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This project was initiated by Dr. Sasan Dadbaksh upon listening to the requirements I presented for my master thesis. My requirements were to do a master thesis project in the field of additive manufacturing specifically fused deposition modeling that should not only involve the research work but should also present an opportunity to develop hardware and should involve experimental testing. Then Sasan came up with the idea of developing a system capable to perform 3D printing with the extruder fixed in one position and the motion required for 3D printing will be provided by the robotic arm. The title of developing green build strategies for robot assisted plastic 3D printing came into being. The main concept behind the title of developing robot assisted plastic 3D printing platform is to develop such a system that can offer additive manufacturing services, specifically of fused deposition modeling 3D printing, as an inbound process during the manufacturing of any part through subtractive processes with the help of a robotic arm along with the repair of any kind of parts with the assistance of fused deposition modeling 3D printing. The main objectives of the master thesis include building a stationary filament extrusion module to interact with a robot hand and establishing a strategy for a robot hand to move the part to appropriate locations to complete building a part on a preform without support structures. The targets that were achieved with the completion of this thesis project includes the development of the complete hardware that consists of a mechanical structure with the option of mounting the components required to run the extrusion setup, learning the basic working of the software that are able to simulate the 3D printing process with the robotic arm (Robot Studio and Robo DK), creation of the simulation of the whole process, achieving communication between the robotic arm and the microcontroller of the extruder and finally the printing of a simple part for the demonstration. The components needed to be installed on the structure includes the motor, extruder, hot end, nozzle, filament. The structure also accumulated the required electronics that includes power supply, microcontroller, and an LCD to monitor the extrusion parameters. The developed machine runs on the state-of-the-art components that belong to the few of the best manufacturers of the technology.

Thermoplastic composites that have been reinforced by thermotropic liquid crystalline (TLCP) fibrils in the microscale and by nanoparticles in the nanoscale are defined as multi-scale wholly thermoplastic composites (WTCs). Multi-scale WTCs have been proposed as lightweight replacements with high performance for some traditional glass fiber (GF) and carbon fiber (CF) reinforced composites materials in various applications. TLCPs are known for performing mechanical properties similar to those of the lower end of CF but significantly better than those of GF. To enhance the mechanical properties of TLPC reinforced WTCs, carbon nanotubes (CNTs) are considered being used as a secondary enhancement in WTCs. CNTs have gathered significant interest in the last 30 years because of their high aspect ratio, high mechanical properties, and other high-performance properties. The focus of this work is on investigating the processing conditions of generating in situ injection-molded multi-scale WTCs, then extending the technology to dual-extrusion and fused filament fabrication (FFF) and obtain high-performance multi-scale WTC products. This dissertation initially focused on investigating the processing conditions, in particular mixing histories and processing temperature profiles, of generating in situ injection-molded multi-scale WTCs, which consist of a representative TLCP, scCO2 aided exfoliated CNTs, and the thermoplastic matrix polyamide 6 (PA 6). The supercooling behavior of the TLCP and thermal stability of PA 6 are studied by applying the rheological methods of small amplitude oscillatory shear (SAOS). Multiple mixing histories with CNTs and processing temperature profiles are analyzed based on the criterion of maximizing tensile properties of multi-scale WTCs and minimizing thermal degradation of the matrix. Under the optimum processing conditions, the in situ injection-molded multi-scale WTCs exhibit a 26% and 34% tensile modulus and strength enhancement, compared to the in situ injection-molded WTCs with no CNTs. Scanning electron micrograph (SEM) images were used to understand the enhancement. The second part of this work is to extend the scCO2 aided in situ multi-scale WTCs processing technology to dual-extrusion and FFF. Multi-scale WTC filaments, which consists of TLCP, CNTs, and polyamide copolymer (PAc), are generated by dual-extrusion, and 3D printed into rectangular specimens in FFF. The 1 wt% CNTs reinforced multi-scale WTC filaments generated by the means of dual-extrusion exhibit 225% and 80% improvement in tensile modulus and strength, respectively, compared to the WTC filaments with no CNTs. In FFF, 40 wt% TLCP/1 wt% CNT/PAc 3D printed specimens with filament laid in longitudinal direction exhibited excellent tensile modulus and strength of 38.92 GPa and 127.16 MPa, respectively. The well-dispersed exfoliated CNTs show high alignment with TLCP microfibrils in the multi-scale WTC filaments and their laid-down specimens, which causes the significant tensile modulus enhancement. Bridging elements are discovered between TLCP fibrils and PAc matrix to improve interfacial adhesion, which is attributed to the well-dispersed exfoliated CNTs. Finally, the significant improvements in tensile properties attributed to scCO2 aided exfoliated CNTs in WTCs are verified on the multi-scale WTCs based on polypropylene (PP). Moreover, additional tensile properties improvements for exfoliated CNTs reinforced multi-scale WTCs are obtained with the use of maleic anhydride grafted polypropylene (MAPP). With 1 wt% CNTs and 16 wt% MAPP