Pub Date : 2024-04-25DOI: 10.1108/rpj-12-2023-0453
Saadet Güler, Ahmet Yavaş, Berk Özler, A. Kılınç
Purpose Three-dimensional (3D) printing is popular for many applications including the production of photocatalysts. This paper aims to focus on developing of 3D-printed photocatalyst-nano composite lattice structure. Digital light processing (DLP) 3D printing of photocatalyst composites was performed using photosensitive resin mixed with 0.5% Wt. of TiO2 powder and varying amounts (0.025% Wt. to 0.2% Wt.) of graphene nanoplatelet powder. The photocatalytic efficiency of DLP 3D-printed photocatalyst TiO2 composite was investigated, and the effects of nano graphite powder incorporation on the photocatalytic activity, thermal and mechanical properties were investigated. Design/methodology/approach Methods involve 3D computer-aided design modeling, printing parameters and comprehensive characterization techniques such as structural equation modeling, X-ray diffraction, thermogravimetric analysis, Fourier-transform infrared (FTIR) and mechanical testing. Findings Results highlight successful dispersion and characteristics of TiO2 and graphene nanoplatelet (GNP) powders, intricate designs of 3D-printed lattice structures, and the influence of GNPs on thermal behavior and mechanical properties. Originality/value The study suggests applicability in wastewater treatment and environmental remediation, showcasing the adaptability of 3 D printing in designing effective photocatalysts. Future research should focus on practical applications and the long-term durability of these 3D-printed composites. Graphical abstract
{"title":"Fabrication of 3D-printed GNP/TiO2/epoxy composites: an investigation on mechanical and photocatalytic properties","authors":"Saadet Güler, Ahmet Yavaş, Berk Özler, A. Kılınç","doi":"10.1108/rpj-12-2023-0453","DOIUrl":"https://doi.org/10.1108/rpj-12-2023-0453","url":null,"abstract":"\u0000Purpose\u0000Three-dimensional (3D) printing is popular for many applications including the production of photocatalysts. This paper aims to focus on developing of 3D-printed photocatalyst-nano composite lattice structure. Digital light processing (DLP) 3D printing of photocatalyst composites was performed using photosensitive resin mixed with 0.5% Wt. of TiO2 powder and varying amounts (0.025% Wt. to 0.2% Wt.) of graphene nanoplatelet powder. The photocatalytic efficiency of DLP 3D-printed photocatalyst TiO2 composite was investigated, and the effects of nano graphite powder incorporation on the photocatalytic activity, thermal and mechanical properties were investigated.\u0000\u0000\u0000Design/methodology/approach\u0000Methods involve 3D computer-aided design modeling, printing parameters and comprehensive characterization techniques such as structural equation modeling, X-ray diffraction, thermogravimetric analysis, Fourier-transform infrared (FTIR) and mechanical testing.\u0000\u0000\u0000Findings\u0000Results highlight successful dispersion and characteristics of TiO2 and graphene nanoplatelet (GNP) powders, intricate designs of 3D-printed lattice structures, and the influence of GNPs on thermal behavior and mechanical properties.\u0000\u0000\u0000Originality/value\u0000The study suggests applicability in wastewater treatment and environmental remediation, showcasing the adaptability of 3 D printing in designing effective photocatalysts. Future research should focus on practical applications and the long-term durability of these 3D-printed composites.\u0000\u0000\u0000Graphical abstract\u0000\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140653636","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}
Purpose The purpose of this paper is to improve the productivity and quality of the wire arc additive manufacturing process by benchmarking the strategies from the selected six strategies, namely, heat treatment process, inter pass cooling process, inter pass cold rolling process, peening process, friction stir processing and oscillation process. Design/methodology/approach To overcome the lack of certainty associated with correlations and relationships in quality functional deployment, fuzzy numbers have been integrated with the quality functional deployment framework. Twenty performance measures have been identified from the literature under five groups, namely, mechanical properties, physical properties, geometrical properties, cost and material properties. Using house of quality weights are allocated to performance measures and groups, relationships are established between performance measures and strategies, and correlations are assigned between strategies. Finally, for each strategy, relative importance, score and crisp values are calculated. Findings Inter pass cold rolling process strategy is computed with the highest crisp value of 15.80 which is followed by peening process, heat treatment process, friction stir processing, inter pass cooling process,] and oscillation process strategy. Originality/value To the best of the authors’ knowledge, there has been no research in the literature that analyzes the strategies to improve the quality and productivity of the wire arc additive manufacturing process.
