SGER: Development of a Planar Layer Deposition System for Freeform Fabrication of Metal Parts

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9812984 Tseng This Small Grant for Exploratory Research is to demonstrate the feasibility of a novel means of producing complex three dimensional shapes of metallic materials by a freeform fabrication system. This project involves building a prototype system, based on the planar layer deposition technology and consists of a planar jet generator equipped with adjustable nozzles, pairs of rollers for pressing, cooling, and leveling, and a deposition chamber equipped with a position-controllable substrate. A sheet or layer with a desirable width formed by the planar jet generator contributes toward the final three-dimensional structure. The planar layer deposition approach changes the current freeform fabrication concept from point-to-point forming to layer-by-layer deposition and as a result, will dramatically improve the production rate. The generator crucible is designed to achieve temperatures up to 1000 degrees centigrade. A relatively low melting temperature metal will be selected for freeforming a metal part with a 0.2-mm accuracy during this project to prove the concept and potential capability of the planar layer deposition technology.