Additive Fertigung – oftmals plakativ „3D-Druck“ genannt – bezeichnet eine Fertigungstechnologie, die die Herstellung physischer Gegenstände auf Basis digitaler, dreidimensionaler Modelle ermöglicht. Das grundlegende Funktionsprinzip und die Gemeinsamkeit aller additiven bzw. generativen Fertigungsverfahren ist die schichtweise Erzeugung des Objekts. Zu den wesentlichen Vorteilen der Technologie gehört die Designfreiheit, die die Integration komplexer Geometrien erlaubt. Aufgrund der zunehmenden Verfügbarkeit kostengünstiger Geräte für den Heimgebrauch und der wachsenden Marktpräsenz von Druckdienstleistern steht die Technologie erstmals Endkunden in einer Art und Weise zur Verfügung wie es vormals, aufgrund hoher Kosten, lediglich großen Konzernen vorbehalten war. Infolgedessen ist die additive Fertigung vermehrt in den Fokus der breiten Öffentlichkeit geraten. Jedoch haben sich Wissenschaft und Forschung bisher vor allem mit Verfahrens- und Materialfragen befasst. Insbesondere Fragestellungen zu wirtschaftlichen und gesellschaftlichen Auswirkungen haben hingegen kaum Beachtung gefunden. Aus diesem Grund untersucht die vorliegende Dissertation die vielfältigen Implikationen und Auswirkungen der Technologie. Zunächst werden Grundlagen der Fertigungstechnologie erläutert, die für das Verständnis der Arbeit eine zentrale Rolle spielen. Neben dem elementaren Funktionsprinzip der Technologie werden relevante Begrifflichkeiten aus dem Kontext der additiven Fertigung vorgestellt und zueinander in Beziehung gesetzt. Im weiteren Verlauf werden dann Entwicklung und Akteure der Wertschöpfungskette der additiven Fertigung skizziert. Anschließend werden diverse Geschäftsmodelle im Kontext der additiven Fertigung systematisch visualisiert und erläutert. Ein weiterer wichtiger Aspekt sind die zu erwartenden wirtschaftlichen Potentiale, die sich aus einer Reihe technischer Charakteristika ableiten lassen. Festgehalten werden kann, dass der Gestaltungsspielraum von Fertigungssystemen hinsichtlich Komplexität, Effizienzsteigerung und Variantenvielfalt erweitert wird. Die gewonnenen Erkenntnisse werden außerdem genutzt, um zwei Vertreter der Branche exemplarisch mithilfe von Fallstudien zu analysieren. Eines der untersuchten Fallbeispiele ist die populäre Online-Plattform und -Community Thingiverse, die das Veröffentlichen, Teilen und Remixen einer Vielzahl von druckbaren digitalen 3D-Modellen ermöglicht. Das Remixen, ursprünglich bekannt aus der Musikwelt, wird im Zuge des Aufkommens offener Online-Plattformen heute beim Entwurf beliebiger physischer Dinge eingesetzt. Trotz der unverkennbaren Bedeutung sowohl für die Quantität als auch für die Qualität der Innovationen auf diesen Plattformen, ist über den Prozess des Remixens und die Faktoren, die diese beeinflussen, wenig bekannt. Aus diesem Grund werden die Remix-Aktivitäten der Plattform explorativ analysiert. Auf Grundlage der Ergebnisse der Untersuchung werden fünf Thesen sowie praxisbezogene Empfehlungen bzw. Implikationen formuliert. Im Vordergrund der Analyse stehen die Rolle von Remixen in Design-Communities, verschiedene Muster im Prozess des Remixens, Funktionalitäten der Plattform, die das Remixen fördern und das Profil der remixenden Nutzerschaft. Aufgrund enttäuschter Erwartungen an den 3D-Druck im Heimgebrauch wurde dieser demokratischen Form der Produktion kaum Beachtung geschenkt. Richtet man den Fokus jedoch nicht auf die Technik, sondern die Hobbyisten selbst, lassen sich neue Einblicke in die zugrunde liegenden Innovationsprozesse gewinnen. Die Ergebnisse einer qualitativen Studie mit über 75 Designern zeigen unter anderem, dass Designer das Konzept des Remixens bereits verinnerlicht haben und dieses über die Plattform hinaus in verschiedenen Kontexten einsetzen. Ein weiterer Beitrag, der die bisherige Theorie zu Innovationsprozessen erweitert, ist die Identifikation und Beschreibung von sechs unterschiedlichen Remix-Prozessen, die sich anhand der Merkmale Fähigkeiten, Auslöser und Motivation unterscheiden lassen. / Additive manufacturing—commonly known as “3D printing”—denotes a manufacturing technology that facilitates the production of physical objects from digital three-dimensional blueprints. Layer manufacturing