Pub Date : 2024-03-26DOI: 10.1108/rpj-01-2024-0021
Vishal Mishra, Ch. Kapil Ror, S. Negi, Simanchal Kar
Purpose This study aims to present an experimental approach to develop a high-strength 3D-printed recycled polymer composite reinforced with continuous metal fiber. Design/methodology/approach The continuous metal fiber composite was 3D printed using recycled and virgin acrylonitrile butadiene styrene-blended filament (RABS-B) in the ratio of 60:40 and postused continuous brass wire (CBW). The 3D printing was done using an in-nozzle impregnation technique using an FFF printer installed with a self-modified nozzle. The tensile and single-edge notch bend (SENB) test samples are fabricated to evaluate the tensile and fracture toughness properties compared with VABS and RABS-B samples. Findings The tensile and SENB tests revealed that RABS-B/CBW composite 3D printed with 0.7 mm layer spacing exhibited a notable improvement in Young’s modulus, ultimate tensile strength, elongation at maximum load and fracture toughness by 51.47%, 18.67% and 107.3% and 22.75% compared to VABS, respectively. Social implications This novel approach of integrating CBW with recycled thermoplastic represents a significant leap forward in material science, delivering superior strength and unlocking the potential for advanced, sustainable composites in demanding engineering fields. Originality/value Limited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.
{"title":"Enhanced fracture toughness and tensile strength of 3D printed recycled ABS composites reinforced with continuous metallic fiber for load-bearing application","authors":"Vishal Mishra, Ch. Kapil Ror, S. Negi, Simanchal Kar","doi":"10.1108/rpj-01-2024-0021","DOIUrl":"https://doi.org/10.1108/rpj-01-2024-0021","url":null,"abstract":"\u0000Purpose\u0000This study aims to present an experimental approach to develop a high-strength 3D-printed recycled polymer composite reinforced with continuous metal fiber.\u0000\u0000\u0000Design/methodology/approach\u0000The continuous metal fiber composite was 3D printed using recycled and virgin acrylonitrile butadiene styrene-blended filament (RABS-B) in the ratio of 60:40 and postused continuous brass wire (CBW). The 3D printing was done using an in-nozzle impregnation technique using an FFF printer installed with a self-modified nozzle. The tensile and single-edge notch bend (SENB) test samples are fabricated to evaluate the tensile and fracture toughness properties compared with VABS and RABS-B samples.\u0000\u0000\u0000Findings\u0000The tensile and SENB tests revealed that RABS-B/CBW composite 3D printed with 0.7 mm layer spacing exhibited a notable improvement in Young’s modulus, ultimate tensile strength, elongation at maximum load and fracture toughness by 51.47%, 18.67% and 107.3% and 22.75% compared to VABS, respectively.\u0000\u0000\u0000Social implications\u0000This novel approach of integrating CBW with recycled thermoplastic represents a significant leap forward in material science, delivering superior strength and unlocking the potential for advanced, sustainable composites in demanding engineering fields.\u0000\u0000\u0000Originality/value\u0000Limited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140210168","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-19DOI: 10.1108/rpj-10-2023-0360
D. Băilă, Filippo Sanfilippo, Tom Savu, Filip Górski, I. Radu, Cătălin Zaharia, Constantina Anca Parau, Martin Zelenay, Pacurar Razvan
Purpose The development of new advanced materials, such as photopolymerizable resins for use in stereolithography (SLA) and Ti6Al4V manufacture via selective laser melting (SLM) processes, have gained significant attention in recent years. Their accuracy, multi-material capability and application in novel fields, such as implantology, biomedical, aviation and energy industries, underscore the growing importance of these materials. The purpose of this study is oriented toward the application of new advanced materials in stent manufacturing realized by 3D printing technologies. Design/methodology/approach The methodology for designing personalized medical devices, implies computed tomography (CT) or magnetic resonance (MR) techniques. By realizing segmentation, reverse engineering and deriving a 3D model of a blood vessel, a subsequent stent design is achieved. The tessellation process and 3D printing methods can then be used to produce these parts. In this context, the SLA technology, in close correlation with the new types of developed resins, has brought significant evolution, as demonstrated through the analyses that are realized in the research presented in this study. This study undertakes a comprehensive approach, establishing experimentally the characteristics of two new types of photopolymerizable resins (both undoped and doped with micro-ceramic powders), remarking their great accuracy for 3D modeling in die-casting techniques, especially in the production process of customized stents. Findings A series of analyses were conducted, including scanning electron microscopy, energy-dispersive X-ray spectroscopy, mapping and roughness tests. Additionally, the structural integrity and molecular bonding of these resins were assessed by Fourier-transform infrared spectroscopy–attenuated total reflectance analysis. The research also explored the possibilities of using metallic alloys for producing the stents, comparing the direct manufacturing methods of stents’ struts by SLM technology using Ti6Al4V with stent models made from photopolymerizable resins using SLA. Furthermore, computer-aided engineering (CAE) simulations for two different stent struts were carried out, providing insights into the potential of using these materials and methods for realizing the production of stents. Originality/value This study covers advancements in materials and additive manufacturing methods but also approaches the use of CAE analysis, introducing in this way novel elements to the domain of customized stent manufacturing. The emerging applications of these resins, along with metallic alloys and 3D printing technologies, have brought significant contributions to the biomedical domain, as emphasized in this study. This study concludes by highlighting the current challenges and future research directions in the use of photopolymerizable resins and biocompatible metallic alloys, while also emphasizing the integration of artificial intelligence in the design pr
