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Page Preface ------------------------------------------------------------------------------------------------- vii Organizing/Advisory Committee -------------------------------------------------------------------- ix

Process Development Microscale Freeform Integration by Directed Self Assembly

Nathan Crane, Mike Nellis, George Nolas, Julie Harmon, University of South Florida----------------------------------------------------------------------------------------1

Control Methods for the Electron Beam Free Form Fabrication Process W. J. Seufzer, K. M. Taminger, NASA Langley Research Center -------------------------- 13

Variable Powder Flow Rate Control in Laser Metal Deposition Processes Lie Tang, Jianzhong Ruan, Robert G. Landers, Frank Liou, University of Missouri-Rolla ------------------------------------------------------------------------------------ 22

Thermocouple Embedding for the Production of a Substrate for Rapid Manufacturing Rana Gunaratnam, Todd E. Sparks, Frank Liou, University of Missouri-Rolla ----------------------------------------------------------------------------------------------- 49

Design of Embedded Resistance Heating Element Using Rapid Manufacturing Process Ravi Philip, Todd E. Sparks, Frank Liou, University of Missouri-Rolla------------------- 55

Freeform Fabrication of Organic Electrochemical Transistors Robin Havener, John Boyea, Evan Malone, Daniel Bernards, John DeFranco, George Malliaras, Hod Lipson, Cornell University ---------------------------- 60

Laser Deposition Cladding On-Line Inspection Using 3-D Scanner Yu Yang, Todd Sparks, Jianzhong Ruan, Lan Ren, Frank Liou, University of Missouri-Rolla--------------------------------------------------------------------------------- 74

Layer Formations in Electron Beam Sintering M. Kahnert, S. Lutzmann, M. F. Zaeh, Technische Universitaet Muenchen--------------- 88

Thermal Modeling and Experimental Validation in the LENS™ Process Liang Wanga, Sergio D. Felicellia, James E. Craigb, aMississippi State University, bStratonics, Inc. --------------------------------------------------------------------100

Implementing Rapid Prototyping Using CNC Machining (CNC-RP) Through a CAD/CAM Interface Matthew C. Frank, Iowa State University ----------------------------------------------------112

Aqueous-Based Extrusion Fabrication of Ceramics on Demand Michael S. Masona, Tieshu Huanga, Robert G. Landersa, Ming C. Leua, Gregory E. Hilmasa, Michael W. Hayesb,aUniversity of Missouri-Rolla, bBoeing Company -------------------------------------------------------------------------------124

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Experimental Investigation of Effect of Environment Temperature on Freeze-form Extrusion Fabrication Xiyue Zhaoa, Michael S. Masona, Tieshu Huanga, Ming C. Leua, Robert G. Landersa, Gregory E. Hilmasa, Samuel J. Easleyb, Michael W. Hayesb, aUniversity of Missouri-Rolla, bBoeing Company-------------------------------------------135

Image Transformations and Printing of Plaster Layers in Spiral Growth Manufacturing C. Hausera, D. M. Lewisa, M. Dunschenb, M. Egana, C. Sutcliffea, aUniversity of Leeds, bFreeSteel ---------------------------------------------------------------147

Process Planning to Build Mask Projection Stereolithography Parts with Accurate Vertical Dimensions Ameya Limaye, David Rosen, Georgia Institute of Technology----------------------------159

Non-Uniform Offsetting and its Applications in Laser Path Planning of Sterolithography Machine Yong Chen, University of Southern California-----------------------------------------------174

Form Accuracy Analysis of Cylindrical Parts Produced by Rapid Prototyping G. R. N. Tagore, Swapnil D. Anjikar, A. Venu Gopal, National Institute of Technology-Warangal --------------------------------------------------------------------------187

Methods of Parallel Voxel Manipulation for 3D Digital Printing Jonathan Hiller, Hod Lipson, Cornell University -------------------------------------------200

Modeling Modeling and Simulation of a Laser Deposition Process

Frank Lioua, Zhiqiang Fana, Heng Pana, Kevin Slatteryb, Mary Kinsellac, Joseph Newkirka, Hsin-Nan Choub, aUniversity of Missouri-Rolla, bBoeing Company, cAFRL/MLLMP --------------------------------------------------------------------212

