Integration of Materials Design and Manufacturing via Free Form Fabrication Processes

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9400213 Ogale The goal of this research is the development of methodologies for the integration of materials design with free form manufacturing. Design will be based on the assumption that the product can be built by decomposing it into layers, and then creating each layer by a free form manufacturing technique. Knowledge of the designed material and stress and strain contours in the product will be used to plan the prototyping process. Surface contour and form error desired, as well as structural analysis results will determine the layer thickness, layout of fibers in each layer, beam diameter, traverse speed and polymerization. The design methodologies will be validated by processing parts in an automated photolithography unit. A continuous fiber dispensing device will provide automatic fiber placement and laser beam motion in the required patterns. In situ addition of fibers will provide an opportunity for the investigation of two fundamental issues, wetting of the fiber surfaces by photoresins and the hindered cure kinetics of photoresins due to the presence of reinforcing fibers. This research will provide information about the movement of liquid fronts along fiber surfaces and give insight into the "slip" phenomenon at the gas-liquid-solid interface, and it will help in developing an understanding of the cure mechanisms in multifunctional photoresins that are used in free form manufacturing techniques.