3D Printing and Additive Manufacturing最新文献

{"title":"Evaluation of Tensile Strength and Repeatability of 3D Printed Carbon Fiber Materials and Processes","authors":"Abigail Batley, Richard Glithro, Bryce Dyer, Philip Sewell","doi":"10.1089/3dp.2022.0262","DOIUrl":"https://doi.org/10.1089/3dp.2022.0262","url":null,"abstract":"As additive manufacturing (AM) with composite materials becomes more widely used in industry to create high-strength components, it is vital to have quantified material properties that provide designers and engineers accurate data to decide which materials are suitable for their applications. This study replicates the build processes and tensile tests undertaken by AM material manufacturers to compare tensile strengths achieved with those stated on the manufacturers' data sheets. These are important data to research and analyze as either it will corroborate properties given by the manufacturers and provide confidence in the values provided or it will show that the manufacturer's values cannot always be achieved and that designers and engineers must be more critical about the values manufacturers are providing when using the materials in their own applications. Tensile tests were performed on additively manufactured specimens that had been built using the same parameters that were used during the manufacturers' testing procedures. Digital image correlation was used to accurately measure strain in the test samples, enabling material properties to be determined. Microscopy analysis enabled the visual inspection of the print quality, the identification of defects, and the determination of volume fraction with the samples. The results show inconsistencies between the tensile strength results achieved during this study and the tensile strengths stated by the manufacturers. The results show that two materials exceeded the expected values and one material did not reach the expected value. Analysis of the 3D printed specimens shows that poor fiber–matrix wetting, large voids, and weak interfacial bonding were accountable for the lower-than-expected tensile strength results. While good print quality, low void percentage, proper fiber–matrix wetting, and good control measures were accountable for results that exceeded expectation. These results show that designers and engineers cannot solely rely on material data sheets to establish the mechanical properties of their 3D printed components.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"44 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136293039","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Establishment of Select Printing Parameters for Low-Cost Fused Deposition Modeling Printed Cast Iron Through Experimental Optimization","authors":"Matthew Drummond, Abdelkrem Eltaggaz, Ibrahim Nouzil, Ibrahim Deiab","doi":"10.1089/3dp.2023.0114","DOIUrl":"https://doi.org/10.1089/3dp.2023.0114","url":null,"abstract":"The fused deposition modeling (FDM) form of additive manufacturing provides a low-cost opportunity to quickly create unique parts with complex geometries using a high degree of precision. This is accomplished through a layer-by-layer extrusion of a metallic infused thermoplastic from a heated nozzle onto a build plate, until the 3D part is achieved. The ability to produce cheaply manufactured FDM printed cast iron parts would allow industries to bypass casting lead times and create custom cast iron parts without a machined mold. However, there has been minimal research into FDM printing of cast iron and the corresponding effects of printing parameters. The current study aims to determine the acceptable printing parameter ranges for FDM printed cast iron. The effects of three printing parameters (flow rate, infill density, and layer height) were studied with regard to the porosity, shrinkage, mass, and volume of the FDM printed cast iron. A flow rate range of 145–185% was determined to provide good-quality print while an infill density in the range of 100–125% for most flow rates provided acceptable print quality. Furthermore, the layer height was determined to have no significant effect on the printed part. Regarding the effect of printing parameters on the shrinkage, mass, and volume of the FDM printed part, the study showed that increasing the flow rate and infill density resulted in reduced shrinkage and a higher relative sintered mass and volume. Additionally, increasing the layer height showed an insignificant change in the sintered mass, volume, and shrinkage. Sintered samples obtained densities ranging between 5.02 and 5.44 g/cc and porosity measurements from 7.14% to 18.85%. This is one of the first studies on the FDM printing of cast iron. The results would enable researchers and hobbyists to successfully print their first cast iron part.