Analysis of layer development and fusing for 3D laser printing

by Mahadevan, Pradeep.

Mahadevan, Pradeep. Analysis of Layer Development and Fusing for 3D Laser Printing. (Under the direction of Dr. Denis Cormier and Dr. Ola L. A. Harrysson.) The purpose of this research is to analyze the layer development and fusing process of a new rapid prototyping process. The new rapid prototyping process is 3D laser printing, and this process is under development by researchers at the Department of Industrial Engineering at North Carolina State University. The 3D laser printing process uses principles of electrophotography (laser printing) for layer development. The layer fusing process is achieved by temperature-pressure fusing. A fiberglass reinforced Teflon sheet is to be used as a transfer medium for the layers. The effectiveness of the layer development and fusing process are evaluated via experimentation. A material testing station was developed to simulate the 3D laser printing process, and the specimens' produced were evaluated for their creep rate and uniform fusing characteristics during the temperature-pressure fusing process. The mass-to-area ratio of the layers developed by a laser printer was evaluated for their suitability for 3D laser printing. The effectiveness of Teflon as a transfer medium was compared with paper in a laser printer. The experiments performed indicate that electrophotography can be used as an effective layer development tool, Teflon can be used as an effective receiving medium for transferring toner for layer development, and temperature-pressure fusing is capable of producing fused layers for producing parts using 3D laser printing. Analysis of Layer Development and Fusing for 3D Laser Printing By Pradeep Mahadevan A thesis submitted to the Graduate Faculty of North Carolina State University in partial fulfillment of the requirements for the Degree of Master of Science