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UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
SFF Processes
B. Khoshnevis
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
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.
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
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
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Commercialized RP Technologies
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Selective Inhibition Sintering (SIS)
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
The working of sintering inhibitor
Sintered powder
Sintered powder
Particles treated with sintering inhibitor
Break-away surface
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Preliminary experiment
Built in one afternoon with an electric heater filament and a light dimmer.
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Preliminary Results
Sintered layer Holes due to inhibitor
Printed inhibitor Separated sections
Single-layer experiments with polystyrene powder
Inhibitors:
- Cooking oil
- Water+alcohol
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
The Alpha Machine
Drive electronicsUse of a halogen lamp heater
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Sintering by Nichrome Pivoting Heater
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
The Alpha Machine
Desk top size
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Driver software
Interface
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Sample Parts
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
2.5 D Parts
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
3D parts
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Moldless Powder Metallurgy (MPM)
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
FAB 4 - August 2007
The MPM-Metal machine
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Elementary parts
Simple copper part made with ceramic inhibitor
Copper Part with complex geometry and sharp edges
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Scaling up
From Fabrication to Construction
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
CCContour Crafting
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
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)
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
3D ceramic parts
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Ceramic and Plastic parts
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Application in building construction
Cavities made with CC and filled with concrete.
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Imbedding Reinforcement
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Co-extrusion of outer and filler materials A 6DOF Nozzle Assembly
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Conventional Structures
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Adobe structures
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Multiple mobile robotics approach
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
CC – The Sass Method
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
IT issues
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Lunar construction – From Earth to Moon
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Deployable CC
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
NASA Trials
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Nozzle for corrugated internal structure
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Nozzle for corrugated internal structure
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Adjustable width nozzle
UNIVERSITY OF SOUTHERN CALIFORNIA
FAB 4 - August 2007
Imbedding sensors and IT components
Conductive concrete may be used to power densely imbedded sensors and actuators.