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"42 3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136293235","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mechanical Properties and Fracture Mechanism of Selective Laser Melting Manufactured Nickel-Based Alloy by Small Punch Test Over a Wide Temperature Range","authors":"Jian Peng, Xiangxuan Geng, Jian Bao, Zhiquan Zuo, Mingxuan Gao, Jiacheng Gu","doi":"10.1089/3dp.2023.0130","DOIUrl":"https://doi.org/10.1089/3dp.2023.0130","url":null,"abstract":"The high-temperature mechanical properties and fracture mechanism of selective laser melting (SLM) manufactured nickel-based alloy are highly important for its application. In this article, small punch test (SPT) method is used to study the mechanical properties of SLM-manufactured GH4169 over a wide temperature range from 25°C to 600°C. With the increase of temperature, the decreasing ratio of maximum load is only 18.75% from 25°C to 600°C, and the yield load fluctuates with temperature, proving that it maintains the excellent load-bearing ability at high temperature. From the variation law of the normalized SPT fracture energy versus temperature, the ductile-to-brittle transition temperature of SLM-manufactured GH4169 is 413.63°C indicating the change of fracture mechanism. Moreover, the “fish scale” printed layer near the fracture surface changes from the difficult deformed microstructure to significant deformed one, leading to the variation of the fracture mechanism from brittle cleavage fracture traversing the printed layers to ductile fracture along the printed layers. This article reveals the variations of strength parameters, fracture energy, and fracture mechanism with temperature for SLM-manufactured GH4169 over a wide temperature range, which provides basic data for its application at different temperatures.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"37 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136293568","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Increasing Printable Solid Loading in Digital Light Processing Using a Bimodal Particle Size Distribution","authors":"Antoine P. Delarue, Ian M. McAninch, Amy M. Peterson, Christopher J. Hansen","doi":"10.1089/3dp.2022.0305","DOIUrl":"https://doi.org/10.1089/3dp.2022.0305","url":null,"abstract":"Digital light processing (DLP) is rapidly growing in popularity as an additive manufacturing method for the fabrication of composite structures, and is an effective way to prepare high-resolution filled parts, such as ceramic green parts or composite magnets. Yet, higher solid loadings of resins and the resulting dramatic increases in viscosity limit DLP printing for applications that depend upon maximization of filler content. In this work, we investigate the capacity of a bimodal particle size distribution to enable the printing of a photosensitive resin containing up to 70 vol% of fillers. Formulations with unimodal and bimodal solid loadings ranging from 50 to 72 vol% are prepared and their viscoelastic properties measured through rotational rheometry. The zero-shear viscosity of these formulations is fit with a Krieger-Dougherty model, and the dense random close packing fraction of particles determined from the fit is found to be 76.3 vol%. Parts with fine positive and negative features are printed to evaluate the resolution achievable with highly filled photosensitive resins. The part printed with a 70 vol% formulation shows negative features as small as 860 μm, and positive feature as small as 380 μm. Finally, parts with complex patterns are prepared with previously tested formulations, and thermogravimetric analysis results show that the filler content within the parts remains relatively constant over a 3-h print, with a decrease of 2 vol% of solids for the final printed layers.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"95 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135146935","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Flexible Thermoplastic Polyurethane Composites with Ultraviolet Resistance for Fused Deposition Modeling 3D Printing","authors":"Andong Wang, Junhao Guo, Chenkang Shao, Caifeng Chen","doi":"10.1089/3dp.2023.0111","DOIUrl":"https://doi.org/10.1089/3dp.2023.0111","url":null,"abstract":"Currently, there is great demand for flexible three-dimensional (3D) printable thermoplastic polyurethane (TPU) wires with excellent ultraviolet (UV) resistance, which have broad application prospects in wearable products. In this study, UV-resistant TPU composites were obtained using a blending modification method. The relationship between the optimized parameters of fused deposition modeling 3D printing and mechanical properties of the TPU composite is discussed using an orthogonal test. This study observed that the UV absorption properties of TPU composites were enhanced, and the TiO2 and TiO2/ZnO fillers improved the tensile strength of TPU composites. After UV aging, the tensile strength and elongation of the TPU composite slightly decreased, but were still much higher than those of pure TPU. Among the printing parameters, printing speed had the greatest influence on the mechanical properties of TPU composites. When the printing speed was 80 mm/s, printing layer thickness was 0.25 mm, nozzle temperature was 220°C, and hot bed temperature was 50°C, the TPU composites exhibited the best elongation at break and tensile strength. After regression analysis, two regression models for the elongation at break and tensile strength of TPU composites were obtained and verified, which provide a reference for predicting the relationship between the printing parameters and mechanical properties of flexible TPU composites.