Process Chain for Numerical Simulation of IMLS G. Branner, G. Strasser, M.F. Zaeh, Technische Universitaet Muenchen----------------224

Modeling and Validation of Temperature and Concentration for Rapid Freeze Prototyping Frances D. Bryant, Ming C. Leu, University of Missouri-Rolla ---------------------------234

Multi Objective Optimisation of Build Orientation for Rapid Prototyping with Fused Deposition Modeling (FDM) G. R. N. Tagore, Swapnil D. Anjikar, A. Venu Gopal, National Institute of Technology-Warangal --------------------------------------------------------------------------246

Numerical Simulation of the Evolution of Solidification Microstructure in Laser Deposition Zhiqiang Fan, Todd E. Sparks, Frank Liou, Anand Jambunathan, Yaxin Bao, Jianzhong Ruan, Joseph W. Newkirk, University of Missouri-Rolla ----------------256

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Materials: Non-Polymers Interface Microstructures and Bond Formation in Ultrasonic

Consolidation G. D. Janaki Rama, Y. Yanga, C. Nylanderb, B. Aydelotteb, B. E. Stuckera, B. L. Adamsb, aUtah State University, bBrigham Young University -----------------------266

Shape Training of Nitinol Wire Using Three-Dimensional (3DP) Fixtures B. Utelaa, R. Andersona, H. Kuhnb, M. Gantera, aUniversity of Washington, bEx One Company-ProMetal -------------------------------------------------------------------284

DMLS and Manufacturing Olli Nyrhilä, Juha Kotila, Maria Latikka, Jouni Hänninen, Tatu Syvänen, EOS Finland--------------------------------------------------------------------------------------292

Effect of Processing Parameters on the Density and Microstructure of Direct Laser Sintered Al-12Si Powders E. O. Olakanmia, R. F. Cochranea, K. W. Dalgarnob,aUniversity of Leeds, bNewcastle University---------------------------------------------------------------------------299

Advances in Electron Beam Melting of Aluminum Alloys T. Mahela, D. Cormier, O. Harrysson, K. Ervin, North Carolina State University ----------------------------------------------------------------------------------------312

Materials: Polymers Intumescent Flame Retardant Polyamide 11 Nanocomposites

S. Laoa, J. H. Kooa, A. Morganb, W. Yonga, C. Towera, H. Jora, T. Moona, G. Wisslerc, L. Pilatoc, Z. P. Luod, aUniversity of Texas-Austin, University of Dayton Research Institute, KAI, LLC, dTexas A&M University -----------------------324

Design of Experiments Approach for Statistical Classification of Stereolithography Manufacturing Build Parameters: Effects of Build Orientation on Mechanical Properties for ASTM D-638 Type I Tensile Test Specimens of DSM Somos® 11120 Resin Rolando Quintanaa, Karina Pueblab, Ryan Wickerb, aUniversity of Texas-San Antonio, bUniversity of Texas-El Paso --------------------------------------------------340

Selective Laser Sintering of Polymer Nanocomposites M. S. Wahaba, K. W. Dalgarnob, R. F. Cochranea, aUniversity of Leeds, bNewcastle University---------------------------------------------------------------------------358

Development of Nanocomposite Powders for the SLS Process to Enhance Mechanical Properties Hyo Chan Kima, Tsuyoshi Saotomea, H. Thomas Hahna, Young Gil Bangb, Sung Woo Baec, Dong Soo Kimc, aUniversity of California-Los Angeles, bLion Chemtech, Co. Ltd., cKorea Institutes of Machinery & Materials ------------------367

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Effect of Surface Preparation Methods on Mechanical Properties of 3D Structures Fabricated by Stereolithography and 3D Printing for Electroless Ni Plating Shine Joseph, Stella Quiñones, Frank Medina, Ryan Wicker, University of Texas-El Paso ------------------------------------------------------------------------------------377

Comparison of Material Properties and Microstructure of Specimens Built Using the 3D Systems Vanguard HS and Vanguard HiQ+HS SLS Systems T. J. Silverman, A. Hall, B. South, W. Yong, J. H. Koo, University of Texas-Austin -------------------------------------------------------------------------------------392