{"title":"Benchmarking the quality improvement strategies of wire arc additive manufacturing process using fuzzy QFD approach","authors":"Naveen Srinivas Madugula, Yogesh Kumar, Vimal K.E.K., Sujeet Kumar","doi":"10.1108/rpj-08-2023-0278","DOIUrl":"https://doi.org/10.1108/rpj-08-2023-0278","url":null,"abstract":"Purpose\u0000The purpose of this paper is to improve the productivity and quality of the wire arc additive manufacturing process by benchmarking the strategies from the selected six strategies, namely, heat treatment process, inter pass cooling process, inter pass cold rolling process, peening process, friction stir processing and oscillation process.\u0000\u0000Design/methodology/approach\u0000To overcome the lack of certainty associated with correlations and relationships in quality functional deployment, fuzzy numbers have been integrated with the quality functional deployment framework. Twenty performance measures have been identified from the literature under five groups, namely, mechanical properties, physical properties, geometrical properties, cost and material properties. Using house of quality weights are allocated to performance measures and groups, relationships are established between performance measures and strategies, and correlations are assigned between strategies. Finally, for each strategy, relative importance, score and crisp values are calculated.\u0000\u0000Findings\u0000Inter pass cold rolling process strategy is computed with the highest crisp value of 15.80 which is followed by peening process, heat treatment process, friction stir processing, inter pass cooling process,] and oscillation process strategy.\u0000\u0000Originality/value\u0000To the best of the authors’ knowledge, there has been no research in the literature that analyzes the strategies to improve the quality and productivity of the wire arc additive manufacturing process.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140672053","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 : 2024-04-22DOI: 10.1108/rpj-09-2023-0316
M. Abas, Tufail Habib, Sahar Noor
Purpose This study aims to investigate the fabrication of solid ankle foot orthoses (SAFOs) using fused deposition modeling (FDM) printing technology. It emphasizes cost-effective 3D scanning with the Kinect sensor and conducts a comparative analysis of SAFO durability with varying thicknesses and materials, including polylactic acid (PLA) and carbon fiber-reinforced (PLA-C), to address research gaps from prior studies. Design/methodology/approach In this study, the methodology comprises key components: data capture using a cost-effective Microsoft Kinect® Xbox 360 scanner to obtain precise leg dimensions for SAFOs. SAFOs are designed using CAD tools with varying thicknesses (3, 4, and 5 mm) while maintaining consistent geometry, allowing controlled thickness impact investigation. Fabrication uses PLA and PLA-C materials via FDM 3D printing, providing insights into material suitability. Mechanical analysis uses dual finite element analysis to assess force–displacement curves and fracture behavior, which were validated through experimental testing. Findings The results indicate that the precision of the scanned leg dimensions, compared to actual anthropometric data, exhibits a deviation of less than 5%, confirming the accuracy of the cost-effective scanning approach. Additionally, the research identifies optimal thicknesses for SAFOs, recommending a 4 and 5 mm thickness for PLA-C-based SAFOs and an only 5 mm thickness for PLA-based SAFOs. This optimization enhances the overall performance and effectiveness of these orthotic solutions. Originality/value This study’s innovation lies in its holistic approach, combining low-cost 3D scanning, 3D printing and computational simulations to optimize SAFO materials and thickness. These findings advance the creation of cost-effective and efficient orthotic solutions.
{"title":"Design and analysis of solid ankle foot orthosis by employing mechanical characterization and a low-cost scanning approach for additive manufacturing","authors":"M. Abas, Tufail Habib, Sahar Noor","doi":"10.1108/rpj-09-2023-0316","DOIUrl":"https://doi.org/10.1108/rpj-09-2023-0316","url":null,"abstract":"\u0000Purpose\u0000This study aims to investigate the fabrication of solid ankle foot orthoses (SAFOs) using fused deposition modeling (FDM) printing technology. It emphasizes cost-effective 3D scanning with the Kinect sensor and conducts a comparative analysis of SAFO durability with varying thicknesses and materials, including polylactic acid (PLA) and carbon fiber-reinforced (PLA-C), to address research gaps from prior studies.\u0000\u0000\u0000Design/methodology/approach\u0000In this study, the methodology comprises key components: data capture using a cost-effective Microsoft Kinect® Xbox 360 scanner to obtain precise leg dimensions for SAFOs. SAFOs are designed using CAD tools with varying thicknesses (3, 4, and 5 mm) while maintaining consistent geometry, allowing controlled thickness impact investigation. Fabrication uses PLA and PLA-C materials via FDM 3D printing, providing insights into material suitability. Mechanical analysis uses dual finite element analysis to assess force–displacement curves and fracture behavior, which were validated through experimental testing.\u0000\u0000\u0000Findings\u0000The results indicate that the precision of the scanned leg dimensions, compared to actual anthropometric data, exhibits a deviation of less than 5%, confirming the accuracy of the cost-effective scanning approach. Additionally, the research identifies optimal thicknesses for SAFOs, recommending a 4 and 5 mm thickness for PLA-C-based SAFOs and an only 5 mm thickness for PLA-based SAFOs. This optimization enhances the overall performance and effectiveness of these orthotic solutions.\u0000\u0000\u0000Originality/value\u0000This study’s innovation lies in its holistic approach, combining low-cost 3D scanning, 3D printing and computational simulations to optimize SAFO materials and thickness. These findings advance the creation of cost-effective and efficient orthotic solutions.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140677197","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}
