Hamed I. Albalawi, Zainab N. Khan, Ranim H. Rawas, Alexander U. Valle-Pérez, Sherin Abdelrahman, Charlotte A. E. Hauser
3D bioprinting has significantly impacted tissue engineering with its capability to create intricate structures with complex geometries that were difficult to replicate through traditional manufacturing techniques. Extrusion-based 3D bioprinting methods tend to be limited when creating complex structures using bioinks of low viscosity. However, the capacity for creating multi-material structures that have distinct properties could be unlocked through the mixture of two solutions before extrusion. This could be used to generate architectures with varying levels of stiffness and hydrophobicity, which could be utilized for regenerative medicine applications. Moreover, it allows for combining proteins and other biological materials in a single 3D-bioprinted structure. This paper presents a standardized fabrication method of disposable nozzle connectors (DNC) for 3D bioprinting with hydrogel-based materials. This method entails 3D printing connectors with dual inlets and a single outlet to mix the material internally. The connectors are compatible with conventional Luer lock needles, offering an efficient solution for nozzle replacement. IVZK (Ac-Ile-Val-Cha-Lys-NH2) peptide-based hydrogel materials were used as a bioink with the 3D-printed DNCs. Extrusion-based 3D bioprinting was employed to print shapes of varying complexities, demonstrating potential in achieving high print resolution, shape fidelity, and biocompatibility. Post-printing of human neonatal dermal fibroblasts, cell viability, proliferation, and metabolic activity were observed, which demonstrated the effectiveness of the proposed design and process for 3D bioprinting using low-viscosity bioinks.
{"title":"3D-Printed disposable nozzles for cost-efficient extrusion-based 3D bioprinting","authors":"Hamed I. Albalawi, Zainab N. Khan, Ranim H. Rawas, Alexander U. Valle-Pérez, Sherin Abdelrahman, Charlotte A. E. Hauser","doi":"10.36922/msam.52","DOIUrl":"https://doi.org/10.36922/msam.52","url":null,"abstract":"3D bioprinting has significantly impacted tissue engineering with its capability to create intricate structures with complex geometries that were difficult to replicate through traditional manufacturing techniques. Extrusion-based 3D bioprinting methods tend to be limited when creating complex structures using bioinks of low viscosity. However, the capacity for creating multi-material structures that have distinct properties could be unlocked through the mixture of two solutions before extrusion. This could be used to generate architectures with varying levels of stiffness and hydrophobicity, which could be utilized for regenerative medicine applications. Moreover, it allows for combining proteins and other biological materials in a single 3D-bioprinted structure. This paper presents a standardized fabrication method of disposable nozzle connectors (DNC) for 3D bioprinting with hydrogel-based materials. This method entails 3D printing connectors with dual inlets and a single outlet to mix the material internally. The connectors are compatible with conventional Luer lock needles, offering an efficient solution for nozzle replacement. IVZK (Ac-Ile-Val-Cha-Lys-NH2) peptide-based hydrogel materials were used as a bioink with the 3D-printed DNCs. Extrusion-based 3D bioprinting was employed to print shapes of varying complexities, demonstrating potential in achieving high print resolution, shape fidelity, and biocompatibility. Post-printing of human neonatal dermal fibroblasts, cell viability, proliferation, and metabolic activity were observed, which demonstrated the effectiveness of the proposed design and process for 3D bioprinting using low-viscosity bioinks.","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-03-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125413049","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Valentin Marchal, Yicha Zhang, N. Labed, R. Lachat, F. Peyraut
Material extrusion (MEX) is an additive manufacturing process that uses thermoplastic layer-by-layer building. The use of continuous fiber-reinforced filament enhances mechanical properties, making MEX suitable for use in aerospace, automotive, and robotics industries. This study proposes a laminate optimization method to improve the stiffness of printed parts with low computing time. The 2D stress-flow-based method optimizes fiber’s orientation for each layer in the stacking direction, giving results for a 3D part optimization in a few minutes. Developed with Ansys Parametric Design Language, the computation tool was tested on printed wrenches, resulting in an 18% increase in stiffness. The proposed method is applicable to any printable shape.
