Pub Date : 2024-07-16DOI: 10.1108/rpj-04-2024-0158
Mahmoud Afshari, M. Khandaei, Reza Shoja Razavi, Seyed Masoud Barekat
Purpose The net power delivered to the surface of parts (i.e. the actual heat flux) is a key parameter in the laser melting process and its exact control has a great impact on the numerical solutions. In this paper, the impact of laser additive manufacturing parameters including laser power, scanning speed and powder injection rate on thermal efficiency, net power delivered to the part and power loss due to powder flow has been investigated. Design/methodology/approach The response surface method was applied to measure the net laser power in laser deposited Inconel 718 using k-type thermocouples. The temperature history obtained by thermocouples was used to calculate the net power delivered by inverse analysis method. The applied model is Rosenthal's optimized model, in which all the thermal properties of the material are considered to vary with temperature. Findings The results indicated that the thermal efficiency, power delivered to the part and power loss can be optimized simultaneously at laser power of 400 W, scanning speed of 2 mm/s and powder injection rate of 200 mg/s. The microstructure analysis indicated that a high-quality sample without microstructural defects was formed under optimal condition of parameters. Moreover, the primary dendrite arm spacing for the optimal sample was higher than that obtained for other samples. Originality/value The novelty of this research summarized as follows: Prediction of the thermal efficiency and power loss during the laser metal deposition of Inconel 718 superalloy using the inverse analysis. Finding the optimal values of thermal efficiency, power delivered to the surface and power loss in the laser metal deposition of Inconel 718 superalloy. Investigating the effect of laser power, powder injection rate and scanning speed on the thermal efficiency and power loss of Inconel 718 superalloy during the laser metal deposition.
{"title":"Sintering parameter optimization by inverse analysis in direct metal deposition of Inconel 718","authors":"Mahmoud Afshari, M. Khandaei, Reza Shoja Razavi, Seyed Masoud Barekat","doi":"10.1108/rpj-04-2024-0158","DOIUrl":"https://doi.org/10.1108/rpj-04-2024-0158","url":null,"abstract":"\u0000Purpose\u0000The net power delivered to the surface of parts (i.e. the actual heat flux) is a key parameter in the laser melting process and its exact control has a great impact on the numerical solutions. In this paper, the impact of laser additive manufacturing parameters including laser power, scanning speed and powder injection rate on thermal efficiency, net power delivered to the part and power loss due to powder flow has been investigated.\u0000\u0000\u0000Design/methodology/approach\u0000The response surface method was applied to measure the net laser power in laser deposited Inconel 718 using k-type thermocouples. The temperature history obtained by thermocouples was used to calculate the net power delivered by inverse analysis method. The applied model is Rosenthal's optimized model, in which all the thermal properties of the material are considered to vary with temperature.\u0000\u0000\u0000Findings\u0000The results indicated that the thermal efficiency, power delivered to the part and power loss can be optimized simultaneously at laser power of 400 W, scanning speed of 2 mm/s and powder injection rate of 200 mg/s. The microstructure analysis indicated that a high-quality sample without microstructural defects was formed under optimal condition of parameters. Moreover, the primary dendrite arm spacing for the optimal sample was higher than that obtained for other samples.\u0000\u0000\u0000Originality/value\u0000The novelty of this research summarized as follows: Prediction of the thermal efficiency and power loss during the laser metal deposition of Inconel 718 superalloy using the inverse analysis. Finding the optimal values of thermal efficiency, power delivered to the surface and power loss in the laser metal deposition of Inconel 718 superalloy. Investigating the effect of laser power, powder injection rate and scanning speed on the thermal efficiency and power loss of Inconel 718 superalloy during the laser metal deposition.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"9 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141642039","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}
Pub Date : 2024-07-16DOI: 10.1108/rpj-02-2024-0102
Maede Mohseni, Saeed Khodaygan
Purpose This paper aims to improve the manufacturability of additive manufacturing (AM) for topology-optimized (TO) structures. Enhancement of manufacturability focuses on modifying geometric constraints and classifying the building orientation (BO) of AM parts to reduce stresses and support structures (SSs). To this end, artificial intelligence (AI) networks are being developed to automate design for additive manufacturing (DfAM). Design/methodology/approach This study considers three geometric constraints for their correction by convolutional autoencoders (CAEs) and transfer learning (TL). Furthermore, BOs of AM parts are classified using generative adversarial (GAN) and classification networks to reduce the SS. To verify the results, finite element analysis (FEA) is performed to compare the stresses of modified components with the original ones. Moreover, one sample is produced by the laser-based powder bed fusion (LB-PBF) in the BO predicted by the AI to observe its SSs. Findings CAE and TL resulted in promoting the manufacturability of TO components. FEA demonstrated that enhancing manufacturability leads to a 50% reduction in stresses. Additionally, training GAN and pre-training the ResNet-18 resulted in 80%, 95% and 96% accuracy for training, validation and testing. The production of a sample with LB-PBF demonstrated that the predicted BO by ResNet-18 does not require SSs. Originality/value This paper provides an automatic platform for DfAM of TO parts. Consequently, complex TO parts can be designed most feasibly and manufactured by AM technologies with minimal material usage, residual stresses and distortions.
