Image-based metrology and tribology of additively manufactured components

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Materials used for high-risk industries such as biomedical devices, aerospace, and automotive manufacturing have long been required to have strong material properties and be produced with tight dimensional tolerances. Now, even consumer devices such as mobile phones and tablet computers utilize advanced, high-tolerance materials. The next generation of materials and devices will come from additive manufacturing, also known as 3D printing or rapid prototyping. To ensure manufactured components will function properly, they need to be examined for appropriate dimensions, wear resistance, and mechanical strength. Even dimensional verification can be challenging for additively manufactured components, due to new design paradigms that enable complex, below the surface internal structures that reduce material use and confer strength in specific regions. Only x-ray based methods such as computed tomography (CT) can provide dimensional measurements for both the outer and inner aspects of a part. The overall goal of this proposal is to develop micro-CT imaging methods to reverse engineer and evaluate the geometry of materials, especially those made from additive manufacturing. Imaging acquisitions will be optimized and automated, to enable rapid, high throughput quality assurance, including of parts that have already been packaged. The potential for ionizing radiation from this imaging to affect the mechanical strength of the scanned parts will be examined. Finally, the dimensional accuracy of additive manufacturing systems will be evaluated and the tribological properties of different raw and processed additively manufactured materials will be determined. Collectively, this work will enhance the capabilities of micro-CT as an industrial quality assurance platform, and advance the state of knowledge on the properties of materials used in additive manufacturing. This program will be well suited for students who will be immersed in an ideal multidisciplinary training environment, working closely with engineers and imaging scientists. Trainees will master imaging assessment, computer aided design, and additive manufacturing, all cutting-edge technologies applicable to a broad range of industries.