This work outlines an Innovation Gap in technology commercialization and presents a novel tool, the Advanced Technology Innovation Mapping (ATIM) tool to address this gap. The tool aims to support technology commercialization in early stages of & prior to the New Product Development Process. The dissertation includes a detailed rationale, description, history, similar and originating methods for this tool based on Value Engineering and Function Maps for Design. This work also demonstrates on several example studies the use of the tool and evaluates via an exploratory study the usefulness of the tool. Research tests the tool in educational and training programs at the University of Texas at Austin and finds that the tool improves user understating of majority of important factors for technology commercialization (customer, technology, development activities). User feedback supports these conclusions. In the future the tool could be further expanded, more standardized and improved. Additionally, the work proposes further ways to study the tool in different settings and with groups of different sizes beyond this early exploratory study. / text

Indirect additive processing of ferrous metals offers the potential to freeform fabricate parts with good surface finish and minimal dimensional variation from the computer solid model. The approach described here is to mix a ferrous powder with a transient binder followed by selective laser sintering (SLS) in a commercial polymer machine to create a “green” part. This part is post-processed to burn off the transient binder and to infiltrate the porous structure with a lower melting point metal/alloy. Commercially available SLSed ferrous components contain copper-based infiltrant in a ferrous preform. The choice of copper alloy infiltrant has led to inferior mechanical properties of these components limiting their use in many non-injection-molding structural applications, particularly at elevated temperature. In the present work, an attempt has been made to replace the copper-based infiltrant considering cast iron as a potential infiltrant because of its fluidity, hardness and stability at comparatively high temperature. A critical consideration is loss of part structural integrity by over-melting after infiltration as chemical diffusion of alloying elements, principally carbon, occurs resulting in a decrease in the melting temperature of tool steel preform. A predictive model was developed which defines the degree of success for infiltration based on final part geometry and depending on the relative density of the preform and infiltration temperature. The processing regime is defined as a function of controllable process parameters. An experimental program was undertaken using commercially available LaserForm[superscript tm] A6 tool steel that was infiltrated with ASTM A532 white cast iron. Guided by Ashby densification maps, pre-sintering of the A6 tool steel SLS part was performed to increase the part initial relative density prior to infiltration. The final infiltrated parts were analyzed for geometry, microstructure and hardness. The model may be extended to other ferrous powder and infiltrant compositions in an effort to optimize the properties and utility of the final infiltrated part. / text

Le frittage sélectif par laser (ou Selective Laser Sintering, SLS) des poudres polymères thermoplastiques est maintenant une technique répandue de fabrication additive. Néanmoins, ce procédé n'est industriellement mature que pour une seule famille de polymères, les polyamides. Pour que ce procédé soit employé dans la fabrication de pièces subissant des contraintes thermiques au-delà de 50 °C, il est ainsi nécessaire d'étendre la gamme des matériaux utilisables à des polymères hautes performances tels que les poly(aryl-éther-cétone) ou les poly(aryl-imide). Cette étude décrit la fabrication additive, couche par couche, de pièces aérospatiales complexes en polymères hautes performances. Pour cela, sept poudres en polymère ont été sélectionnées afin d'étudier l'influence de celles-ci sur les différentes phases du procédé et sur la qualité de la matière frittée/fondue. Ainsi, la morphologie de leurs particules, leurs microstructures ou encore leurs densités versées et tapées sont analysées, de même que leurs stabilités thermiques, leurs capacités à absorber l'eau ou à s'écouler. Dans un second temps, une étude paramétrique du procédé a été réalisée dans le but d'aboutir à la fabrication de pièces de bonne qualité matière, tout en portant un intérêt vis-à-vis des évolutions de la poudre cycle après cycle de fabrication. De plus, il est important, dans un souci d'optimisation, d'utiliser toutes les possibilités de forme qu'offre cette fabrication additive et d'en évaluer la résistance mécanique. C'est pourquoi une loi de comportement mécanique d'un polyamide 12 consolidé sélectivement par laser a été déterminée et implémentée dans un code de calcul par éléments finis (ZéBuLoN®). Cette loi de comportement, dans le domaine linéaire et non linéaire, représentative de l'anisotropie du matériau, a ensuite été validée expérimentalement sur des éprouvettes d'essais mécaniques et sur un démonstrateur aérospatial. / Selective Laser Sintering (SLS) of thermoplastic polymer powders is now widely used as a additive manufacturing technique. Nevertheless, this process is industrially mature for only one family of polymers : the polyamides. To use this process in manufacturing applications that are used above 50 °C, it is necessary to increase the range of useable powders to high temperature resistant families of thermoplastic such as poly(aryl-ether-ketone) or poly(aryl-imide). This study investigates the layer-by-layer additive manufacturing of complex parts by SLS from high temperature resistant thermoplastic powders. Seven polymers powders were selected to study their influences on the process steps and the quality of sintered/melted materials. To do so, morphology of theirs particles, microstructures or tapped and poured density are analysed, and also theirs thermal stabilities, capacities to absorb water or theirs flow abilities. In a second step, a study of the influence of process parameters has been carried out to obtain parts with good material quality, taking into account the evolution of the powder after each cycle of fabrication. Moreover, it is important to use all the possibilities of this process in terms of geometry. That is why a law for the mechanical behaviour of laser sintered polyamide 12 has been determined and implemented in a finite element code (ZeBuLoN®). This law, in its linear and non-linear domain, is representative of the material anisotropy and has been experimentally validated on tensile samples and one aerospace part.