目的 本文旨在提高拓扑优化（TO）结构增材制造（AM）的可制造性。提高可制造性的重点是修改几何约束和对 AM 零件的构建方向 (BO) 进行分类，以减少应力和支撑结构 (SS)。为此，正在开发人工智能（AI）网络，以实现增材制造设计（DfAM）的自动化。本研究考虑了三种几何约束，通过卷积自动编码器（CAE）和迁移学习（TL）对其进行修正。此外，还使用生成对抗（GAN）和分类网络对 AM 零件的 BO 进行分类，以减少 SS。为了验证结果，还进行了有限元分析（FEA），以比较修改后部件与原始部件的应力。此外，在人工智能预测的 BO 中通过激光粉末床熔融（LB-PBF）生产了一个样品，以观察其 SSs。有限元分析表明，提高可制造性可使应力降低 50%。此外，通过训练 GAN 和预训练 ResNet-18，训练、验证和测试的准确率分别达到 80%、95% 和 96%。使用 LB-PBF 生产的样品表明，ResNet-18 预测的 BO 不需要 SS。因此，复杂的 TO 零件可以最可行的方式进行设计，并通过 AM 技术以最少的材料用量、残余应力和变形进行制造。
{"title":"Design for additive manufacturing of topology-optimized structures based on deep learning and transfer learning","authors":"Maede Mohseni, Saeed Khodaygan","doi":"10.1108/rpj-02-2024-0102","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0102","url":null,"abstract":"Purpose\u0000This paper aims to improve the manufacturability of additive manufacturing (AM) for topology-optimized (TO) structures. Enhancement of manufacturability focuses on modifying geometric constraints and classifying the building orientation (BO) of AM parts to reduce stresses and support structures (SSs). To this end, artificial intelligence (AI) networks are being developed to automate design for additive manufacturing (DfAM).\u0000\u0000Design/methodology/approach\u0000This study considers three geometric constraints for their correction by convolutional autoencoders (CAEs) and transfer learning (TL). Furthermore, BOs of AM parts are classified using generative adversarial (GAN) and classification networks to reduce the SS. To verify the results, finite element analysis (FEA) is performed to compare the stresses of modified components with the original ones. Moreover, one sample is produced by the laser-based powder bed fusion (LB-PBF) in the BO predicted by the AI to observe its SSs.\u0000\u0000Findings\u0000CAE and TL resulted in promoting the manufacturability of TO components. FEA demonstrated that enhancing manufacturability leads to a 50% reduction in stresses. Additionally, training GAN and pre-training the ResNet-18 resulted in 80%, 95% and 96% accuracy for training, validation and testing. The production of a sample with LB-PBF demonstrated that the predicted BO by ResNet-18 does not require SSs.\u0000\u0000Originality/value\u0000This paper provides an automatic platform for DfAM of TO parts. Consequently, complex TO parts can be designed most feasibly and manufactured by AM technologies with minimal material usage, residual stresses and distortions.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"15 5","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141641497","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}
Pub Date : 2024-07-16DOI: 10.1108/rpj-01-2024-0034
Shrushti Maheshwari, Anand Kumar, Pyaarjeet Singh Chaurasia, T. Niranjan, Zafar Alam, Sarthak S. Singh
Purpose This study aims to investigate the compression characteristics of the 3D-printed polylactic acid (PLA) samples at temperatures below the glass transition temperature (Tg) with varying strain rates and develop a thermo-mechanical viscoplastic constitutive model to predict the finite strain compression response using a single set of material parameters. Also, the micro-mechanical damage processes are linked to the global stress–strain response at varied strain rates and temperatures through scanning electron microscopy (SEM). Design/methodology/approach Tg of PLA was determined using a dynamic mechanical analyzer. Compression experiments were conducted at strain rates of 2 × 10–3/s and 2 × 10–2/s at 25°C, 40°C and 50°C. The failure mechanisms were examined using SEM. A finite strain thermo-mechanical viscoplastic constitutive model was developed to analyze the deformations at the considered strain rates and temperatures. Findings Tg of PLA was determined as 55°C. While the yield and post-yield stresses drop with increasing temperature, their trend reverses with an increased strain rate. SEM imaging indicated plasticizing effects at higher temperatures, while filament fragmentation and twisting at higher strain rates were identified as the dominant failure mechanisms. Using a non-linear regression analysis to predict the experimental data, an overall R2 value of 0.98 was achieved between experimental and model prediction, implying the robustness of the model’s calibration. Originality/value In this study, a viscoplastic constitutive model was developed that considers the combined effect of temperature and strain rate for FDM-printed PLA experiencing extensive compression. Using appropriate temperature-dependent modulus and flow rate properties, a single set of model parameters predicted the rise in the gap between yield stress and degree of softening as strain rates and temperatures increased.