is the basic principle of the production process of all additive manufactured objects. Major benefits of this technology are that it allows for the creation of very complex models and its flexibility for various design geometries. Today, for the first time, the increasing number of 3D printing service providers and the constantly growing range of affordable printers for home use, make this technology available to consumers, whereas the high costs limited the use to large enterprises in the past. Therefore, this technology is raising more and more public attention. Presently science and research focuses primarily on questions regarding materials and processes, while ignoring or missing out the discussion about economic and social impact. Therefore, this dissertation examines and focusses on the aspect of possible implications and consequences of the technology. The thesis starts by introducing the main aspects of the technology, to establish a common understanding, which is key for understanding the dissertation. Followed by the description of specific techniques and processes, different terminologies of additive manufacturing are introduced to describe in detail how they are related. In the further course the additive manufacturing value chain, its development, and involved stakeholders are outlined. Subsequent diverse business models out of the additive manufacturing context are systematically visualized and elucidated. Another important aspect are expectable economic potentials that can be deduced by a number of technical characteristics. A conclusion that can be drawn is that the room to maneuver is extended with regard to complexity, efficiency enhancement, and variety of versions. Insights gained hereby are also utilized to analyze two representatives of the branch of industry by way of example. Thereafter, the additive manufacturing value chain, its development, and involved stakeholders are outlined. Diverse business models of the additive manufacturing are depicted and explained systematically. Another important aspect is possible future economic potentials that can be deduced by several technical characteristics. The conclusion of the findings show, that there is room for growth with regard to complexity, enhancement of efficiency, and variety of versions. Furthermore, the learnings are the basis for a detailed analysis of two representatives of this industry by way of examples and case studies. One of the cases deals with the popular online platform and community Thingiverse that offers a platform for publishing, sharing, access, and remixing a broad range of printable digital models. The term remixing—originally known from the music domain—is very often used in various emerging open online platforms to describe the phenomenon of repurposing existing materials to create something new. However, despite its obvious relevance for the number and quality of innovations on such platforms, little is known about the process of remixing and its contextual factors. For that reason, an explorative study of remixing activities on the platform was conducted and is presented. Based on the findings of these empirically observed phenomena, a set of five theoretical propositions, practical recommendations and managerial implications are formulated. Predominant in the analysis are the role of remixes in design communities, the different patterns of remixing processes, the platform features that facilitate remixes, and the profile of the remixing platform’s users. Due to disappointed expectations regarding home use 3D printing this democratic form of production has received only little attention. However, not focusing on the technology itself but on the hobbyist users reveals new insights on underlying innovation processes. The findings of a qualitative study with more than 75 designers show amongst other findings, that designers have already internalized the concept of remixing and apply it in various contexts, even beyond the platform. An additional contribution that extends previous research on innovation processes is the identification and description of six different remix processes that can be differentiated by means of the features skill level, trigger and motivation.

