VTechWorks Repository :: Browsing by Author "Williams, Christopher B."

Browsing by Author "Williams, Christopher B."

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3D printing vending machine
(United States Patent and Trademark Office, 2016-08-16)
A vending machine for creating a three-dimensional object having an enclosure having an exterior and interior. The interior receives and houses at least one three-dimensional printer. An interface for accepting an instruction associated with an object to be printed and transmitting the instruction to the printer. A storage section for storing a printed object that provides access to the printed part but limits or prohibits access to the interior.
Additive Manufacturing of Copper via Binder Jetting of Copper Nanoparticle Inks
Bai, Yun (Virginia Tech, 2018-06-01)
This work created a manufacturing process and material system based on binder jetting Additive Manufacturing to process pure copper. In order to reduce the sintered part porosity and shape distortion during sintering, the powder bed voids were filled with smaller particles to improve the powder packing density. Through the investigation of a bimodal particle size powder bed and nanoparticle binders, this work aims to develop an understanding of (i) the relationship between printed part properties and powder bed particle size distribution, and (ii) the binder-powder interaction and printed primitive formation in binder jetting of metals. Bimodal powder mixtures created by mixing a coarse powder with a finer powder were investigated. Compared to the parts printed with the monosized fine powder constituent, the use of a bimodal powder mixture improved the powder flowability and packing density, and therefore increased the green part density (8.2%), reduced the sintering shrinkage (6.4%), and increased the sintered density (4.0%). The deposition of nanoparticles to the powder bed voids was achieved by three different metal binders: (i) a nanoparticles suspension in an existing organic binder, (ii) an inorganic nanosuspension, and (iii) a Metal-Organic-Decomposition ink. The use of nanoparticle binders improved the green part density and reduced the sintering shrinkage, which has led to an improved sintered density when high binder saturation ratios were used. A new binding mechanism based on sintering the jetted metal nanoparticles was demonstrated to be capable of (i) providing a permanent bonding for powders to improve the printed part structural integrity, and (ii) eliminating the need for organic adhesives to improve the printed part purity. Finally, the binder-powder interaction was studied by an experimental approach based on sessile drop goniometry on a powder bed. The dynamic contact angle of binder wetting capillary pores was calculated based on the binder penetration time, and used to describe the powder permeability and understand the binder penetration depth. This gained understanding was then used to study how the nanoparticle solid loading in a binder affect the binder-powder interactions and the printed primitive size, which provided an understanding for determining material compatibility and printing parameters in binder jetting.
Additive Manufacturing of Poly(phenylene Sulfide) Aerogels via Simultaneous Material Extrusion and Thermally Induced Phase Separation
Godshall, Garrett F.; Rau, Daniel A.; Williams, Christopher B.; Moore, Robert B. (Wiley-VCH GmbH, 2023-11)
Additive manufacturing (AM) of aerogels increases the achievable geometric complexity, and affords fabrication of hierarchically porous structures. In this work, a custom heated material extrusion (MEX) device prints aerogels of poly(phenylene sulfide) (PPS), an engineering thermoplastic, via in situ thermally induced phase separation (TIPS). First, pre-prepared solid gel inks are dissolved at high temperatures in the heated extruder barrel to form a homogeneous polymer solution. Solutions are then extruded onto a room-temperature substrate, where printed roads maintain their bead shape and rapidly solidify via TIPS, thus enabling layer-wise MEX AM. Printed gels are converted to aerogels via postprocessing solvent exchange and freeze-drying. This work explores the effect of ink composition on printed aerogel morphology and thermomechanical properties. Scanning electron microscopy micrographs reveal complex hierarchical microstructures that are compositionally dependent. Printed aerogels demonstrate tailorable porosities (50.0–74.8%) and densities (0.345–0.684 g cm⁻³), which align well with cast aerogel analogs. Differential scanning calorimetry thermograms indicate printed aerogels are highly crystalline (≈43%), suggesting that printing does not inhibit the solidification process occurring during TIPS (polymer crystallization). Uniaxial compression testing reveals that compositionally dependent microstructure governs aerogel mechanical behavior, with compressive moduli ranging from 33.0 to 106.5 MPa.
