Engineering Commons^™

Enhanced Performance Of 3d Electroactive Polymer Transducers Via Hierarchical Structures, Frederick B. Holness

Electronic Thesis and Dissertation Repository

Conjugated polymers (CPs) are a class of polymers that exhibit a change in size or shape in response to electrical stimuli. The unique combination of electrical and mechanical properties facilitates the fabrication of novel devices in a broad range of applications including: sensors, actuators, and lab-on-a-chip systems. The alternating single and double bonds along the polymer chain of CPs enables their electroactive properties but is also responsible for processability associated with CPs that has limited fabrication methods. Recently a photosensitive CP composite enabling additive manufacturing (AM) of 3D CP structures was developed. However, the introduction of a copolymer for mechanical …

A Study On Early Age Properties Of Concrete For Precast And 3d Printing, Debalina Ghosh

Doctoral Dissertations

Concrete is the second-most consumed material, leading the global Portland cement production of 4.1 billion tons in 2020 and 5-8% of global Carbon dioxide (CO₂) emission annually. As with any other material and practice, the construction industry is also ever-changing to meet market demand, evolving technology, and resource limitation. In the case of concrete construction, one of the main concerns is the lack of automation. In the last few decades, some new construction methods have risen to address this concern. Some of these economic and successful practices are precast construction, self-compacting concrete (SCC), and 3D printing of concrete(3DPC). …

Direct Ink Writing Of Flexible Piezoelectric Sensors, Amanda M. White

Boise State University Theses and Dissertations

Piezoelectric poly(vinylidene fluoride-co-trifluoroethylene), or PVDF-trFE, builds up significant electrical charges on its surface when stressed. By correlating the mechanical force with the resulting electrical charges or voltages, researchers have developed flexible, broadband, and biocompatible force sensors. PVDF-trFE force sensors are traditionally fabricated via spin coating or solvent casting, which result in large waste production and experience difficulties in forming complex geometries. To tackle these challenges, I leveraged a commercial direct ink writing system (nScrypt microdispenser) to additively manufacture PVDF-trFE force sensors. I first synthesized an unprecedented piezoelectric ink that is compatible with a commercial ink writing system at Boise State …

Design, Evaluation, And Control Of Nexus: A Multiscale Additive Manufacturing Platform With Integrated 3d Printing And Robotic Assembly., Danming Wei

Electronic Theses and Dissertations

Additive manufacturing (AM) technology is an emerging approach to creating three-dimensional (3D) objects and has seen numerous applications in medical implants, transportation, aerospace, energy, consumer products, etc. Compared with manufacturing by forming and machining, additive manufacturing techniques provide more rapid, economical, efficient, reliable, and complex manufacturing processes. However, additive manufacturing also has limitations on print strength and dimensional tolerance, while traditional additive manufacturing hardware platforms for 3D printing have limited flexibility. In particular, part geometry and materials are limited to most 3D printing hardware. In addition, for multiscale and complex products, samples must be printed, fabricated, and transferred among different …

Optimized 3d-Printing Of Carbon Fiber-Reinforced Polyether-Ether-Ketone (Cfr-Peek) For Use In Overmolded Lattice Composite, Ryan C. Ogle

Masters Theses

Current orthopedic implants are overwhelmingly composed from metallic materials. These implants show superior mechanical properties, but this can additionally result in stress shielding due to a modulus mismatch between the bone tissue and implanted device. Polymeric implants reduce this stress shielding effect but have much lower mechanical properties, limiting their use. Polylactic acid (PLA) is a widely used biodegradable thermoplastic polymer, however, its use has been limited by the polymer’s mechanical properties and rapid loss of strength during degradation in vivo. Polyether-ether-ketone (PEEK) is another common biocompatible polymer , with chemical and mechanical properties which make it a popular alternative …

A Numerical Simulation Of The Powder Bed Additive Manufacturing Process With Molecular Dynamics Simulation, Yeasir Mohammad Akib

Theses and Dissertations

Many manufacturing industries utilize powder bed fusion (PBF) since it can produce microscale precision 3D parts. During PBF, powder particles are selectively fused layer by layer using thermal energy. The build quality in the PBF process relies heavily on powder bed properties and thermal energy deposition. Powder flowability, spreadability, and packing fraction are some of the insightful factors that determine the quality of the powder bed. In this study, a two-dimensional powder bed is developed using the LAMMPS package. A cloud-based pouring of powders with varying volumes and initialization is adopted for the work. A blade-type and circular recoater is …