{"title":"3D printing of personalised stents using new advanced photopolymerizable resins and Ti-6Al-4V alloy","authors":"D. Băilă, Filippo Sanfilippo, Tom Savu, Filip Górski, I. Radu, Cătălin Zaharia, Constantina Anca Parau, Martin Zelenay, Pacurar Razvan","doi":"10.1108/rpj-10-2023-0360","DOIUrl":"https://doi.org/10.1108/rpj-10-2023-0360","url":null,"abstract":"\u0000Purpose\u0000The development of new advanced materials, such as photopolymerizable resins for use in stereolithography (SLA) and Ti6Al4V manufacture via selective laser melting (SLM) processes, have gained significant attention in recent years. Their accuracy, multi-material capability and application in novel fields, such as implantology, biomedical, aviation and energy industries, underscore the growing importance of these materials. The purpose of this study is oriented toward the application of new advanced materials in stent manufacturing realized by 3D printing technologies.\u0000\u0000\u0000Design/methodology/approach\u0000The methodology for designing personalized medical devices, implies computed tomography (CT) or magnetic resonance (MR) techniques. By realizing segmentation, reverse engineering and deriving a 3D model of a blood vessel, a subsequent stent design is achieved. The tessellation process and 3D printing methods can then be used to produce these parts. In this context, the SLA technology, in close correlation with the new types of developed resins, has brought significant evolution, as demonstrated through the analyses that are realized in the research presented in this study. This study undertakes a comprehensive approach, establishing experimentally the characteristics of two new types of photopolymerizable resins (both undoped and doped with micro-ceramic powders), remarking their great accuracy for 3D modeling in die-casting techniques, especially in the production process of customized stents.\u0000\u0000\u0000Findings\u0000A series of analyses were conducted, including scanning electron microscopy, energy-dispersive X-ray spectroscopy, mapping and roughness tests. Additionally, the structural integrity and molecular bonding of these resins were assessed by Fourier-transform infrared spectroscopy–attenuated total reflectance analysis. The research also explored the possibilities of using metallic alloys for producing the stents, comparing the direct manufacturing methods of stents’ struts by SLM technology using Ti6Al4V with stent models made from photopolymerizable resins using SLA. Furthermore, computer-aided engineering (CAE) simulations for two different stent struts were carried out, providing insights into the potential of using these materials and methods for realizing the production of stents.\u0000\u0000\u0000Originality/value\u0000This study covers advancements in materials and additive manufacturing methods but also approaches the use of CAE analysis, introducing in this way novel elements to the domain of customized stent manufacturing. The emerging applications of these resins, along with metallic alloys and 3D printing technologies, have brought significant contributions to the biomedical domain, as emphasized in this study. This study concludes by highlighting the current challenges and future research directions in the use of photopolymerizable resins and biocompatible metallic alloys, while also emphasizing the integration of artificial intelligence in the design pr","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140230078","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-18DOI: 10.1108/rpj-10-2023-0370
Yu-Xiang Wang, C. Hung, Hans Pommerenke, Sung-Heng Wu, Tsai-Yun Liu
Purpose This paper aims to present the fabrication of 6061 aluminum alloy (AA6061) using a promising laser additive manufacturing process, called the laser-foil-printing (LFP) process. The process window of AA6061 in LFP was established to optimize process parameters for the fabrication of high strength, dense and crack-free parts even though AA6061 is challenging for laser additive manufacturing processes due to hot-cracking issues. Design/methodology/approach The multilayers AA6061 parts were fabricated by LFP to characterize for cracks and porosity. Mechanical properties of the LFP-fabricated AA6061 parts were tested using Vicker’s microhardness and tensile testes. The electron backscattered diffraction (EBSD) technique was used to reveal the grain structure and preferred orientation of AA6061 parts. Findings The crack-free AA6061 parts with a high relative density of 99.8% were successfully fabricated using the optimal process parameters in LFP. The LFP-fabricated parts exhibited exceptional tensile strength and comparable ductility compared to AA6061 samples fabricated by conventional laser powder bed fusion (LPBF) processes. The EBSD result shows the formation of cracks was correlated with the cooling rate of the melt pool as cracks tended to develop within finer grain structures, which were formed in a shorter solidification time and higher cooling rate. Originality/value This study presents the pioneering achievement of fabricating crack-free AA6061 parts using LFP without the necessity of preheating the substrate or mixing nanoparticles into the melt pool during the laser melting. The study includes a comprehensive examination of both the mechanical properties and grain structures, with comparisons made to parts produced through the traditional LPBF method.