This diploma thesis is focused on additive manufacturing, especially on technology Selective Laser Sintering (SLS) and the implementation of additive manufacturing into existing departments of industry, where current elements of systems are supplemented or directly replaced by new parts produced by these technologies. This thesis solves specific project of manipulation unit for manufacturing line. The main goals of the issue are analysis of current construction design and its deficiency, designing and optimalization of this unit in relation to SLS manufacturing technology, product realization and final evaluating of reached results. Part of the thesis is also design documentation.

Polyamides are commonly used in additive manufacturing for final part production, but the material performance can be affected by environmental conditions. The purpose of this project was to evaluate the effects of moisture and temperature on 3D printed polyamides and how structural optimization can benefit from condition-specific data. Conditioned and unconditioned specimens were tensile tested in regions of -20 °C, 23 °C and 60 °C. Two techniques were evaluated; multi jet fusion and selective laser sintering, and mainly two polyamides; polyamide 11 and polyamide 12. Simulations with the obtained data were performed as well as conceptual structural optimization with the intent of optimizing for the intended end-use environment. Infrared thermography provided specimen temperatures as well as temperature and strain relations present during testing. The stress-strain curves obtained showed generally decreasing stiffness and strength with increasing moisture and temperature, albeit moisture in certain cases increased the tensile modulus at freezing temperatures. Temperature affected stiffness and strength more so than moisture. Polyamide 11 absorbed moisture at a higher rate than polyamide 12. The mechanical performance of laser-sintered polyamide 12 was superior, while laser-sintered polyamide 11 showed great elongation before breakage. Further investigation of polymer crystallinity could explain the behaviour of the 3D printed polyamides.

