In an effort to gain a more comprehensive and complete understanding of the thermal behaviors occurring during the selective laser sintering process, external temperature measurements were taken during the build process. To accomplish this, an infrared camera was aimed directly through a viewport on the front of the sinterstation. The temperature was monitored during the heating process which showed slightly non-uniform heating of the part bed surface. Temperatures were also recorded while the laser was sintering each layer and the subsequent cooling of the entire machine following the build. By directly capturing infrared images of the part bed’s surface, it is clearer how the temperature gradients behave and the impact such variables have on part build efficiency. / text

No / This paper reports the results of an investigation into the selective laser sintering of a prealloyed high-speed steel powder. The structured development of processing conditions for single lines, single layers and multiple layers of material is reported, as are the flexural modulus and strength of the single- and multiple layer components. Infiltration with bronze was used to improve the mechanical properties of the components and it is concluded that selective laser sintering of high-speed steel allied to bronze infiltration can produce material with the mechanical properties to allow for use in load-bearing applications, but that further work is required to improve the density, mechanical properties and build rate if selective laser sintering is to develop as a general manufacturing process for hard metals.

Additive manufacturing introduces a new design paradigm that allows the fabrication of geometrically complex parts that cannot be produced by traditional manufacturing and assembly methods. Using a cellular heat exchanger as a motivational example, this thesis investigates the creation of a hybrid manufacturing approach that combines selective laser sintering with an electroforming process to produce complex, hollow, metal geometries. The developed process uses electroless nickel plating on laser sintered parts that then undergo a flash burnout procedure to remove the polymer, leaving a complex, hollow, metal part. The resulting geometries cannot be produced directly with other additive manufacturing systems. Copper electroplating and electroless nickel plating are investigated as metal coating methods. Several parametric parts are tested while developing a manufacturing process. Copper electroplating is determined to be too dependent on the geometry of the part, with large changes in plate thickness between the exterior and interior of the tested parts. Even in relatively basic cellular structures, electroplating does not plate the interior of the part. Two phases of electroless nickel plating combined with a flash burnout procedure produce the desired geometry. The tested part has a density of 3.16g/cm3 and withstands pressures up to 25MPa. The cellular part produced has a nickel plate thickness of 800µm and consists of 35% nickel and 65% air (empty space). Detailed procedures are included for the electroplating and electroless plating processes developed. / Master of Science

An algorithm was developed to enable efficient segmentation of dimensionally-large objects into smaller components that can be fabricated within the given Rapid Prototyping (RP) machine workspace. The algorithm uses vertical and horizontal flat plane cuts, as well as feature-based volume decomposition. Due considerations were given to the optimisation of the surface accuracy, the build time, the strength and the number of segments generated by the segmentation process. A computer-aided design (CAD) application programme that interfaces with Unigraphics (UG) was also developed to allow import of objects in Standard Triangulated Language (STL) files into UG without loss of accuracy. In addition, the application software provides the functions that facilitate the implementation of the segmentation algorithm in UG. Two case studies were carried out using the algorithm in a Selective Laser Sintering (SLS) RP system. The resulting objects had properties that matched the research objectives with which the proposed algorithm was validated. / Singapore-MIT Alliance (SMA)

Rapid prototyping methods embrace a family of manufacturing methods that are developed to speed up the prototyping stage of product design. The sole needed input for production being the solid model of the part, mold/tool-free production characteristics and the geometric part complexity that can be achieved due to layer-by-layer production have extended the applicability/research areas of these methods beyond prototyping. Local pore formation in part that occurs as a result of the discrete manufacturing nature of rapid prototyping methods can be viewed as an opportunity for material development. In this thesis, the manufacturing-internal (porous) structure-mechanical property relations of porous materials are investigated. These porous parts are produced via Selective Laser Sintering (SLS) which is a rapid prototyping method. The elastic modulus, tensile strength, rupture strength and Poisson&rsquo / s ratio of uniform porous specimens with known porosities are determined through standardized mechanical tests for polymeric materials. The mechanical property variation profiles in graded materials are determined using the mechanical properties of uniform parts. The mechanical behavior of uniform and graded materials under applied loads are modeled using finite element method and simulation results are compared to the results of mechanical tests performed on graded materials. In addition, feasibility of producing resin filled composite parts from these uniform and graded porous parts are sought. Porous parts (both uniformly and graded) that are infiltrated with epoxy resin have been characterized mechanically and the results have been compared with the uninfiltrated porous parts.

Selective laser sintering is a rapid prototyping method (RP), which was originally developed, along with other RP methods, to speed up the prototyping stage of product design. The sole needed input for production being the solid model of the part, the mold/tool-free production characteristics and the geometric part complexity that can be achieved due to layer-by-layer production have extended the applicability/research areas of these methods beyond prototyping towards new applications and material development. Local pore formation in a part that occurs as a result of the discrete manufacturing nature of selective laser sintering is normally considered a defect. In the current research, this is viewed as an opportunity for material development: Exploitation of rapid prototyping methods to produce composites/functionally graded materials with controlled porous structures. That the material interior structure (porous structure) and exterior shape are formed during the same course renders selective laser sintering process as an attractive manufacturing alternative for producing complex-geometry composite/porous materials, which may be difficult or impossible to manufacture with other techniques. In this thesis, the use of selective laser sintering (a rapid prototyping method) in producing uniformly porous and graded polymeric graded porous structures is studied. The material used was polyamide powder (PA 2200) and the selective laser sintering machine used was the EOSINT P 380 system. In this research, three process parameters of the SLS system, the hatching distance, the laser power and the laser scanning speed were varied to produce parts that have different porosities. Porous parts with a homogenous porous microstructure (uniformly porous parts) could be produced, as well as graded porous parts. The results of uniformly porous structure production were utilized to build graded porous structures by imparting different porosities along a certain direction within a single part. Both, uniformly porous and graded structures were characterized physically and mechanically. The porous parts (both uniformly porous and graded porous) were infiltrated with epoxy resin to produce epoxy-PA composites and graded materials. The physical and mechanical properties of these parts were compared with those of the uninfiltrated (porous PA) structures