{"title":"Fabrication of crack-free aluminum alloy 6061 parts using laser foil printing process","authors":"Yu-Xiang Wang, C. Hung, Hans Pommerenke, Sung-Heng Wu, Tsai-Yun Liu","doi":"10.1108/rpj-10-2023-0370","DOIUrl":"https://doi.org/10.1108/rpj-10-2023-0370","url":null,"abstract":"\u0000Purpose\u0000This paper aims to present the fabrication of 6061 aluminum alloy (AA6061) using a promising laser additive manufacturing process, called the laser-foil-printing (LFP) process. The process window of AA6061 in LFP was established to optimize process parameters for the fabrication of high strength, dense and crack-free parts even though AA6061 is challenging for laser additive manufacturing processes due to hot-cracking issues.\u0000\u0000\u0000Design/methodology/approach\u0000The multilayers AA6061 parts were fabricated by LFP to characterize for cracks and porosity. Mechanical properties of the LFP-fabricated AA6061 parts were tested using Vicker’s microhardness and tensile testes. The electron backscattered diffraction (EBSD) technique was used to reveal the grain structure and preferred orientation of AA6061 parts.\u0000\u0000\u0000Findings\u0000The crack-free AA6061 parts with a high relative density of 99.8% were successfully fabricated using the optimal process parameters in LFP. The LFP-fabricated parts exhibited exceptional tensile strength and comparable ductility compared to AA6061 samples fabricated by conventional laser powder bed fusion (LPBF) processes. The EBSD result shows the formation of cracks was correlated with the cooling rate of the melt pool as cracks tended to develop within finer grain structures, which were formed in a shorter solidification time and higher cooling rate.\u0000\u0000\u0000Originality/value\u0000This study presents the pioneering achievement of fabricating crack-free AA6061 parts using LFP without the necessity of preheating the substrate or mixing nanoparticles into the melt pool during the laser melting. The study includes a comprehensive examination of both the mechanical properties and grain structures, with comparisons made to parts produced through the traditional LPBF method.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140234665","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-01DOI: 10.1108/rpj-04-2023-0128
Asif Ur Rehman, P. Navarrete-Segado, M. U. Salamci, Christine Frances, M. Tourbin, D. Grossin
Purpose The consolidation process and morphology evolution in ceramics-based additive manufacturing (AM) are still not well-understood. As a way to better understand the ceramic selective laser sintering (SLS), a dynamic three-dimensional computational model was developed to forecast thermal behavior of hydroxyapatite (HA) bioceramic. Design/methodology/approach AM has revolutionized automotive, biomedical and aerospace industries, among many others. AM provides design and geometric freedom, rapid product customization and manufacturing flexibility through its layer-by-layer technique. However, a very limited number of materials are printable because of rapid melting and solidification hysteresis. Melting-solidification dynamics in powder bed fusion are usually correlated with welding, often ignoring the intrinsic properties of the laser irradiation; unsurprisingly, the printable materials are mostly the well-known weldable materials. Findings The consolidation mechanism of HA was identified during its processing in a ceramic SLS device, then the effect of the laser energy density was studied to see how it affects the processing window. Premature sintering and sintering regimes were revealed and elaborated in detail. The full consolidation beyond sintering was also revealed along with its interaction to baseplate. Originality/value These findings provide important insight into the consolidation mechanism of HA ceramics, which will be the cornerstone for extending the range of materials in laser powder bed fusion of ceramics.