Syftet: Utvärdera produktionstolerans av objekt som producerats genom additiv framställningsteknik (AF) för användning inom tandvård, samt att jämföra denna teknik med subtraktiv framställningsteknik (SF) genom reverse engineering.Material och metod: Tio exemplar av två olika geometriska objekt framställdes från fem olika AF maskiner och en SF maskin. Objekt A efterliknar ett inlay, medan objekt B återspeglar en modell av en fyrledsbro. Alla objekt delades in i olika mätled; X, Y och Z. Mätningarna utfördes med validerade och kalibrerade instrument. Linjära avstånd mättes med ett digitalt skjutmått och hörnradie samt vinklar mättes med ett digitalt mikroskop.Resultat: Vare sig additiv eller subtraktiv framställning uppvisade en perfekt matchning till CAD-filen med hänsyn till de parametrar som utvärderades i denna studie. Standardavvikelsen gällande linjära mätningar för subtraktiv framställning uppvisade konsekventa resultat i alla led, med undantag för X- och Y-led för objektet A och i Y-led för objekt B. Samtliga additiva tillverkningsgrupper hade en konsekvent standardavvikelse i X- och Y-led, men inte i Z-led. Med avseende på hörnradiemätningar, hade SF gruppen i överlag bättre produktionsnoggrannhet för både objekt A och B medan AM grupperna var mindre noggranna.Konklusion: Med hänsyn till begränsningarna med denna in vitro studie, stödjer resultat hypotesen, med hänsyn till att AF hade en bättre förmåga att återskapa komplexa och små geometrier jämfört med SF. Samtidigt identifierades en bättre reproducerbarhet hos SF gällande enkla geometrier och linjära avstånd. Vidare studier krävs för att bekräfta dessa resultat. / Purpose: To evaluate the production tolerance of objects produced by additive manufacturing systems (AM) for usage in dentistry and to compare with subtractive manufacturing system (SM) through reverse engineering. Materials and methods: Ten specimens of two geometrical objects were produced by five different AM machines and one SM machine. Object A mimics an inlay-shaped object, meanwhile object B reflects a four-unit bridge model. All the objects were divided into different measuring-axis; X, Y and Z. Measurements were performed with validated and calibrated equipment. Linear distances were measured with a digital calliper while corner radius and angle were measured with a digital microscope. Results: None of the additive manufacturing or subtractive manufacturing groups presented a perfect match to the CAD-file regarding all parameters included in present study. Considering linear measurements, the standard deviation for subtractive manufacturing group were consistent in all axis, except for X- and Y-axis in object A and Y-axis for object B. Meanwhile additive manufacturing groups had a consistent standard deviation in X- and Y- axis but not in Z-axis. Regarding corner radius measurements, SM group overall had the best accuracy for both object A and B comparing to AM groups. Conclusion: Within the limitations of this in vitro study, results support the hypothesis, considering AM had preferable capability to re-create complex and small geometry compare to SM. Meanwhile, SM were superior producing simple geometry and linear distances. Further studies are required to confirm these results.

No presente trabalho foi desenvolvido um suporte catalítico monolítico para fins aeroespaciais empregando a manufatura aditiva. Para tanto, foi proposta uma geometria que proporcione um escoamento turbulento, permitindo um maior contato entre o reagente e a superfície do catalisador, proporcionando menor perda de carga ao sistema. Esta nova estrutura foi obtida via manufatura aditiva, através da técnica de Sinterização Seletiva a Laser (SLS) indireta. Para utilizar a técnica SLS e material cerâmico, foi necessário desenvolver um revestimento sobre as partículas de alumina para promover a aderência entre as mesmas durante o processo de manufatura aditiva. Em seguida foram definidos, experimentalmente, os parâmetros de aplicação da técnica SLS para o compósito alumina/poliamida. Por fim, foi fabricado, via SLS, o suporte catalítico na forma monolítica. Após a confecção do suporte monolítico, foi desenvolvido um revestimento composto de pseudo-boemita e nitrato de alumínio e aplicado na superfície do monólito, a fim de expandir a área superficial específica do material. Este aumento da área específica favorece a dispersão da fase ativa, composta de óxidos de cobalto e manganês, na superfície do suporte. A caracterização do catalisador monolítico foi realizada a partir das técnicas de Adsorção de Nitrogênio, Análise Termogravimétrica, Microscopia Eletrônica de Varredura e Espectrometria de Emissão Ótica com Fonte de Plasma (ICP-OES). O desempenho do catalisador monolítico na decomposição do H2O2 concentrado foi analisado via teste de gota, monitorado por câmera de alta velocidade. Os bons resultados obtidos nesta reação apontam esta técnica de obtenção de suporte catalítico monolítico através da manufatura aditiva como uma metodologia promissora a ser empregada em sistemas catalíticos com elevada difusão de massa e calor, mas principalmente em sistemas propulsivos a monopropelente. / This work was developed by the additive manufacture monolithic catalytic support to apply aerospace applications. A geometry was proposed to implement a turbulent flow allowing a better contact with catalytic surface and reagent with a low pressure drop in the system. This new structure was obtained by additive manufacture through indirect Selective Laser Sintering (SLS) technique. Firstly, in order to use the SLS for the ceramic material was developed a coating on the alumina particles to promote a melting between them during addictive manufacturing process. Secondly, the printer parameters SLS was configurated into the alumina/polyamide particle. Finally, the monolithic catalytic support was built via SLS. After the monolithic support building, the pseudo-boehmite and aluminum nitrate coating was developed and applied on the monolithic surface to increase the specific superficial area of the material. This increasing of the specific surface area helps the spread of the active phase to made up of cobalt and manganese oxide in the support surface. The characterization of the monolithic catalyst was carried out using the nitrogen adsorption technique, thermogravimetric analysis, scanning electron microscopy and inductive coupled plasma with optical emission spectrometry. The monolithic catalytic performance in the H2O2 concentrated decomposition was analyzed via drop test monitored by the high-speed camera. The good results of this reaction and such a technique of monolithic catalytic support obtainment through the additive manufacture show that a promising methodology can be used in the catalytic system with high diffusion of mass and heat but mainly, in monopropellant propulsive system.

