FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA SFF Processes B. Khoshnevis.

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Presentation transcript:

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA SFF Processes B. Khoshnevis

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Application Areas  Small batch actual production of parts or assemblies  Prototyping of products to test functionality, fit for assembly, marketability, and other factors  Mold, die, and other tool making for other manufacturing processes such as casting, extrusion, etc.  Solid imaging of 3D data in domains such as mathematics, chemistry, medicine, etc.  Sculpturing and other forms of art work.

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Advantages  Possibility of unattended operation  Significant reduction in product design cycle  Ability to produce parts with unlimited geometrical complexity  Radically new possibility of designing the internal structure of parts  Possibility of wasteless and environmentally sound fabrication

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Commercialized RP Technologies

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Selective Inhibition Sintering (SIS)

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA The working of sintering inhibitor Sintered powder Sintered powder Particles treated with sintering inhibitor Break- away surface

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Preliminary experiment Built in one afternoon with an electric heater filament and a light dimmer.

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Preliminary Results Sintered layerHoles due to inhibitor Printed inhibitorSeparated sections Single-layer experiments with polystyrene powder Inhibitors: - Cooking oil - Water+alcohol

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA The Alpha Machine Drive electronics Use of a halogen lamp heater

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Sintering by Nichrome Pivoting Heater

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA The Alpha Machine Desk top size

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Driver software Interface

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Sample Parts

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA 2.5 D Parts

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA 3D parts

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Moldless Powder Metallurgy (MPM)

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA The MPM-Metal machine

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Elementary parts Simple copper part made with ceramic inhibitor Copper Part with complex geometry and sharp edges

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Scaling up From Fabrication to Construction

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA CC Contour Crafting

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Flow analysis for nozzle design Comparison of flow patterns with simulation result and actual process. Side views with a square orifice (top pictures), and side views with an elliptical orifice (bottom pictures)

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA 3D ceramic parts

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Ceramic and Plastic parts

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Application in building construction Cavities made with CC and filled with concrete.

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Imbedding Reinforcement

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Co-extrusion of outer and filler materials A 6DOF Nozzle Assembly

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Conventional Structures

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Adobe structures

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Multiple mobile robotics approach

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA CC – The Sass Method

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA IT issues

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Lunar construction – From Earth to Moon

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Deployable CC

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA NASA Trials

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Nozzle for corrugated internal structure

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Nozzle for corrugated internal structure

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Adjustable width nozzle

FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Imbedding sensors and IT components Conductive concrete may be used to power densely imbedded sensors and actuators.