Advancing Elastomers to Additive Manufacturing Through Tailored Photochemistry and Latex Design
Scott, Philip Jonathan (Virginia Tech, 2020-07-08)
Additive manufacturing (AM) fabricates complex geometries inaccessible through other manufacturing techniques. However, each AM platform imposes unique process-induced constraints which are not addressed by traditional polymeric materials. Vat photopolymerization (VP) represents a leading AM platform which yields high geometric resolution, surface finish, and isotropic mechanical properties. However, this process requires low viscosity (<20 Pa·s) photocurable liquids, which generally restricts the molecular weight of suitable VP precursors. This obstacle, in concert with the inability to polymerize high molecular weight polymers in the printer vat, effectively limits the molecular weight of linear network strands between crosslink points (Mc) and diminishes the mechanical and elastic performance of VP printed objects. Polymer colloids (latex) effectively decouple the relationship between viscosity and molecular weight by sequestering large polymer chains within discrete, non-continuous particles dispersed in water, thereby mitigating long-range entanglements throughout the colloid. Incorporation of photocrosslinking chemistry into the continuous, aqueous phase of latex combined photocurability with the rheological advantages of latex and yielded a high molecular weight precursor suitable for VP. Continuous-phase photocrosslinking generated a hydrogel scaffold network which surrounded the particles and yielded a solid "green body" structure. Photorheology elucidated rapid photocuring behavior and tunable green body storage moduli based on scaffold composition. Subsequent water removal and annealing promoted particle coalescence by penetration through the scaffold, demonstrating a novel approach to semiinterpenetrating network (sIPN) formation. The sIPN's retained the geometric shape of the photocured green body yet exhibited mechanical properties dominated by the high molecular weight latex polymer. Dynamic mechanical analysis (DMA) revealed shifting of the latex polymer and photocrosslinked scaffold T_g's to a common value, a well-established phenomenon due phasemixing in (s)IPN's. Tensile analysis confirmed elastic behavior and ultimate strains above 500% for printed styrene-butadiene rubber (SBR) latexes which confirmed the efficacy of this approach to print high performance elastomers. Further investigations probed the versatility of this approach to other polymer compositions and a broader range of latex thermal properties. Semibatch emulsion polymerization generated a systematic series of random copolymer latexes with varied compositional ratios of hexyl methacrylate (HMA) and methyl methacrylate (MMA), and thus established a platform for investigating the effect of latex particle thermal properties on this newly discovered latex photoprocessing approach. Incorporation of scaffold monomer, N-vinyl pyrrolidone (NVP), and crosslinker, N,N'-methylene bisacrylamide (MBAm), into the continuous, aqueous phase of each latex afforded tunable photocurability. Photorheology revealed higher storage moduli for green bodies embedded with glassy latex particles, suggesting a reinforcing effect. Post-cure processing elucidated the necessity to anneal the green bodies above the T_g of the polymer particles to promote flow and particle coalescence, which was evidenced by an optical transition from opaque to transparent upon loss of the light-scattering particle domains. Differential scanning calorimetry (DSC) provided a comparison of the thermal properties of each neat latex polymer with the corresponding sIPN. Another direction investigated the modularity of this approach to 3D print mixtures of dissimilar particles (hybrid colloids). Polymer-inorganic hybrid colloids containing SBR and silica nanoparticles provided a highly tunable route to printing elastomeric nanocomposite sIPN's. The bimodal particle size distribution introduced by the mixture of SBR (150 nm) and silica (12 nm) nanoparticles enabled tuning of colloid behavior to introduce yield-stress behavior at high particle concentrations. High-silica hybrid colloids therefore exhibited both a shear-induced reversible liquid-solid transition (indicated by a modulus crossover) and irreversible photocrosslinking, which established a unique processing window for UV-assisted direct ink write (UV-DIW) AM. Concentric cylinder rheology probed the yield-stress behavior of hybrid colloids at high particle concentrations which facilitated both the extrusion of these materials through the UV-DIW nozzle and the retention of their as-deposited shaped during printing. Photorheology confirmed rapid photocuring of all hybrid colloids to yield increased moduli capable of supporting subsequent layers. Scanning electron microscopy (SEM) confirmed well-dispersed silica aggregates in the nanocomposite sIPN's. DMA and tensile confirmed significant reinforcement of (thermo)mechanical properties as a result of silica incorporation. sIPN's with relative weight ratio of 30:70 silica:SBR achieved maximum strains above 300% and maximum strengths over 10 MPa. In a different approach to enhancing VP part mechanical properties, thiol-ene chemistry provided simultaneous linear chain extension and crosslinking in oligomeric diacrylate systems, providing tunable increases to Mc of the photocured networks. Hydrogenated polybutadiene diacrylate (HPBDA) oligomers provided the first example of hydrocarbon elastomer photopolymers for VP. 1,6-hexanedithiol provided a miscible dithiol chain extender which introduced linear thiol-ene chain extension to compete with acrylate crosslinking. DMA and tensile confirmed a decrease in T_g and increased strain-at-break with decreased crosslink density. Other work investigated the synthesis and characterization of first-ever phosphonium polyzwitterions. Free radical polymerization synthesized air-stable triarylphosphine-containing polymers and random copolymers from the monomer 4-(diphenylphosphino) styrene (DPPS). ³¹P NMR spectroscopy confirmed quantitative post-polymerization alkylation of pendant triarylphosphines to yield phosphonium ionomers and polyzwitterions. Systematic comparison of neutral, ionomer, and polyzwitterions elucidated significant (thermo)mechanical reinforcement by interactions between large phosphonium sulfobetaine dipoles. Broadband dielectric spectroscopy (BDS) confirmed the presence of these dipoles through significant increases in static dielectric content. Small-angle X-ray scattering (SAX) illustrated ionic domain formation for all charged polymers.