{"title":"Fast layer fiber orientation optimization method for continuous fiber-reinforced material extrusion process","authors":"Valentin Marchal, Yicha Zhang, N. Labed, R. Lachat, F. Peyraut","doi":"10.36922/msam.49","DOIUrl":"https://doi.org/10.36922/msam.49","url":null,"abstract":"Material extrusion (MEX) is an additive manufacturing process that uses thermoplastic layer-by-layer building. The use of continuous fiber-reinforced filament enhances mechanical properties, making MEX suitable for use in aerospace, automotive, and robotics industries. This study proposes a laminate optimization method to improve the stiffness of printed parts with low computing time. The 2D stress-flow-based method optimizes fiber’s orientation for each layer in the stacking direction, giving results for a 3D part optimization in a few minutes. Developed with Ansys Parametric Design Language, the computation tool was tested on printed wrenches, resulting in an 18% increase in stiffness. The proposed method is applicable to any printable shape.","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133887443","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Equiatomic CoCrFeMnNi, one of the well-known high-entropy alloys, possesses attractive mechanical properties for many potential applications. In this research, the effects of heat treatment on additively manufactured CoCrFeMnNi materials were studied. A pilot experiment was conducted to select two selective laser melting (SLM) conditions of different laser scanning speeds based on the density and porosity of obtained materials. Thereafter, microstructure, tensile properties, impact fracture, microhardness, and corrosion resistance were investigated for the materials obtained under the two selected SLM conditions, with and without heat treatment. It was discovered that while the texture with a strong <100> alignment was observed in both as-built and heat treated materials, the texture of heat treated materials was stronger. Also, heat treatment drastically improved the ductility of as-built CoCrFeMnNi by 23 – 59% for the selected SLM conditions, while the ultimate tensile strength showed only negligible change. The increase of ductility was believed to result from the release of residual strain and the increase of average grain size after heat treatment. Moreover, heat treatment was able to bring noticeable improvement in energy absorption for the as-built CoCrFeMnNi, reflected by 11 – 16% more energy absorption. Besides, all studied materials showed signs of ductile fracture, but more signs of brittle fracture, such as cleavage facets, were found in the as-built materials as compared with the heat-treated materials. In addition, higher laser scan speed was found to cause moderate reduction in corrosion resistance. Effect of heat treatment was also negative and mild for lower scanning speed case. However, the highest reduction in corrosion resistance was observed after heat treatment of the high laser scanning speed case.
{"title":"Microstructure, mechanical properties, and corrosion performance of additively manufactured CoCrFeMnNi high-entropy alloy before and after heat treatment","authors":"Roman Savinov, Jing Shi","doi":"10.36922/msam.42","DOIUrl":"https://doi.org/10.36922/msam.42","url":null,"abstract":"Equiatomic CoCrFeMnNi, one of the well-known high-entropy alloys, possesses attractive mechanical properties for many potential applications. In this research, the effects of heat treatment on additively manufactured CoCrFeMnNi materials were studied. A pilot experiment was conducted to select two selective laser melting (SLM) conditions of different laser scanning speeds based on the density and porosity of obtained materials. Thereafter, microstructure, tensile properties, impact fracture, microhardness, and corrosion resistance were investigated for the materials obtained under the two selected SLM conditions, with and without heat treatment. It was discovered that while the texture with a strong <100> alignment was observed in both as-built and heat treated materials, the texture of heat treated materials was stronger. Also, heat treatment drastically improved the ductility of as-built CoCrFeMnNi by 23 – 59% for the selected SLM conditions, while the ultimate tensile strength showed only negligible change. The increase of ductility was believed to result from the release of residual strain and the increase of average grain size after heat treatment. Moreover, heat treatment was able to bring noticeable improvement in energy absorption for the as-built CoCrFeMnNi, reflected by 11 – 16% more energy absorption. Besides, all studied materials showed signs of ductile fracture, but more signs of brittle fracture, such as cleavage facets, were found in the as-built materials as compared with the heat-treated materials. In addition, higher laser scan speed was found to cause moderate reduction in corrosion resistance. Effect of heat treatment was also negative and mild for lower scanning speed case. However, the highest reduction in corrosion resistance was observed after heat treatment of the high laser scanning speed case.","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":"39 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-02-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129877375","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A metal matrix composite with Inconel 718 as the base metal and yttrium oxide (Y2O3) as the reinforcement particles was fabricated by the laser powder bed fusion technology. This paper presents a comprehensive study on the influence of the Y2O3 reinforcement particles on the microstructures and mechanical properties of the heat-treated printed composite. Complex precipitates formation between the Y2O3 nanoparticles and the carbonitride precipitates were shown. The complex precipitates separated into individual Y2O3 and titanium nitride (TiN) nanoparticles after heat treatment. Nano-sized Y-Ti-O precipitates were observed after solutionization due to the release of supersaturated Y in the metal matrix. Grain refinement was also observed in the heat-treated composites due to the high number of nano-sized precipitates. After solutionizing and aging, the grain size of the Y2O3-reinforced sample is 28.2% and 33.9% smaller, respectively, than that of the monolithic Inconel 718 sample. This effectively reduced the segregation of Nbat the grain boundaries and thus, γ′ and γ′′ precipitates were distributed in the metal matrix more homogeneously. Combined with the increased Orowan strengthening from a significantly higher number of nano-sized precipitates and grain boundary strengthening, the composite achieved higher yield strength, and ultimate tensile strength (1099.3 MPa and 1385.5 MPa, respectively) than those of the monolithic Inconel 718 (1015.5 MPa and 1284.3 MPa, respectively).