Purpose Selective laser sintering (SLS) is an essential technology in the field of additive manufacturing. However, SLS technology is limited by the traditional point-laser sintering method and has reached the bottleneck of efficiency improvement. This study aims to develop an image-shaped laser sintering (ISLS) system based on a digital micromirror device (DMD) to address this problem. The ISLS system uses an image-shaped laser light source with a size of 16 mm × 25.6 mm instead of the traditional SLS point-laser light source. Design/methodology/approach The ISLS system achieves large-area image-shaped sintering of polymer powder materials by moving the laser light source continuously in the x-direction and updating the sintering pattern synchronously, as well as by overlapping the splicing of adjacent sintering areas in the y-direction. A low-cost composite powder suitable for the ISLS system was prepared using polyether sulfone (PES), pinewood and carbon black (CB) powders as raw materials. Large-sized samples were fabricated using composite powder, and the microstructure, dimensional accuracy, geometric deviation, density, mechanical properties and feasible feature sizes were evaluated. Findings The experimental results demonstrate that the ISLS system is feasible and can print large-sized parts with good dimensional accuracy, acceptable geometric deviations, specific small-scale features and certain density and mechanical properties. Originality/value This study has achieved the transition from traditional point sintering mode to image-shaped surface sintering mode. It has provided a new approach to enhance the system performance of traditional SLS.
目的选择性激光烧结（SLS）是增材制造领域的一项重要技术。然而，SLS 技术受限于传统的点激光烧结方法，已达到效率提升的瓶颈。本研究旨在开发一种基于数字微镜设备（DMD）的图像形激光烧结（ISLS）系统，以解决这一问题。ISLS 系统使用尺寸为 16 mm × 25.6 mm 的图像形激光光源，而不是传统的 SLS 点激光光源。设计/方法/途径 ISLS 系统通过在 x 方向上连续移动激光光源并同步更新烧结图案，以及在 y 方向上重叠拼接相邻烧结区域，实现了聚合物粉末材料的大面积图像形烧结。以聚醚砜（PES）、松木和炭黑（CB）粉末为原料，制备了适用于 ISLS 系统的低成本复合粉末。实验结果表明，ISLS 系统是可行的，它能打印出具有良好尺寸精度、可接受几何偏差、特定小尺寸特征以及一定密度和机械性能的大型零件。它为提高传统 SLS 的系统性能提供了一种新方法。
{"title":"Research and implementation of large-area sintering technology based on image-shaped laser","authors":"Yifan Guo, Yanling Guo, Jian Li, Yangwei Wang, Deyu Meng, Haoyu Zhang, Jiaming Dai","doi":"10.1108/rpj-11-2023-0408","DOIUrl":"https://doi.org/10.1108/rpj-11-2023-0408","url":null,"abstract":"\u0000Purpose\u0000Selective laser sintering (SLS) is an essential technology in the field of additive manufacturing. However, SLS technology is limited by the traditional point-laser sintering method and has reached the bottleneck of efficiency improvement. This study aims to develop an image-shaped laser sintering (ISLS) system based on a digital micromirror device (DMD) to address this problem. The ISLS system uses an image-shaped laser light source with a size of 16 mm × 25.6 mm instead of the traditional SLS point-laser light source.\u0000\u0000\u0000Design/methodology/approach\u0000The ISLS system achieves large-area image-shaped sintering of polymer powder materials by moving the laser light source continuously in the x-direction and updating the sintering pattern synchronously, as well as by overlapping the splicing of adjacent sintering areas in the y-direction. A low-cost composite powder suitable for the ISLS system was prepared using polyether sulfone (PES), pinewood and carbon black (CB) powders as raw materials. Large-sized samples were fabricated using composite powder, and the microstructure, dimensional accuracy, geometric deviation, density, mechanical properties and feasible feature sizes were evaluated.\u0000\u0000\u0000Findings\u0000The experimental results demonstrate that the ISLS system is feasible and can print large-sized parts with good dimensional accuracy, acceptable geometric deviations, specific small-scale features and certain density and mechanical properties.\u0000\u0000\u0000Originality/value\u0000This study has achieved the transition from traditional point sintering mode to image-shaped surface sintering mode. It has provided a new approach to enhance the system performance of traditional SLS.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140683902","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 : 2024-04-17DOI: 10.1108/rpj-06-2023-0204
Vidyut Raghu Viswanath, Shivashankar Hiremath, Dundesh S. Chiniwar
Purpose The purpose of this study, most recent advancements in threedimensional (3D) printing have focused on the fabrication of components. It is typical to use different print settings, such as raster angle, infill and orientation to improve the 3D component qualities while fabricating the sample using a 3D printer. However, the influence of these factors on the characteristics of the 3D parts has not been well explored. Owing to the effect of the different print parameters in fused deposition modeling (FDM) technology, it is necessary to evaluate the strength of the parts manufactured using 3D printing technology. Design/methodology/approach In this study, the effect of three print parameters − raster angle, build orientation and infill − on the tensile characteristics of 3D-printed components made of three distinct materials − acrylonitrile styrene acrylate (ASA), polycarbonate ABS (PC-ABS) and ULTEM-9085 − was investigated. A variety of test items were created using a commercially accessible 3D printer in various configurations, including raster angle (0°, 45°), (0°, 90°), (45°, −45°), (45°, 90°), infill density (solid, sparse, sparse double dense) and orientation (flat, on-edge). Findings The outcome shows that variations in tensile strength and force are brought on by the effects of various printing conditions. In all possible combinations of the print settings, ULTEM 9085 material has a higher tensile strength than ASA and PC-ABS materials. ULTEM 9085 material’s on-edge orientation, sparse infill, and raster angle of (0°, −45°) resulted in the greatest overall tensile strength