Robust Integrated Assembly Design and Conformance Methods for Direct Digital Manufacturing

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The primary long term objective of the research program is to develop novel methods and tools for simulation, prediction, and validation of mechanical, functional and geometrical quality specifications of functional assemblies for direct digital manufacturing (DDM) processes with a focus on fused deposition modeling and Selective laser sintering/melting processes. Unlike subtractive manufacturing processes, DDM processes have complex, non-linear, highly coupled, time dependent behavior between the feedstock, process, part geometry, and the mechanical properties parameters (deformations, residual stresses). They also suffer from issues related to quality, capability to integrate tolerances, and validation and demonstration. Currently, there is a knowledge gap in the areas of models for simulating and predicting geometric and mechanical behavior, reliability and repeatability (material properties, dimensional accuracy) for multi-component functional assemblies. Having the capability would unlock potential future applications of additive manufacturing (AM) for manufacturing fully functional assemblies which would have an immense effect on reducing the time and cost of design and manufacturing cycle of a mechanical product. Mechanical assemblies are a critical component of machines and are required in all technological systems requiring energy/material transformations. Geometrical and tolerancing precision and predictable mechanical behavior are the most important characteristics of an assembly. Despite having the potential, the current level of maturity of AM processes do not allow direct printing of precision functional assemblies which is required for truly consolidated design elements. The proposed equipment will allow fundamental theoretical and experimental research to create accurate models for design and optimization of critical process parameters as well as multi material/multi component geometric models with a consistent build quality in terms of dimensional, geometric, kinematic, and mechanical property behavior of direct design to manufacturing of functional parts. The project culmination is expected to result into development of novel models that would significantly improve process capability of additive manufacturing process, while simultaneously reducing the waste in form of rework and rejection. It would also reduce the time spent in design and manufacturing leading to shorter cycle times. The deliverables from the process will allow design and printing of consolidated functional assemblies. The project would also train a number of HQP in the field of design and manufacturing with a focus on integrated direct digital design and manufacturing with capabilities and knowledge pf producing precision assemblies.