{"title":"Temperature and strain rate-dependent compression properties of 3D-printed PLA: an experimental and modeling analysis","authors":"Shrushti Maheshwari, Anand Kumar, Pyaarjeet Singh Chaurasia, T. Niranjan, Zafar Alam, Sarthak S. Singh","doi":"10.1108/rpj-01-2024-0034","DOIUrl":"https://doi.org/10.1108/rpj-01-2024-0034","url":null,"abstract":"\u0000Purpose\u0000This study aims to investigate the compression characteristics of the 3D-printed polylactic acid (PLA) samples at temperatures below the glass transition temperature (Tg) with varying strain rates and develop a thermo-mechanical viscoplastic constitutive model to predict the finite strain compression response using a single set of material parameters. Also, the micro-mechanical damage processes are linked to the global stress–strain response at varied strain rates and temperatures through scanning electron microscopy (SEM).\u0000\u0000\u0000Design/methodology/approach\u0000Tg of PLA was determined using a dynamic mechanical analyzer. Compression experiments were conducted at strain rates of 2 × 10–3/s and 2 × 10–2/s at 25°C, 40°C and 50°C. The failure mechanisms were examined using SEM. A finite strain thermo-mechanical viscoplastic constitutive model was developed to analyze the deformations at the considered strain rates and temperatures.\u0000\u0000\u0000Findings\u0000Tg of PLA was determined as 55°C. While the yield and post-yield stresses drop with increasing temperature, their trend reverses with an increased strain rate. SEM imaging indicated plasticizing effects at higher temperatures, while filament fragmentation and twisting at higher strain rates were identified as the dominant failure mechanisms. Using a non-linear regression analysis to predict the experimental data, an overall R2 value of 0.98 was achieved between experimental and model prediction, implying the robustness of the model’s calibration.\u0000\u0000\u0000Originality/value\u0000In this study, a viscoplastic constitutive model was developed that considers the combined effect of temperature and strain rate for FDM-printed PLA experiencing extensive compression. Using appropriate temperature-dependent modulus and flow rate properties, a single set of model parameters predicted the rise in the gap between yield stress and degree of softening as strain rates and temperatures increased.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"63 13","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141643690","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}
Pub Date : 2024-07-16DOI: 10.1108/rpj-02-2024-0095
Muhammad Ibnu Rashyid, Mahendra Jaya, M. Muflikhun
Purpose This paper aims to use hybrid manufacturing (HM) to overcome several drawbacks of material extrusion three-dimensional (3D) printers, such as low dimension ranging from 0.2 to 0.5 µm, resulting in a noticeable staircase effect and elevated surface roughness. Design/methodology/approach Subtractive manufacturing (SM) through computer numerical control milling is renowned for its precision and superior surface finish. This study integrates additive manufacturing (AM) and SM into a single material extrusion 3D printer platform, creating a HM system. Two sets of specimens, one exclusively printed and the other subjected to both printing and milling, were assessed for dimension accuracy and surface roughness. Findings The outcomes were promising, with postmilling accuracy reaching 99.94%. Significant reductions in surface roughness were observed at 90° (93.4% decrease from 15.598 to 1.030 µm), 45° (89% decrease from 26.727 to 2.946 µm) and the face plane (71% decrease from 12.176 to 3.535 µm). Practical implications The 3D printer was custom-built based on material extrusion and modified with an additional milling tool on the same gantry. An economic evaluation based on cost-manufacturing demonstrated that constructing this dual-function 3D printer costs less than US$560 in materials, offering valuable insights for researchers looking to replicate a similar machine. Originality/value The modified general 3D printer platform offered an easy way to postprocessing without removing the workpiece from the bed. This mechanism can reduce the downtime of changing the machine. The proven increased dimension accuracy and reduced surface roughness value increase the value of 3D-printed specimens.
