Advancing metal casting process via 3D sand printing

• Increases design complexity of metal castings
• Improves mechanical properties
• Leads to early identification of defects

Publications (as of May 2023)

https://doi.org/10.3390/ma16020756

https://doi.org/10.1007/s00170-023-11112-x

https://doi.org/10.1007/s40962-023-00966-2

Abrasive Flow Machining on AM thin walls and internal channels

• Walls with thickness > 0.25 mm are not deformed by AFM process
• Novel coupon for ease of inspection
• Novel method to compute surface roughness using micro-CT data
• Dimension and surface roughness evolution for developing design rules

Additive Manufacturing + Mass Finishing Hybrid Manufacturing System (AM+MF)

• Improve metal AM surface finish and cost efficiency through Mass Finishing technologies
• Surface characterization on mass finished metal AM parts with varied build orientations
• Wear analysis on Mass Finished metal L-PBF and EBM Ti6Al4V parts
• Surface standardization and characterization through machine learning based image processing for  as-built and finished metal AM parts
• Manufacturing recommendation for AM+MF hybrid manufacturing system

Publications

http://dx.doi.org/10.26153/tsw/17678

http://dx.doi.org/10.26153/tsw/44335

“Mass Finishing of Additively Manufactured Ti6Al4V Parts: An Investigation of Surface Finish Dependency on Build Orientation and Processing Conditions”. 2023 North American Manufacturing Research Conference (NAMRC) proceedings. Link: Available soon

“Cost Analysis of Mass Fishing Additively Manufactured Metal Parts ”. 2023 Institute of Industrial and System Engineers (IISE) conference proceedings. Link: Available soon

Computer vision-based surface morphology evolution through feature tracking for mass finished metal-AM surfaces

• Time has higher impact on Sa reduction through contour flattening
• Side oriented surfaces have largest attached powder
• Surface finish up to 0.2 um Sa achieved

Developing a Novel Test Artifact Design for Conformal Printing via Material Extrusion

• Re-thinking novel design features for conformal AM
• Identifying design limits for conformal printing using nozzle height and nozzle angle
• Interplay between machine-nozzle configuration

Multi-material and geometric gradation and fabrication of TPMS structures through Laser Powder Bed Fusion

• Comparable mechanical loading responses can be achieved with significant weight/material consumption drop through TPMS structures
• Microstructural and lattice morphological characterization achieved through Micro-CT, SEM, EBSD & EDS

Design of Non-Pneumatic Tires (NPT) using TPMS

• Design Methodology for achieving localized Stiffness in NPT tires.
• Higher and localized stiffness can be achieved using TPMS structures for NPT Tires.
• Applications to rough terrain vehicles- Landrovers in space,etc.
• Mechanical Testing -Uniaxial compression tests using MTS Loadframe and Digital Image Correlation (DIC).

Study of multimodal powder-binder interaction in binder jetting process

• Increase in droplet velocity resulted in deeper penetration (5.4%) of the binder but reduced the area of spread (20.8%) across packing densities.
• An increase in droplet velocity resulted in a shorter spreading time (27.3%).

Additive manufacturing of patient-specific high-fidelity and thickness-controlled cerebral aneurysm geometries

• Achieving a high-fidelity thickness-controlled model
• Compliant model with pressure achieved at 100mmHg
• The aneurysm bulge expanded in both the vertical and horizontal directions by 8.5% and 10.6%

LPBF of Zinc for biodegradable orthopedic implants

• Zinc produces a healthy bone environment to stimulate osseointegration and bone in-growth
• Zinc is capable of being additively manufactured through LPBF with high dense and replicable mechanical/material properties
• Surface roughness and texturing may be designed to tailor the rate of biodegradation

3D Printing Using Polycaprolactone For Small Bone Fracture Fixation

• The biodegradable material, PCL, can be utilized to properly align fractured bone, eliminate the need for an implant removal surgery, and allow the bone to repair itself.
• PCL TPMS structures of 300um pore diameter allow cells to proliferate within the TPMS while also supporting the external mechanical forces of the body.