Virtual simulation and video microscopy for fused deposition methods

Fused deposition is a layered manufacturing (LM) technology, which is being investigated for fabrication of functional parts. Defects and voids in the build process affect the quality and level of accuracy of components. These occur due to several factors, such as the toolpath contours in a layer, material(s) deposited, and the environmental conditions. For a functional part to be constructed, a perfect green part is critical. To fabricate the highest quality of multi-material parts, a virtual simulation system and experimental real time video microscopy have been developed. In this virtual simulation, we can check or test a variety of the LM process parameters, and make the best selection of toolpath and other parameters. To further understand the LM process and make the simulation program realistic, a visualization of the deposition is necessary. The hardware was constructed and mounted on the existing deposition system (liquefier). Real time deposition of layered manufacturing was recorded. Three materials being investigated were: PZT, silicon nitride, and wax. Using the data from these experiments, virtual simulation was enhanced. The results show that we can make selections of part build parameters and make adjustments to the fabricating environment to obtain high quality parts.