of 73.72 MPa. The highest load-bearing strength of ULTEM material was attained with the same procedure, measuring at 2,932 N. The tensile strength of the materials is higher in the on-edge orientation than in the flat orientation. The tensile strength of all three materials is highest for solid infill with a flat orientation and a raster angle of (45°, −45°). All three materials show higher tensile strength with a raster angle of (45°, −45°) compared to other angles. The sparse double-dense material promotes stronger tensile properties than sparse infill. Thus, the strength of additive components is influenced by the combination of selected print parameters. As a result, these factors interact with one another to produce a high-quality product. Originality/value The outcomes of this study can serve as a reference point for researchers, manufacturers and users of 3D-printed polymer material (PC-ABS, ASA, ULTEM 9085) components seeking to optimize FDM printing parameters for tensile strength and/or identify materials suitable for intended tensile characteristics.
{"title":"Using extrusion-based 3D printing technology to investigate the impact of changing print conditions on tensile characteristics","authors":"Vidyut Raghu Viswanath, Shivashankar Hiremath, Dundesh S. Chiniwar","doi":"10.1108/rpj-06-2023-0204","DOIUrl":"https://doi.org/10.1108/rpj-06-2023-0204","url":null,"abstract":"\u0000Purpose\u0000The purpose of this study, most recent advancements in threedimensional (3D) printing have focused on the fabrication of components. It is typical to use different print settings, such as raster angle, infill and orientation to improve the 3D component qualities while fabricating the sample using a 3D printer. However, the influence of these factors on the characteristics of the 3D parts has not been well explored. Owing to the effect of the different print parameters in fused deposition modeling (FDM) technology, it is necessary to evaluate the strength of the parts manufactured using 3D printing technology.\u0000\u0000\u0000Design/methodology/approach\u0000In this study, the effect of three print parameters − raster angle, build orientation and infill − on the tensile characteristics of 3D-printed components made of three distinct materials − acrylonitrile styrene acrylate (ASA), polycarbonate ABS (PC-ABS) and ULTEM-9085 − was investigated. A variety of test items were created using a commercially accessible 3D printer in various configurations, including raster angle (0°, 45°), (0°, 90°), (45°, −45°), (45°, 90°), infill density (solid, sparse, sparse double dense) and orientation (flat, on-edge).\u0000\u0000\u0000Findings\u0000The outcome shows that variations in tensile strength and force are brought on by the effects of various printing conditions. In all possible combinations of the print settings, ULTEM 9085 material has a higher tensile strength than ASA and PC-ABS materials. ULTEM 9085 material’s on-edge orientation, sparse infill, and raster angle of (0°, −45°) resulted in the greatest overall tensile strength of 73.72 MPa. The highest load-bearing strength of ULTEM material was attained with the same procedure, measuring at 2,932 N. The tensile strength of the materials is higher in the on-edge orientation than in the flat orientation. The tensile strength of all three materials is highest for solid infill with a flat orientation and a raster angle of (45°, −45°). All three materials show higher tensile strength with a raster angle of (45°, −45°) compared to other angles. The sparse double-dense material promotes stronger tensile properties than sparse infill. Thus, the strength of additive components is influenced by the combination of selected print parameters. As a result, these factors interact with one another to produce a high-quality product.\u0000\u0000\u0000Originality/value\u0000The outcomes of this study can serve as a reference point for researchers, manufacturers and users of 3D-printed polymer material (PC-ABS, ASA, ULTEM 9085) components seeking to optimize FDM printing parameters for tensile strength and/or identify materials suitable for intended tensile characteristics.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140690581","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 : 2024-04-12DOI: 10.1108/rpj-10-2023-0364
Celia Rufo-Martín, Ramiro Mantecón, Geroge Youssef, Henar Miguelez, José Díaz-Álvarez
Purpose Polymethyl methacrylate (PMMA) is a remarkable biocompatible material for bone cement and regeneration. It is also considered 3D printable but requires in-depth process–structure–properties studies. This study aims to elucidate the mechanistic effects of processing parameters and sterilization on PMMA-based implants. Design/methodology/approach The approach comprised manufacturing samples with different raster angle orientations to capitalize on the influence of the filament alignment with the loading direction. One sample set was sterilized using an autoclave, while another was kept as a reference. The samples underwent a comprehensive characterization regimen of mechanical tension, compression and flexural testing. Thermal and microscale mechanical properties were also analyzed to explore the extent of the appreciated modifications as a function of processing conditions. Findings Thermal and microscale mechanical properties remained almost unaltered, whereas the mesoscale mechanical behavior varied from the as-printed to the after-autoclaving specimens. Although the mechanical behavior reported a pronounced dependence on the printing orientation, sterilization had minimal effects on the properties of 3D printed PMMA structures. Nonetheless, notable changes in appearance were attributed, and heat reversed as a response to thermally driven conformational rearrangements of the molecules. Originality/value This research further deepens the viability of 3D printed PMMA for biomedical applications, contributing to the overall comprehension of the polymer and the thermal processes associated with its implementation in biomedical applications, including personalized implants.