dual reinforcement, 20 wt% TLCP reinforced WTCs based on polypropylene (PP) exhibit 265%, 274%, and 182% improvement in the tensile modulus of the filaments, laid up specimens in the concentric pattern and laid up specimens in ±45° rectilinear pattern, respectively. The dual reinforcement also improves the tensile strength of 20 wt% TLCP reinforced WTC filaments by up to 73%. The high alignment between TLCP fibrils and CNTs are confirmed in the multi-scale WTCs based on PP. Besides the bridging elements attributed to CNTs found in the second part of this work, SEM images show that CNTs are partially trapped in TLCP fibrils. / Doctor of Philosophy / Considering the need for environmentally friendly materials, novel thermoplastic composites with high mechanical performance, lightweight, and potentially high recyclability properties were generated in this work. Two types of thermoplastic matrices, polyamide (PA or nylon) and polypropylene (PP) were reinforced with carbon nanotubes (CNTs) and rigid chain polymers known as thermotropic liquid crystalline polymers (TLCPs). CNTs are known for their high mechanical properties and high aspect ratio, which are helpful to reinforce thermoplastic composite materials. During injection molding and the dual-extrusion processes, TLCPs deform into almost continuous microfibrils and reinforce the thermoplastic matrices. Instead of using traditional glass fibers or carbon fibers to reinforce thermoplastics, TLCP reinforced thermoplastic composites, which are defined as wholly thermoplastic composites (WTCs), can retain their mechanical properties during the recycling process such as in injection molding and have better performance during the lay-down process in fused filament fabrication. The goal of this work was to generate CNTs reinforced WTCs for use in injection molding and fused filament fabrication with high mechanical performance. In the injection molding process for generating CNTs reinforced WTC end-gated plaques, it was determined that the optimum thermal mixing histories for the CNTs could be identified by the inspections of the tensile property measurements and scanning electron microscopy (SEM). With the obtained optimum thermal mixing histories with CNTs, CNTs reinforced WTC filaments were generated by dual extrusion technology and used in fused filament fabrication. With 1 wt% addition of CNTs, the tensile properties of WTCs were significantly enhanced in both the filament materials and the laid-down parts. Especially, the CNT reinforced WTC filaments based on nylon matrices exhibited competitive tensile moduli to long carbon fiber reinforced nylon composite filaments, which was also competitive to the properties of aluminum alloys. In addition, the laid-down parts of CNTs reinforced WTC based on PP presented further tensile strength improvement due to the improved interfacial adhesion between the laid-down filaments and between layers, which was attributed to the addition of maleic anhydride grafted polypropylene.

Today's commercial rapid prototyping systems (i.e., solid freeform fabrication, layered manufacturing) rely on human intervention to load and unload build jobs. Hence, jobs are processed subject to both the machine's and the operator's schedules. In particular, first-in-first-out (FIFO) queuing of such systems will result in machine idle time whenever a build job has been completed and an operator is not available to unload that build job and start up the next one. These machine idle times can significantly affect the system throughput, and, hence, the effective cost rate. This thesis addresses this problem by rearranging the job queue to minimizing the machine idle time, subject to the machine's and operator's schedules. This is achieved by employing a general branch-and-bound search method, that, for efficiency, reduces the search space by identifying contiguous sequences and avoiding reshuffling of those sequences during the branching procedure. The effectiveness of this job scheduling optimization has been demonstrated using a sequence of 30 jobs extracted from the usage log for the FDM 1600 rapid prototyping system in the Department of Mechanical Engineering at Virginia Tech. / Master of Science

As an attempt to improve the overall cost-effectiveness and ease of structural electronics manufacturing, this study characterizes the mechanical and electrical responses of structures which are fabricated from a novel metallopolymer composite material by fused deposition modeling as they are subjected to quasi-static, uniaxial mechanical tension. Baseline values of tensile properties and electrical resistivity were first obtained via ASTM D638-22 standard testing procedures and linear sweep voltammetry (LSV), respectively. A hybrid procedure to measure in-situ mechanically dependent electrical behavior was subsequently developed and implemented. The mechanical and electromechanical testing was followed by the derivation of stochastic values for several mechanical and electrical properties of the printed structures. The mean values of a three-specimen sample’s ultimate tensile strength and tensile modulus were 8.76 and 244.5 megapascals, respectively, and the sample exhibited significant ductility through an average tensile elongation of 70.4 percent at fracture. The electrical resistance of test specimens appeared to be positively correlated to their mechanical strain. Correlation coefficients exceeding 0.95 were obtained for simple linear regression models of the resistance-strain curves for their two distinct regimes of strain sensitivity. The uncoupled mechanical and electrical performance of the printed structures were, however, significantly below what the nominal material properties suggested. Thus, it was concluded that the process of component manufacturing should be further improved, and that the structures’ mechanical and electromechanical behaviors should be more rigorously characterized, before attempting to use such components in applications of structural electronics.

