A voxel-based design approach for creating functionally graded structures via material extrusion additive manufacturing

Daniel R. Spillane, Nicholas A. Meisel

Research output: Chapter in Book/Report/Conference proceedingConference contribution

1 Scopus citations

Abstract

Functionally graded materials (FGMs) are heterogeneous materials engineered to vary material composition across the volume of an object. Controlled mixture and deposition of each material through a manufactured part can ultimately allow for specific material properties defined in different regions of a structure. While such structures are traditionally difficult to manufacture, additive manufacturing processes, such as directed energy deposition, material jetting, and material extrusion, have recently increased the manufacturability of FGMs. However, the existing digital design workflow lacks the ability to accurately mix and assign multiple materials to a given volume, especially in the case of toolpath dependent deposition processes like filament-based material extrusion. In this paper, we will address this limitation by using a voxel-based representation approach, where material values are assigned across a pixel grid on each geometry slice before converting to toolpath information for manufacturing. This approach allows for creation of structures with increased material complexity decoupled from the external geometry of the design space, an approach not yet demonstrated in the existing literature. By using a dual-feed, single melt-pool extrusion nozzle system, this research demonstrates the ability to accurately recreate mathematically derived gradients while establishing a digital workflow capable of integrating with the material extrusion AM process.

Original languageEnglish (US)
Title of host publication44th Design Automation Conference
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791851753
DOIs
StatePublished - Jan 1 2018
EventASME 2018 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC/CIE 2018 - Quebec City, Canada
Duration: Aug 26 2018Aug 29 2018

Publication series

NameProceedings of the ASME Design Engineering Technical Conference
Volume2A-2018

Other

OtherASME 2018 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC/CIE 2018
CountryCanada
CityQuebec City
Period8/26/188/29/18

All Science Journal Classification (ASJC) codes

  • Mechanical Engineering
  • Computer Graphics and Computer-Aided Design
  • Computer Science Applications
  • Modeling and Simulation

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    Spillane, D. R., & Meisel, N. A. (2018). A voxel-based design approach for creating functionally graded structures via material extrusion additive manufacturing. In 44th Design Automation Conference (Proceedings of the ASME Design Engineering Technical Conference; Vol. 2A-2018). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/DETC2018-85618