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The Feasibility of Developing a Physical Model Using Rapid Manufacturing Technologies by Referencing Remotely Sensed Data to Simulate Outdoor Environments
Citation:
Boe, T., A. Mikelonis, S. Lee, W. Calfee, K. Ratliff, S. Roy, T. Loecherbach, M. Uges, AND E. Howard. The Feasibility of Developing a Physical Model Using Rapid Manufacturing Technologies by Referencing Remotely Sensed Data to Simulate Outdoor Environments. U.S. Environmental Protection Agency, Washington, DC, EPA/600/R-18/268, 2018.
Impact/Purpose:
Consequently, there is a need to investigate the feasibility of using rapid manufacturing technologies, and the resulting models for conducting controlled scientific experiments. The objectives of this study were fivefold: (1) determine the feasibility of developing a physical model using rapid manufacturing technologies by referencing remotely sensed data (i.e., LiDAR and spatial extracts) with the purpose simulating outdoor environments; (2) understand whether the scale at which the model operates is representative of the environmental conditions necessary to conduct stormwater experiments, and the extent of data manipulation necessary to represent such conditions; (3) compare and contrast rapid manufacturing technologies; (4) document the steps required to build a physical model; and (5) document any gaps and recommendations for continuing this research.
Description:
This report was prepared to evaluate the feasibility of using rapid manufacturing technologies (i.e., computer numerical controlled (CNC) milling, printing) to develop three-dimensional (3D) physical models as surrogates for outdoor field experiments. These models have the potential to serve as testbeds when working with contaminants that may otherwise pollute the ambient environment or can evaluate specific environmental phenomena. Furthermore, physical models serve as a useful planning or situational tools for emergency responders and decision makers. Two 3D physical models manufactured by separate technologies (CNC milling and 3D printing) were evaluated for use as a potential stormwater testbeds. Models were evaluated according to their completeness, imperfections, manufacturing method, materials, and compatibility. CNC milling was found to produce a more reliable product that was germane to conducting flow experiments. Steps necessary for enhancing and preparing data for manufacturing were also documented. This work serves as a resource for selecting optimal printing materials, hardware, and procedures when developing a 3D physical models using rapid manufacturing technologies. The study concludes with observations and recommendations for conducting future research.