The contributions of nonlinear absorption processes to laser-induced damage of three selected groups of transparent dielectrics were investigated. The studied materials were irradiated and non-irradiated fused silica, doped and undoped fluorozirconate glass and cubic zirconia stabilized with yttria. The laser-induced damage thresholds, prebreakdown transmission, and nonlinear absorption processes were studied for several specimens of each group. Experimental measurements were performed at wavelengths of 1064 nm and 532 nm using nanosecond and picosecond Nd:YAG laser pulses. In the irradiated fused silica and fluorozirconate glasses, we found that there is a correlation between the damage thresholds at wavelength λ and the linear absorption of the studied specimens at λ/2. In other words, the laser-induced breakdown is related to the probability of all possible two-photon transitions. The results are found to be in excellent agreement with a proposed two-photon-initiated electron avalanche breakdown model. In this model, the initial "seed" electrons for the formation of an avalanche are produced by two-photon excitations of E' centers and metallic impurity levels which are located within the bandgaps of irradiated Si02 and fluorozirconate glasses, respectively. Once the initial electrons are liberated in the conduction band, a highly absorbing plasma is formed by avalanche impact ionization. The resultant heating causes optical damage. In cubic zirconia, we present direct experimental evidence that significant energy is deposited in the samples at wavelength 532 nm prior to electron avalanche formation. The mechanism is found to be due to formation of color centers (F+ or F° centers) by the two-photon absorption process. The presence of these centers was directly shown by transmission measurements. The two-photon absorption (2PA) process was independently investigated and 2PA coefficients obtained. The accumulated effects of the induced centers on the nonlinear absorption measurements were also considered and the 2PA coefficients were measured using short pulses where this effect is negligible. At room temperature, the color centers slowly diffuse out of the irradiated region. The density of these centers was monitored as a function of time. The initial distribution of the centers was assumed to have a Gaussian profile. For this model the diffusion equation was solved exactly and the diffusion constant obtained.

Artist Statement The organic patterns all around me are what intrigues and inspires my textile, glass, and painting compositions. I find beauty within the natural growth patterns of things both large and small. My work references the reverberated growth processes in living things from the macroscopic observation of a plant to the microscopic viewpoint of its cells. Like the beauty found within these organic configurations, my process begins with creating serendipitous marks with a reference to natural patterns. Then, I intuitively respond to what I see in front of me. As I work, I use repetitious lines and shapes and a vibrant, non-naturalistic color palette. My choices of colors are personally motivated, and the combinations and manipulations are intuitive. Pattern and color are both visual languages that affect individuals differently. While my use of both is in response to my own experiences, my works allow the viewer to respond and connect in their own way.