{"title":"Multiscale characterization of additively manufactured PMMA: the influence of sterilization","authors":"Celia Rufo-Martín, Ramiro Mantecón, Geroge Youssef, Henar Miguelez, José Díaz-Álvarez","doi":"10.1108/rpj-10-2023-0364","DOIUrl":"https://doi.org/10.1108/rpj-10-2023-0364","url":null,"abstract":"Purpose\u0000Polymethyl methacrylate (PMMA) is a remarkable biocompatible material for bone cement and regeneration. It is also considered 3D printable but requires in-depth process–structure–properties studies. This study aims to elucidate the mechanistic effects of processing parameters and sterilization on PMMA-based implants.\u0000\u0000Design/methodology/approach\u0000The approach comprised manufacturing samples with different raster angle orientations to capitalize on the influence of the filament alignment with the loading direction. One sample set was sterilized using an autoclave, while another was kept as a reference. The samples underwent a comprehensive characterization regimen of mechanical tension, compression and flexural testing. Thermal and microscale mechanical properties were also analyzed to explore the extent of the appreciated modifications as a function of processing conditions.\u0000\u0000Findings\u0000Thermal and microscale mechanical properties remained almost unaltered, whereas the mesoscale mechanical behavior varied from the as-printed to the after-autoclaving specimens. Although the mechanical behavior reported a pronounced dependence on the printing orientation, sterilization had minimal effects on the properties of 3D printed PMMA structures. Nonetheless, notable changes in appearance were attributed, and heat reversed as a response to thermally driven conformational rearrangements of the molecules.\u0000\u0000Originality/value\u0000This research further deepens the viability of 3D printed PMMA for biomedical applications, contributing to the overall comprehension of the polymer and the thermal processes associated with its implementation in biomedical applications, including personalized implants.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140711388","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 : 2024-04-09DOI: 10.1108/rpj-09-2023-0334
Baixi Chen, Weining Mao, Yangsheng Lin, Wenqian Ma, Nan Hu
Purpose Fused deposition modeling (FDM) is an extensively used additive manufacturing method with the capacity to build complex functional components. Due to the machinery and environmental factors during manufacturing, the FDM parts inevitably demonstrated uncertainty in properties and performance. This study aims to identify the stochastic constitutive behaviors of FDM-fabricated polylactic acid (PLA) tensile specimens induced by the manufacturing process. Design/methodology/approach By conducting the tensile test, the effects of the printing machine selection and three major manufacturing parameters (i.e., printing speed S, nozzle temperature T and layer thickness t) on the stochastic constitutive behaviors were investigated. The influence of the loading rate was also explained. In addition, the data-driven models were established to quantify and optimize the uncertain mechanical behaviors of FDM-based tensile specimens under various printing parameters. Findings As indicated by the results, the uncertain behaviors of the stiffness and strength of the PLA tensile specimens were dominated by the printing speed and nozzle temperature, respectively. The manufacturing-induced stochastic constitutive behaviors could be accurately captured by the developed data-driven model with the R2 over 0.98 on the testing dataset. The optimal parameters obtained from the data-driven framework were T = 231.3595 °C, S = 40.3179 mm/min and t = 0.2343 mm, which were in good agreement with the experiments. Practical implications The developed data-driven models can also be integrated into the design and characterization of parts fabricated by extrusion and other additive manufacturing technologies. Originality/value Stochastic behaviors of additively manufactured products were revealed by considering extensive manufacturing factors. The data-driven models were proposed to facilitate the description and optimization of the FDM products and control their quality.
