Lunar Manufacturing Systems And The Role Of Additive Recycling Technologies, Camille A. Newman

Honors Theses

Renewed international interest in sustained lunar exploration has created a growing demand for technologies to support long-duration space exploration. Part of the recent Artemis missions and the Moon to Mars initiative is to improve key mission capabilities and fill critical gaps necessary to sustain lunar habitation. Waste management, recycling systems, and manufacturing systems have been identified as critical technologies that need further development before a sustained mission is possible. This thesis explores the feasibility of an additive manufacturing and recycling system designed to process plastic waste generated during extended lunar habitation. Initial research focused on existing manufacturing and recycling technologies …

Mechanical Behavior Of Additively Manufactured Ti-6al-4v Eli Parts: Effects Of Laser Parameter Selection, Samuel Lopez

UNF Graduate Theses and Dissertations

Additive manufacturing (AM) of TI-6AL‑4V Extra‑Low Interstitial (ELI) enables complex geometries for fatigue‑critical medical device applications, yet fatigue performance remains sensitive to process‑induced defects. This work investigates the effect of laser process parameter selection on the microstructure, mechanical properties, and fatigue behavior of TI- 6AL‑4V ELI fabricated via laser powder bed fusion (L‑PBF) using a Renishaw RenAM system. The influence of laser parameters was isolated by holding powder chemistry, build orientation, scan strategy, sub‑transus annealing, and post‑processing constant between a non‑optimized baseline and an optimized parameter set selected based on tensile performance.

Optical microscopy showed the optimized condition exhibited improved …

Field-Assisted Post-Processing Of Cold-Sprayed Pure Copper, Alan Hensley

Theses and Dissertations--Mechanical and Aerospace Engineering

The properties of materials processed through cold spray, and many other AM processes, are non-uniform and unpredictable. In most cases, post-processing is required to achieve desired properties and better uniformity. In cold spray, the typical method is an annealing heat treatment (AHT), which can improve bond strength, reduce porosity, and restore ductility, among other effects. AHT alone, however, is unable to completely remedy any of the unfavorable properties. In addition, long treatments at high temperatures are often needed for satisfactory results. This increases energy consumption and extends production times for products made by the process. For these reasons, numerous investigations …

Fused Filament Fabrication Additive Manufacturing Of 17-4 Ph Stainless Steel: Process–Structure–Property Relationships In Magnetic Materials, Maanav Patel

Theses and Dissertations

Additive manufacturing (AM) enables the fabrication of complex metallic components through layer-by-layer processing directly from digital models. Among AM techniques, material extrusion–based processes such as fused filament fabrication (FFF) provide an accessible method for producing metal parts using filament feedstocks composed of metal powders and polymer binders. When applied to precipitation-hardening stainless steels such as 17-4 PH, the processing route and heat treatments can influence the resulting microstructure and functional properties. This work investigates the magnetic behavior of 17-4 PH stainless steel fabricated using FFF and evaluates how heat treatment conditions influence measured magnetic properties. Samples were produced and analyzed …

Experimental And Numerical Study On The Influence Of Carbon Fiber Reinforcement On The In-Plane Compressive Properties Of 3d Printed Hexagonal Honeycomb Core Structures, Deon Wallace

All Theses

There is difficulty with numerically replicating the behavior of composite honeycomb core structures numerically due to the trouble of gathering material properties from a hollow structure. Also, complex part geometries and carbon fiber reinforcement strategies can lead to unwanted structural weaknesses and variance in material properties that may not be reflected in numerical analysis when the part is additively manufactured. In this study, edgewise compressive testing is used to characterize the mechanical behavior and performance characteristics of these structures. The experimental results indicate an increase in the Young’s moduli of the honeycomb core structures as carbon fiber concentration increases. However, …

Anisotropic Residual Stress Measurements In Additively Manufactured 316 Stainless Steel Parts, Rajeshree Varma, Donovan Stumpf, Paul R. Mort

15th International Conference on Shot Peening

Additive manufacturing (AM) using laser powder bed fusion (L-PBF) is increasingly used to produce complex parts for industries like aerospace and medical devices. The intrinsic characteristics of AM – layer-wise deposition and rapid thermal cycling – generate significant, anisotropic, residual stresses that can compromise part quality and performance. Recent studies highlight how these stresses are strongly influenced by process parameters and build orientation. X-ray diffraction (XRD) techniques, including sin²ψ and advanced two-dimensional approaches, have become the preferred methods for non-destructive, directionally resolved measurement of residual stress in AM metals. This review surveys advancements in XRD residual stress methods with a …

