Development of a curved layer LOM process for monolithic ceramics and ceramic matrix composites

Abstract

A novel rapid prototyping technology incorporating a curved layer building style was developed. The new process, based on laminated object manufacturing (LOM), was designed for efficient fabrication of curved layer structures made from ceramics and fiber reinforced composites. A new LOM machine was created, referred to as curved layer LOM. This new machine uses ceramic tapes and fiber prepregs as feedstocks and fabricates curved structures on a curved‐layer by curved‐layer basis. The output of the process is a three‐dimensional “green” ceramic that is capable of being processed to a seamless, fully dense ceramic using traditional techniques. A detailed description is made of the necessary software and hardware for this new process. Also reviewed is the development of ceramic preforms and accompanying process technology for net shape ceramic fabrication. Monolithic ceramic (SiC) and ceramic matrix composite (SiC/SiC) articles were fabricated using both the flat layer and curved layer LOM processes. For making curved layer objects, the curved process afforded the advantages of eliminated stair step effect, increased build speed, reduced waste, reduced need for decubing, and maintenance of continuous fibers in the direction of curvature.

Modelling curved-layered printing paths for fabricating large-scale construction components

“…It also minimises the potential peeling off of the layers because (i) the top surface is covered by a single layer rather than revealing multiple layer edges; and (ii) the total number of layers required for curved-layered printing is much less than for flat-layered. Thus, researchers [16][17][18][19][20][21][22][23][24] have attempted to minimise the problems of the conventional flat-layered printing with novel curved-layered printing methods.…”

“…This was necessary to approximate a new layer from a previous layer in terms of fitting a curved surface tangent. Klosterman [17] further developed the concept to achieve optimum mechanical performance of ceramics and fibre-reinforced composites by allowing their fibre continuity in a curved plane particularly in a surface area. Because Kalmanovich and Klosterman's work focused on a Laminated Object Manufacturing (LOM) process, they need a non-planar base to build a first layer.…”

Rapid Prototyping: Technologies, Materials and Advances

“…nevertheless, it is not possible to use material other than paper. In the case of old LOM machines there are some works for creating composites using this technology [9,10]. …”

Getting Rid of the Wires: Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

“…While special FDM systems have been designed for experimental deposition of different types of materials with different techniques and much work has been done on the analysis of the mechanism of deposition [7,8], very little research has been done on depositing material as curved layer. The literature on RP reveals a research project in which the Laminated Object Manufacturing process was used to create curved layers [9] at the University of Dayton in the USA but the results were limited by the ability to evenly stretch a material over a curved mandrel and the small range materials that could be used. This CLFDM technology opens up an entirely new possibility of building complex curved plastic parts that have conductive electronic tracks and components printed directly as part of the plastic component.…”