Investigation of 3D‐printed PLA–stainless‐steel polymeric composite through fused deposition modelling‐based additive manufacturing process for biomedical applications

Widely used additive manufacturing technique for plastic materials is Fused Deposition Modelling (FDM). The FDM technology has gained interest in industry for a wide range of applications, especially today when large number of different materials on the market are available. There are many different manufacturers for the same FDM material where the difference in price goes up to 50%. This experimental study investigates possible difference in strength of the 3D printed PLA material of five different manufacturers. All specimens are 3D printed on Ultimaker S5 printer with the same printing parameters, and they are all the same colour.

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Surface Preparation and Treatment for Large-Scale 3D-Printed Composite Tooling Coating Adhesion

Coatings ◽

10.3390/coatings8120457 ◽

2018 ◽

Vol 8 (12) ◽

pp. 457 ◽

Cited By ~ 3

Author(s):

Philipp Sauerbier ◽

James Anderson ◽

Douglas Gardner

Keyword(s):

Additive Manufacturing ◽

Large Scale ◽

Lower Cost ◽

Numerical Control ◽

Fused Deposition Modelling ◽

Filler Materials ◽

Coating Adhesion ◽

Fused Deposition ◽

Composite Tooling ◽

3D Printed

Recent advances in large-scale thermoplastic additive manufacturing (AM), using fused deposition modelling (FDM), have shown that the technology can effectively produce large aerospace tools with common feed stocks, costing 2.3 $/kg, such as a 20% carbon-filled acrylonitrile butadiene styrene (ABS). Large-scale additive manufacturing machines have build-volumes in the range of cubic meters and use commercially available pellet feedstock thermoplastics, which are significantly cheaper (5–10 $/kg) than the filament feedstocks for desktop 3D printers (20–50 $/kg). Additionally, large-scale AM machines have a higher material throughput on the order of 50 kg/h. This enables the cost-efficient tool production for several industries. Large-scale 3D-printed tooling will be computerized numerical control (CNC)-machined and -coated, to provide a surface suitable for demolding the composite parts. This paper outlines research undertaken to review and improve the adhesion of the coating systems to large, low-cost AM composite tooling, for marine or infrastructure composite applications. Lower cost tooling systems typically have a lower dimensional accuracy and thermal operating requirements than might be required for aerospace tooling. As such, they can use lower cost commodity grade thermoplastics. The polymer systems explored in the study included polypropylene (PP), styrene-maleic anhydride (SMA), and polylactic acid (PLA). Bio-based filler materials were used to reduce cost and increase the strength and stiffness of the material. Fillers used in the study included wood flour, at 30% by weight and spray-dried cellulose nano-fibrils, at 20% by weight. Applicable adhesion of the coating was achieved with PP, after surface treatment, and untreated SMA and PLA showed desirable coating adhesion results. PLA wood-filled composites offered the best properties for the desired application and, furthermore, they have environment-friendly advantages.

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Effect of Perforation Volume on Acoustic Absorption of the 3D Printed Micro-Perforated Panels made of Polylactic Acid reinforced with Wood Fibers

Journal of Physics Conference Series ◽

10.1088/1742-6596/2120/1/012039 ◽

2021 ◽

Vol 2120 (1) ◽

pp. 012039

Author(s):

V Sekar ◽

S Y Eh Noum ◽

S Sivanesan ◽

A Putra ◽

Dg H Kassim ◽

...

Keyword(s):

Additive Manufacturing ◽

Polylactic Acid ◽

Natural Fiber ◽

Fused Deposition Modelling ◽

Acoustic Absorption ◽

Wood Fibers ◽

Fused Deposition ◽

3D Printed ◽

Almost All ◽

Impedance Tube Method

Abstract In recent times, Additive Manufacturing (AM) has been applied rapidly in almost all fields. This study was conducted to apply the additive manufacturing into an acoustic application by 3D printing the Micro-Perforated Panels (MPP) through Fused Deposition Modelling (FDM) made of Polylactic Acid (PLA) reinforced with wood fibers. MPP were fabricated by altering its perforation volume. Later, the effect of perforation volume on acoustic absorption of the fabricated MPP was measured using the two-microphone impedance tube method as per ISO 10534-2 standard. The result shows altering the perforation volume affects the acoustic absorption of the MPP. MPP with a thickness of 2 mm and a perforation diameter of 0.2 mm shows the maximum sound absorption coefficient of 0.93 at 2173 Hz. It is made possible to absorb the 3D printed MPP made of natural fiber reinforced composite at different spectrums by altering the perforation volume.