In-Situ Defect Detection In Selective Laser Melting Using Convolutional Neural Networks, Ethan Gaigalas

Master's Theses

This thesis develops and trains a convolutional neural network (CNN) to classify defects in metal parts produced by selective laser melting (SLM) using acoustic emission (AE) data. The model successfully identified porosity and standard build layers with high accuracy but consistently struggled to classify lack of fusion (LOF) defects, regardless of input type, normalization, or class count. These results suggest that while AE signals contain distinguishable features for certain defect types, LOF signals may be too subtle or inconsistent for reliable detection. The study addresses the ongoing challenge of in-situ quality monitoring in metal additive manufacturing, where defects like cracks, …

Exploring Metal Additive Manufacturing In Martian Atmospheric Environments, Zane Mebruer

Mechanical Engineering Undergraduate Honors Theses

On-surface manufacturing is key to the success of a planetary colonization, especially that of Mars. However, traditional subtractive manufacturing processes are equipment, energy, and material intensive, meaning novel additive manufacturing (AM) processes must be pursued for this end. Selective laser melting, one of the most effective and versatile AM methods, would be incredibly beneficial to a Martian mission but requires an artificial argon atmosphere to create effective parts. The purpose of this study was to examine if carbon dioxide, the gas that makes up over 95% of Mars’ surface atmosphere, would be a sufficient substitute for argon in SLM fabrication. …

Autonomous Defect Detection In Additive Manufacturing, John Samuel Poindexter Iv

Theses and Dissertations

Additive manufacturing (AM) is the process of creating a product by applying layers of material to build up to the final product. AM has revolutionized the field of manufacturing and has allowed more complex products to be manufactured at reasonable cost, quicker manufacturing time, and optimized material usage. Traditional forms of manufacturing were based on subtractive manufacturing, where by a product would be created by removing material from its source. AM is a new manufacturing process and faces significant challenges when it comes to manufacturing due to defects. Defects can vary from type and severity and can overall weaken or …

Deployable Origami Structure, David J. Garcia, Robert Bettinger

AFIT Patents

The present invention relates to deployable origami structures and methods of making and using same. Such deployable origami structures can be folded into a compact state utilizing origami, yet easily deployed as the structures comprise pseudo-elastic connectors. Additive manufacturing techniques can be used to make such deployable origami structures as such techniques can lower cost and structure weight.

A Computational Fluid Dynamics Approach To Analyze The Virtual Impactor In Pneumatic Aerosol Jet Printing, Akashita Sareen

Theses, Dissertations and Capstones

Aerosol jet printing (AJP) is a 3D printing, advanced manufacturing process that generates an aerosol mist appropriate for fine printing small, low-volume electronic parts. The pneumatic aerosol jet printing technology’s virtual impactor is the focus of this study. In this technology, high velocity nitrogen gas aerosolizes various inks in the atomizer. The aerosolized stream of ink is then transported to a virtual impactor (VI) to become dense and concentrated as it begins to enter the deposition head for high precision electronics printing. AJP faces challenges in large-scale adoption due to challenges related to overspray, instability, ink clogging etc. There is …

Improving The Reliability Of Parts Produced Via Laser Powder Bed Fusion Through A Data-Driven Geometry Optimization Methodology, Federico Venturi

Mechanical and Aerospace Engineering Dissertations - Archive

This research aims to qualify the effect of design geometry on quality metrics of additively manufactured (AM) components that define reliability. Through the use of a novel methodology to characterize these quality metrics, AM components are inspected for the presence of defects such as surface roughness notches and porosity. These directly hinder the high-cycle fatigue characteristics demonstrated through the Kitagawa-Takahashi diagram and the El-Haddad model. By demonstrating the effect of geometry through a designed experiment and the adoption of the Murakami square root area parameter and Arola-Ramulu model, the improvement to fatigue life can be quantified. Incorporating this data into …

Experimental And Numerical Modelling-Based Optimization Of Additive Manufacturing Processes, Vishnu V. Ganesan

Mechanical and Aerospace Engineering Dissertations - Archive

ABSTRACT

Experimental and Numerical Modeling-Based Optimization of Additive Manufacturing Processes

Vishnu V Ganesan, Ph.D.