La structuration laser femtoseconde en trois dimensions rencontre un intérêt grandissant du fait de sa facilité de mise en œuvre et des nombreuses applications qu’elle peut couvrir dans le domaine des composants photoniques. Des structures telles que des guides d’onde, des réseaux de diffraction, des mémoires optiques ou des cristaux photoniques peuvent être fabriquées grâce à cette technique. Son emploi sur des verres oxydes est prometteur car ces derniers présentent des avantages certains ; ils sont très résistants au flux et au vieillissement, leur composition chimique peut être changée facilement afin de s’adapter à un cahier des charges précis. On les retrouve déjà dans les amplificateurs Raman, les fibres optiques, les lasers à fibres, etc… Le travail de cette thèse s’articule autour de deux grands axes. Le premier axe consiste à caractériser les propriétés optiques linéaires et non-linéaires de matériaux vitreux massifs afin d’optimiser leur composition en vue d’une application particulière. Dans ce contexte, les propriétés optiques non-linéaires, leurs origines physiques (électronique et nucléaire) ainsi que leurs temps de réponse caractéristiques (de quelques femtosecondes à quelques centaines de picosecondes) sont décrits dans le cadre de l’approximation de Born-Oppenheimer. Ainsi, la silice fondue et plusieurs verres sodo-borophosphates contenant différentes concentrations en oxyde de niobium ont été étudiés. Les résultats montrent que les propriétés optiques non-linéaires dans la silice fondue sont majoritairement d’origine électronique, alors que dans les verres sodo-borophosphates, la contribution d’origine nucléaire peut devenir prépondérante lorsque la concentration en oxyde de niobium dépasse 30%. Le second axe s’articule autour de la structuration des matériaux. Trois échantillons commerciaux de silice fondue présentant des conditions de fabrication différentes (donc des taux d’impuretés distincts) et irradiés avec un laser femtoseconde proche infrarouge ont été étudiés. Les défauts induits par laser ont été identifiés au moyen de plusieurs techniques de spectroscopie. Elles ont montré la formation de centres colorés ainsi qu’une densification au niveau de la zone irradiée. Leurs propriétés optiques linéaire (indice de réfraction) et non-linéaire (susceptibilité du troisième ordre) ont été mesurées. De plus, la structuration de la silice fondue à l’échelle sub-micrométrique sous forme de « nano-réseaux » est observée et la biréfringence de forme induite par ces structures est discutée. En plus des échantillons de silice fondue, plusieurs verres oxydes présentant des compositions chimiques très distinctes ont été étudiés. Un verre sodo-borophosphate contenant de l’oxyde de niobium exhibe des micro-craquelures et des nano-crystallites après irradiation. Un verre silicate contenant ou non de l’argent dévoile des structures en anneau fluorescentes ou en « nano-réseaux ». Un verre zinc phosphate contenant de l’argent présente lui aussi des structures en anneau fluorescentes, d’une taille de l’ordre de 80 nm, bien inférieure à la limite de diffraction. Des techniques pompe-sonde sous microscope ont été mises en œuvre sur ce dernier verre pour étudier l’interaction laser-verre. Le mécanisme d’absorption de l’énergie lumineuse pour ce verre est l’absorption à quatre photons. La densité d’électrons libres générée est de l’ordre de 1017 cm-3, ce qui permet de conclure qu’un gaz d’électrons plutôt qu’un plasma se forme pendant l’irradiation laser. / Three-dimensional femtosecond laser structuring has a growing interest because of its ease of implementation and the numerous possible applications in the domain of photonic components. Structures such as waveguides, diffraction gratings, optical memories or photonic crystals can be fabricated thanks to this technique. Its use with oxide glasses is promising because of several advantages; they are resistant to flux and ageing, their chemical composition can easily be changed to fit the well-defined requirements of an application. They can already be found in Raman amplifiers, optical fibers, fiber lasers, and other devices. This thesis is based on two axes. The first axis consists in characterizing the linear and nonlinear optical properties of bulk vitreous materials in order to optimize their composition with a particular application in view. Within this context, the nonlinear optical properties, their physical origins (electronic and nuclear) as well as their characteristic response times (from a few femtoseconds to a few hundreds of picoseconds) are described within the Born-Oppenheimer approximation. Fused silica and several sodium-borophosphate glasses containing different concentrations in niobium oxide have been studied. Results show that the nonlinear optical properties of fused silica are mainly from electronic origin, whereas in the sodium-borophosphate glasses, the contribution from nuclear origin becomes predominant when the concentration of niobium oxide exceeds 30%. The second axis is based on the structuring of materials. Three commercially available fused silica samples presenting different fabrication conditions (therefore distinct impurity levels) and irradiated with a near infrared femtosecond laser have been studied. The laser induced defects have been identified by means of several spectroscopic techniques. They show the formation of color centers as well as a densification inside the irradiated area. Their linear refractive index and nonlinear third-order susceptibility properties have been measured. Moreover, the structuring of fused silica at the subwavelength scale into “nanogratings” is observed and the form of birefringence induced by these structures is discussed. In addition to the fused silica samples, several oxide glasses presenting very distinct chemical compositions have been studied. A sodium-borophosphate glass containing niobium oxide exhibits micro-cracks and nano-crystallites following irradiation. A silicate glass with or without a silver component reveals fluorescent rings or “nanograting” structures. A zinc phosphate glass containing silver also presents fluorescent ring structures, with a size of the order of 80 nm, well below the diffraction limit. Pump-probe microscope techniques have been performed on this glass to investigate the laser-glass interaction. The absorption mechanism is determined to be four-photon absorption. The generated free electron density is ~ 1017 cm-3, which suggests the conclusion that an electron gas rather than a plasma is formed during the laser irradiation.