{"title":"Influence of Y2O3 reinforcement particles during heat treatment of IN718 composite produced by laser powder bed fusion","authors":"Duy Nghia Luu, Wei Zhou, S. Nai","doi":"10.18063/msam.v1i4.25","DOIUrl":"https://doi.org/10.18063/msam.v1i4.25","url":null,"abstract":"A metal matrix composite with Inconel 718 as the base metal and yttrium oxide (Y2O3) as the reinforcement particles was fabricated by the laser powder bed fusion technology. This paper presents a comprehensive study on the influence of the Y2O3 reinforcement particles on the microstructures and mechanical properties of the heat-treated printed composite. Complex precipitates formation between the Y2O3 nanoparticles and the carbonitride precipitates were shown. The complex precipitates separated into individual Y2O3 and titanium nitride (TiN) nanoparticles after heat treatment. Nano-sized Y-Ti-O precipitates were observed after solutionization due to the release of supersaturated Y in the metal matrix. Grain refinement was also observed in the heat-treated composites due to the high number of nano-sized precipitates. After solutionizing and aging, the grain size of the Y2O3-reinforced sample is 28.2% and 33.9% smaller, respectively, than that of the monolithic Inconel 718 sample. This effectively reduced the segregation of Nbat the grain boundaries and thus, γ′ and γ′′ precipitates were distributed in the metal matrix more homogeneously. Combined with the increased Orowan strengthening from a significantly higher number of nano-sized precipitates and grain boundary strengthening, the composite achieved higher yield strength, and ultimate tensile strength (1099.3 MPa and 1385.5 MPa, respectively) than those of the monolithic Inconel 718 (1015.5 MPa and 1284.3 MPa, respectively).","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":"52 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126849441","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Chuyi Liu, C. Ling, Cheng Chen, Dongsheng Wang, You-wen Yang, Deqiao Xie, C. Shuai
Biomedical magnesium (Mg) alloy with unique biodegradability and excellent biocompatibility is one of the most sought after materials in medical field for orthopedics applications. Nevertheless, the high corrosion rate and inadequate mechanical properties hinder its development. Apart from that, to obtain the best surgical result, the size and shape of the fixation implant need to be adapted to the individual case. Thus, additive manufacturing (AM) processes, such as laser powder bed fusion (LPBF), are used to overcome these issues. This work reviews the recent advancements in biodegradable Mg-based alloys prepared by LPBF for biomedical applications. The influence of feedstock features and manufacturing parameters on the formability and quality is delineated in detail. The mechanical performances, degradation behaviors, and biological behavior of the LPBF-processed parts are discussed. Furthermore, we also made some suggestions for the challenges of Mg alloys in LPBF processing and applications in biomedical.