The University of Texas at Arlington, 2025

Supervising Professor: Dr. Ankur Jain

Experimental and numerical modeling play a pivotal role in advancing additive manufacturing technologies by enabling a deeper understanding of complex, multi-physics processes that govern part quality, performance, and reliability. These manufacturing techniques—ranging from Powder Bed Fusion (PBF) and Material Extrusion (MEX) to Automated Fiber Placement (AFP)—involve tightly coupled thermal, mechanical, and material phenomena that are challenging to capture through empirical observation alone. Experimental methods offer critical validation and insights into real-world behavior, while numerical …

Transient Thermal Finite Element Simulation For Process Modeling In Wire Arc Additive Manufacturing, Satya Sai Kumar Pilli

Dissertations, Master's Theses and Master's Reports

This thesis presents the development of a transient thermal framework for Wire Arc Additive Manufacturing (WAAM) created using ANSYS Workbench. This study aims to understand the inherent properties and thermal behavior of WAAM by using the Finite Element (FE) simulation technique to reduce the need for experiments. Specifically, the transient thermal WAAM simulation framework uses the heat source Goldak model to understand the thermal behavior for a given voltage, initial temperature, and travel speed during the process to predict process temperature. The outcomes of this thesis aim to significantly decrease material waste and repetitive experiments and accelerate production process design …

Effect Of Build Orientation On Tensile Properties And Fractography Of Additive Manufactured Inconel 718 Alloy, Ajay Kumar Maurya, Amit Kumar, Swarnambuj Suman

ASEAN Journal on Science and Technology for Development

The additive manufacturing (AM) technique “Direct Metal Laser Sintering (DMLS)” is used to create 3D objects directly from 3D design data. A lightweight and complexity-free part without any expensive tooling can be fabricated easily using this method, but it is still challenging to achieve the desired mechanical strength from AM parts, as the mechanical properties of AM-produced parts vary with orientation, scan strategy, and process parameters. Inconel 718 alloy is most commonly utilized in the aerospace and automotive industries, because of its high resistance to corrosion and excellent mechanical qualities. This work presents a study to investigate the orientation-based mechanical …

Affordable And Sustainable: Innovating Filament Extrusion For Recycled Materials, Turab S. Rizvi

UROP Posters

The chemical stability, toxicity and non-biodegradability of the polymers pose a significant environmental threat. Addressing end-of-life treatment sustainability is crucial for mitigating these issues. The customized Lyman filament extruder in the Advanced Magnetic Materials Processing Laboratory represents an innovative approach to advancing sustainability in renewable energy production and CO₂ mitigation. Redesigning the thermal system and screw operation will tackle key challenges, including precise temperature control, consistent material flow to handle diverse recycled materials. Integrating an advanced thermal regulation system will reduce the energy consumption by maintaining optimal thermal conditions, thereby lowering the CO₂ footprint of the recycling process. The optimized …

Using Additive Manufacturing To Characterize Effects Of Sparse Infill Density And Sparse Infill Pattern On The Compressive Properties Of Short Strand Carbon Fiber Infused Petg, Luke C. Salisbury

Honors Theses

The advent of additive manufacturing has revolutionized the prototyping, design, and manufacturing of new and innovative products. Through the use of Fused Deposition Modeling (FDM), parts can be manufactured using different sparse infill percentages (the percentage of void space within a printed object) and sparse infill patterns (the lattice structure of material within the object). Through the manipulation of these variables, the same material and part can have different compressive and flexural properties. In addition to sparse infill, the thermoplastics used in fused deposition modeling can be reinforced with carbon fiber strands to create a printable composite material capable of …

Development Of A Manifold Microchannel Heat Sink For The Electrification Of Aircraft, Joshua Mora Sanchez

Mechanical Engineering Undergraduate Honors Theses

The miniaturization of microprocessors and power electronics is leading to critical thermal management challenges. For instance, the heat flux generated in modern computer chips is at the order of 100W/cm², which is well beyond the limit of air cooling. This high heat generation can cause a variety of thermal or mechanical failures in electronic devices. As such, there is a pressing need to devise effective cooling strategies for these microelectronic devices. Liquid cooling with microchannel heat sinks is a promising technology for high power loads. Nevertheless, traditional heat sinks with straight microchannels suffer from two critical challenges: high pressure drop …