目的 基于陶瓷的增材制造（AM）中的固结过程和形态演变尚未得到很好的理解。为了更好地理解陶瓷选择性激光烧结（SLS），我们开发了一个动态三维计算模型，用于预测羟基磷灰石（HA）生物陶瓷的热行为。AM 通过逐层技术提供了设计和几何自由度、快速产品定制和制造灵活性。然而，由于快速熔化和凝固滞后，可打印的材料非常有限。粉末床熔融中的熔融-凝固动力学通常与焊接相关，往往忽略了激光辐照的固有特性；毫不奇怪，可打印材料大多是众所周知的可焊接材料。研究结果确定了 HA 在陶瓷 SLS 设备中加工时的凝固机制，然后研究了激光能量密度的影响，以了解它如何影响加工窗口。研究揭示并详细阐述了过早烧结和烧结机制。这些发现为了解 HA 陶瓷的固结机理提供了重要依据，将为扩大激光粉末床陶瓷熔融的材料范围奠定基础。
{"title":"Understanding the consolidation mechanism of selective laser sintering/powder bed selective laser process of ceramics: Hydroxyapatite case","authors":"Asif Ur Rehman, P. Navarrete-Segado, M. U. Salamci, Christine Frances, M. Tourbin, D. Grossin","doi":"10.1108/rpj-04-2023-0128","DOIUrl":"https://doi.org/10.1108/rpj-04-2023-0128","url":null,"abstract":"\u0000Purpose\u0000The consolidation process and morphology evolution in ceramics-based additive manufacturing (AM) are still not well-understood. As a way to better understand the ceramic selective laser sintering (SLS), a dynamic three-dimensional computational model was developed to forecast thermal behavior of hydroxyapatite (HA) bioceramic.\u0000\u0000\u0000Design/methodology/approach\u0000AM has revolutionized automotive, biomedical and aerospace industries, among many others. AM provides design and geometric freedom, rapid product customization and manufacturing flexibility through its layer-by-layer technique. However, a very limited number of materials are printable because of rapid melting and solidification hysteresis. Melting-solidification dynamics in powder bed fusion are usually correlated with welding, often ignoring the intrinsic properties of the laser irradiation; unsurprisingly, the printable materials are mostly the well-known weldable materials.\u0000\u0000\u0000Findings\u0000The consolidation mechanism of HA was identified during its processing in a ceramic SLS device, then the effect of the laser energy density was studied to see how it affects the processing window. Premature sintering and sintering regimes were revealed and elaborated in detail. The full consolidation beyond sintering was also revealed along with its interaction to baseplate.\u0000\u0000\u0000Originality/value\u0000These findings provide important insight into the consolidation mechanism of HA ceramics, which will be the cornerstone for extending the range of materials in laser powder bed fusion of ceramics.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140088168","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-01-11DOI: 10.1108/rpj-10-2023-0347
Abdul Samad Rafique, Adnan Munir, Numan Ghazali, Muhammad Naveed Ahsan, Aqeel Ahsan Khurram
Purpose The purpose of this study was to develop a correlation between the properties of acrylonitrile butadiene styrene parts 3D printed by material extrusion (MEX) process. Design/methodology/approach The two MEX parameters and their values have been selected by design of experiment method. Three properties of MEX parts, i.e. strength (tensile and three-point bending), surface roughness and the dimensional accuracy, are studied at different build speeds (35 mm/s, 45 mm/s and 55 mm/s) and the layer heights (0.06 mm, 0.10 mm and 0.15 mm). Findings The results show that tensile strength and three-point bending strength both increase with the decrease in build speed and the layer height. The artifact selected for dimensional accuracy test shows higher accuracy of the features when 3D printed with 0.06 mm layer height at 35 mm/s build speed as compared to those of higher layer heights and build speeds. The optical images of the 3D-printed specimen reveal that lower build speed and the layer height promote higher inter-layer diffusion that has the effect of strong bonding between the layers and, as a result, higher strength of the specimen. The surface roughness values also have direct relation with the build speed and the layer height. Originality/value The whole experiments demonstrate that the part quality, surface roughness and the mechanical strength are correlated and depend on the build speed and the layer height.
