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Printing on Objects: Curved Layer Fused Filament Fabrication on Scanned Surfaces with a Parallel Deposition Machine

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dc.contributor.authorCoe, Edward Olinen
dc.contributor.committeechairSullivan, Martha Lynn Luttrellen
dc.contributor.committeememberKelliher, Aislingen
dc.contributor.committeememberKing, Jonathan Leeen
dc.contributor.committeememberWilliams, Christopher B.en
dc.contributor.departmentArchitectureen
dc.date.accessioned2020-12-13T07:00:43Zen
dc.date.available2020-12-13T07:00:43Zen
dc.date.issued2019-06-21en
dc.description.abstractConsumer additive manufacturing (3D printing) has rapidly grown over the last decade. While the technology for the most common type, Fused Filament Fabrication (FFF), has systematically improved and sales have increased, fundamentally, the capabilities of the machines have remained the same. FFF printers are still limited to depositing layers onto a flat build plate. This makes it difficult to combine consumer AM with other objects. While consumer AM promises to allow us to customize our world, the reality has fallen short. The ability to directly modify existing objects presents numerous possibilities to the consumer: personalization, adding functionality, improving functionality, repair, and novel multi-material manufacturing processes. Indeed, similar goals for industrial manufacturing drove the research and development of technologies like direct write and directed energy deposition which can deposit layers onto uneven surfaces. Replicating these capabilities on consumer 3-axis FFF machines is difficult mainly due to issues with reliability, repeatability, and quality. This thesis proposes, demonstrates, and tests a method for scanning and printing dimensionally-accurate (unwarped) digital forms onto physical objects using a modified consumer-grade 3D printer. It then provides an analysis of the machine design considerations and critical process parameters.en
dc.description.abstractgeneralConsumer additive manufacturing (3D printing) has rapidly grown over the last decade. While the technology for the most common type, Fused Filament Fabrication (FFF), has systematically improved and sales have increased, fundamentally, the capabilities of the machines have remained the same. FFF printers are still limited to depositing layers onto a flat build plate. This makes it difficult to combine consumer AM with other objects. While consumer AM promises to allow us to customize our world, the reality has fallen short. The ability to directly modify existing objects presents numerous possibilities to the consumer: personalization, adding functionality, improving functionality, repair, and novel multi-material manufacturing processes. Indeed, similar goals for industrial manufacturing drove the research and development of technologies like direct write and directed energy deposition which can deposit layers onto uneven surfaces. Replicating these capabilities on consumer 3-axis FFF machines is difficult mainly due to issues with reliability, repeatability, and quality. This thesis proposes, demonstrates, and tests a method for scanning and printing dimensionally-accurate (unwarped) digital forms onto physical objects using a modified consumer-grade 3D printer. It then provides an analysis of the machine design considerations and critical process parameters.en
dc.description.degreeMaster of Scienceen
dc.format.mediumETDen
dc.identifier.othervt_gsexam:21257en
dc.identifier.urihttp://hdl.handle.net/10919/101096en
dc.publisherVirginia Techen
dc.rightsIn Copyrighten
dc.rights.urihttp://rightsstatements.org/vocab/InC/1.0/en
dc.subjectAdditive manufacturingen
dc.subject3D Printingen
dc.subjectFused Filament Fabricationen
dc.subjectFFFen
dc.subjectFDMen
dc.subjectConformalen
dc.titlePrinting on Objects: Curved Layer Fused Filament Fabrication on Scanned Surfaces with a Parallel Deposition Machineen
dc.typeThesisen
thesis.degree.disciplineArchitectureen
thesis.degree.grantorVirginia Polytechnic Institute and State Universityen
thesis.degree.levelmastersen
thesis.degree.nameMaster of Scienceen

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