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"53 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135738607","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"3D Printing of Noncytotoxic High-Resolution Microchannels in Bisphenol-A Ethoxylate Dimethacrylate Tissue-Mimicking Materials.","authors":"Roger Domingo-Roca, Lauren Gilmour, Oana Dobre, Stylianos Sarrigiannidis, Mairi E Sandison, Richard O'Leary, Joseph C Jackson-Camargo, Helen E Mulvana","doi":"10.1089/3dp.2021.0235","DOIUrl":"10.1089/3dp.2021.0235","url":null,"abstract":"<p><p>The ability to create cell-laden fluidic models that mimic the geometries and physical properties of vascularized tissue would be extremely beneficial to the study of disease etiologies and future therapies, including in the case of cancer where there is increasing interest in studying alterations to the microvasculature. Engineered systems can present significant advantages over animal studies, alleviating challenges associated with variable complexity and control. Three-dimensional (3D)-printable tissue-mimicking hydrogels can offer an alternative, where control of the biophysical properties of the materials can be achieved. Hydrogel-based systems that can recreate complex 3D structures and channels with diameters <500 μm are challenging to produce. We present a noncytotoxic photo-responsive hydrogel that supports 3D printing of complex 3D structures with microchannels down to 150 μm in diameter. Fine tuning of the 3D-printing process has allowed the production of complex structures, where for demonstration purposes we present a helical channel with diameters between 250 and 370 μm around a central channel of 150 μm in diameter in materials with mechanical and acoustic properties that closely replicate those of tissue. The ability to control and accurately reproduce the complex features of the microvasculature has value across a wide range of biomedical applications, especially when the materials involved accurately mimic the physical properties of tissue. An approach that is additionally cell compatible provides a unique setup that can be exploited to study aspects of biomedical research with an unprecedented level of accuracy.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 5","pages":"1101-1109"},"PeriodicalIF":2.3,"publicationDate":"2023-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10599442/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"54232280","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A Novel Approach of Customized Pelvic Implant Design Based on Symmetrical Analysis and 3D Printing.","authors":"Yuan Chai, Xiao-Bo Chen, Jesse A Estoque, Nick Birbilis, Qinghua Qin, Tomas Ward, Paul N Smith, Rachel W Li","doi":"10.1089/3dp.2021.0121","DOIUrl":"10.1089/3dp.2021.0121","url":null,"abstract":"<p><p>In pelvic trauma patients, the mismatch of complex geometries between the pelvis and fixation implant is a fundamental cause of unstable and displaced pelvic ring disruption, in which secondary intervention is strongly considered. The geometrical matching in the current customized implant design and clinical practice is through the nonfractured hemi-pelvis for the fractured pelvis. This design philosophy overlooks the anatomical difference between the hemipelves, and further, the geometrical asymmetry at local area still remains unknown. This study analyzed the anatomical asymmetry of a patient's 3D pelvic models from 13 patients. The hemipelves of each patient were registered by using an iterative closet algorithm to an optimum position with minimum deviations. The high deviation regions were summarized between the hemipelves in each case, and a color map was drawn on a hemipelvis model that identified the areas that had a high possibility to be symmetrically different. A severe pelvic trauma case was used to comprehend the approach by designing a 3D printed implant. Each fracture was then registered to the mirrored uninjured hemipelvis by using the same algorithm, and customized fixation implants were designed with reference to the fractured model. The customized fixation plates showed that the implants had lower geometrical deviation when attached onto the re-stitched fracture side than onto the mirrored nonfractured bone. These results indicate that the symmetrical analysis of bone anatomy and the deviation color map can assist with implant selection and customized implant design given the geometrical difference between symmetrical bones. The novel approach provides a scientific reference that improves the accuracy and overall standard of 3D printed implants.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"1 1","pages":"984-991"},"PeriodicalIF":2.3,"publicationDate":"2023-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10599429/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41445485","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of the Spatial Arrangement of Floating Builds with Minimum Support on the Microstructural and Mechanical Characteristics of Electron Beam Additively Manufactured Biomedical Ti-6Al-4V Alloys.","authors":"Yi-Cheng Chen, Ping-Ho Chen, Meng-Hsiu Tsai, Shih-Fu Ou","doi":"10.1089/3dp.2021.0291","DOIUrl":"10.1089/3dp.2021.0291","url":null,"abstract":"<p><p>In this study, normal and floating builds of Ti-6Al-4V were fabricated by electron beam additive manufacturing. The effects of the spatial arrangement on the microstructure, mechanical properties, and surface roughness of the parts were investigated. Both the normal and floating builds exhibited an α+β lamellar microstructure, but the normal builds had finer grains compared to the floating builds. The microstructural characteristics were correlated with the thermal history, specifically the cooling rate, resulting from the connection plate (S45C for the normal builds and the powder bed for the floating builds). The compressive yield strength and hardness of the normal builds were higher than those of the floating builds, regardless of build location owing to the grain refinement effects on the normal builds. The top surface (TS) of the sample was smoothest, and the lateral surface of the sample was the roughest for both the normal and floating builds; however, the roughness of the TS and bottom surface samples did not differ significantly between normal and floating builds. There were no noticeable differences in the microstructure and mechanical properties of the builds in five different positions, that is, the center and four corners. Finally, these findings were used to develop a set of conceptual spatial arrangement designs, including floating builds, to optimize the microstructure and mechanical properties.