Design Design for Additive Manufacturing: A Method to Explore Unexplored

Regions of the Design Space David W. Rosen, Georgia Institute of Technology-------------------------------------------402

Multiscale Design for Solid Freeform Fabrication Carolyn Conner Seepersad, David Shahan, Kaarthic Madhavan, University of Texas-Austin---------------------------------------------------------------------416

LENS® and SFF: Enabling Technologies for Optimized Structures D. D. Gilla, C. J. Atwooda, T. E. Votha, J. Robbinsa, P. Dewhurstb, D. G. Taggartb, aSandia National Labs-NM, bUniversity of Rhode Island-Kingston ------------------------------------------------------------------------------------------428

Automated Design of Tissue Engineering Scaffolds by Advanced CAD E. Ramin, R. A. Harris, Loughborough University ------------------------------------------435

Freeform Fabrication of Biological Scaffolds by Projection Photopolymerization Li-Hsin Han, Gazill Mapili, Shaochen Chen, Krishnendu Roy, University of Texas-Austin----------------------------------------------------------------------------------450

Multi-Material Stereolithography: Spatially-Controlled Bioactive Poly(Ethylene Glycol) Scaffolds for Tissue Engineering Karina Arcautea, Nubia Zuverzaa, Brenda Mannb, Ryan Wickera, aUniversity of Texas-Austin, bUniversity of Utah -------------------------------------------458

Analysis of the Effects of 3DP Parameters on Part Feature Dimensional Accuracy Tamas D. Szucs, Dermot Brabazon, Dublin City University -------------------------------470

The Use of Layered Freeform Fabrication Technologies to Produce Tissue Engineering Scaffolds for Skull Patches Molly Purser, Omer Cansizoglu, Carla Haslauer, Ola L. A. Harrysson, Elizabeth Loboa, North Carolina State University-------------------------------------------482

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Applications Laser Sintering Fabrication of Highly Porous Models Utilizing Water

Leachable Filler-Experimental Investigation into Process Parameters Toshiki Niino, Shunsuke Oizumi, Hiroyuki Otsuki, University of Tokyo -----------------494

Printing Embedded Circuits Daniel Periard, Evan Malone, Hod Lipson, Cornell University ---------------------------503

Freeform Fabrication of a Complete Electrochemical Relay Evan Malone, Hod Lipson, Cornell University ----------------------------------------------513

Deposition of Ti/TiC Composite Coatings on Implant Structures Using Laser Engineered Net Shaping G. D. Janaki Ram, Y. Yang, B. E. Stucker, Utah State University--------------------------527

Accuracy and Mechanical Properties of Open-Cell Microstructures Fabricated by Selective Laser Sintering S. Eosolya, G. Ryderb, T. Tanseyb, L. Looneya, aDublin City University, bInstitute of Technology Tallaght--------------------------------------------------------------540

Layered Fabrication of Branched Networks Using Lindenmayer Systems O. Yasar, M. Martin, C. Harris, S. Sun, B. Starly, University of Oklahoma -------------552

Printing Food Dan Periarda, Noy Schaalb, Maor Schaalb, Evan Malonea, Hod Lipsona, aCornell University, bManual High School, Louisville, KY --------------------------------564

Integrated Layered Manufacturing of a Novel Wireless Motion Sensor System with GPS Misael Navarretea, Amit Lopesa, Jacqueline Acunaa, Raul Estradaa, Eric MacDonalda, Jeremy Palmerb, Ryan Wickera, aUniversity of Texas-El Paso, bSandia National Labs-NM--------------------------------------------------------------575

Manufacturing Metallic Parts with Designed Mesostructure via Three-Dimensional Printing of Metal Oxide Powder Christopher B. Williams, David W. Rosen, Georgia Institute of Technology---------------------------------------------------------------------------------------586

Topology Design and Freeform Fabrication of Deployable Structures with Lattice Skins Uma Maheshwaraa, Carolyn Conner Seepersad, David Bourell, University of Texas-Austin---------------------------------------------------------------------597

Author/Attendee List --------------------------------------------------------------------------------609