Characterization Of Materials Properties In Additively Manufactured Aisi-420 Martensitic Steel Deposited By Laser Engineered Net Shaping, Md Mehadi Hassan

Nanoscience and Microsystems ETDs

Metal additive manufacturing (AM) is a disruptive technology enabling the fabrication of complex and near-net-shaped parts by adding material layer-wise. It offers reduced lead production time. AM processes are finding applications in many industrial sectors such as aerospace, automotive, biomedical, and mold tooling. Despite the tremendous advantages of AM, some challenges still prevent this technology's adoption in high-standard applications. Anisotropy and inhomogeneity in the mechanical properties of the as-built parts and the existence of pores and lack-of-fusion defects are considered the main issues in directed energy deposition (L-DED) parts. Laser-engineered net shaping LENS® offers excellent possibilities to fabricate metal tools …

Hardware Security For Wireless Communications Systems Using Antenna-Based Radio Frequency Fingerprint Engineering, Noemi Miguelez Gomez

Doctoral Dissertations and Master's Theses

The design and application of novel physical-layer security techniques have been increasing in the last decades as means to enhance the security that more traditional techniques provide to wireless communications systems. Well-known hardware security techniques, such as radio frequency fingerprinting, use unintended manufacturing process variations and unique hardware structures in the semiconductors for applications such as identification and classification of the source of different transmitted signals, and detection of hardware modifications. The uniqueness of the features that two different modules present, even maintaining the same design, can be used for modules characterization at a lower cost and complexity than other …

Enabling Nanoimprint Lithography Techniques Across Multiple Manufacturing Processes, Vincent Einck

Doctoral Dissertations

Advanced nanooptics in the areas of flat lenses, diffractive elements, and tunable emissivity require a route to high throughput manufacturing. Nanooptics are often demanding of high refractive index materials, nanometer precision and ease of fabrication. Nanoimprint lithography (NIL) is a low-cost, high throughput manufacturing technique beginning to be realized in commercial industry.^1,2 The NIL process is an ideal manufacturing candidate due to its ability to have a fast process time, efficient use of materials, repeatability and high precision while also having wide diversity of potential structures and material choices. Appling NIL techniques to other facets of manufacturing enable the …

Finite Fatigue Life Prediction Of Additively Manufactured Aircraft Engine Turbine Blade With Respect To Internal Defect Size And Location, Daniel G. Miller

Theses and Dissertations

Current fatigue life modeling techniques with respect to defects emphasize the dependence on the defect size with respect to fatigue life, but does not account for the effects of where a defect might be located. This research outlines a process to include defect location into the model analysis for a more precise prediction of the number of cycles to failure and where the finial failure could occur within a component. The focus is on a turbine blade structure using IN718 subjected to a pure vibratory load. The basic model predicts component life using a stress map from the frequency analysis …

Additive Manufacturing Of Molybdenum For High Temperature Structural Applications, Megan L. Bustin

Theses and Dissertations

This research considered additive manufactured (AM) molybdenum (Mo) and the effect of three variables on microstructure, mechanical properties, and the relationship between the two. Test temperature, laser speed, and shield gas or build atmosphere were varied, and samples tested and analyzed using a three-point bending test, chemical composition, and optical and scanning electron microscopy. The relationship among variables and results using a Design of Experiments was limited compared to the inclusion of every tested sample. Most effects were expected: samples tested at room temperature were brittle without statistical significance; increasing laser speed resulted in decreased ductility and strain, smaller grain …

Mechanical Properties And Tension-Tension Fatigue Behavior Of A Novel Additively Manufactured Polymer Matrix Composite At Room And Elevated Temperature, Grayson M. Harber

Theses and Dissertations

The tension-tension fatigue behavior of a novel additively manufactured AM carbon fiber reinforced polymer matrix composite was studied. This novel material system consists of T1100 carbon fibers, and a UV photocured resin developed by Continuous Composites and Sartomer. Tensile properties and tension-tension fatigue were investigated for the 090 fiber orientation as well as for the ±45 fiber orientation. Specimens with 0/90 fiber orientation were tested at ambient laboratory temperature 23 °C and at elevated temperature 150 °C, while the specimens with the ±45 fiber orientation were tested only at ambient laboratory temperature. Tension-tension fatigue testing was carried out with a …

Additively Manufactured Polymer And Metal Lattice Structures With Eulerian Path, Adeeb Ibne Alam

Electronic Theses and Dissertations

Lattice structure manufacturing with polymers and metals can benefit from the use of Eulerian paths. In this research, two types of lattice fabrication methods are studied where the Eulerian path can be applicable. Polymer lattice is improved by using a new assembly design, while a new way of metal lattice fabrication is discussed.

