Abstract
The purpose of this research is to develop the material dispensing head and manufacturing processes of the new “Flexible 3D Freeform Techniques” using tin alloys and steel. The research made systematic tests and observations using prototype devices of various designs with the target metals in order to understand the forming characteristics of molten metal, such as melting, flowing, bonding and solidifying. By analyzing 3D geometry, five basic process operations were summarized as the fundamental operations to build a 3D object by the Flexible 3D Freeform Techniques. In the forming of tin alloys, a soldering iron system was used as the heat source and copper was used to make the dispensing heads. Various dispensing head prototypes were developed and successfully tested to dispense and form tin alloys of different geometric shape features and demonstrated the five basic process operations. In the forming of steels, a micro plasma arc welding system was used as the heat source and similar demonstrations were achieved. The potential application of this technique is rapid prototyping and production of injection molding molds with good surface finish at significantly higher speeds and lower costs compared to existing rapid prototyping processes.