{"title":"Extreme roughness reduction and ultrafine quality of innovative dual function material extrusion 3D printer","authors":"Muhammad Ibnu Rashyid, Mahendra Jaya, M. Muflikhun","doi":"10.1108/rpj-02-2024-0095","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0095","url":null,"abstract":"\u0000Purpose\u0000This paper aims to use hybrid manufacturing (HM) to overcome several drawbacks of material extrusion three-dimensional (3D) printers, such as low dimension ranging from 0.2 to 0.5 µm, resulting in a noticeable staircase effect and elevated surface roughness.\u0000\u0000\u0000Design/methodology/approach\u0000Subtractive manufacturing (SM) through computer numerical control milling is renowned for its precision and superior surface finish. This study integrates additive manufacturing (AM) and SM into a single material extrusion 3D printer platform, creating a HM system. Two sets of specimens, one exclusively printed and the other subjected to both printing and milling, were assessed for dimension accuracy and surface roughness.\u0000\u0000\u0000Findings\u0000The outcomes were promising, with postmilling accuracy reaching 99.94%. Significant reductions in surface roughness were observed at 90° (93.4% decrease from 15.598 to 1.030 µm), 45° (89% decrease from 26.727 to 2.946 µm) and the face plane (71% decrease from 12.176 to 3.535 µm).\u0000\u0000\u0000Practical implications\u0000The 3D printer was custom-built based on material extrusion and modified with an additional milling tool on the same gantry. An economic evaluation based on cost-manufacturing demonstrated that constructing this dual-function 3D printer costs less than US$560 in materials, offering valuable insights for researchers looking to replicate a similar machine.\u0000\u0000\u0000Originality/value\u0000The modified general 3D printer platform offered an easy way to postprocessing without removing the workpiece from the bed. This mechanism can reduce the downtime of changing the machine. The proven increased dimension accuracy and reduced surface roughness value increase the value of 3D-printed specimens.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"8 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141641323","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}
Pub Date : 2024-07-15DOI: 10.1108/rpj-11-2023-0410
Manuel Rodríguez-Martín, Rosario Domingo, João Ribeiro
Purpose This study aims to investigate the scientific impact of additive manufacturing in recent years, considering its evolution as an Industry 4.0 technology and also in the current context of Industry 5.0. For this aim, advanced statistics and scientometric tools have been used. Design/methodology/approach This study aims to explore the trends and impacts of additive manufacturing, focusing on its evolution and its relationship with Industry 4.0 and 5.0. For this purpose, a scientometric study and a meta-analysis of data extracted from the scientific Scopus database have been carried out. R programming and specific bibliometric software have been used to conduct the research. Initially, the data were evaluated from various perspectives, including sources, topics and impact indexes, to assess trends derived from the volume of publications, the impact of sources and affiliations, as well as the production segmented by country and the relationships between authors from different countries. Subsequently, a meta-analysis on keywords has been carried out using two distinct clustering methodologies: link strength and fractionalization. The results obtained were compared to establish a specific taxonomy of the AM subtopics, considering AM as a single body of knowledge related to Industries 4.0 and 5.0 paradigms. The analyses carried out have shown the impact and strong evolution of additive manufacturing as a field of knowledge at the world level, both from the point of view of manufacturing processes and from the point of view of materials science. In addition, some differences have been detected depending on the country. As a result of the meta-analysis, four different subtopics have been detected, some of which are highly related to other technologies and approaches in Industries 4.0 and 5.0 paradigms. Additionally, it establishes a comprehensive taxonomy for AM research, serving as a foundational reference for future studies aimed at exploring the evolution and transformative impact of this technology. Findings The analyses carried out have shown the impact and strong evolution of additive manufacturing as a field of knowledge at the world level, both from the point of view of manufacturing processes and from the point of view of materials science. In addition, some differences have been detected depending on the country. As a result of the meta-analysis, four different subtopics have been detected: one of them directly related to the use of recently developed Industry 4.0 technologies in additive manufacturing. The results provide a starting point for prospective studies to understand the evolution and disruption of this technology. Originality/value The paper is original and is based on data systematically extracted from scientific databases. Then, a specific methodology based on different advanced tools was applied for scientometric evaluation and meta-analysis.
目的本研究旨在调查近年来增材制造对科学的影响，同时考虑其作为工业 4.0 技术以及在当前工业 5.0 背景下的演变。本研究旨在探索增材制造的趋势和影响，重点关注其演变及其与工业 4.0 和 5.0 的关系。为此，我们对从科学 Scopus 数据库中提取的数据进行了科学计量学研究和元分析。研究使用了 R 编程和特定的文献计量软件。首先，从来源、主题和影响指数等不同角度对数据进行了评估，以评估从出版物数量、来源和附属机构的影响以及按国家划分的产量和不同国家作者之间的关系中得出的趋势。随后，使用两种不同的聚类方法：链接强度和分化，对关键词进行了元分析。通过对所获得的结果进行比较，建立了一个特定的 AM 子专题分类法，将 AM 视为与工业 4.0 和 5.0 范式相关的单一知识体系。所进行的分析表明，无论是从制造工艺的角度还是从材料科学的角度来看，增材制造作为一个知识领域在世界范围内都有着巨大的影响和发展。此外，还发现了一些因国家而异的差异。通过元分析，我们发现了四个不同的子课题，其中一些与工业 4.0 和 5.0 范式中的其他技术和方法高度相关。此外，它还为增材制造研究建立了一个全面的分类法，为今后旨在探索该技术的演变和变革性影响的研究提供了基础参考。 研究结果所进行的分析表明，无论是从制造工艺的角度还是从材料科学的角度来看，增材制造作为一个知识领域在世界范围内都产生了影响并发生了巨大的演变。此外，还发现了一些因国家而异的差异。荟萃分析的结果发现了四个不同的子课题：其中一个直接与在增材制造中使用最新开发的工业 4.0 技术有关。这些结果为前瞻性研究提供了一个起点，以了解该技术的演变和颠覆。原创性/价值本文具有原创性，基于从科学数据库中系统提取的数据。然后，采用基于不同先进工具的特定方法进行科学计量学评估和荟萃分析。
