Mechanical performance of lightweight ceramic structures via binder jetting of microspheres

AbstractGeometrically-complex and lightweight ceramic parts manufactured via 3D printing are prospective structures that seem to provide excellent thermal, wear and dielectric performance. In the present work, binder jetted parts based on synthetic lightweight ceramic hollow microspheres were manufactured and evaluated under different testing conditions in order to characterize their mechanical performance. The resulting structures were assessed in terms of quasi-static flexural and compressive strength, and density. Furthermore, microscopy analyses highlighted the composition of the final structures and fracture mechanisms. The printed system mainly consisted of aluminum silicon dioxide, fly ash and traces of metal. The samples yielded similar strength as that achieved on conventional bulk-based 3D printed ceramic structures. It was observed that the strength of the printed microspheres increased by sintering the parts to near-fusion temperatures due to viscous flow of material during sintering. The combination of the proposed process and feedstock represents an attractive manufacturing method for fabricating lightweight structures for applications like composite tooling molds, electromagnetic devices, and biomedical implants.

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Drivers of mechanical performance variance in 3D ‐printed fused filament fabrication parts: An Onyx FR case study

Polymer Composites ◽

10.1002/pc.26187 ◽

2021 ◽

Author(s):

Christine Ma ◽

Jessica Faust ◽

Joseph D. Roy‐Mayhew

Keyword(s):

Mechanical Performance ◽

Fused Filament Fabrication ◽

3D Printed

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Investigation of Energy-Absorbing Properties of a Bio-Inspired Structure

Metals ◽

10.3390/met11060881 ◽

2021 ◽

Vol 11 (6) ◽

pp. 881

Author(s):

Adrian Dubicki ◽

Izabela Zglobicka ◽

Krzysztof J. Kurzydłowski

Keyword(s):

Absorption Capacity ◽

Compression Tests ◽

Element Analysis ◽

Lightweight Structures ◽

New Energy ◽

Absorbing Material ◽

Lightweight Structure ◽

3D Printed ◽

Deformation Force ◽

Energy Absorbing

Numerous engineering applications require lightweight structures with excellent absorption capacity. The problem of obtaining such structures may be solved by nature and especially biological structures with such properties. The paper concerns an attempt to develop a new energy-absorbing material using a biomimetic approach. The lightweight structure investigated here is mimicking geometry of diatom shells, which are known to be optimized by nature in terms of the resistance to mechanical loading. The structures mimicking frustule of diatoms, retaining the similarity with the natural shell, were 3D printed and subjected to compression tests. As required, the bio-inspired structure deformed continuously with the increase in deformation force. Finite element analysis (FEA) was carried out to gain insight into the mechanism of damage of the samples mimicking diatoms shells. The experimental results showed a good agreement with the numerical results. The results are discussed in the context of further investigations which need to be conducted as well as possible applications in the energy absorbing structures.

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Optimization of a 3D-Printed Permanent Magnet Coupling Using Genetic Algorithm and Taguchi Method

Electronics ◽

10.3390/electronics10040494 ◽

2021 ◽

Vol 10 (4) ◽

pp. 494

Author(s):

Ekaterina Andriushchenko ◽

Ants Kallaste ◽

Anouar Belahcen ◽

Toomas Vaimann ◽

Anton Rassõlkin ◽

...

Keyword(s):

Genetic Algorithm ◽

Taguchi Method ◽

Permanent Magnet ◽

Optimization Problems ◽

Optimization Method ◽

Taguchi Optimization ◽

Torque Density ◽

Electromagnetic Devices ◽

3D Printed ◽

Manufacturing Techniques

In recent decades, the genetic algorithm (GA) has been extensively used in the design optimization of electromagnetic devices. Despite the great merits possessed by the GA, its processing procedure is highly time-consuming. On the contrary, the widely applied Taguchi optimization method is faster with comparable effectiveness in certain optimization problems. This study explores the abilities of both methods within the optimization of a permanent magnet coupling, where the optimization objectives are the minimization of coupling volume and maximization of transmitted torque. The optimal geometry of the coupling and the obtained characteristics achieved by both methods are nearly identical. The magnetic torque density is enhanced by more than 20%, while the volume is reduced by 17%. Yet, the Taguchi method is found to be more time-efficient and effective within the considered optimization problem. Thanks to the additive manufacturing techniques, the initial design and the sophisticated geometry of the Taguchi optimal designs are precisely fabricated. The performances of the coupling designs are validated using an experimental setup.

