Layerless Additive Manufacturing of 3D Objects with Wide Solid Cross Sections

具有宽实心横截面的 3D 物体的无层增材制造

• 批准号: 1563477
• 负责人: Yayue Pan
• 金额: $ 29.53万
• 依托单位: University of Illinois at Chicago
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2016
• 资助国家: 美国
• 起止时间: 2016-07-01 至 2019-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1563477&HistoricalAwards=false
• 关键词: Layerless; Additive; Manufacturing; 3D; Objects

Additive manufacturing, also known as three-dimensional (3D) printing, is a class of manufacturing technologies that make 3D objects by accumulating rather than removing material (e.g. machining). Most current additive manufacturing technologies accumulate material in a layer-by-layer process. Recently, layerless additive manufacturing techniques based on vat processing have been suggested. Advantages include faster processing speed, smoother surfaces and better part quality using layerless techniques. However, processing speed and part quality are critical challenges for producing parts with relatively wide solid cross sections. This award supports fundamental research to provide new knowledge for layerless additive manufacturing of arbitrary 3D objects with wide solid cross sections. The establishment of a fast, layerless additive manufacturing process would enable the production of part shapes and sizes beyond trusses or shells. The research involves multiple disciplines of physics, surface science, microfluidics and manufacturing technology and will contribute new knowledge to advanced manufacturing. The research will have significant impact on a large number of minority students and enhance STEM education.Continuous Liquid Interface Production is a layerless additive manufacturing technology based on vat photopolymerization that can achieve build speeds 25 to 100 times faster than layer-by-layer photopolymerization. However, the horizontal distance over which the replenishment polymer can travel before polymerization occurs is limited, which prohibits printing of parts with large cross-sections. This grant will establish a fundamental understanding of the manufacturing process by investigating the resin flow-curing dynamics. The research team will perform liquid-gel-solid multi-phase modeling to understand the resin flow, explore new window designs to accelerate resin replenishment, and establish new light delivery strategies to coordinate resin flow and curing processes. This research will test the hypothesis that the integration of a textured window and a gradient light delivery strategy will enable continuous printing of arbitrary objects with wide solid cross sections.

增材制造，也称为三维（3D）打印，是一类通过积累而不是去除材料（例如机加工）来制造3D物体的制造技术。目前大多数增材制造技术都是在逐层过程中积累材料。最近，已经提出了基于大桶加工的无层增材制造技术。优点包括更快的加工速度，更光滑的表面和更好的零件质量使用无层技术。 然而，加工速度和零件质量是生产具有相对宽的实心横截面的零件的关键挑战。该奖项支持基础研究，为具有宽实体横截面的任意3D物体的无层增材制造提供新知识。建立一种快速、无层的增材制造工艺，将能够生产超出桁架或壳体的零件形状和尺寸。该研究涉及物理学、表面科学、微流体和制造技术等多个学科，将为先进制造业贡献新知识。 该研究将对大量少数民族学生产生重大影响，并加强STEM教育。连续液体界面生产是一种基于光聚合的无层增材制造技术，可以实现比逐层光聚合快25至100倍的构建速度。然而，补充聚合物在聚合发生之前可以行进的水平距离是有限的，这禁止打印具有大横截面的部件。该补助金将通过调查树脂流动固化动力学来建立对制造过程的基本理解。研究团队将进行液体-凝胶-固体多相建模，以了解树脂流动，探索新的窗口设计以加速树脂补充，并建立新的光传输策略以协调树脂流动和固化过程。 这项研究将测试一个假设，即纹理窗口和梯度光传输策略的集成将使连续打印任意对象与宽固体横截面。