For the fused filament fabrication process, a new interlocking design and assemble-based lattice structure building approach is investigated by increasing continuity in layers and avoiding support structures. To minimize contour plurality, Eulerian paths between the edges were enforced. Two configurations in the form of cubic and octet …

Ferrous Alloy Manufacturing For The Martian Surface Through In-Situ Resource Utilization With Ionic Liquids Harvested Iron And Bosch Process Carbon, Blake C. Stewart

Theses and Dissertations

As research continues for the habitation of the Lunar and Martian surfaces, the need for materials for construction of structural parts, mechanical components, and tools remains as a major milestone. The use of in-situ resource utilization (ISRU) techniques is critical due to the financial, physical, and logistical burdens of sending supplies beyond low-Earth orbit. The Bosch process is currently in development as a life support system at the National Aeronautics and Space Administration’s (NASA) Marshall Space Flight Center (MSFC) to regenerate oxygen (O2) from metabolic carbon dioxide (CO2) with the byproduct of elemental carbon (C). The Bosch process presents a …

Flow And Thermal Transport In Additively Manufactured Metal Lattices Based On Novel Unit-Cell Topologies, Inderjot Kaur

Theses and Dissertations

The emergence of metal Additive Manufacturing (AM) over the last two decades has opened venues to mitigate the challenges associated with stochastic open-cell metal foams manufactured through the traditional foaming process. Regular lattices with user-defined unit cell topologies have been reported to exhibit better mechanical properties in comparison to metal foams which extend their applicability to multifunctional heat exchangers subjected to both thermal and mechanical loads. The current study aims at investigating the thermal-hydraulic characteristics of promising novel unit cell topologies realizable through AM technologies. Experimental investigation was conducted on four different topologies, viz (a) Octet, (b) Face-diagonal (FD) cube, …

Fundamental Understanding Of The Transient Melt Pool Dynamics, Solidification Kinetics And Build Texture In Spot-Melt Additive Manufacturing Of Ti-6al-4v, Rakesh Rajaram Kamath

Doctoral Dissertations

The overarching goal of this dissertation is to better understand the underlying process-structure relationships in play during the implementation of a spot melt strategy for metal additive manufacturing, which has become a popular alternative to the conventional raster melt strategy for site-specific microstructure control. In the first part of this dissertation, the effect of a spot melt strategy on the solidification texture, variant selection, phase fraction, and their variations along the build height of an E-PBF Ti-6Al-4V is investigated in comparison to a conventional linear melt strategy using high-energy synchrotron x-ray diffraction. In spite of the thermal excursions involved, the …

Characterization Of 3d Printed Parts Containing Integrated Functionality Via Ultrasonically Embedded Wires, David Abraham Sepulveda

Open Access Theses & Dissertations

Material extrusion additive manufacturing has been widely adopted because it offers freedom of design, which allows complex geometry fabrication, and rapid prototyping. Interest in producing components with integrated functionality allowed forms of hybrid manufacturing to be developed such as the Multi3D system. This system produces parts with embedded components by combining additive, subtractive, soldering, dispensing, and embedding techniques. However, this involves pausing the printing process (which takes place in a controlled environment) and exposing it to ambient temperature where embedding takes places. In this research, the effect of embedding parts with 24 AWG copper for improved functionality was quantified mechanically. …

Development Of A Custom, 3d-Printed, Multi-Microphone, Noise-Cancelling, Hearing Protection Device With A Magnetically Attached Printed Ear Canal For Sound Localization Preservation, Brenda Leticia Valadez Mesta

Open Access Theses & Dissertations

Hearing loss is a prominent health issue that affects a significant fraction of the global population. One of the main causes behind hearing loss is exposure to harmful noise levels in the workplace. There have been multiple efforts to prevent hearing loss from excessive noise in occupational settings, such as hearing conservation programs and use of hearing protection devices (HPDs), however, these are often ineffective. Although HPDs are frequently available in the workspace, they are not used as intended since they usually generate discomfort and hindered sound localization. The loss of sound localization can be hazardous in occupational settings, since …