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A design of experiment approach to 3D-printed mouthpieces sound analysis

Progress in Additive Manufacturing ◽

10.1007/s40964-021-00183-5 ◽

2021 ◽

Author(s):

Antonio Bacciaglia ◽

Alessandro Ceruti ◽

Alfredo Liverani

Keyword(s):

Additive Manufacturing ◽

Design Of Experiment ◽

Musical Instruments ◽

Rapid Expansion ◽

Fused Deposition Modelling ◽

Layer By Layer ◽

Fused Deposition ◽

3D Printed ◽

Processing Techniques ◽

Short Time

AbstractNowadays additive manufacturing is affected by a rapid expansion of possible applications. It is defined as a set of technologies that allow the production of components from 3D digital models in a short time by adding material layer by layer. It shows enormous potential to support wind musical instruments manufacturing because the design of complex shapes could produce unexplored and unconventional sounds, together with external customization capabilities. The change in the production process, material and shape could affect the resulting sound. This work aims to compare the music performances of 3D-printed trombone mouthpieces using both Fused Deposition Modelling and Stereolithography techniques, compared to the commercial brass one. The quantitative comparison is made applying a Design of Experiment methodology, to detect the main additive manufacturing parameters that affect the sound quality. Digital audio processing techniques, such as spectral analysis, cross-correlation and psychoacoustic analysis in terms of loudness, roughness and fluctuation strength have been applied to evaluate sounds. The methodology herein applied could be used as a standard for future studies on additively manufactured musical instruments.

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3D-Printed PCL/PLA Composite Stents: Towards a New Solution to Cardiovascular Problems

Materials ◽

10.3390/ma11091679 ◽

2018 ◽

Vol 11 (9) ◽

pp. 1679 ◽

Cited By ~ 36

Author(s):

Antonio Guerra ◽

Paula Cano ◽

Marc Rabionet ◽

Teresa Puig ◽

Joaquim Ciurana

Keyword(s):

Cell Proliferation ◽

Manufacturing Process ◽

Vascular Tissue ◽

Fused Deposition Modelling ◽

Average Cell ◽

Dynamic Mechanical ◽

Fused Deposition ◽

Degradation Rates ◽

Biodegradable Stents ◽

3D Printed

Biodegradable stents (BRS) offer enormous potential but first they must meet five specific requirements: (i) their manufacturing process must be precise; (ii) degradation should have minimal toxicity; (iii) the rate of degradation should match the recovery rate of vascular tissue; (iv) ideally, they should induce rapid endothelialization to restore the functions of vascular tissue, but at the same time reduce the risk of restenosis; and (v) their mechanical behavior should comply with medical requirements, namely, the flexibility required to facilitate placement but also sufficient radial rigidity to support the vessel. Although the first three requirements have been comprehensively studied, the last two have been overlooked. One possible way of addressing these issues would be to fabricate composite stents using materials that have different mechanical, biological, or medical properties, for instance, Polylactide Acid (PLA) or Polycaprolactone (PCL). However, fashioning such stents using the traditional stent manufacturing process known as laser cutting would be impossible. Our work, therefore, aims to produce PCL/PLA composite stents using a novel 3D tubular printer based on Fused Deposition Modelling (FDM). The cell geometry (shape and area) and the materials (PCL and PLA) of the stents were analyzed and correlated with 3T3 cell proliferation, degradation rates, dynamic mechanical and radial expansion tests to determine the best parameters for a stent that will satisfy the five strict BRS requirements. Results proved that the 3D-printing process was highly suitable for producing composite stents (approximately 85–95% accuracy). Both PCL and PLA demonstrated their biocompatibility with PCL stents presenting an average cell proliferation of 12.46% and PLA 8.28% after only 3 days. Furthermore, the PCL/PLA composite stents demonstrated their potential in degradation, dynamic mechanical and expansion tests. Moreover, and regardless of the order of the layers, the composite stents showed (virtually) medium levels of degradation rates and mechanical modulus. Radially, they exhibited the virtues of PCL in the expansion step (elasticity) and those of PLA in the recoil step (rigidity). Results have clearly demonstrated that composite PCL/PLA stents are a highly promising solution to fulfilling the rigorous BRS requirements.