目的熔融沉积建模（FDM）是一种广泛使用的快速成型制造方法，能够制造复杂的功能部件。由于制造过程中的机械和环境因素，FDM 零件不可避免地会表现出属性和性能的不确定性。本研究旨在确定 FDM 制造的聚乳酸（PLA）拉伸试样在制造过程中的随机构成行为。通过进行拉伸试验，研究了印刷机选择和三个主要制造参数（即印刷速度 S、喷嘴温度 T 和层厚度 t）对随机构成行为的影响。还解释了加载速率的影响。研究结果表明，聚乳酸拉伸试样刚度和强度的不确定行为分别受印刷速度和喷嘴温度的影响。所开发的数据驱动模型可以准确捕捉制造引起的随机构成行为，在测试数据集上的 R2 超过 0.98。数据驱动框架获得的最佳参数为 T = 231.3595 °C、S = 40.3179 mm/min 和 t = 0.2343 mm，这些参数与实验结果非常吻合。原创性/价值通过考虑广泛的制造因素，揭示了快速成型产品的随机行为。提出的数据驱动模型有助于描述和优化 FDM 产品并控制其质量。
{"title":"Manufacturing-induced stochastic constitutive behaviors of additive manufactured specimens: testing, data-driven modeling, and optimization","authors":"Baixi Chen, Weining Mao, Yangsheng Lin, Wenqian Ma, Nan Hu","doi":"10.1108/rpj-09-2023-0334","DOIUrl":"https://doi.org/10.1108/rpj-09-2023-0334","url":null,"abstract":"\u0000Purpose\u0000Fused deposition modeling (FDM) is an extensively used additive manufacturing method with the capacity to build complex functional components. Due to the machinery and environmental factors during manufacturing, the FDM parts inevitably demonstrated uncertainty in properties and performance. This study aims to identify the stochastic constitutive behaviors of FDM-fabricated polylactic acid (PLA) tensile specimens induced by the manufacturing process.\u0000\u0000\u0000Design/methodology/approach\u0000By conducting the tensile test, the effects of the printing machine selection and three major manufacturing parameters (i.e., printing speed S, nozzle temperature T and layer thickness t) on the stochastic constitutive behaviors were investigated. The influence of the loading rate was also explained. In addition, the data-driven models were established to quantify and optimize the uncertain mechanical behaviors of FDM-based tensile specimens under various printing parameters.\u0000\u0000\u0000Findings\u0000As indicated by the results, the uncertain behaviors of the stiffness and strength of the PLA tensile specimens were dominated by the printing speed and nozzle temperature, respectively. The manufacturing-induced stochastic constitutive behaviors could be accurately captured by the developed data-driven model with the R2 over 0.98 on the testing dataset. The optimal parameters obtained from the data-driven framework were T = 231.3595 °C, S = 40.3179 mm/min and t = 0.2343 mm, which were in good agreement with the experiments.\u0000\u0000\u0000Practical implications\u0000The developed data-driven models can also be integrated into the design and characterization of parts fabricated by extrusion and other additive manufacturing technologies.\u0000\u0000\u0000Originality/value\u0000Stochastic behaviors of additively manufactured products were revealed by considering extensive manufacturing factors. The data-driven models were proposed to facilitate the description and optimization of the FDM products and control their quality.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140725608","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 : 2024-04-05DOI: 10.1108/rpj-10-2023-0365
Rahul Soni, Madhvi Sharma, Ponappa K., Puneet Tandon
Purpose In pursuit of affordable and nutrient-rich food alternatives, the symbiotic culture of bacteria and yeast (SCOBY) emerged as a selected food ink for 3D printing. The purpose of this paper is to harness SCOBY’s potential to create cost-effective and nourishing food options using the innovative technique of 3D printing. Design/methodology/approach This work presents a comparative analysis of the printability of SCOBY with blends of wheat flour, with a focus on the optimization of process variables such as printing composition, nozzle height, nozzle diameter, printing speed, extrusion motor speed and extrusion rate. Extensive research was carried out to explore the diverse physical, mechanical and rheological properties of food ink. Findings Among the ratios tested, SCOBY, with SCOBY:wheat flour ratio at 1:0.33 exhibited the highest precision and layer definition when 3D printed at 50 and 60 mm/s printing speeds, 180 rpm motor speed and 0.8 mm nozzle with a 0.005 cm3/s extrusion rate, with minimum alteration in colour. Originality/value Food layered manufacturing (FLM) is a novel concept that uses a specialized printer to fabricate edible objects by layering edible materials, such as chocolate, confectionaries and pureed fruits and vegetables. FLM is a disruptive technology that enables the creation of personalized and texture-tailored foods, incorporating desired nutritional values and food quality, using a variety of ingredients and additions. This research highlights the potential of SCOBY as a viable material for 3D food printing applications.