{"title":"Mapping and prospective of additive manufacturing in the context of Industry 4.0 and 5.0","authors":"Manuel Rodríguez-Martín, Rosario Domingo, João Ribeiro","doi":"10.1108/rpj-11-2023-0410","DOIUrl":"https://doi.org/10.1108/rpj-11-2023-0410","url":null,"abstract":"Purpose\u0000This study aims to investigate the scientific impact of additive manufacturing in recent years, considering its evolution as an Industry 4.0 technology and also in the current context of Industry 5.0. For this aim, advanced statistics and scientometric tools have been used.\u0000\u0000Design/methodology/approach\u0000This study aims to explore the trends and impacts of additive manufacturing, focusing on its evolution and its relationship with Industry 4.0 and 5.0. For this purpose, a scientometric study and a meta-analysis of data extracted from the scientific Scopus database have been carried out. R programming and specific bibliometric software have been used to conduct the research. Initially, the data were evaluated from various perspectives, including sources, topics and impact indexes, to assess trends derived from the volume of publications, the impact of sources and affiliations, as well as the production segmented by country and the relationships between authors from different countries. Subsequently, a meta-analysis on keywords has been carried out using two distinct clustering methodologies: link strength and fractionalization. The results obtained were compared to establish a specific taxonomy of the AM subtopics, considering AM as a single body of knowledge related to Industries 4.0 and 5.0 paradigms. The analyses carried out have shown the impact and strong evolution of additive manufacturing as a field of knowledge at the world level, both from the point of view of manufacturing processes and from the point of view of materials science. In addition, some differences have been detected depending on the country. As a result of the meta-analysis, four different subtopics have been detected, some of which are highly related to other technologies and approaches in Industries 4.0 and 5.0 paradigms. Additionally, it establishes a comprehensive taxonomy for AM research, serving as a foundational reference for future studies aimed at exploring the evolution and transformative impact of this technology.\u0000\u0000Findings\u0000The analyses carried out have shown the impact and strong evolution of additive manufacturing as a field of knowledge at the world level, both from the point of view of manufacturing processes and from the point of view of materials science. In addition, some differences have been detected depending on the country. As a result of the meta-analysis, four different subtopics have been detected: one of them directly related to the use of recently developed Industry 4.0 technologies in additive manufacturing. The results provide a starting point for prospective studies to understand the evolution and disruption of this technology.\u0000\u0000Originality/value\u0000The paper is original and is based on data systematically extracted from scientific databases. Then, a specific methodology based on different advanced tools was applied for scientometric evaluation and meta-analysis.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"23 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141646522","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}
Pub Date : 2024-07-12DOI: 10.1108/rpj-01-2024-0015
María Higueras, Ana Carrasco-Huertas, A. I. Calero-Castillo, Manuel Moreno Alcaide, Francisco José Collado Montero
Purpose This paper aims to study the suitability of a selection of 3D printing liquid photopolymer resins for their application in the cultural heritage context. Design/methodology/approach The main concerns regarding the conservation and restoration of cultural assets are the chemical composition and long-term behavior of the new materials that will be in contact with the original object. Because of this, four different LED curing resins were exposed to an accelerated aging procedure and tested to identify the materials which demonstrated a better result. Some specific properties of the material (color, glossiness, pH and volatile organic compound emissions) were measured before and after the exposure. Findings Some of the properties measured reported good results demonstrating a decent stability against the selected aging conditions. The main changes were produced in the colorimetric aspect, probably indicating other chemical reactions in the material. Likewise, a case study could be also executed to demonstrate the usefulness of these materials in the cultural field. Research limitations/implications It is necessary to study in more detail the long-lasting behavior of the materials employed with these technologies. Further analysis should be carried out highlighting the chemical composition and degradation process of the materials proposed. Originality/value This paper contributes to the introduction of curing 3D printing resins in the restoration methodologies of cultural assets. For this, the study of a selection of properties represents the first stage to suggest or reject their use.
设计/方法/途径 保护和修复文化资产的主要关注点是将与原物接触的新材料的化学成分和长期行为。因此，对四种不同的 LED 固化树脂进行了加速老化程序和测试，以确定哪种材料的效果更好。在曝晒前后，对材料的一些特定属性（颜色、光泽度、pH 值和挥发性有机化合物排放）进行了测量。主要变化出现在色度方面，这可能表明材料中发生了其他化学反应。同样，还可以通过案例研究来证明这些材料在文化领域的实用性。本文有助于在文化资产修复方法中引入固化 3D 打印树脂。为此，对部分特性的研究是建议或拒绝使用这些材料的第一阶段。
{"title":"Study of liquid photopolymer 3D printing resins exposed to accelerated aging for cultural heritage purposes","authors":"María Higueras, Ana Carrasco-Huertas, A. I. Calero-Castillo, Manuel Moreno Alcaide, Francisco José Collado Montero","doi":"10.1108/rpj-01-2024-0015","DOIUrl":"https://doi.org/10.1108/rpj-01-2024-0015","url":null,"abstract":"\u0000Purpose\u0000This paper aims to study the suitability of a selection of 3D printing liquid photopolymer resins for their application in the cultural heritage context.\u0000\u0000\u0000Design/methodology/approach\u0000The main concerns regarding the conservation and restoration of cultural assets are the chemical composition and long-term behavior of the new materials that will be in contact with the original object. Because of this, four different LED curing resins were exposed to an accelerated aging procedure and tested to identify the materials which demonstrated a better result. Some specific properties of the material (color, glossiness, pH and volatile organic compound emissions) were measured before and after the exposure.\u0000\u0000\u0000Findings\u0000Some of the properties measured reported good results demonstrating a decent stability against the selected aging conditions. The main changes were produced in the colorimetric aspect, probably indicating other chemical reactions in the material. Likewise, a case study could be also executed to demonstrate the usefulness of these materials in the cultural field.\u0000\u0000\u0000Research limitations/implications\u0000It is necessary to study in more detail the long-lasting behavior of the materials employed with these technologies. Further analysis should be carried out highlighting the chemical composition and degradation process of the materials proposed.\u0000\u0000\u0000Originality/value\u0000This paper contributes to the introduction of curing 3D printing resins in the restoration methodologies of cultural assets. For this, the study of a selection of properties represents the first stage to suggest or reject their use.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"14 9","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141654131","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}