Focused Led Sintering, Dylan Defazio, Nilav Maulik, Branden Majors, Michael Fontillas

Mechanical Engineering

This report provides a detailed overview of the final design of our light-emitting diode (LED) focusing system. Our system incorporates a converging lens and a specially designed "glass funnel," which acts as a thick fiber optic that narrows the light to a fine point through internal reflection. The glass components of our system are precisely housed in a part made using advanced computer-numeric controlled (CNC) Mill and CNC Lathe manufacturing processes. This ensures high precision and durability of the overall system. Our LED focusing system is designed with a 60-watt stage light. The decision to use a glass funnel as …

Feasibility And Characterization Of Leak-Tight Single-Track Thin Walls Produced By Laser Powder Bed Fusion In 316l Stainless Steel, Peyton J. Archibald

Master's Theses

This thesis explores the optimization of process parameters for producing single-track thin walls using Laser Powder Bed Fusion (LPBF) additive manufacturing. Using two different coupon designs, the study assesses the feasibility of creating the thinnest possible leak-tight structures within LPBF and evaluating their mechanical properties, including burst pressure and modulus of elasticity under pressure loads. A series of experimental iterations were conducted, varying laser power and laser speed to identify optimal conditions. The findings indicate that a narrow range of process parameters can produce consistently leak-tight thin walls. The results contribute to understanding how to achieve high quality, reliable thin …

Materials Testing For Large Format 3d Printing, William Jenkins

Williams Honors College, Honors Research Projects

An ABS Carbon Fiber blend was printed into single walled hexagons at a variety of settings on a Cincinnati BAAM large format 3D printer. These hexagons were then cut down into sheets and had tensile and flexural test samples cut out of them, in order for materials testing to be performed. Tensile strength, tensile strain, young’s modulus, flexural strength, deflection and elastic modulus were all determined. A desktop CNC machine and a planer were purchased for the manufacturing of these samples, and an efficient cutting procedure was designed and optimized. After all data collection concluded, this data was thoroughly analyzed, …

Short Strand Carbon Fiber Reinforced Polylactic Acid Filament For Additive Manufacturing, Dale Chenoweth, Lukas Seggi, Luke Phillips

Williams Honors College, Honors Research Projects

In this design project, the additive manufacturing filament of short strand carbon fiber (SSCF) reinforced polylactic acid (PLA) composite was developed. The micro-size, precision cut SSCFs were mixed with the PLA pellets through a melting homogenization process. Through this process the composite material block is cut and divided into pieces for ease of pelletizing. The material block pieces are then pelletized to be fed through the single screw extruder to develop the SSCF-PLA composite filament. The SSCF-PLA filaments were manufactured with a varying amount of SSCF ranging from 0.5% to 10% of the material block's weight. Development of a 1% …

3d Printed Drone (Body And Controls), Michael Dick, Hayden Pinkelman, Tanner Henderson, Logan Prince

Williams Honors College, Honors Research Projects

The objective is to build a scaled down model of a 3D printed drone capable of carrying a payload scalable to 50 lbs. for a wide array of applications. Some applications of the drone could include delivering support materials during natural disasters, such as foam to put out fire or medical aid packs to provide aid to injured people, food or package delivery, or military applications. The project has been split up into two groups. One group will be focusing on the propulsion aspect of the project, such as the electric motors and airfoil. Simultaneously, this group will design the …

Assessment Of Surface Waviness In A Wire Arc Additive Manufacturing Process, Shammas Mahmood Shafi

Dissertations, Master's Theses and Master's Reports

Wire Arc Additive Manufacturing (WAAM) is increasingly recognized for its ability to produce metal components with high deposition rates and efficiency, particularly in the aerospace and automotive sectors. However, one significant challenge that WAAM faces is achieving surface quality that complies with industry standards, as well as creating geometries that closely resemble the initial design. A crucial factor contributing to this challenge is surface waviness, which is an inherent characteristic of the WAAM process. This waviness arises from the geometry of the weld beads and the overlap distance between them. It can adversely affect the fusion quality of successive layers, …

