Abstract
Various nomenclatures are in use to describe SFF processes that create metal and ceramic objects. At the University of Texas and in this book, the three major processing methods are called transfer methods, indirect methods, and direct methods. In simple terms, transfer methods use patterns, either castings or spray metal patterns. Indirect methods1 (which could also be called low-density matrix methods) involve making relatively low-density objects and then infiltrating or post-sintering these objects to high density. Direct methods (which could also be called high-density methods) create high density structures without a secondary processing step. There is already commercial application of the indirect methods; the direct methods are all still in the research stage. Transfer and indirect methods are the subject of this chapter. A discussion of direct methods is deferred until Chapter 7.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Preview
Unable to display preview. Download preview PDF.
References
Agarwala, M.K., R. van Weeren, R. Vaidyanathan, J. Burlew, R. Donaldson, P. Whalen, C. Ballard: “Structural Ceramics by Fused Deposition of Ceramics”, Solid Freeform Fabrication Proceedings, Austin, Texas, 1995. The University of Texas, Austin, Texas, pp. 1–8.
Apelskog-Killander, L., “Rapid Mould: Epoxy-Infiltrated, Laser Sintered Inserts”, Rapid Prototyping J., 1996, 2, pp. 34–40.
ASM Handbook Committee, Metals Handbook 10th Edition, Volume 2 Properties and Selection: Nonferrous Alloys and Pure Metals, ASM International, 1990, pp. 45–49.
Badrinarayan, B. “Study of the Selective Laser Sintering of Metal-Polymer Powders,” PhD. Dissertation, The University of Texas at Austin, Dec. 1995.
Badrinarayan, B., and Barlow, J. W., “Selective Laser Sintering of a Copper-PMMA System,” Solid Freeform Fabrication Proceedings, The University of Texas: Austin, Texas, 1991, pp. 245–250.
Badrinarayan, B., and Barlow, J. W., “Manufacture of Injection Molds using SLS,” Solid Freeform Fabrication Proceedings, The University of Texas: Austin, Texas, 1994, 371–378.
Barlow, J. W., et al, U. S. Patent Appl., 1994, “Mold Useful for Injection Molding of Plastics and Methods of Production and Uses Thereof.”
Barlow, J. W., Beaman, J. J., and Badrinarayan, B., “A Rapid Mould Making System: Material Properties and Design Considerations,” Rapid Prototyping Journal, 1996, 2, pp. 4–15.
Bernhardt, E. C., Processing of Thermoplastic Materials, Van Nostrand Reinhold Company: New York, 1959, pp. 359–378.
Biddle, K., et al.: “The Chemistry of Ethyl Silicate Binders in Refractory Technology”, Journal of Applied Chemistry and Biotechnology 27, 1977, pp. 565–573.
Bird, R. B., Stewart, W. E., and Lightfoot, E. N., Transport Phenomena, J. Wiley: New York, 1960, p.748.
Bowman, L., “CAD to Product — the LOM Route”, Proceedings of the 2nd European Conference on Rapid Prototyping and Manufacturing, University of Nottingham, 1993.
Bunnell, D. E., Das, S., Bourell, D. L., Beaman, J. J., and Marcus, H. L., “Fundamentals of Liquid Phase Sintering During Selective Laser Sintering,” Solid Freeform Fabrication Proceedings, The University of Texas: Austin, Texas, 1995, pp. 440–447.
Bunnell, D.E., “Fundamentals of Selective Laser Sintering of Metals”, PhD Dissertation, The University of Texas at Austin, Austin, Texas, 1995.
Carslaw, H. S., and Jaeger, J. C., Conduction of Heat in Solids, 2nd Ed., Oxford University Press: New York, 1959.
Carter, W.T. and M.G. Jones, “Direct Laser Sintering of Metals”, Solid Freeform Fabrication Proceedings, The University of Texas at Austin, Austin, TX, 1993, pp. 51–59.
Cima, M.J., E.M. Sachs, L.G. Cima, J. Yoo, S. Khanuja, S.W. Borland, B. Wu, R.A. Giordano: “Computer-Derived Microstructures by 3D Printing: Bio-and Structural Materials”, Solid Freeform Fabrication Proceedings, The University of Texas at Austin, Austin, Texas, 1994, pp. 181–190.
Cima, M.J., J. Yoo, S. Khanuja, M. Rynerson, D. Nammour, B. Giritlioglu, J. Grau, E.M. Sachs: “Structural Ceramic Components by 3D Printing”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1995. pp. 479–488.
Comb, J.W. and W.R. Priedeman: “Control Parameters and Material Selection Criteria for Rapid Prototyping Systems”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1993, pp. 86–91.
