Thesis (M. Phil.)--University of Hong Kong, 2007. / Title proper from title frame. Also available in printed format.

The accuracy issue of a rapid prototyping-direct laser sintering system is studied in this paper. The sources of errors are analyzed for their contribution to the final accuracy of built parts. The error sources are related to the hardware and software of the machine, the materials and the process. Special measures were exploited to improve the accuracy of the direct laser sintering system and process. For the errors caused by hardware like laser scanner, compensation by software was developed to correct the errors resulting from galvano-mirrors and F-θ lens. A compensation function mode was added to the slicing software to compensate the errors caused by material shrinkage and laser beam offset. Based on the analysis and improvement, a desired accuracy of 0.2mm has been achieved for the direct laser sintering system, which was verified by experiments. / Singapore-MIT Alliance (SMA)

Additive manufacturing processes, which utilize selective deposition of material rather than traditional subtractive methods, are very promising due to their ability to build complex, highly specific geometries in short periods of time. Three-dimensional direct inkjet printing is a relatively new additive process that promises to be more efficient, scalable, and financially feasible than others. Due to its novelty, however, numerous technical challenges remain to be overcome before it can attain widespread use. This thesis identifies those challenges and finds that material limitations are the most critical at this point. In the case of deposition of high viscosity polymers, for example, it is found that droplet formation is a limiting factor. Acoustic resonance jetting, a technology recently developed at Georgia Institute of Technology, may have the potential to address this limitation because it generates droplets using a physical mechanism different from those currently in use. This process focuses ultrasonic waves using cavity resonances to form a standing wave with high pressure gradients near the orifice of the nozzle, thereby ejecting droplets periodically. This thesis reports initial exploratory testing of this technologys performance with various material and process parameters. In addition, analytical and numerical analyses of the physical phenomena are presented. Results show that, while the pressures generated by the system are significant, energy losses due to viscous friction within the nozzle may prove to be prohibitive. This thesis identifies and begins evaluation of many of the process variables, providing a strong basis for continued investigation of this technology.

Techn. Hochsch., Diss.--Aachen, 2006.

Zugl.: Chemnitz, Techn. Univ., Diss., 2009

Thesis (M.S.)--California Polytechnic State University, 2009. / Mode of access: Internet. Title from PDF title page; viewed on Feb. 9, 2010. Major professor: Dr. Robert Crockett. "Presented to the faculty of California Polytechnic State University, San Luis Obispo, California." "In partial fulfillment of the requirements for the degree [of] Master of Science in Engineering." "November 2009." Includes bibliographical references (p. 47-52).

This dissertation presents the investigation of thermal radiation from three-dimensional electromagnetic crystals (EMXT), as well as the development of a THz rapid prototyping fabrication technique and its application in THz EMXT components and micro-system fabrication and integration. First, it is proposed that thermal radiation from a 3-D EMXT would be greatly enhanced at the band gap edge frequency due to the redistribution of photon density of states (DOS) within the crystal. A THz thermal radiator could thus be built upon a THz EMXT by utilizing the exceptional emission peak(s) around its band gap frequency. The thermal radiation enhancement effects of various THz EMXT including both silicon and tungsten woodpile structures (WPS) and cubic photonic cavity (CPC) array are explored. The DOS of all three structures are calculated, and their thermal radiation intensities are predicted using Planck's Equation. These calculations show that the DOS of the silicon and tungsten WPS can be enhanced by a factor of 11.8 around 364 GHz and 2.6 around 406 GHz respectively, in comparison to the normal blackbody radiation at same frequencies. An enhancement factor of more than 100 is obtained in calculation from the CPC array. A silicon WPS with a band gap around 200 GHz has been designed and fabricated. Thermal emissivity of the silicon WPS sample is measured with a control blackbody as reference. And enhancements of the emission from the WPS over the control blackbody are observed at several frequencies quite consistent with the theoretical predictions. Second, the practical challenge of THz EMXT component and system fabrication is met by a THz rapid prototyping technique developed by us. Using this technique, the fabrications of several EMXTs with 3D electromagnetic band gaps in the 100-400 GHz range are demonstrated. Characterization of the samples via THz Time-domain Spectroscopy (THz-TDS) shows very good agreement with simulation, confirming the build accuracy of this prototyping approach. Third, an all-dielectric THz waveguide is designed, fabricated and characterized. The design is based on hollow-core EMXT waveguide, and the fabrication is implemented with the THz prototyping method. Characterization results of the waveguide power loss factor show good consistency with the simulation, and waveguide propagation loss as low as 0.03 dB/mm at 105 GHz is demonstrated. Several design parameters are also varied and their impacts on the waveguide performance investigated theoretically. Finally, a THz EMXT antenna based on expanding the defect radius of the EMXT waveguide to a horn shape is proposed and studied. The boresight directivity and main beam angular width of the optimized EMXT horn antenna is comparable with a copper horn antenna of the same dimensions at low frequencies, and much better than the copper horn at high frequencies. The EMXT antenna has been successfully fabricated via the same THz prototyping, and we believe this is the first time an EMXT antenna of this architecture is fabricated. Far-field measurement of the EMXT antenna radiation pattern is undergoing. Also, in order to integrate planar THz solid-state devices (especially source and detector) and THz samples under test with the potential THz micro-system fabricate-able by the prototyping approach, an EMXT waveguide-to-microstrip line transition structure is designed. The structure uses tapered solid dielectric waveguides on both ends to transit THz energy from the EMXT waveguide defect onto the microstrip line. Simulation of the transition structure in a back-to-back configuration yields about -15 dB insertion loss mainly due to the dielectric material loss. The coupling and radiation loss of the transition structure is estimated to be -2.115 dB. The fabrication and characterization of the transition system is currently underway. With all the above THz components realized in the future, integrated THz micro-systems manufactured by the same prototyping technique will be achieved, with low cost, high quality, self-sufficiency, and great customizability.

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