Title: Layer alignment tooling and bonding process for the fully dense freeform fabrication (FDFF) adaptive layering process

Authors: Bahram Asiabanpour; Mohammad Hayasi

Addresses: Ingram School of Engineering, Texas State University-San Marcos, Texas 78666, USA ' Ingram School of Engineering, Texas State University-San Marcos, Texas 78666, USA

Abstract: The Fully Dense Freeform Fabrication (FDFF) process utilises an adaptive layering method for predefined sheets and uses slices cut by an abrasive waterjet cutter or laser cutter machine for manufacturing functional parts through smart layer alignment and compatible bonding materials. Under pressure and heat, layers are attached and form a 3D prototype from a fully dense material. This paper presents an integrated alignment and compression bonding mechanism that is functional for a variety of complex parts. It also explores the benefits of using induction heaters to reach the brazing quality layer bonding heat for the metallic parts. Finally, feasible settings for producing functional metallic parts for variety of geometries and materials are presented.

Keywords: FDFF; fully dense freeform fabrication; layer alignment; layer bonding; sacrificed tab; induction heating; adaptive manufacturing; layered manufacturing; compression bonding; complex parts.

DOI: 10.1504/IJRAPIDM.2013.053687

International Journal of Rapid Manufacturing, 2013 Vol.3 No.2/3, pp.172 - 194

Available online: 04 May 2013 *

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