Electrically conductive polymer composites are suitable for use in the manufacture of antistatic products and components for electronic interconnects, fuel cells and electromagnetic shielding. The most widely used processing techniques for producing electrically conductive polymer composites place an inherent constraint on the geometry and architecture of the part that can be fabricated. Hence, this thesis investigates selective laser sintering (SLS), a rapid prototyping technique, to fabricate and characterize electrically conductive nanocomposites of Nylon-12 filled with 4% by weight of carbon black. The objective of the dissertation was to study the effects of the SLS process on the microstructure and properties of the nanocomposite. The effect of laser power and the scan speed on the flexural modulus and part density of the nanocomposite was studied. The set of parameters that yielded the maximum flexural modulus and part density were used to fabricate specimens to study the tensile, impact, rheological and viscoelastic properties. The electrical conductivity of the nanocomposite was also investigated. The thermo-mechanical properties and electrical conductivity of the nanocomposites produced by SLS were compared with those produced by extrusion-injection molding. The structure and morphology of the SLS-processed and extrusion-injection molded nanocomposites were characterized using gas pycnometry, gel permeation chromatography, differential scanning calorimetry, electron microscopy, polarized light microscopy and x-ray diffraction. Physical models were developed to explain the effects of the processing technique on the structure and properties of the nanocomposites. Finally, a one-dimensional heat transfer model of the SLS process that accounted for sintering-induced densification and thermal degradation of the polymer was implemented in order to study the variation in part density with respect to the energy density of the laser beam. This dissertation demonstrated that SLS can be successfully used to fabricate electrically conductive polymer nanocomposites with a relatively low percolation threshold. This capability combined with the ability of SLS to fabricate complicated three-dimensional objects without part-specific tooling could open up several new opportunities.

La conception sur-mesure de matériaux architecturés à l'échelle du milli/centimètre est une stratégie pour développer des matériaux de structure plus performants vis-à-vis de cahiers des charges multifonctionels. Ce travail de thèse s'intéresse en particulier à la conception optimale de panneaux architecturés périodiques, dans le but de combiner des exigences mécaniques de flexion et de cisaillement, ainsi que de conductivité thermique. Le comportement élastique peut être prédit grâce à l'identification sur la cellule périodique des coefficients de la matrice des souplesses équivalente. Ces calculs d'homogénéisation ont été mis en oeuvre par éléments finis pour estimer en particulier les souplesses en flexion et en cisaillement transverse. Après validation expérimentale, cette méthode de calcul constitue un outil d'évaluation des performances mécaniques pour chaque géométrie de cellule périodique (2D ou 3D). À titre d'exemple, et dans un contexte de développement de solutions matériaux architecturés pour l'automobile, la conception de tôles "texturées" est proposée en menant une étude paramétrique à l'aide de cet outil. L'implémentation d'un algorithme d'optimisation topologique couplé à la procédure d'homogénéisation permet d'enrichir les méthodes de conception sur-mesure en élargissant l'espace de recherche des "architectures". Après l'étude modèle du compromis entre flexion et cisaillement, le cas industriel d'un panneau sandwich isolant est traité. Dans ce cas, l'optimisation fournit plusieurs compromis prometteurs entre rigidité en cisaillement et isolation thermique. Ces géométries ont été réalisées et testées, et une nouvelle version améliorée du panneau sandwich a été sélectionnée. / The "material by design" strategy consists in tailoring architectured materials in order to fulfill multi-functional specifications. This PhD study focuses more specifically on designing architectured panels in regards with mechanical compliances (bending and transverse shear), as well as thermal conductivity. Recent advances on periodic homogenization of plates are integrated into a finite elements tool that enables to identify the Reissner-Mindlin effective compliance from the unit cell geometry. The comparison with four-point bending tests illustrates a discussion on the shear loading for homogenization, and its contribution to the global bending stiffness. In a context of architectured steel solutions for automotive, a parametric study is treated on "embossed" steel sheets using this homogenization tool. As a try to enlarge the space of available "architectures", a topological optimization algorithm (using the level-set method) is coupled to the homogenization procedure. The influence of each parameters of the method are studied on the optimization problem of compromising flexural and shear compliances. Finally, the industrial case of an insulation sandwich panel is treated. Few optimized geometries, with a high combination of shear stiffness and thermal insulation, are built, produced and tested. An improved design is highlighted and proposed as next version of this product.