Advancing Manufacturing Quality Control Capabilities Through The Use Of In-Line High-Density Dimensional Data
Wells, Lee Jay (Virginia Tech, 2014-01-15)
Through recent advancements in high-density dimensional (HDD) measurement technologies, such as 3D laser scanners, data-sets consisting of an almost complete representation of a manufactured part's geometry can now be obtained. While HDD data measurement devices have traditionally been used in reverse engineering application, they are beginning to be applied as in-line measurement devices. Unfortunately, appropriate quality control (QC) techniques have yet to be developed to take full advantage of this new data-rich environment and for the most part rely on extracting discrete key product characteristics (KPCs) for analysis. In order to maximize the potential of HDD measurement technologies requires a new quality paradigm. Specifically, when presented with HDD data, quality should not only be assessed by discrete KPCs but should consider the entire part being produced, anything less results in valuable data being wasted. This dissertation addresses the need for adapting current techniques and developing new approaches for the use of HDD data in manufacturing systems to increase overall quality control (QC) capabilities. Specifically, this research effort focuses on the use of HDD data for 1) Developing a framework for self-correcting compliant assembly systems, 2) Using statistical process control to detect process shifts through part surfaces, and 3) Performing automated part inspection for non-feature based faults. The overarching goal of this research is to identify how HDD data can be used within these three research focus areas to increase QC capabilities while following the principles of the aforementioned new quality paradigm.
Assessing Global Competence and Teamology for Collaborative Engineering
Cobert, Matthew John (Virginia Tech, 2011-10-07)
There is a need to make measureable improvements to the global competency of engineering students that will enable them to work more effectively with overseas colleagues. However, there are few assessment tools that offer clear guidance on which types of global exposure (coursework, virtual collaboration, or education abroad) provide substantial benefit. Additionally, with the increasing reliance on teams to solve problems in both industry and academia, there is a need to ensure high-performance and inventiveness. This thesis addresses these two challenges by 1) developing a new assessment tool for gauging global competency and evaluating a commercially-available tool, and 2) validating and simplifying Wilde's teamology method for assembling better teams. The newly developed Global Competence Survey (GCS) is a quick and effective tool that is able to delineate between student groups based upon duration of education abroad. In its current form, the GCS works by assessing student knowledge of key facts about USA and Germany, and their ability to recognize cultural images. This first attempt shows statistically significant differences between domestic, three-month abroad, and year-long abroad students in these critical areas. Additionally, the teamology method was confirmed empirically by analyzing the performance of two-person global research teams assembled using traditional selection criteria. This analysis shows that teams with greater personality diversity exhibit far higher performance and stronger cohesion. When coupled with functional role requirements, teamology provides an opportunity to dramatically enhance the team performance and cohesion of an available talent pool.
Beyond the Classroom: Understanding the Educational Significance of Non-Curricular Engineering Design Experiences
Kusano, Stephanie Marie (Virginia Tech, 2015-01-29)
The purpose of my dissertation study is to better understand the educational experiences of undergraduate engineering students within non-curricular learning environments, specifically in the form of extracurricular engineering groups or programs. I first conducted a content analysis of engineering education literature to identify where engineering design learning occurs, and to synthesize the implications of studies regarding engineering design learning. Aiming to fill a gap in the literature regarding non-curricular learning contexts, this study investigated what extracurricular groups and programs can educationally provide undergraduate engineering students by observing and interviewing students engaging in these environments. This study also aimed to identify if and how engineering students find navigational flexibility within engineering curricula, and how non-curricular learning environments might provide navigational flexibility. With regard to where engineering design learning occurs, the literature points to various educational contexts that effectively deliver engineering design education. Strategies that involve authentic and longer-term engineering design experiences tend to be the most impactful in terms of student outcomes and perceptions, however those experiences are not always implementable at larger scale. More traditional educational approaches to engineering design learning, though less impactful, are still effective delivery methods for introducing key aspects of engineering design education (e.g. modeling, global/societal/economic/environmental factors, communication skills). However, there was limited literature regarding more non-curricular learning experiences, such as learning in designed settings, outreach learning, learning media, and everyday informal learning. This literature review is one of the first attempts towards synthesizing where and how engineering design learning occurs, and has identified a significant gap in the literature regarding non-curricular educational settings. Addressing the identified gap in engineering education literature regarding non-curricular learning experiences, this dissertation study investigated five non-curricular engineering learning sites for undergraduate engineering students at a large research-driven state institution. Informed by the preliminary findings of a pilot study, I first investigated the salient features of engineering-related non-curricular activities from the students' perspectives using a self-directed