This paper summarizes a design project entitled "Choose Your Own Teaching Adventure" completed for the Instructional Psychology and Technology Department at Brigham Young University. The purpose of the design project was to prototype a learning tool that instructs beginning pre-service teachers in the classroom application of the principles of behaviorism. Originally, the project was designed to be a static learning object that would be combined with other similar learning modules for additional topics of an Educational Psychology course. At the conclusion of the first prototyping round, however, the project was generalized to become a testing ground for a simulation builder project that would allow other instructors to create their own learning simulation based on the findings of this prototype. The Rapid Prototyping methodology used in this project allowed for quick revisions, lower stakes testing, and more flexibility in the design. The various stages of the design and evaluation process, including revisions and prototypes, are shown and discussed in this paper.

In the area of MEMS there exists a tremendous need for communication between the micro-device and the macro world. A standard protocol or at least multiple standards would be of great use. Electrical connections have been standardized for many uses and configurations by the integrated circuit industry. Standardization in the IC industry has created a marketplace for digital devices unprecedented. In addition to the number of "off the shelf" products available, there exists the possibility for consumers to mix and match many devices from many different manufacturers. This research proposes some similar solutions as those for integrated circuits for fluid connections and mechanical configurations that could be used on many different devices. In conjunction with offering the capability to facilitate communication between the micro and macro worlds, the packaging solutions should be easy to fabricate. Many devices are by nature non-standard, unique, designs that make a general solution difficult. At the same time, the micro-devices themselves will inevitably need to evolve some standardization. In BioMEMS devices the packaging issue is concerned with delivering a sample to the device, conducting the sample to the sensor or sensors, and removing the sample. Conducting the sample to the sensor or sensors is usually done with microchannels created by standard MEMS fabrication techniques. Many current designs then utilize conventional machining techniques to create the inlet and outlet for the sample. This work proposes a rapid prototyping method for creating the microchannel and inlet / outlet in simplified steps. The packages developed from this process proved to be an effective solution for many applications.

This research defined and evaluated mechanical properties of prototypes created using a plaster based three-dimensional printing (3DP) system commercialized by Z Corporation. 3DP is one of the fastest growing forms of rapid prototyping. Till date, there is little or no information available on material properties of infiltrants used in 3DP. This research work evaluated and documented some of the useful information for 3DP users by determining the effect of build position, build orientation and infiltration materials on the strength of prototypes. The study was performed in three different phases to limit the processing variables and to arrive at definite conclusions on relationship between materials properties and process variables. All specimens were built on the Z Corporation Spectrum Z510. In Phase 1, effects of build location on specimen strength was studied. Phase 2 evaluated the influence of build orientation on specimen strength. System Three Clear Coat epoxy was used during both Phase 1 and 2 for infiltration. The same infiltrant was in both of these phases to limit variables. Using results of Phase 1 & 2, the effects of infiltrant material on tensile strength of prototypes was calculated in Phase 3. Seven different infiltrating materials were tested during Phase 3. These materials included 2 cyanoacrylates and 5 epoxies. The tensile strength, flexural strength, and density and porosity of the specimens were determined and correlated. In each phase six specimens were built for each test performed. Two consistent methods of infiltration were utilized to infiltrate cyanoacrylates and epoxies into the as-processed specimens. It was found that the orientation of the specimen has more of an impact on strength than position within the build platform. The layering build process of rapid prototyping creates a variance in strength depending on the build orientation. Specimens infiltrated with epoxy achieved much higher strength than the specimens infiltrated with cyanoacrylate. Cyanoacrylates may be a good choice in making color concept models; however they are not good candidate materials where strength requirement is important. The epoxies with lower viscosities demonstrated higher part strength among the materials tested.

Cell culturing on three-dimensional structures has increased the possibilities in tissue engineering and bioreactor research. These structures enable cells to differentiate, proliferate, mobilize, and function in a conformation that more accurately mimics in vivo conditions. Computer generated models aid in development and rapid alteration of three-dimensional cell substrates, defining their internal structure as well as their external morphology. The rapid transition from substrate design to a viable culture is imperative to quickly advance research in biomedical and tissue engineering applications. The aim of this thesis is to investigate the feasibility of a rapid prototyping process by selectively cross-linking and assembling biocompatible films. This investigation revealed that selectively cross-linking and layering gelatin films could produce a three-dimensional substrate with a defined structure after dissolving uncross-linked gelatin. The study also revealed that freeze-drying aided in the rapid dissolution of uncross-linked gelatin. The line width resolution obtained during tests was .5 mm using a template treatment method and was limited by the template construction resolution. Finally, alteration in treatment time, rinsing agitation, and rinsing temperature yielded stable films that better retained their size and shape compared to films produced in previous processes.