目的为了寻求经济实惠、营养丰富的食品替代品，细菌和酵母的共生培养物（SCOBY）成为 3D 打印的首选食品墨水。本文的目的是利用 SCOBY 的潜力，使用 3D 打印的创新技术创造出具有成本效益且营养丰富的食品选择。设计/方法/途径 本作品对 SCOBY 与小麦粉混合物的可打印性进行了比较分析，重点关注打印成分、喷嘴高度、喷嘴直径、打印速度、挤出电机速度和挤出速率等工艺变量的优化。研究结果在测试的各种比例中，SCOBY 与小麦粉的比例为 1:0.33，当以 50 和 60 毫米/秒的打印速度、180 转/分钟的电机速度和 0.原创性/价值食品分层制造（FLM）是一个新颖的概念，它使用专门的打印机，通过将巧克力、糖果、水果和蔬菜泥等可食用材料分层来制造可食用物品。分层制造是一种颠覆性技术，它能利用各种配料和添加物，制造出个性化和质地定制的食品，并融入所需的营养价值和食品质量。这项研究强调了 SCOBY 作为 3D 食品打印应用的可行材料的潜力。
{"title":"SCOBY: an alternate solution to develop cheap and nutritious food by food layered manufacturing (FLM)","authors":"Rahul Soni, Madhvi Sharma, Ponappa K., Puneet Tandon","doi":"10.1108/rpj-10-2023-0365","DOIUrl":"https://doi.org/10.1108/rpj-10-2023-0365","url":null,"abstract":"\u0000Purpose\u0000In pursuit of affordable and nutrient-rich food alternatives, the symbiotic culture of bacteria and yeast (SCOBY) emerged as a selected food ink for 3D printing. The purpose of this paper is to harness SCOBY’s potential to create cost-effective and nourishing food options using the innovative technique of 3D printing.\u0000\u0000\u0000Design/methodology/approach\u0000This work presents a comparative analysis of the printability of SCOBY with blends of wheat flour, with a focus on the optimization of process variables such as printing composition, nozzle height, nozzle diameter, printing speed, extrusion motor speed and extrusion rate. Extensive research was carried out to explore the diverse physical, mechanical and rheological properties of food ink.\u0000\u0000\u0000Findings\u0000Among the ratios tested, SCOBY, with SCOBY:wheat flour ratio at 1:0.33 exhibited the highest precision and layer definition when 3D printed at 50 and 60 mm/s printing speeds, 180 rpm motor speed and 0.8 mm nozzle with a 0.005 cm3/s extrusion rate, with minimum alteration in colour.\u0000\u0000\u0000Originality/value\u0000Food layered manufacturing (FLM) is a novel concept that uses a specialized printer to fabricate edible objects by layering edible materials, such as chocolate, confectionaries and pureed fruits and vegetables. FLM is a disruptive technology that enables the creation of personalized and texture-tailored foods, incorporating desired nutritional values and food quality, using a variety of ingredients and additions. This research highlights the potential of SCOBY as a viable material for 3D food printing applications.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140736671","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}
Purpose Because of the advantages of high deposition efficiency and low manufacturing cost compared with other additive technologies, robotic wire arc additive manufacturing (WAAM) technology has been widely applied for fabricating medium- to large-scale metallic components. The additive manufacturing (AM) method is a relatively complex process, which involves the workpiece modeling, conversion of the model file, slicing, path planning and so on. Then the structure is formed by the accumulated weld bead. However, the poor forming accuracy of WAAM usually leads to severe dimensional deviation between the as-built and the predesigned structures. This paper aims to propose a visual sensing technology and deep learning–assisted WAAM method for fabricating metallic structure, to simplify the complex WAAM process and improve the forming accuracy. Design/methodology/approach Instead of slicing of the workpiece modeling and generating all the welding torch paths in advance of the fabricating process, this method is carried out by adding the feature point regression branch into the Yolov5 algorithm, to detect the feature point from the images of the as-built structure. The coordinates of the feature points of each deposition layer can be calculated automatically. Then the welding torch trajectory for the next deposition layer is generated based on the position of feature point. Findings The mean average precision score of modified YOLOv5 detector is 99.5%. Two types of overhanging structures have been fabricated by the proposed method. The center contour error between the actual and theoretical is 0.56 and 0.27 mm in width direction, and 0.43 and 0.23 mm in height direction, respectively. Originality/value The fabrication of circular overhanging structures without using the complicate slicing strategy, turning table or other extra support verified the possibility of the robotic WAAM system with deep learning technology.
