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Additive Manufacturing (AM) is a unique method of fabrication that, in contrast to traditional manufacturing methods, builds objects layer by layer. The ability of AM (when partnered with 3D scanning) to clone physical objects has raised concerns in the area of intellectual property (IP). To address this issue, the goal of this dissertation is to characterize and model a method to incorporate unique security features within AM builds. By adding optically detectable nanoparticles into transparent AM media, Physical Unclonable Function (PUFs) can be embedded into AM builds and serve as an anti-counterfeiting measure. The nanoparticle selected for this work is a Quantum Dot (QD), which absorbs UV light and emits light in the visible spectrum. This unique interaction with light makes the QDs ideal for a security system since the challenge (UV light) is a different signal from the response (the visible light emitted by the QDs). PolyJet, the AM process selected for this work, utilizes inkjet to deposit a photopolymer into layers, which are then cured with a UV light. An investigation into the visibility of the QDs within the printed PolyJet media revealed that the QDs produce PUF patterns visible via fluorescent microscopy. Furthermore, rheological data shows that the ink-jetting properties of the printing media are not significantly affected by QDs in sufficient concentrations to produce PUFs. The final objective of this study is to characterize the effects of the QDs on photocuring. The mathematical model to predict the critical exposure of the QD-doped photopolymer utilizes light scattering theory, QD characterization results, and photopolymer-curing characterization results. This mathematical representation will contribute toward the body of knowledge in the area of Additive Manufacturing of nanomaterials in photopolymers. Overall, this work embodies the first investigations of the effects of QDs on rheological characteristics of ink-jetted media, the effects of QDs on curing of AM photopolymer media, visibility of nanoparticles within printed AM media, and the first attempt to incorporate security features within AM builds. Finally, the major scientific contribution of this work is the theoretical model developed to predict the effects of QDs on the curing properties of AM photopolymers. / Ph. D.

This diploma thesis has an aim to fabricate a prototype of esthetical prosthesis using solely Rapid Prototyping aditive technology and to explore the possibility of using commercially available biocompatible materials. In the theoretical part, a description of types of ocular prosthesis types with the focus being on esthetic ocular prosthesis. is given. The practical part of the work offers a comprehensive view on the whole process of the prototype fabrication. It provides a description of creating the 3D model by scanning, geometrical adjustments of the model, textures mapping, print optimization and the printing itself. The closing part of the thesis consists of a discussing focused on an evaluation of the fabricated prototype followed by technical-economical assesment, a proposal of next steps, and a proposal of current usage of the created method.

No description available.

The work herein is, in part, motivated by the idea of creating optimized, actuating structures using additive manufacturing processes (AM). By developing a consistent, repeatable method for designing and manufacturing multi-material compliant mechanisms, significant performance improvements can be seen in application, such as increased mechanism deflection. There are three distinct categories of research that contribute to this overall motivating idea: 1) investigation of an appropriate multi-material topology optimization process for multi-material jetting, 2) understanding the role that manufacturing constraints play in the fabrication of complex, optimized structures, and 3) investigation of an appropriate process for embedding actuating elements within material jetted parts. PolyJet material jetting is the focus of this dissertation research as it is one of the only AM processes capable of utilizing multiple material phases (e.g., stiff and flexible) within a single build, making it uniquely qualified for manufacturing complex, multi-material compliant mechanisms. However, there are two limitations with the PolyJet process within this context: 1) there is currently a dearth of understanding regarding both single and multi-material manufacturing constraints in the PolyJet process and 2) there is no robust embedding methodology for the in-situ embedding of foreign actuating elements within the PolyJet process. These two gaps (and how they relate to the field of compliant mechanism design) will be discussed in detail in this dissertation. Specific manufacturing constraints investigated include 1) "design for embedding" considerations, 2) removal of support material from printed parts, 3) self-supporting angle of surfaces, 4) post-process survivability of fine features, 5) minimum manufacturable feature size, and 6) material properties of digital materials with relation to feature size. The key manufacturing process and geometric design factors that influence each of these constraints are experimentally determined, as well as the quantitative limitations that each constraint imposes on design. / Ph. D.