learner autonomy framework to guide the study. Students participating in extracurricular engineering environments exhibited strong attributes of self-directed learners, particularly a willingness and ability to be challenged and to learn. The educational environments of the extracurricular opportunities cultivated these self-directed learning attributes by providing students a space to be exposed to an engineering community, authentic engineering work, and accessible resources. Findings from this portion of the dissertation indicated necessary modifications to the self-directed learner autonomy framework used to guide this study. The modified framework contributes a possible approach towards future assessment or research pursuits regarding non-curricular learning experiences in engineering. I also investigated the role non-curricular activities play in providing engineering students navigational flexibility through engineering curricula. Extracurricular engineering environments afford navigational flexibility by offering students opportunities to work on motivating challenges with and among supportive communities. By providing a space for students to express their engineering selves in primarily self-directed ways, extracurricular engineering experiences cultivate students' drive to find and pursue personally meaningful curricular and non-curricular educational experiences. However, institutional barriers, particularly time constraints and institutionally recognized achievements, stifle students' flexibility and willingness to pursue personally meaningful experiences. The findings of this study have helped uncover the various affordances non-curricular learning experiences provide engineering students, but more importantly, have identified the institutional barriers that prevent students from taking full advantage of non-curricular learning experiences. Based on these findings, I recommend that university and program level structures be reevaluated to encourage and provide students with more flexibility to find personalized learning experiences in and out of the classroom.
Career Goals and Actions of Early Career Engineering Graduates
Winters, Katherine Elaine (Virginia Tech, 2012-03-19)
Much of engineering education research focuses on improving undergraduate engineering education. However, in order to help new engineers prepare for and successfully transition to the workplace, and therefore improve retention within the engineering practice, it is vitally important to understand the experiences of these early career engineers. The purpose of this study is to identify and explain the career goals and actions of early career engineering graduates. To accomplish this goal, this research addressed the question "What factors influence early career engineering graduates" career goals near the end of their undergraduate engineering studies, career-related actions taken in the subsequent four years, and their future career plans? Data were predominantly qualitative. Thirty participants were interviewed and surveyed near the end of their undergraduate studies, then completed pre-questionnaires and an interview as early career engineering graduates. Participants were graduates from three different universities and were diverse with respect to sex, race, and undergraduate major. Data analysis was framed by Social Cognitive Career Theory, as developed by Lent, Brown, and Hackett, and followed case study methods. Results show that early career engineering graduates had diverse goals and interests, but similar influencing factors. They generally wanted to find appealing work and acted towards that goal. Relationships with faculty and expectations of positive outcomes heavily influenced participants' decisions to pursue graduate degrees, and family commitments geographically constrained career choices while also increasing the desire for stability. The economic downturn impacted job availability for most participants, but many participants were able to broaden their career searches to find interesting and fulfilling work. Participants that exhibited an ability to adapt to changing conditions reported the greater levels of satisfaction with their careers. The findings of this research provide important information to engineering educators and employers as they mentor the next generation of engineers, and early career engineering graduates themselves as they seek to achieve their goals.
Characterization and Modeling of the Thermal Properties of Photopolymers for Material Jetting Processes
Mikkelson, Emily Cleary (Virginia Tech, 2014-03-25)
One emerging application of additive manufacturing is building parts with embedded electronics, but the thermal management of these assemblies is a potential issue. Electrical components have efficiency losses, and a significant portion of that lost energy is converted into heat. Embedding electronics in PolyJet parts is of particular interest since material jetting additive manufacturing has the ability to deposit multiple, functionally graded materials on a pixel by pixel basis. Although there is existing literature on other PolyJet material properties, there is limited research on their thermal characterization. The goal of this work is to determine the thermal conductivities of select PolyJet photopolymers (VeroWhitePlus, TangoBlackPlus, and Grey60) by using the heat flow meter method. The resulting thermal conductivities are then applied in finite element analysis (FEA) simulations to model the thermal distribution of heated PolyJet parts. Two FEA models of one-dimensional conduction in PolyJet parts are defined and compared to a corresponding physical model to verify the thermal conductivity measurements; one simulation expresses thermal conductivity as a function of temperature and the other uses an average value of thermal conductivity. The thermal conductivities were determined for a range of temperatures, and the average values were 0.2376 W/(m•K), 0.2307 W/(m•K), and 0.2272 W/(m•K) for VeroWhitePlus, TangoBlackPlus, and Grey60, respectively. When applying the thermal conductivity results to an FEA model, it was concluded that defining thermal conductivity as a function of temperature (as opposed to a constant value), reduced the average error in the predicted temperatures by less than 1%.