设计/方法/途径通过实验设计法选择了两个 MEX 参数及其值。研究结果表明，拉伸强度和三点弯曲强度均随构建速度和层高的降低而增加。与更高的层高和构建速度相比，以 35 mm/s 的构建速度、0.06 mm 的层高进行三维打印时，选作尺寸精度测试的工件显示出更高的特征精度。三维打印试样的光学图像显示，较低的构建速度和层高可促进较高的层间扩散，从而使层间产生较强的结合力，进而提高试样的强度。整个实验表明，零件质量、表面粗糙度和机械强度与构建速度和层高相关，并取决于构建速度和层高。
{"title":"Correlation between the part quality, strength and surface roughness of material extrusion process","authors":"Abdul Samad Rafique, Adnan Munir, Numan Ghazali, Muhammad Naveed Ahsan, Aqeel Ahsan Khurram","doi":"10.1108/rpj-10-2023-0347","DOIUrl":"https://doi.org/10.1108/rpj-10-2023-0347","url":null,"abstract":"\u0000Purpose\u0000The purpose of this study was to develop a correlation between the properties of acrylonitrile butadiene styrene parts 3D printed by material extrusion (MEX) process.\u0000\u0000\u0000Design/methodology/approach\u0000The two MEX parameters and their values have been selected by design of experiment method. Three properties of MEX parts, i.e. strength (tensile and three-point bending), surface roughness and the dimensional accuracy, are studied at different build speeds (35 mm/s, 45 mm/s and 55 mm/s) and the layer heights (0.06 mm, 0.10 mm and 0.15 mm).\u0000\u0000\u0000Findings\u0000The results show that tensile strength and three-point bending strength both increase with the decrease in build speed and the layer height. The artifact selected for dimensional accuracy test shows higher accuracy of the features when 3D printed with 0.06 mm layer height at 35 mm/s build speed as compared to those of higher layer heights and build speeds. The optical images of the 3D-printed specimen reveal that lower build speed and the layer height promote higher inter-layer diffusion that has the effect of strong bonding between the layers and, as a result, higher strength of the specimen. The surface roughness values also have direct relation with the build speed and the layer height.\u0000\u0000\u0000Originality/value\u0000The whole experiments demonstrate that the part quality, surface roughness and the mechanical strength are correlated and depend on the build speed and the layer height.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-01-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139438960","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-01-09DOI: 10.1108/rpj-09-2023-0317
James Tarver, Kieran Nar, Candice Majewski
Purpose The purpose of this paper is to elucidate the extent to which the mechanisms of polymer melt viscous flow and finish layer powder particle adhesion influence the top surface topographies of laser sintered polyamide (PA12) components. Design/methodology/approach Laser sintered specimens were manufactured at varying laser parameters in accordance with a full factorial design of experiments. Focus variation microscopy was used to ascertain insight into their top surface heights and peak/valley distributions. Subsequently, regression expressions were generated to model the former with respect to applied laser parameters. Auxiliary experimental analysis was also performed to validate the proposed mechanisms and statistical models. Findings Within the parameter range tested, this work found the root mean square (Sq) and skewness (Ssk) roughness responses of laser sintered PA12 top surfaces to be inversely related to one another, and both also principally influenced by beam spacing. Furthermore, it was demonstrated that using optimised laser parameters (to promote polymer melt dispersion) and building without finish layers (to avert subsequent powder particle adhesion) reduced the mean Sq roughness of resultant topographies by 30.8% and 47.9% relative to standard laser sintered PA12 top surfaces, respectively. Practical implications The scope to which laser sintered PA12 top surfaces can be modified was highlighted. Originality/value This research demonstrated the impact the mechanisms of polymer melt viscous flow and finish layer powder particle adhesion have on laser sintered PA12 top surfaces.
{"title":"An investigation into the mechanisms that influence laser sintered polyamide-12 top surfaces","authors":"James Tarver, Kieran Nar, Candice Majewski","doi":"10.1108/rpj-09-2023-0317","DOIUrl":"https://doi.org/10.1108/rpj-09-2023-0317","url":null,"abstract":"\u0000Purpose\u0000The purpose of this paper is to elucidate the extent to which the mechanisms of polymer melt viscous flow and finish layer powder particle adhesion influence the top surface topographies of laser sintered polyamide (PA12) components.\u0000\u0000\u0000Design/methodology/approach\u0000Laser sintered specimens were manufactured at varying laser parameters in accordance with a full factorial design of experiments. Focus variation microscopy was used to ascertain insight into their top surface heights and peak/valley distributions. Subsequently, regression expressions were generated to model the former with respect to applied laser parameters. Auxiliary experimental analysis was also performed to validate the proposed mechanisms and statistical models.\u0000\u0000\u0000Findings\u0000Within the parameter range tested, this work found the root mean square (Sq) and skewness (Ssk) roughness responses of laser sintered PA12 top surfaces to be inversely related to one another, and both also principally influenced by beam spacing. Furthermore, it was demonstrated that using optimised laser parameters (to promote polymer melt dispersion) and building without finish layers (to avert subsequent powder particle adhesion) reduced the mean Sq roughness of resultant topographies by 30.8% and 47.9% relative to standard laser sintered PA12 top surfaces, respectively.\u0000\u0000\u0000Practical implications\u0000The scope to which laser sintered PA12 top surfaces can be modified was highlighted.\u0000\u0000\u0000Originality/value\u0000This research demonstrated the impact the mechanisms of polymer melt viscous flow and finish layer powder particle adhesion have on laser sintered PA12 top surfaces.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139442897","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-01-09DOI: 10.1108/rpj-08-2023-0267