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Surface Roughness Effect on the 3d Printed Butt Joints Strength

Proceedings of the 8th International Scientific Conference "BALTTRIB 2015" ◽

10.15544/balttrib.2015.21 ◽

2015 ◽

Cited By ~ 2

Author(s):

V. Kovan ◽

G. Altan ◽

E.S. Topal ◽

H.E. Camurlu

Keyword(s):

Surface Roughness ◽

Additive Manufacturing ◽

3D Printing ◽

Three Dimensional ◽

Thickness Effect ◽

Fused Deposition Modelling ◽

Three Dimensional Printing ◽

Fused Deposition ◽

3D Printed ◽

Dimensional Object

Three-dimensional printing or 3D printing (also called additive manufacturing) is any of various processes used to make a three-dimensional object. Fused deposition modelling (FDM) is an additive manufacturing technology commonly used for modelling, prototyping, and production applications. It is one of the techniques used for 3D printing. FDM is somewhat restricted in the size and the variation of shapes that may be fabricated. For parts too large to fit on a single build, for faster job builds with less support material, or for parts with finer features, sectioning and bonding FDM parts is a great solution. The strength of adhesive bonded FDM parts is affected by the surface roughness. In this study, the layer thickness effect on bonding strength is experimentally studied and the results are discussed.

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3D printed fluidics with embedded analytic functionality for automated reaction optimisation

Beilstein Journal of Organic Chemistry ◽

10.3762/bjoc.13.14 ◽

2017 ◽

Vol 13 ◽

pp. 111-119 ◽

Cited By ~ 30

Author(s):

Andrew J Capel ◽

Andrew Wright ◽

Matthew J Harding ◽

George W Weaver ◽

Yuqi Li ◽

...

Keyword(s):

Additive Manufacturing ◽

Reaction Medium ◽

Flow Chemistry ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

Fluidic Devices ◽

3D Printed ◽

Solvent Systems ◽

Temperature And Pressure ◽

Set Up

Additive manufacturing or ‘3D printing’ is being developed as a novel manufacturing process for the production of bespoke micro- and milliscale fluidic devices. When coupled with online monitoring and optimisation software, this offers an advanced, customised method for performing automated chemical synthesis. This paper reports the use of two additive manufacturing processes, stereolithography and selective laser melting, to create multifunctional fluidic devices with embedded reaction monitoring capability. The selectively laser melted parts are the first published examples of multifunctional 3D printed metal fluidic devices. These devices allow high temperature and pressure chemistry to be performed in solvent systems destructive to the majority of devices manufactured via stereolithography, polymer jetting and fused deposition modelling processes previously utilised for this application. These devices were integrated with commercially available flow chemistry, chromatographic and spectroscopic analysis equipment, allowing automated online and inline optimisation of the reaction medium. This set-up allowed the optimisation of two reactions, a ketone functional group interconversion and a fused polycyclic heterocycle formation, via spectroscopic and chromatographic analysis.

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Plastic and metal additive manufacturing technologies for microwave passive components up toKaband

International Journal of Microwave and Wireless Technologies ◽

10.1017/s1759078717001465 ◽

2018 ◽

Vol 10 (7) ◽

pp. 772-782

Author(s):

Johann Sence ◽

William Feuray ◽

Aurélien Périgaud ◽

Olivier Tantot ◽

Nicolas Delhote ◽

...

Keyword(s):