Characterization of the Integration of Additively Manufactured All-Aromatic Polyimide and Conductive Direct-Write Silver Inks
Oja, Thomas Edward (Virginia Tech, 2020-12-07)
Hybridizing additive manufacturing (AM) structures and direct write (DW) deposition of conductive traces enables the design and physical creation of integrated, complex, and conformal electronics such as embedded electronics and complex routing on a fully AM structure. Although this hybridization has a promising outlook, there are several key AM substrate-related limitations that limit the final performance of these hybridized AM-DW electronic parts. These limitations include low-temperature processability (leading to high trace resistivity) and poor surface finish (leading to electronic shorts and disconnections). Recently discovered ultraviolet-assisted direct ink write (UV-DIW) all-aromatic polyimide (PI) provides an opportunity to address these previous shortcomings previously due to its high-temperature stability (450C) and superior surface finish (relative to other AM processes). The primary goal of this thesis is to characterize the integration of this UV-DIW PI with DW-printed conductive inks as a means for obtaining high-performance hybrid AM-DW electronics. This goal has been achieved through an investigation into the increased temperature stability of AM PI on the conductivity and adhesion of DW extrusion and aerosol jet (AJ) silver inks, determining the dielectric constant and dissipation factor of processed UV-DIW PI, and determining the achievable microwave application performance of UV-DIW PI. These performance measurements are compared to commercially-available PI film and relative to existing AM substrates, such as ULTEM 1010. The temperature stability of UV-DIW PI enabled higher-temperature post-processing for the printed silver traces, which decreased DIW trace resistivity from 14.94±0.55 times the value of bulk silver at 160 °C to 2.16±0.028 times the resistivity of bulk silver at 375 °C, and AJ silver trace resistivity from 5.27±0.013 times the resistivity of bulk silver at 200 °C to 1.95±0.15 times the resistivity of bulk silver at 350 °C. The adhesion of these traces was not negatively affected by higher processing temperatures, and the traces performed similarly on UV-DIW PI and commercial PI. Furthermore, at similar thicknesses, UV-DIW PI was found to have a similar dielectric constant and dissipation factor to commercial Dupont Kapton PI film from 1 kHz to 1 MHz, indicating its ability to perform highly as a dielectric electronics substrate. Finally, the decrease in resistivity was able to decrease the gap in microwave stripline transmission line performance when compared with ULTEM 1010 processed at 200°C, with peak 10 GHz S21 loss differences decreasing from 2.46 dB to 1.32 dB after increasing the UV-DIW processing temperature from 200 °C to 400°C.
Characterizing Student Attention in Technology-Infused Classrooms Using Real-time Active Window Data
Mohammadi-Aragh, Mahnas Jean (Virginia Tech, 2013-06-06)
As computers become more prevalent (and required) in engineering classrooms, it becomes increasingly important to address the dichotomy in our current understanding of their impact on student attention and learning. While some researchers report increased student learning, others report computers as a distraction to learning. To address this conflict, the research community must gain a fundamental understanding of how students use their computers in-class and how student attention is connected to learning and pedagogical practice. By gaining such an understanding, instructors\' design of classroom interventions aimed at increasing positive computer usage will be better informed. The purpose of this quantitative research study is to answer the overarching question "How do students use computers in technology-infused classrooms?" through an investigation of student attention. Based on the premise that one\'s senses must be oriented towards a stimulus to receive the stimulus, it is hypothesized that attention in a technology-infused classroom can be measured by monitoring a students\' top-most, active window (the Active Window Method). This novel approach mitigates issues with prior data collection methods, and allows researchers the opportunity to capture real-time student computer usage. This research serves the dual purpose of validating the Active Window Method and investigating applications of the method. The Active Window Method is validated by comparing real-time active window data with in-class observations of attention in engineering courses with large enrollments. The bootstrap resampling technique is used to estimate mean error rate. Post-tests are used to establish convergent validity by relating learning to active window data. Polytomous logistic regression is used to examine the probability of post-test score (response) over the range of attention levels (factor). Subsequent to validation, two applications of the Active Window Method were pursued. First, student computer use is characterized in multiple large lecture sections. Second, in answering calls to link student computer usage to pedagogical practices, an investigation into the relationship between pedagogy and attention is conducted by aligning time stamps of the active window record with technology-infused pedagogical activities identified in video recordings of lectures. An intervention time series analysis is employed to quantify the change in average attention due to pedagogical activities. Results demonstrate strong construct validity when directly comparing active window and attention. Convergent validity was weak when relating active window to learning. Results from the two applications illustrate that instructors\' use of technology and their pedagogical practices impact student computer use. Specifically, collecting student-generated content and polling question activities encourage on-task behavior. However, activities that include a website link encourage off-task behavior.
