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Acknowledgement I would like to express my sincere and devoted gratitude to the primary supervisor, Dr Sarat Singamneni, for his continuous encouragement, support, guidance throughout this project without which this wouldn’t have been completed. He has always been behind in every step of this project and has always stood for any problems, difficult situations whatsoever. Dr Sarat has always kept me cheering in difficult times, days when I have felt lost and given up, he has brought me to the right track not once or twice but at so many times that I have no words to thank him in any sort of way. I am also grateful to the School of Engineering, AUT University for providing me with all the equipment required for the completion of the project. Again, I would like to thank Dr Sarat for part funding for this project which has been extremely beneficial. Finally I would like to thank my parents and my friends who have always been supportive during the tough times of this project and always encouraged me to go strong despite the numerous challenges. Vivek Anand viii
List of Figures 1.1 The Rapid prototyping Cycle...............................................................................15 1.2 The Rapid prototyping Methodology....................................................................16 1.3 Stereolithography.................................................................................................17 1.4 Selective Laser Sintering.....................................................................................18 1.5 Laminated Object Manufacturing.........................................................................19 1.6 A Sample LENS process.....................................................................................21 1.7 A FDM Schematic................................................................................................24 1.8 Deposition Head..................................................................................................25 1.9 Sample of parts made by SLS and FDM.............................................................26 1.10 Stair case effect.................................................................................................28 1.11 Layers and finish quality....................................................................................28 1.12 Curved layer deposition.....................................................................................38 2.1 Procedure of Rapid prototyping...........................................................................40 2.2 Faces, Edges and Vertices..................................................................................43 2.3 “Apple” made with the revolve feature.................................................................43 2.4 Extrusion..............................................................................................................44 2.5 Sweeping.............................................................................................................44 2.6 Constructive Solid Geometry...............................................................................45 2.7 A Sphere in STL Format......................................................................................46 2.8 A sample Binary STL File....................................................................................49 2.9 Stereolithography Apparatus...............................................................................50 ix
Page 1 and 2: An Investigation into curved layer
Page 3 and 4: Contents Abstract..................
Page 5 and 6: 3.5.2 Fabepoxy.....................
Page 7: methodology to print simple curved
Page 11 and 12: 4.3 Parts being tested with Hounsfi
Page 13 and 14: List of Abbreviations 3D: Three dim
Page 15 and 16: Fig 1.1 The Rapid prototyping Cycle
Page 17 and 18: 1.1.1 Stereolithography Stereolitho
Page 19 and 20: The object to be made is first mode
Page 21 and 22: 1.1.5 Laser Engineered Net Shaping
Page 23 and 24: 1.2 Fused Deposition Modeling A det
Page 25 and 26: Fig 1.8 Deposition Head Different t
Page 27 and 28: 900mc is capable of producing parts
Page 29 and 30: noted that the parts built in this
Page 31 and 32: structure. Honeycomb scaffold archi
Page 33 and 34: optimal direction to build a part t
Page 35 and 36: processing treatment was analyzed w
Page 37 and 38: The actual influence of the curved
Page 39 and 40: Separating the Main part with its s
Page 41 and 42: limited to simple models. It could
Page 43 and 44: Fig 2.2 Faces, Edges and Vertices o
Page 45 and 46: 2.1.5 Constructive Solid Geometry C
Page 47 and 48: A STL file is a triangular represen
Page 49 and 50: Fig 2.8 A sample Binary STL File Sl
Page 51 and 52: Different processes may either vary
Page 53 and 54: At the very outset of generating th
Page 55 and 56: and correction of each point to sat
Page 57 and 58: apid prototyping machine are remove
Page 59 and 60:
Fig 2.13 Main Part Fig 2.14 Support
Page 61 and 62:
As this text file is to be used wit
Page 63 and 64:
mounted to the axes carriage. Timin
Page 65 and 66:
Fig 3.1 The deposition head At the
Page 67 and 68:
3.2.3 Assembling Electronics and ca
Page 69 and 70:
microcontroller is now disconnected
Page 71 and 72:
The relationship between test point
Page 73 and 74:
on the mechanical properties and po
Page 75 and 76:
3.5.1 Silicone with other materials
Page 77 and 78:
Fab@home machine. Since our require
Page 79 and 80:
are printed using the two suitable
Page 81 and 82:
The support structure‟s dimension
Page 83 and 84:
machine Fig 3.13 Flat and curved la
Page 85 and 86:
4.1 Experimental conditions Chapter
Page 87 and 88:
have many factors from contention a
Page 89 and 90:
4.3 Taguchi methods There are two t
Page 91 and 92:
Such steps usually identify the nee
Page 93 and 94:
Nominal is best Larger is better S
Page 95 and 96:
Control of material flow - The lead
Page 97 and 98:
Fig 4.3 Parts being tested with Hou
Page 99 and 100:
values in all cases are almost doub
Page 101 and 102:
level. The other parameters were in
Page 103 and 104:
The finite element method has had a
Page 105 and 106:
performance of finished FDM parts [
Page 107 and 108:
ehaviour with failure occurring at
Page 109 and 110:
Fig. 2 (a) is the thin curved part
Page 111 and 112:
Table 5.1 Property data: Fabepoxy M
Page 113 and 114:
optimum number. The final finite el
Page 115 and 116:
Fig. 5.11 Load and boundary conditi
Page 117 and 118:
overall deflection pattern of two s
Page 119 and 120:
Fig. 5.13 Variation of compressive
Page 121 and 122:
Fig. 5.15 shows the overall deforma
Page 123 and 124:
The effectiveness of the deposition
Page 125 and 126:
[11] M. Greul, T. Pintat, M. Greuli
Page 127 and 128:
[32] Philip J. Ross, 1988, “Taguc
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