Pub Date : 2024-07-10DOI: 10.1108/rpj-11-2023-0388
Michele Conconi, N. Sancisi, Reid Backus, Christian Argenti, Albert J Shih
Purpose 3D-printed devices proved their efficacy across different clinical applications, helping personalize medical treatments. This paper aims to present the procedure for the design and production of patient-specific dynamic simulators of the human knee. The scope of these simulators is to improve surgical outcomes, investigate the motion and load response of the human knee and standardize in-vitro experiments for testing orthopedic devices through a personalized physical representation of the patient’s joint. Design/methodology/approach This paper tested the approach on three volunteers. For each, a patient-specific mathematical joint model was defined from an magnetic resonance imaging (MRI) of the knee. The model guided the CAD design of the simulators, which was then realized through stereolithography printing. Manufacturing accuracy was tested by quantifying the differences between 3D-printed and CAD geometry. To assess the simulator functionality, its motion was measured through a stereophotogrammetric system and compared with the natural tibio-femoral motion of the volunteers, measured as a sequence of static MRI. Findings The 3D-printing accuracy was very high, with average differences between ideal and printed parts below ± 0.1 mm. However, the assembly of different 3D-printed parts resulted in a higher average error of 0.97 mm and peak values of 2.33 mm. Despite that, the rotational and translational accuracy of the simulator was about 5° and 4 mm, respectively. Originality/value Although improvements in the production process are needed, the proposed simulators successfully replicated the individual articular behavior. The proposed approach is general and thus extendible to other articulations.
目的3D打印设备在不同的临床应用中证明了其功效，有助于实现个性化医疗。本文旨在介绍设计和制作患者专用的人体膝关节动态模拟器的程序。这些模拟器的目的是改善手术效果，研究人体膝关节的运动和负载响应，并通过对患者关节的个性化物理表示，将测试矫形设备的体外实验标准化。根据膝关节的核磁共振成像（MRI），为每名志愿者定义了患者特定的数学关节模型。该模型指导了模拟器的 CAD 设计，然后通过立体光刻印刷实现。通过量化 3D 打印与 CAD 几何图形之间的差异，测试了制造精度。为了评估模拟器的功能，我们通过立体摄影测量系统测量了模拟器的运动，并将其与志愿者的胫骨-股骨自然运动（通过静态核磁共振成像序列进行测量）进行了比较。然而，不同 3D 打印部件的组装导致平均误差达到 0.97 毫米，峰值为 2.33 毫米。尽管如此，模拟器的旋转和平移精度分别约为 5° 和 4 毫米。所提出的方法具有通用性，因此可扩展到其他关节。
{"title":"A 3D-printed, dynamic, patient-specific knee simulator","authors":"Michele Conconi, N. Sancisi, Reid Backus, Christian Argenti, Albert J Shih","doi":"10.1108/rpj-11-2023-0388","DOIUrl":"https://doi.org/10.1108/rpj-11-2023-0388","url":null,"abstract":"Purpose\u00003D-printed devices proved their efficacy across different clinical applications, helping personalize medical treatments. This paper aims to present the procedure for the design and production of patient-specific dynamic simulators of the human knee. The scope of these simulators is to improve surgical outcomes, investigate the motion and load response of the human knee and standardize in-vitro experiments for testing orthopedic devices through a personalized physical representation of the patient’s joint.\u0000\u0000Design/methodology/approach\u0000This paper tested the approach on three volunteers. For each, a patient-specific mathematical joint model was defined from an magnetic resonance imaging (MRI) of the knee. The model guided the CAD design of the simulators, which was then realized through stereolithography printing. Manufacturing accuracy was tested by quantifying the differences between 3D-printed and CAD geometry. To assess the simulator functionality, its motion was measured through a stereophotogrammetric system and compared with the natural tibio-femoral motion of the volunteers, measured as a sequence of static MRI.\u0000\u0000Findings\u0000The 3D-printing accuracy was very high, with average differences between ideal and printed parts below ± 0.1 mm. However, the assembly of different 3D-printed parts resulted in a higher average error of 0.97 mm and peak values of 2.33 mm. Despite that, the rotational and translational accuracy of the simulator was about 5° and 4 mm, respectively.\u0000\u0000Originality/value\u0000Although improvements in the production process are needed, the proposed simulators successfully replicated the individual articular behavior. The proposed approach is general and thus extendible to other articulations.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"3 11","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141661550","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}
Pub Date : 2024-07-09DOI: 10.1108/rpj-02-2024-0081
A. Pellegrini, F. Lavecchia, M. G. Guerra
Purpose This work is focused on the realization of copper parts using the material extrusion additive manufacturing debinding and sintering (MEX+D&S) technology. Design/methodology/approach A highly filled filament with 90 Wt.% of copper is used to realize nine different combinations varying the printing speed and the flow rate. The following thermal debinding and sintering are performed at 483 °C and 1057 °C, respectively, burying the samples in specific refractory powder and carbon. The green and sintered density are measured and an inspection at optical microscope is implemented for a detailed internal analysis of the defects. Findings The samples, that reported the highest values of the green density, become the worst in the sintered condition due to evident swelling defect generated by the entrapped polymer during the thermal debinding. On the other hand, the parts with the lower values of green density allowed to achieve a satisfying density value without significant external defects. Originality/value The realization of copper parts through laser-based additive manufacturing technologies shows several troubles related to the rapid heat transfer and the high reflectivity of copper, which is a hinder of the absorption of the laser power. The MEX+D&S becomes an easier and economical alternative for the realization of copper parts. The internal inspection of the samples revealed the need for the improvement on the process chain, adopting a different debinding process to open channels during the thermal debinding to avoid the entrapment of the polymer.