Chunfu Wu, Guorui Ye, Yonghong Zhao, Baowen Ye, Tao Wang, Liangmo Wang, Zeming Zhang
Purpose Auxetics metamaterials show high performance in their specific characteristics, while the absolute stiffness and strength are much weaker due to substantial porosity. This paper aims to propose a novel auxetic honeycomb structure manufactured using selective laser melting and study the enhanced mechanical performance when subjected to in-plane compression loading. Design/methodology/approach A novel composite structure was designed and fabricated on the basis of an arrowhead auxetic honeycomb and filled with polyurethane foam. The deformation mechanism and mechanical responses of the structure with different structural parameters were investigated experimentally and numerically. With the verified simulation models, the effects of parameters on compression strength and energy absorption characteristics were further discussed through parametric analysis. Findings A good agreement was achieved between the experimental and simulation results, showing an evidently enhanced compression strength and energy absorption capacity. The interaction between the auxetic honeycomb and foam reveals to exploit a reinforcement effect on the compression performance. The parametric analysis indicates that the composite with smaller included angel and higher foam density exhibits higher plateau stress and better specific energy absorption, while increasing strut thickness is undesirable for high energy absorption efficiency. Originality/value The results of this study served to demonstrate an enhanced mechanical performance for the foam filled auxetic honeycomb, which is expected to be exploited with applications in aerospace, automobile, civil engineering and protective devices. The findings of this study can provide numerical and experimental references for the design of structural parameters.
{"title":"Experimental and numerical study of in-plane uniaxial compression response of PU foam filled aluminum arrowhead auxetic honeycomb","authors":"Chunfu Wu, Guorui Ye, Yonghong Zhao, Baowen Ye, Tao Wang, Liangmo Wang, Zeming Zhang","doi":"10.1108/rpj-08-2023-0267","DOIUrl":"https://doi.org/10.1108/rpj-08-2023-0267","url":null,"abstract":"\u0000Purpose\u0000Auxetics metamaterials show high performance in their specific characteristics, while the absolute stiffness and strength are much weaker due to substantial porosity. This paper aims to propose a novel auxetic honeycomb structure manufactured using selective laser melting and study the enhanced mechanical performance when subjected to in-plane compression loading.\u0000\u0000\u0000Design/methodology/approach\u0000A novel composite structure was designed and fabricated on the basis of an arrowhead auxetic honeycomb and filled with polyurethane foam. The deformation mechanism and mechanical responses of the structure with different structural parameters were investigated experimentally and numerically. With the verified simulation models, the effects of parameters on compression strength and energy absorption characteristics were further discussed through parametric analysis.\u0000\u0000\u0000Findings\u0000A good agreement was achieved between the experimental and simulation results, showing an evidently enhanced compression strength and energy absorption capacity. The interaction between the auxetic honeycomb and foam reveals to exploit a reinforcement effect on the compression performance. The parametric analysis indicates that the composite with smaller included angel and higher foam density exhibits higher plateau stress and better specific energy absorption, while increasing strut thickness is undesirable for high energy absorption efficiency.\u0000\u0000\u0000Originality/value\u0000The results of this study served to demonstrate an enhanced mechanical performance for the foam filled auxetic honeycomb, which is expected to be exploited with applications in aerospace, automobile, civil engineering and protective devices. The findings of this study can provide numerical and experimental references for the design of structural parameters.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139443599","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-01-02DOI: 10.1108/rpj-03-2023-0085
G. Guerrero-Vacas, Jaime Gómez-Castillo, Ó. Rodríguez-Alabanda
Purpose Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using fused filament fabrication (FFF) with polylactic acid (PLA) and glycol-modified polyethylene terephthalate (PETG) is proposed as an economical, simpler and faster solution compared to traditional metallic molds or three-dimensional (3D) printing with other difficult-to-print thermoplastics, which are prone to shrinkage and delamination (acrylonitrile butadiene styrene, polypropilene-PP) or high-cost due to both material and printing equipment expenses (PEEK, polyamides or polycarbonate-PC). The purpose of this study has been to evaluate the ease of release of PUR foam on these materials in combination with release agents to facilitate the mulding/demoulding process. Design/methodology/approach PETG, PLA and hardenable polylactic acid (PLA 3D870) have been evaluated as mold materials in combination with aqueous and solvent-based release agents within a full design of experiments by three consecutive molding/demolding cycles. Findings PLA 3D870 has shown the best demoldability. A mold expressly designed to manufacture a foam cushion has been printed and the prototyping has been successfully achieved. The demolding of the part has been easier using a solvent-based release agent, meanwhile the quality has been better when using a water-based one. Originality/value The combination of PLA 3D870 and FFF, along with solvent-free water-based release agents, presents a compelling low-cost and eco-friendly alternative to traditional metallic molds and other 3D printing thermoplastics. This innovative approach serves as a viable option for rapid tooling in PUR foam molding.