Understanding the interactions of polymer interfaces is essential to improve polymer-based designs, as the properties of the interface are often different than those of the bulk material. This thesis explores the interfacial interactions of polymer interfaces for two classes of materials, additive manufacturing materials and fiber-reinforced composites. Additive manufacturing (AM) refers to a number of processes which rely on data generated from computer-aided design (CAD) programs to construct components by adding material in a layer-by-layer fashion. AM continues to generate a substantial amount of interest to produce fully functional products while reducing tooling costs associated with traditional manufacturing techniques such as casting and welding. Recent advancements in the field have led to the production of multi-material printing that has the potential to create products with enhanced mechanical properties and additional functionality. This thesis attempts to characterize the fracture resistance of AM materials produced by the PolyJet process. Test standards established for mode I fracture testing of adhesive joints are adapted to evaluate the fracture resistance and interface between two printed acrylic-based photopolymers. Significant differences in fracture energy and loci of failure between the selected test configurations were observed depending on the print orientation. Failures were nominally seen to occur at the interface, alternating from one adherend interface to another in a random fashion. Results demonstrated a decreasing trend in fracture energy at slower crack propagation rates, indicating that such dependency is associated with the fracture resistance of the interface. T-peel tests conducted on specimens prepared with both constant and graded interlayers revealed enhanced peel resistance with gradient interlayers, suggesting design opportunities of enhanced fracture toughness by implementing intricate material patterns at the interface of the two photopolymers. Fiber reinforced composite (FRCs) materials have become increasingly desirable in a number of industrial applications where weight reduction is critical for increased payloads and higher performance. When manufacturing structures from these materials, the presence of friction in the composite forming process is seen to have a major effect on the finished quality. Friction between the plies, or between the composite laminate and forming tool, can be undesirable as shape distortions such as wrinkles can appear and compromise the structural integrity of the finished product. To evaluate these frictional processes, a standard rheometer is used to evaluate tool-ply friction on dry textile fabrics and graphite/epoxy prepregs over a range of temperatures, pressures, and sliding velocities. The results provide some general insights into the frictional response of composite prepregs as a function of the manufacturing environment. The materials tested are shown to have different mechanisms that govern the frictional processes. In particular, the results of friction testing on the prepreg indicate that friction comes from a contribution of both Coulomb and viscous-related mechanisms, the latter which become especially at higher temperatures. / Master of Science

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In the Manufacturing Industry there is a subset of technologies referred to as Rapid Technologies which are those technologies that create the ability to compress the time to market for new products under development . Of this subset, Additive Fabrication (AF), or more commonly known as Rapid Prototyping (RP), acquires much attention due to its unique and futuristic approach to the production of physical parts directly from 3D CAD data, CT or MRI scans, or data from laser scanning systems by utilizing various techniques to consecutively generate cross-sectional layers of a given thickness upon the previous layer to form 3D objects. While Rapid Prototyping is the most common name for the production technology it is also referred to as Additive Manufacturing, Layer Based Manufacturing, Direct Digital Manufacturing, Free-Form Fabrication, and 3-Dimensional Printing. With over 35 manufacturers of Additive Fabrication equipment in 2006 , the selection of an AF process and material for a specific application can become a significant task, especially for those with little or no technical experience with the technology and to add to this challenge, many of the various processes have multiple material options to select from . This research was carried out in order to design and construct a system that would allow a person, regardless of their level of technical knowledge, to quickly and easily filter through the large number of Additive Fabrication processes and their associated materials in order to find the most appropriate processes and material options to create physical reproductions of any part. The selection methodology used in this paper is a collection of assumptions and rules taken from the author's viewpoint of how, in real world terms, the selection process generally takes place between a consumer and a service provider. The methodology uses those assumptions in conjunction with a set of expert based rules to direct the user to a best set of qualifying processes and materials suited for their application based on as many or as few input fields the user may be able to complete.