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Paste Deposition Modelling, Deconstructing the Additive Manufacturing Process: Development of Novel Multi- Material Tools and Techniques for Craft Practitioners

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PASTE DEPOSITION MODELLING, DECONSTRUCTING THE ADDITIVE MANUFACTURING PROCESS: DEVELOPMENT OF NOVEL MULTI- MATERIAL TOOLS AND TECHNIQUES FOR CRAFT PRACTITIONERS A thesis submitted for the degree of Doctor of Philosophy by Esteban Schunemann Department of Engineering and Design, Brunel University London 2015 ii I. Abstract A novel paste deposition process was developed to widen the range of possible materials and applications. This experimental process developed an increasingly complex series of additive manufacturing machines, resulting in new combinations of novel materials and deposition paths without sacrificing many of the design freedoms inherit in the craft process. The investigation made use of open-source software together with an approach to programming user originated infill geometries to form structural parts, differing from the somewhat automated processing by 'closed' commercial RP systems. A series of experimental trials were conducted to test a range of candidate materials and machines which might be suitable for the PDM process. The combination of process and materials were trailed and validated using a series of themed case studies including medical, food industry and jewellery. Some of the object created great interest and even, in the case of the jewellery items, won awards. Further evidence of the commercial validity was evidenced through a collaborative partnership resulting in the development of a commercial version of the experimental system called Newton3D. A number of exciting potential future directions having been opened up by this project including silicone fabrics, bio material deposition and inclusive software development for user originated infills and structures. iii II. Acknowledgments First and foremost I would like to extend my deepest gratitude to both my supervisors, Dr. Sarah Silve and Dr. Richard Bateman, without whom this project would have been impossible, the advice, guidance, critique and assistance in report writing was instrumental in the success of this research project. I would like to thank Dr. Atanas Ivanov, Prof. Kai Cheng and Prof Tony Anson whose enthusiasm, support, provision of facilities and equipment were pivotal for the research. I must acknowledge Brunel University and the School of Engineering and Design, including academic and technical staff, in particular Dr. Richard Rakowski for his words of encouragement and for allowing me to teach alongside him, giving me a positive change in routine. Paul Barrett, for his patience in my endless requests for laser cutting, and Paul Yates for his knowledge and expertise in CNC machining. I also recognise the input by MSc students Efthimios Drakos and Jonathan Oxley for collaborating with me during the research project and bringing in valuable enthusiasm, feedback and companionship. I would also like to extend my gratitude to the following people whose advice and enthusiasm were of great benefit during the metal clay study development and validation: Helen O'Neal from the PMC studio whose vast knowledge in PMC and the provision of materials were of great help for the feasibility study and the latter applications of AM in metal clay; Frank Cooper from the Jewellery Innovation Centre in Birmingham City University for his support of the project as a judge in the Goldsmiths' 2013 awards; Ann Marie Shillito for including my work in her book; Digital Crafts. And last but not least Silvain Promount from IMakr for his valuable support, patience and faith in the project which has led to a partnership and a start- up that will allow to project to remain alive for years to come. iv I recognise that this research project would have been impossible without the funding provided by the Doctoral Training Grant scheme by the EPSRC, (ET/P504848/1) for which I am very thankful. v III. Declaration Author’s declaration I declare that the work in this dissertation was carried out in accordance with the requirements of the University’s Regulations and Code of Practice for Taught Programmes and that it has not been submitted for any other academic award. Except where indicated by specific reference in the text, this work is my own work. Work done in collaboration with, or with the assistance of others, is indicated as such. I have identified all material in this dissertation which is not my own work through appropriate referencing and acknowledgement. Where I have quoted or otherwise incorporated material which is the work of others, I have included the source in the references. Any views expressed in the dissertation, other than referenced material, are those of the author. SIGNED: ……………………………………………………………. DATE: …………….. (Signature of student) vi IV. Publication And Awards Arising From This Work Making futures 2013, paper and presentation, peer-reviewed Paste Deposition Modelling (PDM) A hybrid ALM/Craft process Praxis & Poetics 2013, paper and presentation Additive Manufacturing with Precious Metal Clay (PMC); Aesthetic Opportunities that Bridge Digital and Traditional Craft ResCon 2013 Brunel University, Research Student Conference, Abstract and presentation Books Some research outputs have also been published in Digital Crafts; industrial technologies for applied artists and designer makers. By Ann Marie Shillito. pages 114 and 124. Awards Silver and Joint winner of the 3D technological Innovation award at the Goldsmiths' Craft and Design Council 2013 awards. Inclusion of silver piece "Seashell" in the curated Ganoksin online gallery. 3rd place in the EPSRC science photo competition 2013, equipment category. vii V. Table of contents I. Abstract ............................................................................................................................ ii II. Acknowledgments ........................................................................................................... iii III. Declaration ....................................................................................................................... v IV. Publication And Awards Arising From This Work ........................................................... vi V. Table of contents ........................................................................................................... vii VI. List of Figures ................................................................................................................. xii VII. List of Tables ................................................................................................................ xxiv VIII. List of equations ............................................................................................................ xxv IX. Nomenclature .............................................................................................................. xxvi Chapter 1 Introduction ..................................................................................................... 1 1.1 Introduction ......................................................................................................... 2 1.2 Aim ....................................................................................................................... 4 1.3 Objectives ............................................................................................................. 4 1.4 Structure Of Thesis ............................................................................................... 5 Chapter 2 Literature Review ............................................................................................. 6 2.1 Chapter Introduction ........................................................................................... 7 2.2 Introduction to Additive Manufacturing .............................................................. 8 2.2.1 File processing .............................................................................................. 9 2.2.2 Build Times in ALM ..................................................................................... 10 2.3 Computer Numerical Control (CNC) ................................................................... 10 2.3.1 Motion control ........................................................................................... 12 2.3.2 G-code, machine programming ................................................................. 14 2.4 Additive Manufacture Systems .......................................................................... 18 2.4.1 Fused Deposition Modelling and Fused Filament Fabrication ................... 18 2.4.2 StereoLithography Apparatus (SLA) ........................................................... 27 2.4.3 Laser Additive Manufacturing .................................................................... 31 2.4.4 Inkjet 3d Printing (3dp) .............................................................................. 38 2.4.5 Inkjet 3DP in metals ................................................................................... 43 2.4.6 Polyjet, Multi Jet Modelling (MJM) And Multi Jet Printing (MJP) ............. 44 2.4.7 Laminated Object Manufacturing .............................................................. 46 2.5 Ceramic Additive Manufacturing ....................................................................... 48 2.5.1 Robocasting ................................................................................................ 48 2.5.2 Unfold......................................................................................................... 50 viii 2.5.3 WASP - Large Delta ...................................................................................
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