{"title":"Manufacture of thermoplastic molds by fused filament fabrication 3D printing for rapid prototyping of polyurethane foam molded products","authors":"G. Guerrero-Vacas, Jaime Gómez-Castillo, Ó. Rodríguez-Alabanda","doi":"10.1108/rpj-03-2023-0085","DOIUrl":"https://doi.org/10.1108/rpj-03-2023-0085","url":null,"abstract":"Purpose Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using fused filament fabrication (FFF) with polylactic acid (PLA) and glycol-modified polyethylene terephthalate (PETG) is proposed as an economical, simpler and faster solution compared to traditional metallic molds or three-dimensional (3D) printing with other difficult-to-print thermoplastics, which are prone to shrinkage and delamination (acrylonitrile butadiene styrene, polypropilene-PP) or high-cost due to both material and printing equipment expenses (PEEK, polyamides or polycarbonate-PC). The purpose of this study has been to evaluate the ease of release of PUR foam on these materials in combination with release agents to facilitate the mulding/demoulding process. Design/methodology/approach PETG, PLA and hardenable polylactic acid (PLA 3D870) have been evaluated as mold materials in combination with aqueous and solvent-based release agents within a full design of experiments by three consecutive molding/demolding cycles. Findings PLA 3D870 has shown the best demoldability. A mold expressly designed to manufacture a foam cushion has been printed and the prototyping has been successfully achieved. The demolding of the part has been easier using a solvent-based release agent, meanwhile the quality has been better when using a water-based one. Originality/value The combination of PLA 3D870 and FFF, along with solvent-free water-based release agents, presents a compelling low-cost and eco-friendly alternative to traditional metallic molds and other 3D printing thermoplastics. This innovative approach serves as a viable option for rapid tooling in PUR foam molding.","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139124803","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-01-02DOI: 10.1108/rpj-04-2023-0144
Fernando Peña, J. C. Rico, P. Zapico, G. Valiño, Sabino Mateos
Purpose The purpose of this paper is to provide a new procedure for in-plane compensation of geometric errors that often appear in the layers deposited by an additive manufacturing (AM) process when building a part, regardless of the complexity of the layer geometry. Design/methodology/approach The procedure is based on comparing the real layer contours to the nominal ones extracted from the STL model of the part. Considering alignment and form deviations, the compensation algorithm generates new compensated contours that match the nominal ones as closely as possible. To assess the compensation effectiveness, two case studies were analysed. In the first case, the parts were not manufactured, but the distortions were simulated using a predictive model. In the second example, the test part was actually manufactured, and the distortions were measured on a coordinate measuring machine. Findings The geometric deviations detected in both case studies, as evaluated by various quality indicators, reduced significantly after applying the compensation procedure, meaning that the compensated and nominal contours were better matched both in shape and size. Research limitations/implications Although large contours showed deviations close to zero, dimensional overcompensation was observed when applied to small contours. The compensation procedure could be enhanced if the applied compensation factor took into account the contour size of the analysed layer and other geometric parameters that could have an influence. Originality/value The presented method of compensation is applicable to layers of any shape obtained in any AM process.