{"title":"Laser additive manufacturing of magnesium alloys and its biomedical applications","authors":"Chuyi Liu, C. Ling, Cheng Chen, Dongsheng Wang, You-wen Yang, Deqiao Xie, C. Shuai","doi":"10.18063/msam.v1i4.24","DOIUrl":"https://doi.org/10.18063/msam.v1i4.24","url":null,"abstract":"Biomedical magnesium (Mg) alloy with unique biodegradability and excellent biocompatibility is one of the most sought after materials in medical field for orthopedics applications. Nevertheless, the high corrosion rate and inadequate mechanical properties hinder its development. Apart from that, to obtain the best surgical result, the size and shape of the fixation implant need to be adapted to the individual case. Thus, additive manufacturing (AM) processes, such as laser powder bed fusion (LPBF), are used to overcome these issues. This work reviews the recent advancements in biodegradable Mg-based alloys prepared by LPBF for biomedical applications. The influence of feedstock features and manufacturing parameters on the formability and quality is delineated in detail. The mechanical performances, degradation behaviors, and biological behavior of the LPBF-processed parts are discussed. Furthermore, we also made some suggestions for the challenges of Mg alloys in LPBF processing and applications in biomedical.","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-12-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130908160","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Heng Dong, Feng Liu, Lin Ye, Xiaoqiong Ouyang, Qiang Wang, Li Wang, Lan Huang, Liming Tan, X. Jin, Y. Liu
To accelerate the optimization of selective electron-beam melting (SEBM) processing parameters, two machine learning models, Gaussian process regression, and support vector regression were applied in this work to predict the relative density of Inconel 718 from experimental data. The experimental validation indicated that the trained algorithms can precisely predict the relative density of SEBM samples. Moreover, the effects of different parameters on surface integrity, internal defects, and mechanical properties are discussed in this paper. The Inconel 718 samples with high density (>99.5%) prepared by the same SEBM energy density exhibit different mechanical properties, which are related to the existence of the unmelted powder, Laves phase, and grain structure. Finally, Inconel 718 sample with superior strength and plasticity was fabricated using the optimized processing parameters.
{"title":"Process optimization and mechanical property investigation of Inconel 718 manufactured by selective electron beam melting","authors":"Heng Dong, Feng Liu, Lin Ye, Xiaoqiong Ouyang, Qiang Wang, Li Wang, Lan Huang, Liming Tan, X. Jin, Y. Liu","doi":"10.18063/msam.v1i4.23","DOIUrl":"https://doi.org/10.18063/msam.v1i4.23","url":null,"abstract":"To accelerate the optimization of selective electron-beam melting (SEBM) processing parameters, two machine learning models, Gaussian process regression, and support vector regression were applied in this work to predict the relative density of Inconel 718 from experimental data. The experimental validation indicated that the trained algorithms can precisely predict the relative density of SEBM samples. Moreover, the effects of different parameters on surface integrity, internal defects, and mechanical properties are discussed in this paper. The Inconel 718 samples with high density (>99.5%) prepared by the same SEBM energy density exhibit different mechanical properties, which are related to the existence of the unmelted powder, Laves phase, and grain structure. Finally, Inconel 718 sample with superior strength and plasticity was fabricated using the optimized processing parameters.","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114899241","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Sound absorption is one of the important properties of porous materials such as foams and lattices. Many mathematical models in the literature are capable of modeling the acoustic properties of lattices. However, appropriate models need to be chosen for specific lattice structures on a case-by-case basis and require significant experience in acoustic modeling. This work aims to provide simplified insights into different mathematical models for the simple cubic lattice. The strut lengths and radii of the unit cells were varied, and the sound absorption properties were measured using an impedance tube. The sound absorption coefficients of the lattices generally increased and exhibited more resonant-like behavior as the strut radius increased. The Delany-Bazley (DB) model and the multi-layered micropore-cavity (MMC) model were used to simulate the acoustic properties of the lattices. The correction factors in the MMC were calculated based on empirical relations fitted using experimental data of the design geometry parameters. Results show that the DB model was able to model the sound absorption coefficients for lattice samples with porosities as low as 0.7, while the MMC with resonator theory is a more appropriate acoustics approach for lattices with porosities lower than 0.7. This work will be highly useful for materials researchers who are studying the acoustic properties of novel porous materials, as well as manufacturers of acoustic materials interested in the additive manufacturing of lattice structures for sound absorption and insulation applications.
