NSF Young Investigator: Scanned Thermal Rapid Prototyping Processes

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9457206 Doumanidis The research addresses the issue of simultaneous, real-time regulation of part geometry and thermal field, in thermal rapid prototyping, by redesigning the process arrangement and implementing a scanned thermal actuation. In thermal rapid prototyping, both the material supply, by a wire feeder or spray, and heat transfer, by a plasma or laser source, need to be modulated during the process as successive layers of material are deposited or removed from the part surface. The layer profile geometry and thermal distribution on the product surface will be measured by a laser vision system, and an infrared camera respectively, and used for feedback to the thermo-geometrical controller. This will adjust the material and heat source intensity and guide their motion on dynamic trajectories to the areas where their action is needed most, so as to obtain the desired geometric tolerances, the material structure and properties, and stress effects in the part. The calibrated controller will be implemented experimentally on several rapid prototyping techniques, i.e. laminated object manufacturing, laser milling, fused material deposition and thermal spray deposition. The research will also be coupled to supportive teaching activities, enriching the thermal manufacturing curriculum at the university. These include the establishment of a graduate manufacturing automation seminar with guest lectures and industrial sponsorship. A series of motivating introductory courses will also be developed, with multidisciplinary manufacturing content and hands-on prototyping projects, in the laboratory.