No presente trabalho foi desenvolvido um suporte catalítico monolítico para fins aeroespaciais empregando a manufatura aditiva. Para tanto, foi proposta uma geometria que proporcione um escoamento turbulento, permitindo um maior contato entre o reagente e a superfície do catalisador, proporcionando menor perda de carga ao sistema. Esta nova estrutura foi obtida via manufatura aditiva, através da técnica de Sinterização Seletiva a Laser (SLS) indireta. Para utilizar a técnica SLS e material cerâmico, foi necessário desenvolver um revestimento sobre as partículas de alumina para promover a aderência entre as mesmas durante o processo de manufatura aditiva. Em seguida foram definidos, experimentalmente, os parâmetros de aplicação da técnica SLS para o compósito alumina/poliamida. Por fim, foi fabricado, via SLS, o suporte catalítico na forma monolítica. Após a confecção do suporte monolítico, foi desenvolvido um revestimento composto de pseudo-boemita e nitrato de alumínio e aplicado na superfície do monólito, a fim de expandir a área superficial específica do material. Este aumento da área específica favorece a dispersão da fase ativa, composta de óxidos de cobalto e manganês, na superfície do suporte. A caracterização do catalisador monolítico foi realizada a partir das técnicas de Adsorção de Nitrogênio, Análise Termogravimétrica, Microscopia Eletrônica de Varredura e Espectrometria de Emissão Ótica com Fonte de Plasma (ICP-OES). O desempenho do catalisador monolítico na decomposição do H2O2 concentrado foi analisado via teste de gota, monitorado por câmera de alta velocidade. Os bons resultados obtidos nesta reação apontam esta técnica de obtenção de suporte catalítico monolítico através da manufatura aditiva como uma metodologia promissora a ser empregada em sistemas catalíticos com elevada difusão de massa e calor, mas principalmente em sistemas propulsivos a monopropelente. / This work was developed by the additive manufacture monolithic catalytic support to apply aerospace applications. A geometry was proposed to implement a turbulent flow allowing a better contact with catalytic surface and reagent with a low pressure drop in the system. This new structure was obtained by additive manufacture through indirect Selective Laser Sintering (SLS) technique. Firstly, in order to use the SLS for the ceramic material was developed a coating on the alumina particles to promote a melting between them during addictive manufacturing process. Secondly, the printer parameters SLS was configurated into the alumina/polyamide particle. Finally, the monolithic catalytic support was built via SLS. After the monolithic support building, the pseudo-boehmite and aluminum nitrate coating was developed and applied on the monolithic surface to increase the specific superficial area of the material. This increasing of the specific surface area helps the spread of the active phase to made up of cobalt and manganese oxide in the support surface. The characterization of the monolithic catalyst was carried out using the nitrogen adsorption technique, thermogravimetric analysis, scanning electron microscopy and inductive coupled plasma with optical emission spectrometry. The monolithic catalytic performance in the H2O2 concentrated decomposition was analyzed via drop test monitored by the high-speed camera. The good results of this reaction and such a technique of monolithic catalytic support obtainment through the additive manufacture show that a promising methodology can be used in the catalytic system with high diffusion of mass and heat but mainly, in monopropellant propulsive system.