Hostname: page-component-78c5997874-8bhkd Total loading time: 0 Render date: 2024-11-17T19:14:46.895Z Has data issue: false hasContentIssue false
  • English
  • Français

Freeform Fabrication of Components with Designed Cellular Structure

Published online by Cambridge University Press:  10 February 2011

W. R. Zimbeck  and
R. W. Rice
W. R. Zimbeck
Affiliation:
Ceramic Composites, Inc. Annapolis, MD 21401, zimbo@techassess.com
R. W. Rice
Affiliation:
Consultant, Springfield, VA 22310
Get access

Abstract

One of the more intriguing freeform fabrication application areas is the fabrication of bodies with designed microstmctures. While design of reinforced composite microstructures has received much attention, construction of designed porous or cellular structures may have greater technical feasibility and offers attractive practical benefits. Freeform fabrication advantages compared to existing foam and honeycomb fabrication techniques are discussed with emphasis on control over pore size, shape, orientation and distribution including hierarchical and functionally graded pore structures, all in combination with the ability to fabricate near net shape objects of complex geometry. Potential applications include the use of designed surface and bulk porosity to enhance both short and long term fixation of structural metal implants to bone, and lightweighting of aerospace components to approach optimized mass efficiency based on predicted stress distributions within a part. Progress using a stereo/photolithographic fabrication technique to construct designed pore structures in stainless steel bodies is presented. Various techniques used to fabricate fine porosity (size less than a layer thickness), coarse porosity (size greater than a layer thickness), and truss, open cell and honeycomb structures with characteristically high cell volume fraction (i.e., greater than 50 percent) are described.

Type
Research Article
Information
MRS Online Proceedings Library (OPL) , Volume 542: Symposium V – Solid Freeform and Additive Fabrication , 1998 , 165
Copyright
Copyright © Materials Research Society 1999

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

1 Aubin, , Richard, F.; ”A World Wide Assessment of Rapid Prototyping Technologies”, Report for the Intelligent Manufacturing Systems IMS Test Case on Rapid Product Development, UTRC Report # 94-13, p. 9, January 1994.Google Scholar
2 Zimbeck, W., Pope, M., Rice, R. W., “Microstructures and Strengths of Metals and Ceramics made by Photopolymer-based Rapid Prototyping” Solid Freeform Fabrication Proceedings, September, 1996, pp 411 – 18.Google Scholar
3 Griffith, M. L., and Halloran, J. W., J. Am. Cer. Soc. 79 [10] 2601–608 (1996).Google Scholar
4 Hinczewski, C., Corbel, S., Chartier, T., J. of Eur. Cer. Soc. 18, 583 – 590 (1998).Google Scholar
5 Rice, R. W., “Evaluation and Extension of Physical Property-Porosity Models Based on Minimum Solid Area”, J. Mat. Sci., 31, pp 102 – 8, 1996.Google Scholar
6 Rice, R. W., “The Porosity Dependence of Physical Properties of Materials - A Summary Review”, Porous Ceramic Materials, Fabrication, Characterization, Applications, Liu, D. Mo, ed., Trans Tech Pub., Zurich, Switzerland, 1 – 19, (1996)Google Scholar
7 Knudsen, F. P., “Dependence of Mechanical Strength of Brittle Polycrystalline Specimens on Porosity and Grain Size”, J. Am. Cer. Soc., 42 (8), 367 – 388, (1959)Google Scholar
8 Rice, R.W.,”Comparison of Physical Property-Porosity Behavior with Minimum Solid Area Models”, J. Mat. Sci., 31, 1509–28, (1996)Google Scholar
9 Lakes, R., “Materials with Structural Hierarchy”, Nature, 361, 511–15, (1993)Google Scholar
10 Rozvany, G.I.N., Bendsoe, M.P., Kirsch, U., “Layout Optimization of Structures,” Appl Mech Rev, 48, no.2, 41 – 118 (1995)Google Scholar
11 Bendsoe, M.P., and Kikuchi, N., “Generating Optimal Topology in Structural Design using a Homogenization Method,” Comp Meth Appl Mech Eng 71, 197 – 224, (1988)Google Scholar
12 Bendsoe, M. P., and Kikuchi, N., “Topology and Layout Optimization of Discrete and Continuum Structures,” In Kamat, MP, ed. Structural Optimization – Status and Promise, 517 – 547. AIAA, Washington, DC (1993)Google Scholar
13 Rietbergen, B. Van, Huiskes, R., Weinans, H., Sumner, D.R., Turner, M.T. and Galante, J.O., “The mechanism of bone remodeling and resorption around press-fitted THA stems”, J. Biomech., 26 (4–5) 369–382 (1993)Google Scholar
14 Bobyn, J.D., Glassman, A.H., Goto, H., Krygier, J.J., Miller, J.E., and Brooks, C.E., “The effect of stem stiffness on femoral bone resorption after canine porous-coated total hip arthroplasty”, Clin. Orthop. 261, 196 – 213 (1990)Google Scholar
15 Maloney, W.J., Sychterz, C., Bragdon, C., McGovern, T., Jasty, M., Engh, C.A., Harris, W.H., “Skeletal response to well fixed femoral components inserted with and without cement”, Clin. Orthop., 333, 15–26 (1996)Google Scholar
16 Morscher, E.W., and Dick, W., “Cementless fixation of “isoelastic” hip endoprosthesis manufactured from plastic materials”, Clin. Orthop. 176:77 (1983)Google Scholar
17 Jakim, I., Barlin, C., and Sweet, M.B.E., “RM isoelastic total hip arthroplasty. A review of 34 cases”; J. Arthroplasty 3:191 (1988)Google Scholar
18 Skinner, H. B., “Composite technology for total hip arthroplasty”; Clin. Orthop. 235 224 (1988)Google Scholar
19 Gorski, J.M., “Modular noncemented total hip arthroplasty for congenital dislocation of the hip: Case report and design rationale”, Clin. Orthop. 228:110, (1988)Google Scholar
20 Kuiper, J.H., Huiskes, R., “Mathematical optimization of elastic properties: application to cementless hip stem design”, J. Biomech. Eng.,119(May):166–174 (1997)Google Scholar
21 Kuiper, J.H., Huiskes, R., “The Predictive value of Stress Shielding for Quantification of Adaptive Bone Resorption Around Hip Replacements”, J. Biomech. Eng. 119(Aug):229–231 (1997).Google Scholar
22 Gibson, Lorna J. and Ashby, Michael F.; Cellular Solids, Second ed. (Cambridge University Press, New York, 1997), p. 430.Google Scholar
23 J., Shields; Adhesives Handbook, 3rd ed. 1985, Butterworth, London.Google Scholar
* hollow ceramic (Al2O3/SiO2) microspheres (cenospheres from Sphere Services, Inc., TN).Google Scholar
24 Peter Matic, private communication.Google Scholar