Abstract

Fully dense freeform fabrication (FDFF) is a process based on thin line cutting processes, variable thickness layering, slicing in different orientations, and bulk layer attachment. The combination of these capabilities enables the production of good quality complex parts from practically any material at a very fast pace. To improve the quality of the fabricated functioning products, multiple design and operational factors affecting the response value are required to be optimized. In this research, affecting factors (e.g., types of bonding materials, a range of heating temperatures, types of metal sheets, etc.) on the quality of the fabricated prototypes using a statistical design of experiments are investigated. Following the statistical analysis, the feasible bonding process in terms of optimal response value (tensile strength) that is achieved in regard with the most influential single or combined factors are presented.

Issue Section:
Research Papers
Keywords:
fully dense freeform fabrication, FDFF, design of experiments, DOE, metal bonding, soldering

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