Masters Theses

Keywords and Phrases

Ceramic On-Demand Extrusion; Design for Additive Manufacturing; DfAM; Direct Ink Writing

Abstract

"Design for Additive Manufacturing (DfAM) has made much progress for polymer material extrusion processes (MEX-P), like Fused Deposition Modeling (FDM), but very little progress for ceramic MEX processes (MEX-C) like Direct Ink Writing (DIW). This thesis leverages MEX-P design guidelines to create an initial set of design guidelines for DIW. FDM and DIW processes and material properties are compared, and the effect of these factors on the differences in rules is discussed. Five design guidelines are identified as applying to all MEX. For three of these, an exact limit for DIW of alumina is studied: minimum corner radius in the build plane, minimum gap needed between movable joints in a print-in-place assembly, and maximum self-supported gap-spanning distance (or ‘bridging’ distance). The effects of printing variables (flow rate, travel speed, extrudate/bead/line/layer height and width, and corner blending toolpath planning modes) on these three limits are determined by experiments and statistical data analysis. For gap-spanning distance, a mathematical model from literature and material properties is used to explain the differences between the specific MEX-P and MEX-C limits. One unique design rule for DIW MEX-C is presented, suggesting that designers should modify their designs for more uniform drying of layers. Finally, these initial design guidelines are summarized, and the impact of their use is demonstrated with 3D prints. The creation of these guidelines demonstrates a method of linking developments across MEX subprocesses through shared mechanisms and printing variables. Adopting a similar approach could accelerate research and adoption of every MEX subprocess"-- Abstract, p. iii

Advisor(s)

Leu, M. C. (Ming-Chuan)

Committee Member(s)

Hilmas, Greg
Watts, Jeremy Lee, 1980-

Department(s)

Mechanical and Aerospace Engineering

Degree Name

M.S. in Mechanical Engineering

Publisher

Missouri University of Science and Technology

Publication Date

2026

Pagination

x, 87 pages

Note about bibliography

Includes_bibliographical_references_(pages 83-86)

Rights

© 2024 Hollis Hervey Waites , All Rights Reserved

Document Type

Thesis - Open Access

File Type

text

Language

English

Thesis Number

T 12635

Download

Included in

Manufacturing Commons

Share

 
COinS