{"title":"Deep learning assisted fabrication of metallic components using the robotic wire arc additive manufacturing","authors":"Pingyang Zheng, Shaohua Han, Dingqi Xue, Ling Fu, Bifeng Jiang","doi":"10.1108/rpj-04-2023-0133","DOIUrl":"https://doi.org/10.1108/rpj-04-2023-0133","url":null,"abstract":"\u0000Purpose\u0000Because of the advantages of high deposition efficiency and low manufacturing cost compared with other additive technologies, robotic wire arc additive manufacturing (WAAM) technology has been widely applied for fabricating medium- to large-scale metallic components. The additive manufacturing (AM) method is a relatively complex process, which involves the workpiece modeling, conversion of the model file, slicing, path planning and so on. Then the structure is formed by the accumulated weld bead. However, the poor forming accuracy of WAAM usually leads to severe dimensional deviation between the as-built and the predesigned structures. This paper aims to propose a visual sensing technology and deep learning–assisted WAAM method for fabricating metallic structure, to simplify the complex WAAM process and improve the forming accuracy.\u0000\u0000\u0000Design/methodology/approach\u0000Instead of slicing of the workpiece modeling and generating all the welding torch paths in advance of the fabricating process, this method is carried out by adding the feature point regression branch into the Yolov5 algorithm, to detect the feature point from the images of the as-built structure. The coordinates of the feature points of each deposition layer can be calculated automatically. Then the welding torch trajectory for the next deposition layer is generated based on the position of feature point.\u0000\u0000\u0000Findings\u0000The mean average precision score of modified YOLOv5 detector is 99.5%. Two types of overhanging structures have been fabricated by the proposed method. The center contour error between the actual and theoretical is 0.56 and 0.27 mm in width direction, and 0.43 and 0.23 mm in height direction, respectively.\u0000\u0000\u0000Originality/value\u0000The fabrication of circular overhanging structures without using the complicate slicing strategy, turning table or other extra support verified the possibility of the robotic WAAM system with deep learning technology.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140366027","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 : 2024-03-29DOI: 10.1108/rpj-06-2023-0191
Hübannur Şeremet, Nazim Babacan
Purpose This paper aims to examine the static compression characteristics of cell topologies in body-centered cubic with vertical struts (BCCZ) and face-centered cubic with vertical struts (FCCZ) along with novel BCCZZ and FCCZZ lattice structures. Design/methodology/approach The newly developed structures were obtained by adding extra interior vertical struts into the BCCZ and FCCZ configurations. The samples, composed of the AlSi10Mg alloy, were fabricated using the selective laser melting (SLM) additive manufacturing technique. The specific compressive strength and failure behavior of the manufactured lattice structures were investigated, and comparative analysis among them was done. Findings The results revealed that the specific strength of BCCZZ and FCCZZ samples with 0.5 mm strut diameter exhibited approximately a 23% and 18% increase, respectively, compared with the BCCZ and FCCZ samples with identical strut diameters. Moreover, finite element analysis was carried out to simulate the compressive response of the lattice structures, which could be used to predict their strength and collapse mode. The findings showed that while the local buckling of lattice cells is the major failure mode, the samples subsequently collapsed along a diagonal shear band. Originality/value An original and systematic investigation was conducted to explore the compression properties of newly fabricated lattice structures using SLM. The results revealed that the novel FCCZZ and BCCZZ structures were found to possess significant potential for load-bearing applications.
{"title":"Compressive properties of AlSi10Mg lattice structures with novel BCCZZ and FCCZZ configurations fabricated by selective laser melting","authors":"Hübannur Şeremet, Nazim Babacan","doi":"10.1108/rpj-06-2023-0191","DOIUrl":"https://doi.org/10.1108/rpj-06-2023-0191","url":null,"abstract":"\u0000Purpose\u0000This paper aims to examine the static compression characteristics of cell topologies in body-centered cubic with vertical struts (BCCZ) and face-centered cubic with vertical struts (FCCZ) along with novel BCCZZ and FCCZZ lattice structures.\u0000\u0000\u0000Design/methodology/approach\u0000The newly developed structures were obtained by adding extra interior vertical struts into the BCCZ and FCCZ configurations. The samples, composed of the AlSi10Mg alloy, were fabricated using the selective laser melting (SLM) additive manufacturing technique. The specific compressive strength and failure behavior of the manufactured lattice structures were investigated, and comparative analysis among them was done.\u0000\u0000\u0000Findings\u0000The results revealed that the specific strength of BCCZZ and FCCZZ samples with 0.5 mm strut diameter exhibited approximately a 23% and 18% increase, respectively, compared with the BCCZ and FCCZ samples with identical strut diameters. Moreover, finite element analysis was carried out to simulate the compressive response of the lattice structures, which could be used to predict their strength and collapse mode. The findings showed that while the local buckling of lattice cells is the major failure mode, the samples subsequently collapsed along a diagonal shear band.\u0000\u0000\u0000Originality/value\u0000An original and systematic investigation was conducted to explore the compression properties of newly fabricated lattice structures using SLM. The results revealed that the novel FCCZZ and BCCZZ structures were found to possess significant potential for load-bearing applications.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2024-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140366775","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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