Doctoral Dissertations


"Rapid Freeze Prototyping (RFP) is a freeform fabrication method that freezes water droplets into ice in a layer-by-layer manner to additively create a 3-dimensional part. Each layer of a geometry is deposited and allowed to freeze before the next layer is added. Ice parts produced by RFP can be used in investment casting to replace wax patterns and in other applications which may benefit from the unconventional method of using ice as a pattern or mold. More recently, a sacrificial support material has been incorporated into RFP so that over-hung areas and complex geometries can be fabricated. The research presented in this PhD dissertation study intends to provide information about a selected support material that has been implemented into the RFP process. The work first presents an overview of the process parameters of the system and the effects they have on the overall build dimensions and surface finish. The work continues on to the investigation process of finding a suitable support material to be used in conjunction with water/ice in RFP. The work then presents a model which illustrates the interaction occurring during fabrication of the main build material (i.e. water freezing to ice) and the support material. Two types of models are derived and explained, which are thermal and concentration models. These models are derived, described in detail, and their solutions obtained by finite element analysis are given. Experimentally obtained data is compared to predictions from the thermal and concentration models. Dimensional accuracy of finished ice parts is also examined for various build parameters. Measurements of geometric features of ice parts are presented as an indication of the dimensional accuracy build capability of RFP. Surface roughness measurements are also given. Sample ice parts are shown throughout the dissertation document--Abstract, page iii.


Leu, M. C. (Ming-Chuan)

Committee Member(s)

Liou, Frank W.
Bertrand, Gary L.
Hilmas, Greg
Landers, Robert G.


Mechanical and Aerospace Engineering

Degree Name

Ph. D. in Mechanical Engineering


National Science Foundation (U.S.)
United States. Department of Education


Missouri University of Science and Technology

Publication Date

Fall 2008


xii, 94 pages

Note about bibliography

Includes bibliographical references (pages 91-93).


© 2008 Frances Denise Bryant, All rights reserved.

Document Type

Dissertation - Open Access

File Type




Subject Headings

Manufacturing processes
Prototypes, Engineering
Rapid prototyping
Solid freeform fabrication

Thesis Number

T 9454

Print OCLC #


Electronic OCLC #