With the growing interest in software defined radios (SDRs), cognitive radios, the Joint Tactical Radio System (JTRS), and the Software Communication Architecture (SCA) comes the need for a rapid prototyping approach to radio design. In the past, radios have traditionally been designed to have a static implementation with the express goal of implementing a specific type of communication, such as 802.11b, CDMA voice communication, or just a simple FM tuner. However, when designing an SDR, the developer must not only be able to understand the radio engineering aspects of the design, but also be able to interface correctly with the underlying core software framework. This added software complexity, along with the general need for faster, more economical waveform development, illuminates the need for a rapid prototyping SDR development environment. This thesis takes a fresh look at the task of providing radio designers with a functional, straightforward design tool that enables the developer to focus more on the radio design than the tedious task of interacting with CORBA, IDL, and the SCA Core Framework. The design approach used to create such a tool is investigated along with an overview of general SDR concepts and an introduction to MPRG's open source SCA Core Framework, OSSIE. Discussion on the design methodology behind creating an SCA waveform is provided and the final result of this research, OSSIE Waveform Developer (OWD), is introduced and explored in detail. The code generated using OWD is detailed and waveform design approaches are presented with some suggested modifications. Finally, the improvements gained by using OSSIE Waveform Developer instead of the traditional approach of manually developing waveforms are presented. / Master of Science

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A new flying wing design has been developed at the Unmanned Systems Lab (USL) at Virginia Tech to serve delivery and remote sensing applications in the developing world. The fully autonomous unmanned aerial vehicle (UAV), named EcoSoar, was designed with the goal of creating a business opportunity for local entrepreneurs in low-resource communities. The system was developed in such a way that local fabrication, operation, and maintenance of the aircraft are all possible. In order to present a competitive financial model for sustained drone services, EcoSoar is made with reliable low-cost materials and electronics. This paper lays out the rapid prototyping and flight experiment efforts that went into polishing the design, test results from an EcoSoar centered drone workshop in Kasungu, Malawi, and finally a range optimization study with flight test validation. / Master of Science / A new humanitarian drone has been developed at the Unmanned Systems Lab (USL) at Virginia Tech. The unmanned aerial vehicle (UAV), named EcoSoar, was designed with the goal of creating a business opportunity for local entrepreneurs in low-resource communities. In order to be a viable solution in the developing world EcoSoar utilizes customizable 3D-printed parts and wings made from cheap materials like posterboard and packing tape. In addition, tools for building the drone have been developed in such a way that anyone can learn to construct and operate EcoSoar regardless of experience. This paper lays out the engineering efforts that went into the design, lessons learned from an EcoSoar-centered workshop in Kasungu, Malawi, and finally offers an upgraded design.

Rapid Prototyping (RP) is the process of building three-dimensional objects, in layers, using additive manufacturing. Rapid Manufacturing (RM) is the use of RP technologies to manufacture end-use, or finished, products. At small lot sizes, such as with customized products, traditional manufacturing technologies become infeasible due to the high costs of tooling and setup. RM offers the opportunity to produce these customized products economically. Coupled with the customization opportunities afforded by RM is a certain degree of uncertainty. This uncertainty is mainly attributed to the lack of information known about what the customers specific requirements and preferences are at the time of production. In this thesis, the author presents an overall method for selection of a RM technology, as an investment decision, under the geometric uncertainty inherent to mass customization. Specifically, the author defines the types of uncertainty inherent to RM (epistemic), proposes a method to account for this uncertainty in a selection process (interval analysis), and proposes a method to select a technology under uncertainty (Decision Theory under strict uncertainty). The author illustrates the method with examples on the selection of an RM technology to produce custom caster wheels and custom hearing aid shells. In addition to the selection methodology, the author also develops universal build time and part cost models for the RM technologies. These models are universal in the sense that they depend explicitly on the parameters that characterize each technology and the overall part characteristics.