{"title":"Experimental and numerical studies on the acoustic performance of simple cubic structure lattices fabricated by digital light processing","authors":"Zhejie Lai, Miao Zhao, C. H. Lim, Jun Wei Chua","doi":"10.18063/msam.v1i4.22","DOIUrl":"https://doi.org/10.18063/msam.v1i4.22","url":null,"abstract":"Sound absorption is one of the important properties of porous materials such as foams and lattices. Many mathematical models in the literature are capable of modeling the acoustic properties of lattices. However, appropriate models need to be chosen for specific lattice structures on a case-by-case basis and require significant experience in acoustic modeling. This work aims to provide simplified insights into different mathematical models for the simple cubic lattice. The strut lengths and radii of the unit cells were varied, and the sound absorption properties were measured using an impedance tube. The sound absorption coefficients of the lattices generally increased and exhibited more resonant-like behavior as the strut radius increased. The Delany-Bazley (DB) model and the multi-layered micropore-cavity (MMC) model were used to simulate the acoustic properties of the lattices. The correction factors in the MMC were calculated based on empirical relations fitted using experimental data of the design geometry parameters. Results show that the DB model was able to model the sound absorption coefficients for lattice samples with porosities as low as 0.7, while the MMC with resonator theory is a more appropriate acoustics approach for lattices with porosities lower than 0.7. This work will be highly useful for materials researchers who are studying the acoustic properties of novel porous materials, as well as manufacturers of acoustic materials interested in the additive manufacturing of lattice structures for sound absorption and insulation applications.","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":" 3","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131809462","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Nowadays, additive manufacturing (AM) technologies have been widely used in construction, medical, military, aerospace, fashion, etc. The advantages of AM (e.g., more design freedom, no restriction on the complexity of parts, and rapid prototyping) have attracted a growing number of researchers. Increasing number of papers are published each year. Until now, thousands of review papers have already been published in the field of AM. It is, therefore, perhaps timely to perform a survey on AM review papers so as to provide an overview and guidance for readers to choose their interested reviews on some specific topics. This survey gives detailed analysis on these reviews, divides these reviews into different groups based on the AM techniques and materials used, highlights some important reviews in this area, and provides some discussions and insights.
{"title":"A survey of additive manufacturing reviews","authors":"Xiaoya Zhai, Liuchao Jin, Jingchao Jiang","doi":"10.18063/msam.v1i4.21","DOIUrl":"https://doi.org/10.18063/msam.v1i4.21","url":null,"abstract":"Nowadays, additive manufacturing (AM) technologies have been widely used in construction, medical, military, aerospace, fashion, etc. The advantages of AM (e.g., more design freedom, no restriction on the complexity of parts, and rapid prototyping) have attracted a growing number of researchers. Increasing number of papers are published each year. Until now, thousands of review papers have already been published in the field of AM. It is, therefore, perhaps timely to perform a survey on AM review papers so as to provide an overview and guidance for readers to choose their interested reviews on some specific topics. This survey gives detailed analysis on these reviews, divides these reviews into different groups based on the AM techniques and materials used, highlights some important reviews in this area, and provides some discussions and insights.","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":"14 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114154306","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ana Paula Clares, Yawei Gao, Ryan Stebbins, A. V. van Duin, G. Manogharan
Binder jetting is an additive manufacturing (AM) technology that has gained popularity and attention in recent years for production applications in tooling, biomedical, energy, and defense sectors. When compared to other powder bed fusion-based AM methods, binder jetting processes powder feedstock without the need of an energy source during printing. This avoids defects associated with melting, residual stresses, and rapid solidification within the parts. However, one of the challenges of this process is the relatively lower densities which impacts part density, and subsequently, sintering and mechanical properties. In this study, we investigated the influence of bimodal powder size distributions (a mixture of coarse to fine particles) as a method for increasing part density and mechanical strength, and used stainless steel (SS) 316L bimodal mixtures in this case. Four unimodal and two bimodal groups were evaluated under similar AM processing conditions for sintered density measurements and flexural strengths. Our results demonstrated that bimodal size distributions showed a statistically significant increase in density by 20% and ultimate flexural strength by 170% when compared to the highest performing unimodal group. In addition to experimental findings, reactive molecular dynamics simulations showed that the presence of finer powders along with coarser particles in the bimodal particle mixture contribute to additional bonds that are stronger across the particle interfaces. Findings from this study can be used to design bimodal particle size distributions to achieve higher density and better mechanical properties in binder jetting AM process.