Fabrication And Testing Of Catalyst-Infused Filament For 3d Printing Of Ignition-Augmented Hybrid Rocket Fuels, Kurt C. Olsen

All Graduate Theses and Dissertations, Spring 1920 to Summer 2023

This thesis describes and addresses the need for reliable ignition in small satellite hybrid propulsion systems using higher density oxidizers. It describes methods of creating custom 3D printing ABS plastic based filaments that contain small amounts of catalysts. These catalysts lead to a more reliable and energy-efficient ignition of a hybrid rocked propulsion system using catalyst-infused ABS and nitrous oxide and oxygen blend called Nytrox, commonly known as ”laughing gas.” The ”laughing gas” has a higher density and can therefore provide more ”miles per gallon” in a hybrid propulsion system on a small satellite when compared to gaseous oxygen (GOX). …

Additive Manufacturing Of Aluminum Alloy By Metal Fused Filament Fabrication (Mf3)., Luke J. Malone

Electronic Theses and Dissertations

This research studies metal-fused filament fabrication (MF3) for manufacturing aluminum alloy parts. An aluminum alloy powder-based feedstock with a polymer-binder system was extruded via capillary rheometry to form a filament. The filament was used to print green parts that were involved in a two-step debinding process combining solvent and thermal extraction of the polymer binder, then sintered in a partial vacuum. Resulting grain structure, sintered density, and mechanical properties will be characterized and compared to metal injection molded (MIM) specimens. The main objective is to gain an understanding of the MF3 process characteristics and the ensuing material properties and microstructure …

Experimental Characterization Of Additively Manufactured Multi-Feather Wingtip Devices, Patricio Garzon

Doctoral Dissertations and Master's Theses

Soaring birds have evolved to fly for long periods of time without flapping their wings. Inspired by the flight of these birds, the proposed thesis presents an experimental investigation focused on wingtip devices designed based on biomimicry. The overarching engineering objective was to reduce the induced drag as a means to improve the fuel efficiency via these experimental wingtips. An associated secondary objective was to establish a method for manufacturing complex structures suitable for wing tunnel testing. A manufacturing technique that involved using composite weaves to reinforce additively manufactured structures was developed. This technique has the potential to reduce manufacturing …

Additive Manufacturing Of Sub-Micron Features And Mechanical Linkages, David K. Limberg

Doctoral Dissertations

In recent years material constraints have become the limiting factor in several fields, including batteries, robotics, and medicine, and these needs have prompted the development of materials with programmable properties. To this end, much effort has been dedicated to designing metamaterials that have unprecedented optical, mechanical, and thermal properties, along with systems for additive manufacturing to build their complex structures with high precision and throughput. The field of additive manufacturing has proved to be a platform for innovation across many industries yet is still limited with regards to feature sizes, print rates, and diversity of materials. Mechanical devices like linkages …

Controlled Pre-Wetting Of Spread Powder And Its Effects On Part Formation And Printing Parameters In Binder Jetting Additive Manufacturing, Colton G. Inkley

Theses and Dissertations

Binder jetting is an additive manufacturing process that layer by layer builds a 3D model by selectively binding regions of powder using binder deposited though an inkjet printhead. The process offers several advantages over other additive manufacturing processes including fast build rates, vast material selection, decreased cost, and part resolution. The main disadvantage of binder jetting is poor mechanical properties, stemming from a poor understanding of the process physics. Porosity in final parts is not uncommon, but there is little understanding of where the porosity originates. The purpose of this thesis is to report the investigation of increased powder bed …

Performance Study Of Post-Processed Additively Manufactured Low Thrust Nozzles, Tyler W. Gerhold

Theses and Dissertations

This research explores metal post-processing techniques to effectively reduce the large anomalous protrusions found in small additively manufactured low thrust rocket nozzles. Research has found that nozzles of this kind can experience losses in thrust of over 40%. Analytic theory of adiabatic nozzle flow with viscous losses for additively manufactured nozzles does not align with what has been found when tested experimentally. Compressible flow losses, such as shock wave formation inside the nozzle diverging cone, are likely the leading causes of such loss. Reduction in nozzle irregularities can likely yield results seen in analytic theory with similar performance to traditional …

On The Effects Of Additive Manufacturing Process Parameters On The Performance Of Hastelloy-X: A Neutron Diffraction Experiment And Crystal Plasticity Finite Element Model, Ahmed Aburakhia

Electronic Thesis and Dissertation Repository

Additive manufacturing (AM) is increasingly becoming one of the favourable manufacturing techniques in various industries, such as transportation and energy. The reason for the extensive use of AM lies in the ability to use a wide range of process parameters for manufacturing engineering parts with complex geometries that cannot be effectively manufactured using traditional methods such as casting or forging. Understanding the role of process parameters is crucial for developing predictive models, as well as for manufacturing engineering components with the desired properties.

