-Scale, Flexible Electronic Structures Using Fused Deposition Modeling, Seyeon Hwang

Open Access Theses & Dissertations

The 3 dimensional printing (3DP), called to additive manufacturing (AM) or rapid prototyping (RP), is emerged to revolutionize manufacturing and completely transform how products are designed and fabricated. A great deal of research activities have been carried out to apply this new technology to a variety of fields. In spite of many endeavors, much more research is still required to perfect the processes of the 3D printing techniques especially in the area of the large-scale additive manufacturing and flexible printed electronics.

The principles of various 3D printing processes are briefly outlined in the Introduction Section. New types of thermoplastic polymer …

Applications Of Ultrasonic Non-Destructive Testing In 3d Printing, Parker Lawley

The Journal of Undergraduate Research

To determine the capabilities of ultrasonic non-destructive testing methods in 3D printing, test specimens were designed to evaluate advantages and limitations in using ultrasoundC-scanning to determine 3D printing effectiveness. A Matlab program was written to process the data obtained from the UTwin software and ultrasound tank, as well as produce 3D models of the parts being tested. Thickness, types of features, and various printing methods were evaluated to determine how these characteristics vary in effectiveness of C-scan imaging. Results from the UTwin software C-scans were compared to the Matlab program’s imaging and three-dimensional modeling. After determining the capabilities of ultrasonic …

Defeating Anisotropy In Material Extrusion 3d Printing Via Materials Development, Ángel Ramón Torrado Pérez

Open Access Theses & Dissertations

Additive Manufacturing technologies has been in continuous development for more than 35 years. Specifically, the later denominated Material Extrusion Additive Manufacturing (MEAM), was first developed by S. Scott Crump around 1988 and trademarked later as Fused Deposition Modeling (FDM). Although all of these technologies have been around for a while, it was not until recently that they have been more accessible to everyone. Today, the market of 3D printers covers all ranges of price, from very specialized, heavy and expensive machines, to desktop printers of only a few cubic inches in volume. Until recently, FDM technology had remained somewhat stagnant …