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

2. 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.

3. 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

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

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

6. 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

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

8. 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

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

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

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

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

13. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Sample Parts

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

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

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

17. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

18. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

19. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

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

21. 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

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

23. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

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

25. 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)

26. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

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

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

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

30. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Imbedding Reinforcement

31. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

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

33. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Conventional Structures

34. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Adobe structures

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

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

37. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA IT issues

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

39. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA Deployable CC

40. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA

41. FAB 4 - August 2007 UNIVERSITY OF SOUTHERN CALIFORNIA NASA Trials

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

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

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

45. 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.