{"title":"A layerwise geometric error compensation procedure for additive manufacturing","authors":"Fernando Peña, J. C. Rico, P. Zapico, G. Valiño, Sabino Mateos","doi":"10.1108/rpj-04-2023-0144","DOIUrl":"https://doi.org/10.1108/rpj-04-2023-0144","url":null,"abstract":"\u0000Purpose\u0000The purpose of this paper is to provide a new procedure for in-plane compensation of geometric errors that often appear in the layers deposited by an additive manufacturing (AM) process when building a part, regardless of the complexity of the layer geometry.\u0000\u0000\u0000Design/methodology/approach\u0000The procedure is based on comparing the real layer contours to the nominal ones extracted from the STL model of the part. Considering alignment and form deviations, the compensation algorithm generates new compensated contours that match the nominal ones as closely as possible. To assess the compensation effectiveness, two case studies were analysed. In the first case, the parts were not manufactured, but the distortions were simulated using a predictive model. In the second example, the test part was actually manufactured, and the distortions were measured on a coordinate measuring machine.\u0000\u0000\u0000Findings\u0000The geometric deviations detected in both case studies, as evaluated by various quality indicators, reduced significantly after applying the compensation procedure, meaning that the compensated and nominal contours were better matched both in shape and size.\u0000\u0000\u0000Research limitations/implications\u0000Although large contours showed deviations close to zero, dimensional overcompensation was observed when applied to small contours. The compensation procedure could be enhanced if the applied compensation factor took into account the contour size of the analysed layer and other geometric parameters that could have an influence.\u0000\u0000\u0000Originality/value\u0000The presented method of compensation is applicable to layers of any shape obtained in any AM process.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139452484","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-01-01DOI: 10.1108/rpj-02-2023-0042
Shrutika Sharma, Vishal Gupta, D. Mudgal, Vishal Srivastava
Purpose Three-dimensional (3D) printing is highly dependent on printing process parameters for achieving high mechanical strength. It is a time-consuming and expensive operation to experiment with different printing settings. The current study aims to propose a regression-based machine learning model to predict the mechanical behavior of ulna bone plates. Design/methodology/approach The bone plates were formed using fused deposition modeling (FDM) technique, with printing attributes being varied. The machine learning models such as linear regression, AdaBoost regression, gradient boosting regression (GBR), random forest, decision trees and k-nearest neighbors were trained for predicting tensile strength and flexural strength. Model performance was assessed using root mean square error (RMSE), coefficient of determination (R2) and mean absolute error (MAE). Findings Traditional experimentation with various settings is both time-consuming and expensive, emphasizing the need for alternative approaches. Among the models tested, GBR model demonstrated the best performance in predicting both tensile and flexural strength and achieved the lowest RMSE, highest R2 and lowest MAE, which are 1.4778 ± 0.4336 MPa, 0.9213 ± 0.0589 and 1.2555 ± 0.3799 MPa, respectively, and 3.0337 ± 0.3725 MPa, 0.9269 ± 0.0293 and 2.3815 ± 0.2915 MPa, respectively. The findings open up opportunities for doctors and surgeons to use GBR as a reliable tool for fabricating patient-specific bone plates, without the need for extensive trial experiments. Research limitations/implications The current study is limited to the usage of a few models. Other machine learning-based models can be used for prediction-based study. Originality/value This study uses machine learning to predict the mechanical properties of FDM-based distal ulna bone plate, replacing traditional design of experiments methods with machine learning to streamline the production of orthopedic implants. It helps medical professionals, such as physicians and surgeons, make informed decisions when fabricating customized bone plates for their patients while reducing the need for time-consuming experimentation, thereby addressing a common limitation of 3D printing medical implants.
{"title":"Machine learning for forecasting the biomechanical behavior of orthopedic bone plates fabricated by fused deposition modeling","authors":"Shrutika Sharma, Vishal Gupta, D. Mudgal, Vishal Srivastava","doi":"10.1108/rpj-02-2023-0042","DOIUrl":"https://doi.org/10.1108/rpj-02-2023-0042","url":null,"abstract":"Purpose Three-dimensional (3D) printing is highly dependent on printing process parameters for achieving high mechanical strength. It is a time-consuming and expensive operation to experiment with different printing settings. The current study aims to propose a regression-based machine learning model to predict the mechanical behavior of ulna bone plates. Design/methodology/approach The bone plates were formed using fused deposition modeling (FDM) technique, with printing attributes being varied. The machine learning models such as linear regression, AdaBoost regression, gradient boosting regression (GBR), random forest, decision trees and k-nearest neighbors were trained for predicting tensile strength and flexural strength. Model performance was assessed using root mean square error (RMSE), coefficient of determination (R2) and mean absolute error (MAE). Findings Traditional experimentation with various settings is both time-consuming and expensive, emphasizing the need for alternative approaches. Among the models tested, GBR model demonstrated the best performance in predicting both tensile and flexural strength and achieved the lowest RMSE, highest R2 and lowest MAE, which are 1.4778 ± 0.4336 MPa, 0.9213 ± 0.0589 and 1.2555 ± 0.3799 MPa, respectively, and 3.0337 ± 0.3725 MPa, 0.9269 ± 0.0293 and 2.3815 ± 0.2915 MPa, respectively. The findings open up opportunities for doctors and surgeons to use GBR as a reliable tool for fabricating patient-specific bone plates, without the need for extensive trial experiments. Research limitations/implications The current study is limited to the usage of a few models. Other machine learning-based models can be used for prediction-based study. Originality/value This study uses machine learning to predict the mechanical properties of FDM-based distal ulna bone plate, replacing traditional design of experiments methods with machine learning to streamline the production of orthopedic implants. It helps medical professionals, such as physicians and surgeons, make informed decisions when fabricating customized bone plates for their patients while reducing the need for time-consuming experimentation, thereby addressing a common limitation of 3D printing medical implants.","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139128984","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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