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Fire Behavior of 3D-Printed Polymeric Composites

Journal of Materials Engineering and Performance ◽

10.1007/s11665-021-05627-1 ◽

2021 ◽

Author(s):

Karthik Babu ◽

Oisik Das ◽

Vigneshwaran Shanmugam ◽

Rhoda Afriye Mensah ◽

Michael Försth ◽

...

Keyword(s):

Flexible Manufacturing ◽

Human Life ◽

Fire Behavior ◽

Polymeric Materials ◽

Polymeric Composites ◽

Direct Relation ◽

Manufacturing Method ◽

The Poor ◽

Flammability Characteristics ◽

3D Printed

Abstract3D printing or additive manufacturing (AM) is considered as a flexible manufacturing method with the potential for substantial innovations in fabricating geometrically complicated structured polymers, metals, and ceramics parts. Among them, polymeric composites show versatility for applications in various fields, such as constructions, microelectronics and biomedical. However, the poor resistance of these materials against fire must be considered due to their direct relation to human life conservation and safety. In this article, the recent advances in the fire behavior of 3D-printed polymeric composites are reviewed. The article describes the recently developed methods for improving the flame retardancy of 3D-printed polymeric composites. Consequently, the improvements in the fire behavior of 3D-printed polymeric materials through the change in formulation of the composites are discussed. The article is novel in the sense that it is one of the first studies to provide an overview regarding the flammability characteristics of 3D-printed polymeric materials, which will further incite research interests to render AM-based materials fire-resistant.

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Preparation and Performance Evaluation of Duotone 3D-Printed Polyetheretherketone as Oral Prosthetic Materials: A Proof-of-Concept Study

Polymers ◽

10.3390/polym13121949 ◽

2021 ◽

Vol 13 (12) ◽

pp. 1949

Author(s):

Ling Ding ◽

Wei Lu ◽

Jiaqi Zhang ◽

Chuncheng Yang ◽

Guofeng Wu

Keyword(s):

Titanium Dioxide ◽

Performance Evaluation ◽

Mechanical Performance ◽

Mechanical Tests ◽

Flexural Properties ◽

Proof Of Concept ◽

Tooth Color ◽

Dental Application ◽

3D Printed ◽

And Performance

Literature has reported the successful use of 3D printed polyetheretherketone (PEEK) to fabricate human body implants and oral prostheses. However, the current 3D printed PEEK (brown color) cannot mimic the vivid color of oral tissues and thus cannot meet the esthetical need for dental application. Therefore, titanium dioxide (TiO2) and ferric oxide (Fe2O3) were incorporated into PEEK to prepare a series of tooth-color and gingival-color PEEK composites in this study. Through color measurements and mechanical tests, the color value and mechanical performance of the 3D printed PEEK composites were evaluated. In addition, duotone PEEK specimens were printed by a double nozzle with an interface between tooth-color and gingival-color parts. The mechanical performance of duotone PEEK with two different interfaces (horizontal and vertical) was investigated. With the addition of TiO2 and Fe2O3, the colors of 3D printed PEEK composites become closer to that of dental shade guides. 3D printed PEEK composites generally demonstrated superior tensile and flexural properties and hence have great potential in the dental application. In addition, duotone 3D printed PEEK with a horizontal interfacial orientation presented better mechanical performance than that with a vertical one.

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Epoxy infiltrated 3D printed ceramics for composite tooling applications

Additive Manufacturing ◽

10.1016/j.addma.2018.10.036 ◽

2019 ◽

Vol 25 ◽

pp. 59-63 ◽

Cited By ~ 5

Author(s):

Michael Maravola ◽

Brett Conner ◽

Jason Walker ◽

Pedro Cortes

Keyword(s):

Composite Tooling ◽

3D Printed

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Mechanical Performance Under Various Conditions of 3D Printed Polylactide Composites With Natural Fibers

10.21203/rs.3.rs-517727/v1 ◽

2021 ◽

Author(s):

Karolina E. Mazur ◽

Aleksandra Borucka ◽

Paulina Kaczor ◽

Szymon Gądek ◽

Stanislaw Kuciel

Keyword(s):