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"10 5","pages":"1055-1063"},"PeriodicalIF":2.3,"publicationDate":"2023-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10599422/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"54232298","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Thermomechanical Properties of Polyjet Voxel-Printed Parts and the Effect of Percolation","authors":"Chengyeh Ho, Jiali Bao, Jing Xu","doi":"10.1089/3dp.2023.0126","DOIUrl":"https://doi.org/10.1089/3dp.2023.0126","url":null,"abstract":"The use of deformable materials in 3D printing has allowed for the fabrication of intricate soft robotics prototypes. Polyjet technology, with its ability to print multiple materials in a single print, has been popular in creating such designs. Vero and Agilus, the commercial materials provided by Polyjet, possess shape memory properties, making Polyjet ideal for high-precision and transformable applications. Voxel printing, where users assign materials to voxels, has allowed for the further expansion of design possibilities by tuning the properties of the jetted material. This study aims to investigate how different compositions of uniformly distributed Vero and Agilus voxels affect the thermomechanical properties of the voxel-printed part. In addition, high stiffness Vero droplets surrounded by a soft matrix of Agilus resemble polymer composites, thus calling for the examination of percolation, which is an important phenomenon in polymer composites. The study explores the presence of percolation in voxel-printed mixtures of Vero and Agilus and its impact on mechanical properties. Using dynamic thermomechanical analysis and thermomechanical analysis, the study characterizes the glass transition temperature (), maximum allowable strain, and modulus of the voxel-printed material at different compositions. The study found a highly linear relationship between and maximum yield strain with composition, and maximum yield strain occurs at 7°C above . On the other hand, there is a nonlinear relationship between the modulus and composition, which suggested that the percolation phenomenon might have altered the load distribution, therefore causing this inconsistency. So, in this study we used light microscopy, Monte Carlo simulations, and provided mathematical proofs to reveal the percolation threshold in voxel-printed parts, where Vero droplets suddenly form a single network that spreads across the material, altering the load distribution. This study is the first to highlight the percolation phenomenon in Polyjet voxel-printed parts and provides a useful guide for researchers in selecting suitable materials for their specific applications.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"34 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134960217","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Analysis of Multiple Print-Head Displacement Mechanisms in 3D Space for Material Extrusion Machine","authors":"Ishant Singhal, Bobby Tyagi, Abhishek Raj, Akash Jain, Shashank Kapoor, Ankit Sahai, Rahul Swarup Sharma","doi":"10.1089/3dp.2023.0096","DOIUrl":"https://doi.org/10.1089/3dp.2023.0096","url":null,"abstract":"For wider adoption of the material extrusion (MatEx)-based additive manufacturing (AM) process, it is important to understand the systems for an improved production rate of the machine. This AM process is the most adaptable and popular due to its wide availability, scalability, compatibility with a broad range of thermoplastic materials, and decreasing cost of personal MatEx-based systems. The performance limits are being explored by many researchers, but none have tried to find the efficacy of different kinematic configurations. Kinematic configurations can significantly alter the efficiency of the machines. Most machines are operating on Cartesian positioning systems nowadays. Delta and polar positioning systems are not yet been extensively explored. In this study, Cartesian, delta, and polar systems of MatEx 3D printers are analyzed and compared based on physical inspection, print head dynamics and printed parts surface finish, dimensional accuracy, and build time. Based on the comparative study, the results show that the delta system-based 3D printer gives better surface finish and dimensional accuracy than polar and Cartesian system-based 3D printers. The analysis of build time with respect to the different infill densities and different printing speeds shows that the polar system-based 3D printers performed faster than the other two positing systems.","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":"38 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134886896","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}