A Conceptual Design and Economic Analysis of a Small Autonomous Harvester
French Jr, William David (Virginia Tech, 2014-04-30)
Current trends in agricultural equipment have led to an increasing degree of autonomy. As the state of the art progresses towards fully autonomous vehicles, it is important to consider assumptions implicit in the design of these vehicles. Current automation in harvesters have led to increased sensing and automation on current combines, but no published research examines the effect of machine size on the viability of the autonomous system. The question this thesis examines is: if a human is no longer required to operate an individual harvester, is it possible to build smaller equipment that is still economically viable? This thesis examines the appropriateness of automating these machines by developing a conceptual model for smaller, fully autonomous harvesters. This model includes the basic mechanical subsystems, a conceptual software design, and an economic model of the total cost of ownership. The result of this conceptual design and analysis is a greater understanding of the role of autonomy in harvest. By comparing machine size, machine function, and the costs to own and operate this equipment, design guidelines for future autonomous systems are better understood. It is possible to build an autonomous harvesting system that can compete with current technologies in both harvest speed and overall cost of ownership.
Contextual Shaping of Student Design Practices: The Role of Constraint in First-Year Engineering Design
Goncher, Andrea (Virginia Tech, 2012-12-07)
Research on engineering design is a core area of concern within engineering education, and a fundamental understanding of how engineering students approach and undertake design is necessary in order to develop effective design models and pedagogies. This dissertation contributes to scholarship on engineering design by addressing a critical, but as yet underexplored, problem: how does the context in which students design shape their design practices? Using a qualitative study comprising of video data of design sessions, focus group interviews with students, and archives of their design work, this research explored how design decisions and actions are shaped by context, specifically the context of higher education. To develop a theoretical explanation for observed behavior, this study used the "nested structuration" framework proposed by Perlow, Gittell, & Katz (2004). This framework explicated how teamwork is shaped by mutually reinforcing relationships at the individual, organizational, and institutional levels. I appropriated this framework to look specifically at how engineering students working on a course-related design project identify constraints that guide their design and how these constraints emerge as students interact while working on the project. I first identified and characterized the parameters associated with the design project from the student perspective and then, through multi-case studies of four design teams, I looked at the role these parameters play in student design practices. This qualitative investigation of first-year engineering student design teams revealed mutual and interconnected relationships between students and the organizations and institutions that they are a part of. In addition to contributing to research on engineering design, this work provides guidelines and practices to help design educators develop more effective design projects by incorporating constraints that enable effective design and learning. Moreover, I found that when appropriated in the context of higher education, multiple sublevels existed within nested structuration's organizational context and included course-level and project-level factors. The implications of this research can be used to improve the design of engineering course projects as well as the design of research efforts related to design in engineering education.
Controlling Object Heat Release Rate using Geometrical Features
Kraft, Stefan Marc (Virginia Tech, 2017-06-08)
An experimental study was conducted to determine the effect of complex geometries on the burning rate of materials made using additive manufacturing. Controlling heat release rate has applicability in limiting fire hazards as well as for designing fuels for optimal burning rate. The burning rate of a structure is a function of the material properties as well as the airflow through it, which is dictated by the geometry. This burning rate is generally proportional to the porosity for objects in which the flow is limited by the path constriction. The relations between porosity and burning rate are well studied for wood cribs, which are layers of wood sticks. Crib and other objects with various geometric features were constructed of ABS plastic and coal powder using additive manufacturing processes. A cone calorimeter using oxygen calorimetry was used to measure the heat release rate of the crib specimens. Within the flow limited burning regime, the burning rate of an object is proportional to the porosity factor. Porosity factors calculated from a 1-D theoretical burn rate model as well as from two empirical models were found to correlate the heat release rate results for the crib samples. The heat release rate results of the complex geometries generally correlated to the same porosity factor; however, the model was modified to account for differences between regularly shaped cribs and objects with different sized flow areas. Using the empirical models provides good correlation for the crib burning data and gives a clearer delineation between the flow-limited and surface area controlled regimes.
Creating Complex Hollow Metal Geometries Using Additive Manufacturing and Metal Plating
McCarthy, David Lee (Virginia Tech, 2012-06-25)
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.
