Additive Manufacturing Graduate Projects (ME 557)

Lattice Structures - Radiation Glasses

Radiation glasses are typically manufactured with leaded glass, adding significant weight. By latticing the arms, weight is reduced without sacrificing functionality, increasing comfort for the user and improving aesthetics.

Radiation glasses were designed in SolidWorks and the lattice structures implemented via Inspire software. Forces were placed to mimic the weight of the lenses under different head positions and the arms optimized for stiffness with 70% material removal. The glasses were printed on the Form 2 SLA printer using draft resin.

LEGO Batman Metal Print - SLM GE Concept Laser

LEGO Batman was designed in SolidWorks to fit within the print area of the GE Concept Laser. To reduce warping, thermal management was improved by reducing overhangs to <.5mm and <2mm wall thickness after hollowing the part.

Using Materialize software, supports were placed to separate the part from the build plate and minimize thermal stress. The part was oriented 45 degrees to the wiper blade to prevent the part from being damaged by friction against the blade.

In the final part, details came out relatively free of defects due to careful placement of supports and optimal design for thermal management.

Topological Optimization - Bike Crank

Topological optimization allows the structural design of a component to be optimized while reducing material and weight.

Using Inspire software, topological optimization was used mimic the forces applied to a simple bike crank arm. A point load was applied where the bike crank attaches to the spindle and pedal.  Compressive loads were added in the positive and negative vertical directions, an additional load to simulate the pedal on the other side of the bike, and a moment to simulate a biker shifting weight. Inspire removed unnecessary material for the applied loads, then the part was re-modeled in SolidWorks and printed on the Form 2 SLA printer.

Investment Casting - Jewelry Making from 3D-printed Molds

Investment Casting is a manufacturing process in which metal parts are created through a complex process of mold making and metal pouring. Additive manufacturing allows greater flexibility in design and repeatability than traditional casting.

Four jewelry pieces were designed in SolidWorks and installed on a wax tree and printed in Formlabs castable wax resin. The tree contains a central sprue that provides a pathway for molten metal to follow as it is poured. The tree is covered in a plaster-like material  (“investment”) and heated in a kiln to burn out the wax, leaving behind a cavity.  Molten metal is poured into the cavity. After the metal solidifies, the investment cast is broken, revealing the completed parts. 

Design Considerations

• Sprues on the moon ring created channels to fill to areas of fine detail.

• Thick parts were shelled to minimize expansion forces during burnout.

• Sharp edges should be avoided so that metal must flows smoothly into the mold. The geode part (center) tests whether print orientation will affect feasibility of sharp corners. As seen above, with careful consideration of print orientation and design parameters, manufacturing recommendations can be pushed with success.