{"title":"Increasing density and mechanical performance of binder jetting processing through bimodal particle size distribution","authors":"Ana Paula Clares, Yawei Gao, Ryan Stebbins, A. V. van Duin, G. Manogharan","doi":"10.18063/msam.v1i3.20","DOIUrl":"https://doi.org/10.18063/msam.v1i3.20","url":null,"abstract":"Binder jetting is an additive manufacturing (AM) technology that has gained popularity and attention in recent years for production applications in tooling, biomedical, energy, and defense sectors. When compared to other powder bed fusion-based AM methods, binder jetting processes powder feedstock without the need of an energy source during printing. This avoids defects associated with melting, residual stresses, and rapid solidification within the parts. However, one of the challenges of this process is the relatively lower densities which impacts part density, and subsequently, sintering and mechanical properties. In this study, we investigated the influence of bimodal powder size distributions (a mixture of coarse to fine particles) as a method for increasing part density and mechanical strength, and used stainless steel (SS) 316L bimodal mixtures in this case. Four unimodal and two bimodal groups were evaluated under similar AM processing conditions for sintered density measurements and flexural strengths. Our results demonstrated that bimodal size distributions showed a statistically significant increase in density by 20% and ultimate flexural strength by 170% when compared to the highest performing unimodal group. In addition to experimental findings, reactive molecular dynamics simulations showed that the presence of finer powders along with coarser particles in the bimodal particle mixture contribute to additional bonds that are stronger across the particle interfaces. Findings from this study can be used to design bimodal particle size distributions to achieve higher density and better mechanical properties in binder jetting AM process.","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133646331","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
S. Alzaid, N. Hammad, Hamed I. Albalawi, Zainab N. Khan, Eter Othman, C. Hauser
This research highlights the development of a two-dimensional (2D) and three-dimensional (3D) preview software for additive manufacturing (AM). The presented software can produce a virtual representation of an actuator’s path movements by reading and parsing the orders of the desired geometric code (G-code) file. It then simulates the coded sections into separate 2D layers and colored 3D objects in a graphical model. This allows users to validate the shapes before the 3D printing process. G-code is an operation language which is based on command lines of code written in an alphanumeric format. Each line of these commands controls one machining operation; this instructs the machine’s motion to move in an arc, a circle, or a straight line to perform a specific shape after compiling all code lines. AM technology is widely used in most manufacturing fields (e.g., medical, chemical, and research laboratories) as a prototyping technology due to its ability to produce rapid prototyping models. 3D printing creates physical 3D models by extruding material layer by layer as 2D layers. At present, the most critical challenges in AM technology are drastically reducing prototyping materials’ consumption and time spent. To address these challenges, the proposed software allows for visualization of G-code files and predicting the overall layers’ shapes, allowing both structure prediction and subsequent printing error reduction.
{"title":"Advanced software development of 2D and 3D model visualization for TwinPrint, a dual-arm 3D bioprinting system for multi-material printing","authors":"S. Alzaid, N. Hammad, Hamed I. Albalawi, Zainab N. Khan, Eter Othman, C. Hauser","doi":"10.18063/msam.v1i3.19","DOIUrl":"https://doi.org/10.18063/msam.v1i3.19","url":null,"abstract":"This research highlights the development of a two-dimensional (2D) and three-dimensional (3D) preview software for additive manufacturing (AM). The presented software can produce a virtual representation of an actuator’s path movements by reading and parsing the orders of the desired geometric code (G-code) file. It then simulates the coded sections into separate 2D layers and colored 3D objects in a graphical model. This allows users to validate the shapes before the 3D printing process. G-code is an operation language which is based on command lines of code written in an alphanumeric format. Each line of these commands controls one machining operation; this instructs the machine’s motion to move in an arc, a circle, or a straight line to perform a specific shape after compiling all code lines. AM technology is widely used in most manufacturing fields (e.g., medical, chemical, and research laboratories) as a prototyping technology due to its ability to produce rapid prototyping models. 3D printing creates physical 3D models by extruding material layer by layer as 2D layers. At present, the most critical challenges in AM technology are drastically reducing prototyping materials’ consumption and time spent. To address these challenges, the proposed software allows for visualization of G-code files and predicting the overall layers’ shapes, allowing both structure prediction and subsequent printing error reduction.","PeriodicalId":422581,"journal":{"name":"Materials Science in Additive Manufacturing","volume":"255 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133818761","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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