Stainless Steel ◽

Additive Manufacturing ◽

Dielectric Material ◽

Mode Converter ◽

Fused Deposition ◽

3D Printed ◽

The Creation ◽

Manufacturing Technologies ◽

Plastic Parts ◽

The Impact

AbstractThis paper illustrates the different possibilities given by additive manufacturing technologies for the creation of passive microwave hardware. The paper more specifically highlights a prototyping scheme where the 3D-printed plastic parts can be used as initial proofs of concept before considering more advanced 3D-printed parts (metal parts, for instance). First, a characterization campaign has been made on common plastics used by a 3D printer using the fused deposition modeling and material jetting (Polyjet©) technologies. The impact of the manufacturing strategy (high-speed or high-accuracy) on the part roughness, as well as on the dielectric material permittivity and loss tangent, has been specifically studied at 10 and 16 GHz. Based on a specifically optimized and deeply explained characterization method, the conductivity of a coating based on silver paint has also been characterized on such plastic parts at 10 and 40 GHz. These plastic materials and coating have been used for the creation of quasi-elliptic and tuning-free bandpass filters centered at 6 and 12 GHz and compared with a similar filter made of stainless steel by selective laser melting. Finally, a compact rectangularTE10to circularTE01mode converter also undergoes one prototyping step out of plastic before moving to an advanced part made out of stainless steel. This mode converter, which is made in a single part, is designed to operate from 28 to 36 GHz as a tuning-free final demonstrator.

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Study of Printing Orientation on Mechanical Properties in Additive Manufacturing Process

Volume 2A: Advanced Manufacturing ◽

10.1115/imece2019-11997 ◽

2019 ◽

Author(s):

Peyman Honarmandi ◽

Hongbin Xu

Keyword(s):

Mechanical Properties ◽

Additive Manufacturing ◽

Young’S Modulus ◽

Manufacturing Process ◽

Young's Modulus ◽

Innovative Technology ◽

Build Orientation ◽

Fused Deposition ◽

3D Printed

Abstract Additive manufacturing (AM) is an innovative technology that creates parts by adding small portions of materials layer by layer, which frees designers to create parts that were not possible to manufacture with subtractive manufacturing processes previously. This led to wide-spread popularity of 3D-printing technology. In this technology. fused deposition modeling (FDM) is the most affordable one in the market now. Therefore, it is vital to understand how the print orientation, which can be customized very easily, affects the mechanical properties of the prints to maximize the strength of the product. This paper aims to present the methodology and results of the experimental characterization of the acrylonitrile butadiene styrene (ABS) 3D-printed part. Tensile characterization of ABS was performed to analyze anisotropic nature of 3D-printed parts caused by its unique manufacturing process. Specimens were printed with six different configurations: four raster ([45/−45], [30/−60], [15/−75] and [0/90]) and three build orientations (0 or flat, 45, and 90 degrees with respect to the build plate, all printed in [45/−45] raster orientation). Dogbone tensile specimens were printed and pulled using the tensile test machine. The young’s modulus, yield strength, ultimate strength, strain at failure, breaking strength were found for each configuration. As the build orientation angle increased and the raster orientation goes from [45/−45] to [0/90], mechanical properties decreased steadily except the Young’s modulus. For build orientation, Young’s modulus decreased first then increased as angle increased, and for the raster orientation, there was no statistically significant difference as raster changed from [45/−45] to [0/90]. Overall, [45/−45] flat configuration is the strongest and the most stable configuration.

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Structural Integrity of Polymeric Components Produced by Additive Manufacturing (AM)—Polymer Applications

Polymers ◽

10.3390/polym13244420 ◽

2021 ◽

Vol 13 (24) ◽

pp. 4420

Author(s):

Rui F. Martins ◽

Ricardo Branco ◽

Filippo Berto ◽

Nuno Soares ◽

Sebastião Bandeira

Keyword(s):

Additive Manufacturing ◽

Structural Integrity ◽

Fused Deposition Modelling ◽

Mass Reduction ◽

The Finite Element Method ◽

Fused Deposition ◽

Major Constraint ◽

3D Printed ◽

Fit For Purpose ◽

Functional Components

In the work presented herein, the structural integrity of polymeric functional components made of Nylon-645 and Polylactic acid (PLA) produced by additive manufacturing (Fused Deposition Modelling, FDM) is studied. The PLA component under study was selected from the production line of a brewing company, and it was redesigned and analyzed using the Finite Element Method, 3D printed, and installed under real service. The results obtained indicated that, even though the durability of the 3D printed part was lower than the original, savings of about EUR 7000 a year could be achieved for the component studied. Moreover, it was shown that widespread use of AM with other specific PLA components could result in even more significant savings. Additionally, a metallic hanger (2700 kg/m3) from the cockpit of an airplane ATR 70 series 500 was successfully redesigned and additively manufactured in Nylon 645, resulting in a mass reduction of approximately 60% while maintaining its fit-for-purpose. Therefore, the components produced by FDM were used as fully functional components rather than prototype models, which is frequently stated as a major constraint of the FDM process.

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