Resonant Ultrasound Spectroscopy(Rus) For Material Characterization Of Metal Am Parts, Malik Marks

College of Graduate Studies: Theses & Dissertations

Additive manufacturing (AM) has revolutionized the manufacturing industry by offering flexibility, customization, and rapid prototyping capabilities. However, ensuring the quality and reliability of AM parts remains a significant challenge due to variations in material properties and process parameters. The NDE method used in this study is Resonant Ultrasound Spectroscopy (RUS). This method was used to evaluate and understand its ability to detect internal voids and defects. Dog-bone samples were made using the 316L stainless steel alloy which were fabricated by powder bed fusion (PBF) AM technique at different processing conditions and post processing conditions. These samples were tested to find …

Development And Characterization Of Vegetable Oil Based, Acrylated Resins For Stereolithography 3d Printing, Julius A. Adeyera

College of Graduate Studies: Theses & Dissertations

The increase in the demand for additively manufactured parts and the drive towards a sustainable economy with less environmental pollution has necessitated the need for renewable materials for use in 3D printing. This study shows the development and characterization of vegetable oil based, acrylated resins for 3D printing. Bio-based 3D resins were formulated using bio-based oils with a minimum of 70% bio-based content and were ready to be polymerized using the stereolithography (SLA) 3D printing process. Two distinct vegetable oils were used to develop biobased photopolymers. Biobased acrylated epoxidized photopolymers were successfully developed that have good mechanical and chemical properties. …

Laser Assisted Direct Writing Of Liquid Metal For Microprinting Applications, Olga Vargas Cruz

Theses and Dissertations

This paper presents a research study for potential printing of a Liquid Metal (LM) Eutectic Gallium Indium alloy (EGaIn) through the applications of the innovative additive manufacturing technology LIFT (Laser Induced Forward Transfer). LIFT is a precise printing technology that allows to create small, detailed printing. The liquid metal in study, EGaIn, has demonstrated great potential for microelectronics applications due to its minimum toxicity and high conductivity. Throughout this research different printing parameters are studied to comprehend the behavior of EGaIn printing with LIFT technique, these include laser energy, laser pulse, receiver material substrate, donor layer thickness, and …

An Investigation Into The Challenges Of Contemporary Additive Manufacturing: Insights Into The Metallurgical Response Of Materials And Relevant Solution, Huan Ding

LSU Doctoral Dissertations

Additive Manufacturing (AM) has gained attention in recent years due to its unique capabilities in the fabrication of complex parts. As with any new research, there is still a lack of sufficient understanding in the field of additive manufacturing, and further investigation is needed to solve existing problems. Ultimately, the aim is to enable the widespread use of AM components across various industries.

Chapter One provides a brief introduction to the background and current bottlenecks of additive manufacturing technology. Chapter two focuses on the development of high-strength 7075 aluminum alloy (Al7075) for Fused Deposition Modeling and Sintering (FDMS) technology. Al7075 …

Additive Manufacturing For Medical Education, Michael Noon

College of Engineering Summer Undergraduate Research Program

A growing body of evidence is suggesting that anatomical knowledge, the keystone of many medical specialties, is suffering among new graduates. While a host of reasons are provided, one common thread that many point to is the decline of cadaver dissections in the classroom. Many virtual audio-visual tools are used to address this gap, yet evidence has shown their ineffectiveness. Given this gap, the high degree of flexibility found in additive manufacturing (AM), and the many uses AM has already found in the medical field, we propose its use to fill this gap, allowing for students to learn with touch …

Optimizing Mn-Al Permanent Magnet Performance Through Control Of The Phase Transformation, Ternary Element Addition, And Advanced Processing, Thomas R. Keller

Dartmouth College Ph.D Dissertations

The growing need for electrical power in machines and vehicles brings with it a growing need for critical materials. The current high-performance permanent magnets (PMs) based on rare-earth (RE) elements Nd and Sm cannot escape the problem of raw material cost, geographic scarcity in the earth’s crust, and lack of circular global supply chains. This poses a problem of industrial ecology: can PMs be made from inexpensive, more abundant materials while still meeting sufficient performance criteria? PMs based on the magnetic τ phase of Mn-Al offer a possible alternative to REPMs. However, years of innovation have not yet achieved real-world …