Abstract
Abstract
This paper describes the fluid mechanics of the slot-coating process in the context of rapid layered manufacturing. It has been conjectured that slot-coating would successfully address a number of common difficulties encountered in the formation of thin layers from a highly viscous fibre—photopolymer composite liquid. The objective of the present study was therefore the development of an engineering analysis tool to assist with the design of a slot-coating-based liquid layer formation mechanism for use as an integral part of a lithography-based rapid layered composite parts manufacturing (RLCM) system.
In addition to an analytical model, the paper presents a numerical model based on a volume-of-fluid (VOF) algorithm. This algorithm allows (a) solution of non-steady-state problems, (b) tracking of the free surface of the fluid undergoing large deformations and (c) easy modification of the model's domain to facilitate experimentation with coater geometry. Results from a set of simulated experiments establish a relationship between the liquid-coat height and several design and process parameters.
Physical examination of cross-sections of several test parts built on an RLCM prototype system in the authors’ laboratory confirmed the ability of the new coater design to form solid layers of good quality, as predicted by the numerical simulations.
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