Curved Layer

y Fused Deposition
p
Modeling for Conductive Polymer
dd e Manufacturing
Additive a u ac u g

O. Diegel, S. Singamneni, B. Huang, I. Gibson

AEPR 2010, Paris, France
 Curved Layer FDM Project

Being undertaken by Auckland University of

Technology in Collaboration with the
National University of Singapore and India
Institute of Technology, Kharagpur

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 Additive Manufacturing 101
 Generate a 3D model
 Software slices the 3D model
into thin slices
 M hi
Machine b
builds
ild it llayer b
by
layer
Traditional Fused Deposition Modeling
Traditional Fused Deposition Modeling

Flat layers:
•Stair-case effect gives poor surface quality
•Requires many layers
Weakness in lamination causes
•Weakness ca ses poor strength

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 Curved-Layer FDM (CLFDM)

IInstead
t d off depositing
d iti ththe llayers off material
t i l as flflatt llayers, we d
deposit
it
them as curved layers following the natural shape of the product.
Curved-Layer FDM (CLFDM)

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 Proof-of-Concept Hardware

The Hardware
 The Fab@home: Four Axis Control System
 Hardware Modifications

 TTwini Syringe
S i H
Head d
 Filament extrusion head (manufactured
from modified RepRap extrusion head
 Polymer
y g
granule extrusion head

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Deposition heads

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 Software

 For initial trials a simple

p csv file of the step
p
by step x,y & z coordinates was used to
transmit the tool p path for each layer
y to
the FDM hardware
 This was done in two separate stages: First
the file for the flat support layers was sent
and manufactured by the hardware,
hardware and
then the curved layer file was sent (after
suitable hardening of the support
material) and manufactured on top of
the support material
 Initial material tests

 IIcing
i sugar
 RTV Silicone
 Light cured resin
 FabEpoxy
 Wood Fibre reinforced polymers

 Coming soon:
 Glass Fibre reinforced polymers
 ABS, and other polymers
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CLFDM initial test results
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 CLFDM initial test results

 Successfully demonstrated the concept of

curved layer fused deposition modeling
 Removal of staircase effect in z direction
 30% increase in strength under tensile
loading

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Conductive CLFDM

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 Conductive CLFDM

 With conductive parts product design

would no longer be constrained by PCBs
 Products could be designed without
shape
h restrictions
t i ti
 Complex wire looms could be integrated
into the plastic shell that makes up the
product
 Components could be ‘printed’ as part
of the circuit

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 Current status
 Initial tests with carbon black ABS mixture to
create conductive filaments deposited
through Dimension BST 3D printer
 Carbon black RTV silicone mixture deposited
through Fab@Home system
 Working on software to convert 2D PCB
designs to 3D tool paths
 Recently received funds to build real machine
 X-Y-Z mechanism built and working
 Building multiple material extrusion head for
real proof
proof-of-concept
of concept system
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 Thank You

www.ciri.org.nz/conference3
g

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