设计/方法/途径 使用含铜量为 90 Wt.% 的高填充长丝，改变打印速度和流速，实现九种不同的组合。随后分别在 483 °C 和 1057 °C 下进行热脱脂和烧结，将样品埋入特定的耐火粉末和碳中。测量了生坯密度和烧结密度，并用光学显微镜对缺陷进行了详细的内部分析。研究结果表明，生坯密度值最高的样品，由于在热脱胶过程中夹带的聚合物产生了明显的膨胀缺陷，因此在烧结状态下的生坯密度最差。另一方面，绿色密度值较低的零件可以达到令人满意的密度值，且没有明显的外部缺陷。 原创性/价值通过基于激光的增材制造技术实现铜零件，会遇到一些与快速传热和铜的高反射率有关的问题，这阻碍了对激光功率的吸收。而 MEX+D&S 则成为实现铜零件的一种更简便、更经济的替代方案。对样品的内部检查表明，有必要对工艺链进行改进，采用不同的排胶工艺，在热排胶过程中打开通道，以避免聚合物堵塞。
{"title":"Additive manufacturing of copper parts using extrusion and sinter-based technology: evaluation of the influence of printing parameters and debinding method","authors":"A. Pellegrini, F. Lavecchia, M. G. Guerra","doi":"10.1108/rpj-02-2024-0081","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0081","url":null,"abstract":"Purpose\u0000This work is focused on the realization of copper parts using the material extrusion additive manufacturing debinding and sintering (MEX+D&S) technology.\u0000\u0000Design/methodology/approach\u0000A highly filled filament with 90 Wt.% of copper is used to realize nine different combinations varying the printing speed and the flow rate. The following thermal debinding and sintering are performed at 483 °C and 1057 °C, respectively, burying the samples in specific refractory powder and carbon. The green and sintered density are measured and an inspection at optical microscope is implemented for a detailed internal analysis of the defects.\u0000\u0000Findings\u0000The samples, that reported the highest values of the green density, become the worst in the sintered condition due to evident swelling defect generated by the entrapped polymer during the thermal debinding. On the other hand, the parts with the lower values of green density allowed to achieve a satisfying density value without significant external defects.\u0000\u0000Originality/value\u0000The realization of copper parts through laser-based additive manufacturing technologies shows several troubles related to the rapid heat transfer and the high reflectivity of copper, which is a hinder of the absorption of the laser power. The MEX+D&S becomes an easier and economical alternative for the realization of copper parts. The internal inspection of the samples revealed the need for the improvement on the process chain, adopting a different debinding process to open channels during the thermal debinding to avoid the entrapment of the polymer.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"62 15","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141663412","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}
Pub Date : 2024-07-08DOI: 10.1108/rpj-12-2023-0429
Kunal Arora, Mohit Kumar, Varun Sharma
Purpose The paper aims to fabricate shape memory composites using polylactic acid (PLA) matrix and graphite. Shape memory polymers are a promising family of materials for biomedical applications because of their favourable mechanical properties, fast reactions and good biocompatibility. For most SMPs, however, achieving controllable sequential shape change is challenging. Design/methodology/approach In the present work, 4D printing technology is used to fabricate shape memory composites using polylactic acid (PLA) matrix and graphite. A comparative study of pure PLA and graphite’s different weight % composition has been done. Findings By carefully managing the deformation state, PLA with graphite shape memory composites produced controllable sequential deformation with an amazing shape memory effect. Surface morphology, thermal properties, melt flow index and shape recovery tests have all been carried out to assess the qualities of manufactured samples. Originality/value This is a one-of-a-kind to fabricate shape memory composites using graphite and a PLA matrix. Thus, this research attempts to deliver the possible use of PLA/graphite composites fabricated using 4D printing in robotics and biomedical devices. Graphical Abstract
{"title":"Investigations into 4D printed PLA/graphite composite with thermal induced shape memory effect","authors":"Kunal Arora, Mohit Kumar, Varun Sharma","doi":"10.1108/rpj-12-2023-0429","DOIUrl":"https://doi.org/10.1108/rpj-12-2023-0429","url":null,"abstract":"Purpose\u0000The paper aims to fabricate shape memory composites using polylactic acid (PLA) matrix and graphite. Shape memory polymers are a promising family of materials for biomedical applications because of their favourable mechanical properties, fast reactions and good biocompatibility. For most SMPs, however, achieving controllable sequential shape change is challenging.\u0000\u0000Design/methodology/approach\u0000In the present work, 4D printing technology is used to fabricate shape memory composites using polylactic acid (PLA) matrix and graphite. A comparative study of pure PLA and graphite’s different weight % composition has been done.