Support materials development and integration for ultrasonic consolidation

Support materials play a vital role across the entire field of additive manufacturing (AM) technologies. They are essential to provide the ability to create complex structures and features using AM. Successful implementation of support materials in ultrasonic consolidation (UC) will provide a vast opportunity for improvement of geometric complexity. Experimentation was performed to evaluate suitable support materials and their effectiveness within UC. Additionally a fused deposition modeling (FDM) system was integrated into the UC build environment to create an automated support deposition system. Finally several unique structures were built using support materials to demonstrate the improved geometric capability and to develop design rules for use in UC.