La fabrication additive est un procédé d’élaboration permettant la mise en forme d’une pièce par ajout de matière, par empilement de couches successives. Bien que de plus en plus de polymères puissent être mis en œuvre par cette technologie, les polymères chargés en sont quasiment absents, alors qu’ils sont largement utilisés dans les autres types de procédés de mise en forme. Les objectifs scientifiques et technologiques du projet concernent (i) une meilleure compréhension des relations entre le comportement rhéologique de systèmes polymères et leur aptitude à la mise en forme par les technologies de fabrication additive FDM, (ii) le développement de formulations de base de polymères bio-sourcés adaptées à ces technologies et apportant une multifonctionnalité. Le premier objectif nécessitera tout d’abord d’identifier les conditions (température, gradients de vitesse, nature des contraintes, …) imposées par les procédés considérés puis de mettre en place et/ou d’adapter les moyens de caractérisation du comportement rhéologique des systèmes polymères dans ces conditions. Le comportement rhéologique en cisaillement mais aussi en élongation pourra être considéré. Il conviendra en particulier d’identifier les compromis nécessaires entre comportement adapté à l’écoulement en filière ou en buse et aptitude à la fusion et à la consolidation couche par couche. Enfin, l’effet des différentes voies de fonctionnalisation envisagées sur le comportement rhéologique et thermique et donc sur l’aptitude à la mise en forme devra être analysé. De façon à adapter les polymères bio-sourcés à un large panel d’applications, diverses voies de fonctionnalisation seront considérées, basées sur le compoundage avec des charges particulaires. / Additive manufacturing process is a preparation for the forming of a workpiece by the addition of material, by stacking successive layers. Although more and more polymers can be implemented by this technology, the filled polymers are practically absent, so they are widely used in other types of shaping methods. The scientific and technological objectives of the project are (i) a better understanding of the relationship between the rheological behavior of polymer systems and their ability to shaping by additive manufacturing technologies FDM, (ii) the development of polymer-based formulations biosourced adapted to these technologies and providing multifunctionality. The first goal will require first of all to identify the conditions (temperature, velocity gradients, nature constraints ...) imposed by the processes considered then to implement and / or adapt the means of characterization of the rheological behavior of polymer systems under these conditions. The rheological behavior in shear but also in elongation may be considered. It should in particular identify the necessary compromise between behavior adapted to the flow at the die or nozzle and meltability and consolidation layer by layer. Finally, the effect of different ways of functionalization considered on the rheological and thermal behavior and thus on the ability to formatting will be analyzed. In order to adapt the bio-sourced polymers for a wide range of applications, various routes of functionalization will be considered based on compounding with particulate fillers.

O estudo comparativo da distribuição de tensões de von Mises em dente endodonticamente tratado, com dois formatos de retentores intra-radiculares, pré-fabricado cilíndrico/escalonado e fundido cônico, foi realizado pelo método dos elementos finitos em modelos tridimensionais de caninos superiores com geometria axi-simétrica e restaurados com coroas metalocerâmicas, aplicando-se uma carga oblíqua de 100N com 45 º de inclinação em relação ao seu longo eixo. Os resultados indicaram uma discreta diferença nos dois modelos (formatos) de retentores. O pino escalonado neutralizou mais as cargas no sentido corono-apical e no pino cônico ficou evidenciado o efeito de cunha. / The aim of this study was to compare the von Mises stress distribution on a human canine teeth endodontically treated and restored with two types of post and core. The analysis was made using the three dimensional Finite Element Analysis method. For the analysis was created and axy-simetric structure of the teeth, including a porcelain fused to metal crown, a cement layer, and the periodontal structures. The model was analyzed when a 100N load was applied on the surface of the crown with 45º angulation with the long axis of the teeth. The results showed that both models exhibit little difference, the “stair shape" post system neutralized the axial loads, and the conical shape post showed a wedge effect on the apical third of the root.