\u0000\u0000Findings\u0000By carefully managing the deformation state, PLA with graphite shape memory composites produced controllable sequential deformation with an amazing shape memory effect. Surface morphology, thermal properties, melt flow index and shape recovery tests have all been carried out to assess the qualities of manufactured samples.\u0000\u0000Originality/value\u0000This is a one-of-a-kind to fabricate shape memory composites using graphite and a PLA matrix. Thus, this research attempts to deliver the possible use of PLA/graphite composites fabricated using 4D printing in robotics and biomedical devices.\u0000\u0000Graphical Abstract\u0000\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":" 11","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141668876","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}
Pub Date : 2024-07-03DOI: 10.1108/rpj-02-2024-0099
Andreas Maier, Manuel Rühr, Katja Tangermann-Gerk, Marcel Stephan, S. Roth, Michael Schmidt
Purpose Additive manufacturing (AM) of duplex stainless steels (DSS) is still challenging in terms of simultaneously generating structures with high build quality and adequate functional properties. This study aims to investigate comprehensive process-material-property relationships resulting from both laser-directed energy deposition (DED-LB/M) and laser powder bed fusion (PBF-LB/M) of DSS 1.4462 in as-built (AB) and subsequent heat-treated (HT) states. Design/methodology/approach Cuboid specimens made of DSS 1.4462 were generated using both AM processes. Porosity and microstructure analyses, magnetic-inductive ferrite and Vickers hardness measurements, tensile and Charpy impacts tests, fracture analysis, critical pitting corrosion temperature measurements and Huey tests were performed on specimens in the AB and HT states. Findings Correlations between the microstructural aspects and the resulting functional properties (mechanical properties and corrosion resistance) were demonstrated and compared. The mechanical properties of DED-LB/M specimens in both material conditions fulfilled the alloy specifications of 1.4462. Owing to the low ductility and toughness of PBF-LB/M specimens in the AB state, a post-process heat treatment was required to exceed the minimum alloy specification limits. Furthermore, the homogenization heat treatment significantly improved the corrosion resistance of DED- and PBF-processed 1.4462. Originality/value This study fulfills the need to investigate the complex relationships between process characteristics and the resulting material properties of additively manufactured DSS.
{"title":"Additive manufacturing of duplex stainless steel by DED-LB/M and PBF-LB/M – process-material-property relationships","authors":"Andreas Maier, Manuel Rühr, Katja Tangermann-Gerk, Marcel Stephan, S. Roth, Michael Schmidt","doi":"10.1108/rpj-02-2024-0099","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0099","url":null,"abstract":"\u0000Purpose\u0000Additive manufacturing (AM) of duplex stainless steels (DSS) is still challenging in terms of simultaneously generating structures with high build quality and adequate functional properties. This study aims to investigate comprehensive process-material-property relationships resulting from both laser-directed energy deposition (DED-LB/M) and laser powder bed fusion (PBF-LB/M) of DSS 1.4462 in as-built (AB) and subsequent heat-treated (HT) states.\u0000\u0000\u0000Design/methodology/approach\u0000Cuboid specimens made of DSS 1.4462 were generated using both AM processes. Porosity and microstructure analyses, magnetic-inductive ferrite and Vickers hardness measurements, tensile and Charpy impacts tests, fracture analysis, critical pitting corrosion temperature measurements and Huey tests were performed on specimens in the AB and HT states.\u0000\u0000\u0000Findings\u0000Correlations between the microstructural aspects and the resulting functional properties (mechanical properties and corrosion resistance) were demonstrated and compared. The mechanical properties of DED-LB/M specimens in both material conditions fulfilled the alloy specifications of 1.4462. Owing to the low ductility and toughness of PBF-LB/M specimens in the AB state, a post-process heat treatment was required to exceed the minimum alloy specification limits. Furthermore, the homogenization heat treatment significantly improved the corrosion resistance of DED- and PBF-processed 1.4462.\u0000\u0000\u0000Originality/value\u0000This study fulfills the need to investigate the complex relationships between process characteristics and the resulting material properties of additively manufactured DSS.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"96 8","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141683715","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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