While amputee gait has been studied in great detail, the influence of prosthetic foot sagittal and coronal plane stiffness on amputee walking biomechanics is not well understood. In order to investigate the effects of sagittal and coronal plane foot stiffness on amputee walking, a framework for manipulating the stiffness of a prosthetic foot needs to be developed. The sagittal and coronal plane stiffness of a low profile carbon fiber prosthetic foot was manipulated through coupling with selective-laser-sintered prosthetic ankles. The carbon fiber foot provided an underlying non-linear stiffness profile while the ankle modified the overall stiffness of the ankle-foot combination. A design of experiments was performed to determine the effect of four prosthetic ankle dimensions (keel thickness, keel width, space between the ankle top and bottom faces, and the location of the pyramid connection) on ankle-foot sagittal and coronal plane stiffness. Ankles were manufactured using selective laser sintering and statically tested to determine stiffness. Two of the dimensions, space between the ankle top and bottom faces and the location of the pyramid connection, were found to have the largest influence on both sagittal and coronal plane stiffness. A third dimension, keel thickness, influenced only coronal plane stiffness. A number of prosthetic ankle-foot combinations were created that encompassed a range of sagittal and coronal plane stiffness levels that were lower than that of the low profile carbon fiber foot alone. To further test the effectiveness of the framework to manipulate sagittal and coronal plane stiffness, two ankle-foot combinations, one stiffer than the other in the sagittal and coronal planes, were used in a case study analyzing amputee walking biomechanics. Differences in stiffness were large enough to cause noticeable changes in amputee kinematics and kinetics during turning and straight-line walking. Future work will expand the range of ankle-foot stiffness levels that can be created using this framework. The framework will then be used to create ankle-foot combinations to investigate the effect of sagittal and coronal plane stiffness on gait mechanics in a large sample of unilateral transtibial amputees. / text

Individuals with various lower-limb neuromuscular and musculoskeletal impairments are often prescribed passive-dynamic ankle-foot orthoses (PD-AFOs) to compensate for impaired ankle muscle weakness. Several studies have demonstrated the beneficial effects of PD-AFOs on pathological gait, but few studies have examined the influence of the AFO stiffness characteristics on gait performance. One challenge to performing such studies is the difficulty of manufacturing custom AFOs with a wide range of controlled stiffness levels. However, selective laser sintering (SLS) is a well-suited additive manufacturing technique for generating subject-specific PD-AFOs of varied stiffness. Therefore, the overall goal of this study was to use SLS manufactured PD-AFOs to identify the relationships between AFO stiffness and gait performance in patients with various lower-limb neuromuscular and musculoskeletal impairments. Six subjects with unilateral impairments were enrolled in this study. For each subject, one subject-specific PD-AFO equivalent to the subject’s clinically prescribed carbon fiber PD-AFO (nominal), one 20% more compliant and one 20% more stiff were manufactured using SLS. Three-dimensional kinematic and kinetic data were collected from each subject while ambulating with each PD-AFO at two different speeds to allow a comprehensive biomechanical analysis to assess the influence of PD-AFO stiffness on gait performance. The results showed that in the compliant AFO condition, the AFO limb vertical ground reaction force (GRF) impulse during loading and the non-AFO limb medial GRF impulse during push-off decreased. In addition, the AFO limb braking GRF impulse during loading and the non-AFO limb braking GRF impulse in early single-limb stance decreased. Furthermore, in the compliant AFO condition, negative knee work during early single-limb stance increased while positive hip work in early swing decreased in the AFO limb. Overall, as AFO stiffness decreased, the AFO limb contributed less to body support and braking. In addition, a decreased medial GRF impulse coupled with an increased vertical GRF impulse during non-AFO single-limb stance suggests that walking stability may be compromised as AFO stiffness decreases. Thus, a tradeoff may exist between preserving stability and increasing net propulsion, which should be considered when assessing the mobility needs of individuals prescribed PD-AFOs as a result of various neuromuscular and musculoskeletal impairments. / text

This thesis provides investigation into the interaction between quartz lamp emitters and polyether ether ketone (PEEK) powder. Calculations and experiments concerning the conductivity and emissivity of the powder at various temperatures are performed. The thermal profile of the emitter on a flat powder bed is captured using thermal imaging. The effect of exposing a pile of powder to the emitter and the subsequent thermal gradient through the pile is measured and analyzed. Based on these results, ramifications for the application of these emitters to selective laser sintering (SLS) machines for processing high temperature polymers such as PEEK are discussed. / text

For pediatric amputees in developing countries, where characteristically rapid growth of children is compounded by a lack of medical services, maintaining proper socket fit is a challenging but necessary endeavor. A socket design that adjusts for radial and longitudinal growth will allow patients to wear the same socket for a longer period of time saving them the expense of subsequent fittings and hardware. Manufacture of such a socket poses a challenge for contemporary manufacturing processes. Due to its ability to rapidly manufacture complex part geometries, Selective Laser Sintering (SLS) is particularly suited to this application. Several preliminary design concepts for a volume adjustable transtibial SLS prosthetic socket for pediatric amputees in developing countries have been generated. These current design concepts utilize fasteners such as ratchet hooks and threads. Results from design and validation of theoretical models of these fastener concepts are the focus of this thesis. / text