Demonstration of Vulnerabilities in Globally Distributed Additive Manufacturing
Norwood, Charles Ellis (Virginia Tech, 2020-06-24)
Globally distributed additive manufacturing is a relatively new frontier in the field of product lifecycle management. Designers are independent of additive manufacturing services, often thousands of miles apart. Manufacturing data must be transmitted electronically from designer to manufacturer to realize the benefits of such a system. Unalterable blockchain legers can record transactions between customers, designers, and manufacturers allowing each to trust the other two without needing to be familiar with each other. Although trust can be established, malicious printers or customers still have the incentive to produce unauthorized or pirated parts. To prevent this, machine instructions are encrypted and electronically transmitted to the printing service, where an authorized printer decrypts the data and prints an approved number of parts or products. The encrypted data may include G-Code machine instructions which contain every motion of every motor on a 3D printer. Once these instructions are decrypted, motor drivers send control signals along wires to the printer's stepper motors. The transmission along these wires is no longer encrypted. If the signals along the wires are read, the motion of the motor can be analyzed, and G-Code can be reverse engineered. This thesis demonstrates such a threat through a simulated attack on a G-Code controlled device. A computer running a numeric controller and G-Code interpreter is connected to standard stepper motors. As G-Code commands are delivered, the magnetic field generated by the transmitted signals is read by a Hall Effect sensor. The rapid oscillation of the magnetic field corresponds to the stepper motor control signals which rhythmically move the motor. The oscillating signals are recorded by a high speed analog to digital converter attached to a second computer. The two systems are completely electronically isolated. The recorded signals are saved as a string of voltage data with a matching time stamp. The voltage data is processed through a Matlab script which analyzes the direction the motor spins and the number of steps the motor takes. With these two pieces of data, the G-Code instructions which produced the motion can be recreated. The demonstration shows the exposure of previously encrypted data, allowing for the unauthorized production of parts, revealing a security flaw in a distributed additive manufacturing environment.
Deposition path planning for material extrusion using specified orientation fields
Kubalak, Joseph R.; Wicks, Alfred L.; Williams, Christopher B. (Elsevier, 2019)
The thermal characteristics of the material extrusion additive manufacturing (AM) process produce weak bonds between layers and adjacent depositions, resulting in an overall anisotropic mechanical performance. Design for AM guidelines advise printing load-bearing parts such that load is applied strictly along the deposition paths, but this can be difficult to achieve with complex loading conditions. Recent works have explored toolpath generation techniques capable of generating deposition paths that are aligned with complicated load paths, but the methods rely on assumptions about the shape of the load paths relative to the geometry. In this paper, the authors present an algorithm for generating deposition paths for any arbitrary geometry and anticipated load paths. Deposition paths are planned using a streamline placement algorithm - commonly used for visualizing fluid flow fields - that treats the load paths as a velocity field. The algorithm is demonstrated on an example geometry, and the volumetric coverage of the resulting toolpath is compared to a toolpath generated using a standard toolpath planning technique. Through this comparative study, it is demonstrated that the toolpath resulting from the authors’ proposed algorithm is able to follow the load paths while still achieving similar volumetric coverage to the standard toolpath.
Design and Additive Manufacturing of Carbon-Fiber Reinforced Polymer Microlattice with High Stiffness and High Damping
Kadam, Ruthvik Dinesh (Virginia Tech, 2019-10-17)
Carbon fiber reinforced polymer (CFRP) composites are known for their high stiffness-to-weight and high strength-to-weight ratios and hence are of great interest in several engineering fields such as aerospace, automotive and defense. However, despite their light weight, high stiffness and high strength, their application in these fields is limited due to their poor energy dissipation and vibration damping capabilities. This thesis presents a two-phase microlattice design to overcome this problem. To realize this design, a novel tape casting integrated multi-material stereolithography system is developed and mechanical properties of samples fabricated using this system are evaluated. The design incorporating a stiff phase (CFRP) and a high loss phase, exhibiting high stiffness as well as high damping, is studied via analytical and experimental approaches. To investigate its damping performance, mechanical properties at small-strain and large-strain regimes are measured through dynamic material analysis (DMA) and quasi-static cyclic compression tests respectively. It is seen that both intrinsic (small-strain) and structural (large-strain) damping in terms of a figure of merit (FOM), E1/3tanδ/ρ, can be enhanced by a small addition of a high loss phase in Reuss configuration. Moreover, it is seen that structural damping is improved at low relative densities due to the presence of elastic buckling during deformation. For design usefulness, tunability maps, displaying FOM in terms of design parameters, are developed by curve fitting of experimental measurements. The microlattice design is also evaluated quantitatively by comparing it with existing families of materials in a stiffness-loss map, which shows that the design is as stiff as commercial CFRP composites and as dissipative as elastomers.
