Additive Manufacturing is critical in the development of high energy density storage devices for its flexibility to manufacture complex parts... Show moreAdditive Manufacturing is critical in the development of high energy density storage devices for its flexibility to manufacture complex parts with different discrete compositions like cathodes, anodes and electrolytes. Such storage devices under sub- millimeter scale with micro-structured interdigitated layout could significantly improve its power and energy density. Over the past few years, scientific communities in Rapid Prototyping technology have been mainly focusing on various methods of Modeling and representing Multi-Material Object under single CAD data structure which would enable post processing and rapid prototyping of Multi-Material Object (MMO). This thesis will address the processes involved in the development of Multi-Material Micro Extrusion (M3E) device for manufacturing high density energy storage devices through discrete composition control in Solid Freeform Fabrication (SFF). The primary goal of the research is to develop a rectilinear motion platform with a multi-extrusion system and an open loop control interface to regulate the unreliable extrusion of slurries of different discrete composition. The dissertation will also address the software methodology to discretize 3D-CAD models to represent multiple material composition followed by slicing it into 2.5D layers, which will enable to create Computer Numeric Control (CNC) path program. The scope of this research is further extended to study and optimize various mechanical process inputs with respect to extrusion output parameters. M.S. in Mechanical and Aerospace Engineering, May 2014 Show less
