Solid Freeform Fabrication: A New Direction in Manufacturing

Solid Freeform Fabrication is a set of manufacturing processes that are capable of producing complex freeform solid objects directly from a computer model of an object without part-specific tooling or knowledge. In essence, these methods are miniature manufacturing plants which come complete with material handling, information processing and materials processing. As such, these methods require technical knowledge from many disciplines; therefore, researchers, engineers, and students in Mechanical, Chemical, Electrical, and Manufacturing Engineering and Materials and Computer Science will all find some interest in this subject. Particular subareas of concern include manufacturing methods, polymer chemistry, computational geometry, control, heat transfer, metallurgy, ceramics, optics, and fluid mechanics. History of technology specialists may also find Chapter 1 of interest. Although this book covers the spectrum of different processes, the emphasis is clearly on the area in which the authors have the most experience, thermal laser processing. In particular, the authors have all been developers and inventors of techniques for the Selective Laser Sintering process and laser gas phase techniques (Selective Area Laser Deposition). This is a research book on the subject of Solid Freeform Fabrication.

Solid Freeform Fabrication is a set of manufacturing processes that are capable of producing complex freeform solid objects directly from a computer model of an object without part-specific tooling or knowledge.

1. Introduction.- 1.1 Background and Definitions.- 1.2 Historical Perspective.- 1.3 Book Outline.- References.- 2. Process Methods.- 2.1 Background.- 2.2 Process Techniques.- 2.3 Role of Machining.- 2.4 Chronology.- References.- 3. Information Processing.- 3.1 Geometric Models for SFF.- 3.2 Interprocess Interfaces.- 3.3 Slicing Algorithms.- 3.4 Scanning Patterns.- 3.5 Support Structures.- 3.6 Summary.- References.- 4. Polymers in Solid Freeform Fabrication.- 4.1 Polymer Material Properties.- 4.2 Dimensional Accuracy.- 4.3 Chemistry Considerations.- 4.4 Polymer Binders.- References.- 5. Indirect Fabrication of Metals and Ceramics.- 5.1 Transfer Processes.- 5.2 Indirect Methods.- 5.3 Secondary/Post Processing.- 5.4 Summary.- References.- 6. SLS Process Modeling and Control.- 6.1 Properties of Powder Beds.- 6.2 Sintering Kinetics.- 6.3 Process Models And Simulations.- 6.4 Commercial SLS Process Behavior/Properties.- 6.5 SLS Process Control Considerations.- 6.6 SLS Part Accuracy - Benchmark Data.- References.- 7. Direct SLS Fabrication of Metals And Ceramics.- 7.1 SLS Binding Mechanisms.- 7.2 SLS Processing of Binary Metallic Powder Blends.- 7.3 SLS Processing of Cermets.- 7.4 Direct SLS Processing of Ceramic Powder Blends.- 7.5 Reactive Sintering of Binary Powder.- 7.6 Density of SLS Processed Parts.- 7.7 Mechanical Behavior of SLS Processed Parts.- 7.8 Other Direct SFF Methods.- References.- 8. Solid Freeform Fabrication Using Gas Phase Precursors.- 8.1 Selective Area Laser Deposition.- 8.2 Chemical Kinetics and SALD.- 8.3 Organometallic Precursors for SALD.- 8.4 Selective Laser Reactive Sintering System for Gases.- 8.5 Selective Area Laser Deposition Vapor Infiltration.- 8.6 Modeling and Simulation.- 8.7 Summary.- References.- 9. SLS Applications.- 9.1 Background.- 9.2Plastic Part Prototyping at the Speed Scientific School, University of Louisville.- 9.3 Rapid Tooling Benchmarking at Sunstrand Aerospace.- 9.4 Advanced Applications.- 9.5 Summary.- References.