SBIR Phase I: Fast Freeform Fabrication Using Planar Layer Deposition Techniques

这个小企业创新研究（SBIR）第一阶段项目将开发一个平面层沉积系统，用于自由成形制造三维设计原型。所述平面层是由装有可调平面喷嘴的容器产生的，该喷嘴由一个或两个开槽板组成，由微米分辨率的电动位置控制装置调节。开槽板是这样组装的，它们彼此滑动，使喷嘴的开口可以调整，根据需要，从完全打开到完全关闭。因此，喷嘴可以形成所需宽度的半固化片，该半固化片在沉积在基板上后经历快速凝固。这形成了对最终产品结构有贡献的增量沉积。该系统的挤压性能将通过制作各种蜡的原型来测试。通过挤压平面层，而不是沉积或固化材料，一次单一的头或束宽度，这种快速原型组件的方法可以减少100倍的构建时间，从而在小批量制造和原型制作过程中实现固体自由成形。不断减少产品周期的需要需要更短的原型时间。然而，大多数自由曲面制造方案是复杂和缓慢的，使得生产速度缓慢，生产运行没有吸引力，特别是对于大型零件。这种新的自由曲面技术有望制造高强度和高温精密金属和陶瓷零件。它比目前的自由曲面制造技术更简单、更快，将降低产品开发成本和周期时间。它也可用于航空和空间应用的先进材料和结构的大规模和有控制的制造。

9860715 This Small Business Innovation Research (SBIR) Phase I project will develop a planar layer deposition system for freeform fabricating three-dimensional design prototypes. The planar layer is generated by a container equipped with an adjustable planar nozzle consisting of one or two slotted plates regulated by a motorized position-controlling device of micrometer resolution. The slotted plates are assembled such that they slide over one another, enabling the nozzle opening to be adjusted, as needed, from fully open to completely closed. The nozzle can therefore form a semi-solidified sheet of desirable width, which undergoes rapid solidification after deposition on a substrate. This forms an incremental deposit that contributes toward the final product structure. The extrusion properties of this system will be tested by making prototypes from a variety of waxes. By extruding planar layers instead of depositing or curing material, a single bead or beam width at a time, this approach for rapid prototyping components could have build-times a hundred fold less and thus enable solid freeforming in low-volume manufacturing as well as the prototyping process. The continuing need to reduce product cycle time requires shorter prototyping time. Most freeform fabrication schemes, however, are complex and slow, making production rates slow and production runs unattractive, particularly for large parts. This new freeform technology is expected to fabricate high-strength and high-temperature precision metal and ceramic parts. Being much simpler and faster than the current freeform fabrication technology, it would decrease product development cost and cycle times. It may also used in large-scale and controlled manufacturing of advanced materials and structures for aeronautic and space applications.