Elevated Temperatures ◽

Mechanical Performance ◽

Natural Fibers ◽

Crystallization Rate ◽

Mechanical Tests ◽

Hydrothermal Degradation ◽

3D Printed ◽

The Impact ◽

Different Levels ◽

Additive Methods

Abstract In the study, polylactide-based (PLA) composites modified with natural particles (wood, bamboo, and cork) and with different levels of infilling (100%, 80%, and 60%) obtained by additive methods were tested. The effect of type fiber, infill level and crystallization rate on the mechanical properties were investigated by using tensile, flexural, and impact tests. The materials were subjected to mechanical tests carried out at 23 and 80 °C. Furthermore, hydrothermal degradation was performed, and its effect on the properties was analyzed. The addition of natural fillers and different level of infilling result in a similar level of reduction in the properties. Composites made of PLA are more sensitive to high temperature than to water. The decrease in Young's modulus of PLA at 80 °C was 90%, while after 28 days of hydrodegradation ~ 9%. The addition of fibers reduced this decrease at elevated temperatures. Moreover, the impact strength has been improved by 50% for composites with cork particles and for other lignocellulosic composites remained at the same level as for resin.

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EXPERIMENTAL INVESTIGATION AND SIMULATION OF 3D-PRINTED LATTICE STRUCTURES

Acta Polytechnica CTU Proceedings ◽

10.14311/app.2019.25.0052 ◽

2019 ◽

Vol 25 ◽

pp. 52-57

Author(s):

Eva Heiml ◽

Anna Kalteis ◽

Zoltan Major

Keyword(s):

Mechanical Performance ◽

Bulk Material ◽

Deformation Behaviour ◽

Lightweight Design ◽

Thermoplastic Polyurethane ◽

Selective Laser Sintering ◽

Structural Performance ◽

Lattice Structures ◽

3D Printed ◽

Manufacturing Techniques

Lattice structures are currently of high interest, especially for lightweight design. They generally have better structural performance per weight than parts made of bulk material. With conventional manufacturing techniques they are diﬃcult to produce, but with additive manufacturing (AM) fabricationisfeasible. To better understand their behaviour under various loading conditions two lattice structures in diﬀerent conﬁgurations were observed. For each structure three diﬀerent test specimens were designed and manufactured using selective laser sintering (SLS). To investigate the mechanical performance under large deformations the specimens were made of a thermoplastic polyurethane(TPU), which shows a hyperelastic material behaviour. Beside the experimental observations also ﬁnite element analyses (FEA) were conducted to investigate the deformation behaviour in more detail.

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Modeling and experimental investigation of out-of-plane deformation on mechanical performance of composites manufactured by ATL

Journal of Reinforced Plastics and Composites ◽

10.1177/0731684416675747 ◽

2016 ◽

Vol 36 (5) ◽

pp. 347-359 ◽

Cited By ~ 3

Author(s):

Qiyi Chu ◽

Yong Li ◽

Jun Xiao ◽

Dajun Huan ◽

Xiaodong Chen

Keyword(s):

Tensile Strength ◽

Deformation Rate ◽

Mechanical Performance ◽

Plane Deformation ◽

Experimental Results ◽

Predicting Model ◽

Fiber Waviness ◽

Manufacturing Method ◽

Four Point Bending ◽

Out Of Plane

The change of mold normal curvature along the trajectory may result in out-of-plane waviness during the automated laying process, on which the layup speed and temperature would have an effect. A new parameter, deformation rate, was defined by combining the effect of mold curvature change rate and layup speed. A predicting model was proposed based on the fiber waviness and interlaminar sliding model to calculate the relationship between stiffness retention and the layup process parameters, including deformation rate and temperature. An experimental study on the effect of different deformation parameters on the tensile performance of composites was carried out based on a new manufacturing method of plated specimens with different levels of waviness by means of a four-point bending fixture. The experimental results showed that when the deformation temperature increases from 20℃ to 80℃, the tensile strength increases first and then decreases while the tensile module keeps increasing. While the deformation rate decreases from 0.40 to 0.04 mm−1/s, both tensile strength and module showed an increasing trend. The predicting model being validated by experimental results can be utilized to optimize the layup process parameter to satisfy the quality and efficiency requirements.

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