Design and Fabrication of a Mask Projection Microstereolithography System for the Characterization and Processing of Novel Photopolymer Resins
Lambert, Philip Michael (Virginia Tech, 2014-09-17)
The goal of this work was to design and build a mask projection microstereolithography (MPμSL) 3D printing system to characterize, process, and quantify the performance of novel photopolymers. MPμSL is an Additive Manufacturing process that uses DLP technology to digitally pattern UV light and selectively cure entire layers of photopolymer resin and fabricate a three dimensional part. For the MPμSL system designed in this body of work, a process was defined to introduce novel photopolymers and characterize their performance. The characterization process first determines the curing characteristics of the photopolymer, namely the Critical Exposure (Ec) and Depth of Penetration (Dp). Performance of the photopolymer is identified via the fabrication of a benchmark test part, designed to determine the minimum feature size, XY plane accuracy, Z-axis minimum feature size, and Z-axis accuracy of each photopolymer with the system. The first characterized photopolymer was poly (propylene glycol) diacrylate, which was used to benchmark the designed MPμSL system. This included the achievable XY resolution (212 micrometers), minimum layer thickness (20 micrometers), vertical build rate (360 layers/hr), and maximum build volume (6x8x36mm3). This system benchmarking process revealed two areas of underperformance when compared to systems of similar design, which lead to the development of the first two research questions: (i) 'How does minimum feature size vary with exposure energy?' and (ii) 'How does Z-axis accuracy vary with increasing Tinuvin 400 concentration in the prepolymer?' The experiment for research question (i) revealed that achievable feature size decreases by 67% with a 420% increase in exposure energy. Introducing 0.25wt% of the photo-inhibitor Tinuvin 400 demonstrated depth of penetration reduction from 398.5 micrometers to 119.7 micrometers. This corresponds to a decrease in Z-axis error from 119% (no Tinuvin 400) to 9% Z-axis error (0.25% Tinuvin 400). Two novel photopolymers were introduced to the system and characterized. Research question (iii) asks 'What are the curing characteristics of Pluronic L-31 how does it perform in the MPμSL system?' while Research Question 4 similarly queries 'What are the curing characteristics of Phosphonium Ionic Liquid and how does it perform in the MPμSL system?' The Pluronic L-31 with 2wt% photo-initiator had an Ec of 17.2 mJ/cm2 and a Dp of 288.8 micrometers, with a minimum feature size of 57.3 ± 5.7 micrometers, with XY plane error of 6% and a Z-axis error of 83%. Phosphonium Ionic Liquid was mixed in various concentrations into two base polymers, Butyl Diacrylate (0% PIL and 10% PIL) and Poly Ethylene Dimethacrylate (5% PIL, 15% PIL, 25% PIL). Introducing PIL into either base polymer caused the Ec to increase in all samples, while there is no significant trend between increasing concentrations of IL in either PEGDMA or BDA and depth of penetration. Any trends previously identified between penetration depth and Z accuracy do not seem to extend from one resin to another. This means that overall, among all resins, depth of penetration is not an accurate way to predict the Z axis accuracy of a part. Furthermore, increasing concentrations of PIL caused increasing % error in both XY plane and Z-axis accuracy .
Design for Additive Manufacturing Considerations for Self-Actuating Compliant Mechanisms Created via Multi-Material PolyJet 3D Printing
Meisel, Nicholas Alexander (Virginia Tech, 2015-06-09)
The work herein is, in part, motivated by the idea of creating optimized, actuating structures using additive manufacturing processes (AM). By developing a consistent, repeatable method for designing and manufacturing multi-material compliant mechanisms, significant performance improvements can be seen in application, such as increased mechanism deflection. There are three distinct categories of research that contribute to this overall motivating idea: 1) investigation of an appropriate multi-material topology optimization process for multi-material jetting, 2) understanding the role that manufacturing constraints play in the fabrication of complex, optimized structures, and 3) investigation of an appropriate process for embedding actuating elements within material jetted parts. PolyJet material jetting is the focus of this dissertation research as it is one of the only AM processes capable of utilizing multiple material phases (e.g., stiff and flexible) within a single build, making it uniquely qualified for manufacturing complex, multi-material compliant mechanisms. However, there are two limitations with the PolyJet process within this context: 1) there is currently a dearth of understanding regarding both single and multi-material manufacturing constraints in the PolyJet process and 2) there is no robust embedding methodology for the in-situ embedding of foreign actuating elements within the PolyJet process. These two gaps (and how they relate to the field of compliant mechanism design) will be discussed in detail in this dissertation. Specific manufacturing constraints investigated include 1) "design for embedding" considerations, 2) removal of support material from printed parts, 3) self-supporting angle of surfaces, 4) post-process survivability of fine features, 5) minimum manufacturable feature size, and 6) material properties of digital materials with relation to feature size. The key manufacturing process and geometric design factors that influence each of these constraints are experimentally determined, as well as the quantitative limitations that each constraint imposes on design.

Browsing by Author "Williams, Christopher B."

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