Comb, J.W., W.R. Priedeman, and P.W. Turley, “FDM Technology Process Improvements”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1994, pp. 42–49.
Crockett, R.S., J. O’Kelly, P.D. Calvert, B.D. Fabes, K. Stuffle, P. Creegan, R. Hoffman: “Predicting and Controlling Resolution and Surface Finish of Ceramic Objects Produced by Stereodeposition Processes”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1995, pp. 17–24.
Deckard, L., and Claar, T. D., “Fabrication of Ceramic and Metal Matrix Composites from Selective Laser Sintered Ceramic Preforms,” Solid Freeform Fabrication Proceedings, The University of Texas: Austin, Texas, 1993, 215–222.
DTM Corporation, Guidelines for Using RapidCasting Polycarbonate Patterns in the Investment Casting Process, DTM Corporation, Austin, TX, 1995.
Emblem, H.G., “Ethyl Silicate Bonded Refractories”, Materials Chemistry and Physics, 8 (1983) pp. 265–277.
Ferguson, B.L. and O.D. Smith: “Ceracon Process”, in Metals Handbook 9th Edition, Volume 7 Powder Metallurgy, ASM International, 1984, pp. 537–541.
German, R.M., Powder Metallurgy Science, Second Edition, Metal Powder Industries Federation, Princeton, NJ, 1994.
German, R.M., Particle Packing Characteristics, Metal Powder Industries Federation, Princeton, NJ, 1989.
German, R.M., Liquid Phase Sintering, Plenum Press, New York, NY, 1985.
Griffin, Curtis, JoDee Daufenbach, Scott McMillin: “Solid Freeform Fabrication of Functional Ceramic Components Using a Laminated Object Manufacturing Technique”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1994, pp. 17–24.
Griffith, Michelle L., John W. Halloran: “Ultraviolet Curing of Highly Loaded Ceramic Suspensions for Stereolithography of Ceramics”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1994, pp. 396–403.
Griffith, Michelle L., Tien-Min Chu, Warren Wagner, John W. Halloran: “Ceramic Stereolithography For Investment Casting and Biomedical Applications”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1995, pp. 31–38.
Hausner, H.H. and M.K. Mal, Handbook of Powder Metallurgy, Second Edition, Chemical Publishing Company, New York, NY, 1982.
Janney M.A., “Method for Molding Ceramic Powders”, U.S. Patent No. 4, 894, 194, Jan. 16, 1990.
Jones, W.D., Fundamental Principles of Powder Metallurgy, Edward Arnold Publishers, London, UK, 1960.
Jurand, R., ed., Modern Plastics Encyclopedia, McGraw-Hill: New York, 1989, pp 576–619.
Kashigawi, T., Hirata, T., and Brown, J. E., “Thermal and Oxidative Degradation of Poly(methyl methacrylate): Molecular Weight,” Macromolecules, 18[2], (1985), pp. 131–138.
Kine, B. B. and Novak, R. W., “Acrylic and Methacrylic Ester Polymers,” Encyclopedia of Polymer Science and Engineering, 2nd Ed., Vol. 1, J. Wiley & Sons: New York, 1985, p. 241.
Krantz, T., “Effect of density and composition on dimensional stability and strength of iron-copper alloys”, International Journal of Powder Metallurgy, Volume 5, Number 3, 1969, pp. 35–43.
Lee, G.-H., Barlow, J. W., “Selective Laser Sintering of Calcium Phosphate Powders,” Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1994, 191–197.
Lenel, F.V., Powder Metallurgy Principles and Applications, Metal Powder Industries Federation, Princeton, NJ, 1980.
Marin, J. and Sauer, J. A. Strength of Materials, MacMillan Company: New York, 1954, pp 76–85, p. 508.
Masters, K., Spray Drying Handbook, J. Wiley & Sons: New York, 1985.
McAdams, W. H., Heat Transmission, 3rd Ed., McGraw-Hill: New York, 1954, p. 224.
Menges, G. and P. Mohren, How to Make Injection Molds, Hanser Publishers, New York, 1986, p. 35.
Michaels, S., E.M. Sachs, M.J. Cima: “Metal Parts Generation by Three Dimensional Printing”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1992, pp. 244–250.
Pang, T.H. and P.F. Jacobs, “Stereolithography Epoxy Resin Development: Accuracy and Dimensional Stability”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1993, pp. 11–26.
Pitts, D. R., and Sisson, L. E., Heat Transfer, McGraw-Hill: New York, 1977, chapt. 11 & Appendix B.
Progelhof, R. C. and Throne, J. L., Polymer Engineering Principles. Properties, Processes, Tests for Design, Hanser/Gardner Publications: Cincinnati, Ohio, 1993, chapt. 5.