This research aims to characterize the influence of AM process parameters on the deformation mechanisms of Hastelloy-X, …

Multi-Material 3d-Printed Silicone Vocal Fold Models, Clayton Adam Young

Theses and Dissertations

Self-oscillating synthetic vocal fold (VF) models are often used to study human voice production. In this thesis, a method for fabricating multi-layer self-oscillating synthetic VF models using silicone 3D printing is presented. Multi-material 3D printing enables faster fabrication times with more complex geometries than traditional casting methods and builds a foundation for producing VF models with potentially more life-like geometries, materials, and vibratory characteristics. The printing method in this study used a custom dual extruder and slicing software to print UV-curable liquid silicone into a gel-like support matrix. The extruder was fabricated using high-torque stepper motors with high resolution leadscrews …

Particle Formation And Thermal Radiation In Laminar Diffusion Flames With Applications To Energy And Materials, Phillip Irace

McKelvey School of Engineering Theses & Dissertations

Fossil fuels supply over 80% of the world’s primary energy, and if current policy and technology trends continue, global energy and energy-related carbon dioxide (CO2) emissions are predicted to increase for at least several decades owing to population and economic growth, leading to serious concerns regarding global warming. Natural gas releases less CO2 than other fossil fuels (e.g., coal and oil) and can help meet future CO2 emission targets. Natural gas combustion, however, has poor radiation heat transfer when compared to other fossil fuels owing to its low propensity for soot formation, making it difficult to use as a drop-in …

Additive Manufacturing Of Variable Contrast Computed Tomography Anatomical Phantoms Using A Single Feedstock In Fused Filament Fabrication, Cory J. Darling

University of New Orleans Theses and Dissertations

Anatomical phantoms used in biomedical education and training benefit greatly from Fused filament fabrication’s (FFF) ability to rapidly produce complex and unique models. Current materials and methods used in FFF have limited ability to accurately produce phantoms that can mimic the radiological properties of multiple biological tissues. This research demonstrates that the CT contrast of FFF produced models can be modified by varying the concentration of bismuth oxide in acrylonitrile butadiene styrene (ABS) filaments and a tunable CT contrast that mimics the CT contrast ranging from fatty tissue to cortical bone using a single composite filament without introducing artificial image …

Single Asperity Fretting Corrosion Of Traditional And Additively Manufactured Metallic Biomaterials: Quantitative Analysis From Acetabular Tapers To Micron And Nanometer Scale Tribocorrosion, Annsley Mace

All Dissertations

Mechanically assisted crevice corrosion (MACC) of metallic biomaterials continues to be a significant degradation mode. This is, in part, due to a lack of understanding of fundamental micron- and sub-micron scale mechanisms of metal degradation in biological environments. Metal-metal (or metal-hard) load bearing surfaces of hip arthroplasties are subjected to fretting crevice corrosion (FCC, one form of MACC). Current work in tribocorrosion involves large contact area tests with multiple asperities, with a distribution of load and wear that changes over time. A more systematic and controlled study of the FCC micro- and nanomechanics is needed.

Therefore, the goal of this …

Effects Of Sizing Agents On Mechanical Properties Of Carbon Fiber–Polymer Composites Via Fused Filament Fabrication Additive Manufacturing., Benjamin D. Mitchell

Electronic Theses and Dissertations

This study demonstrated the effects of changing the sizing agent parameter during the preparation of carbon fibers on the mechanical properties of composite made with acrylonitrile butadiene styrene (ABS) as the matrix material and carbon fibers as the fiber material. Three types of sizing agents produced by Allnex were used to coat three different batches of carbon fibers that were mixed with a torque rheometer and extruded with a barrel-style melt extruder into continuous spools of 1.75 mm filament for use with commercial 3D printers. Tensile tests were conducted on the filaments and tensile bars printed from the materials. Results …