Rohsenow, W. M., Hartnett, J. P., and Ganic, E. N., Eds., Handbook of Heat Transfer Fundamentals, 2nd Ed., McGraw-Hill: New York, 1985, pp. 3–113.
Sachs, E.M., S. Allen, M.J. Cima, E. Wylonis, H. Guo: “Production of Injection Molding Tooling with Conformal Cooling Channels using the Three Dimensional Printing Process”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1995., pp. 448–467.
Sih, S. S. and Barlow, J. W., “Emissivity of Powder Beds,” Marcus, H. L., et al, Eds., Solid Freeform Fabrication Proceedings, The University of Texas: Austin, Texas, 1995, 402–408.
Stuffle, K., A. Mulligan, J. Lombardi, P. Calvert: “Solid Freebody Forming of Ceramics from Polymerizable Slurry”, Materials Research Society Symposium Proceedings, 286 (1993a) pp. 309–314.
Stuffle, Kevin, Anthony Mulligan, Paul Calvert, John Lombardi: “Solid Freebody Forming from Polymerizable Slurry”, i Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1993.b, pp. 60–63.
Tadmor, Z. and Gogos, C. G., Principles of Polymer Processing, John Wiley & Sons: New York, 1979, chapt. 14.
Tobin, J. R., Badrinarayan, B., Barlow, J. W., Beaman, J. J., and Bourell, D. L., “Indirect Metal Composite Part Manufacture Using the SLS Process,” Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1993, pp. 303–307.
Vail, N. K., Barlow, J. W., and Marcus, H. L., “Silicon Carbide Preforms for Metal Infiltration by Selective Laser Sintering of Polymer Encapsulated Powders,” Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1993, 204–214.
Vail, N. K., and Barlow, J. W., “Effect of Polymer Coatings as Intermediate Binders on Sintering of Ceramic Parts,” Solid Freeform Fabrication Proceedings, The University of Texas: Austin, Texas, 1991, 195–204.
Vail, N. K., and Barlow, J. W., “A Method for Producing High Temperature Parts by Low Temperature Sintering,” U. S. Patent No. 5, 284, 695, Feb. 8, 1994.
Vail, N. K., “Preparation and Characterization of Microencapsulated, Finely Divided Ceramic Materials for Selective Laser Sintering,” Ph.D. Dissertation, The University of Texas at Austin, 1994.
Venus, A.D., “Improving Product Development for Automotive Cast Components”, Proceedings for the Dedicated Conference on Rapid Prototyping in the Automotive Industries, Automotive Automation Limited, Croydon, England, 1995, pp. 307–319.
Walters, W., “Rapid Prototyping Using FDM: A Fast, Precise, Safe Technology”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1992, pp. 301–308.
Warner, C., “New Trends in Pattern Making Using LOM”, Proceedings for the Dedicated Conference on Rapid Prototyping in the Automotive Industries, Automotive Automation Limited, Croydon, England, 1995, pp. 59–70.
Yoo, J., M.J. Cima, S. Khanuja, E.M. Sachs: “Structural Ceramic Components by 3D Printing”, Solid Freeform Fabrication Proceedings, The University of Texas, Austin, Texas, 1993, pp. 40–50.
Young, A.C., O.O. Omatete, M.A. Janney, P.A. Menchofer: “Gel Casting — A New Ceramic Forming Process”, Journal of the American Ceramic Society 74#3 (1991) pp. 612–618.
Young, A.G., “Linking Prototyping and Production”, IMS International Conference on Rapid Product Development, Stuttgart, Germany, 1994.
Zong, G., Wu, Y., Tran, N., Lee, I., Bourell, D. L., and Marcus, H. L., “Direct Selective Laser Sintering of High Temperature Materials,” Solid Freeform Fabrication Proceedings, The University of Texas: Austin, Texas, 1992, 72–85.
Author information
Authors and Affiliations
Rights and permissions
Copyright information
© 1997 Springer Science+Business Media New York
About this chapter
Cite this chapter
Beaman, J.J., Barlow, J.W., Bourell, D.L., Crawford, R.H., Marcus, H.L., McAlea, K.P. (1997). Indirect Fabrication of Metals and Ceramics. In: Solid Freeform Fabrication: A New Direction in Manufacturing. Springer, Boston, MA. https://doi.org/10.1007/978-1-4615-6327-3_5
Download citation
DOI: https://doi.org/10.1007/978-1-4615-6327-3_5
Publisher Name: Springer, Boston, MA
Print ISBN: 978-0-7923-9834-9
Online ISBN: 978-1-4615-6327-3
eBook Packages: Springer Book Archive