Mechanical anisotropy and fracture mode of binder jetting 3D printed calcium sulfate moldings

PurposeThis paper aims to investigate the mechanical behavior of three-dimensional (3D) calcium sulfate porous structures created by a powder-based 3D printer. The effects of the binder-jetting and powder-spreading orientations on the microstructure of the specimens are studied. A micromechanical finite element model is also examined to predict the properties of the porous structures under the load.Design/methodology/approachThe authors printed cylindrical porous and solid samples based on a predefined designed model to study the mechanical behavior of the prototypes. They investigated the effect of three main build bed orientations (x, y and z) on the mechanical behavior of solid and porous specimens fabricated in each direction then evaluated the micromechanical finite-element model for each direction. The strut fractures were analyzed by scanning electron microscopy, micro-computed tomography and the von Mises stress distribution.FindingsResults showed that the orientation of powder spreading and binder jetting substantially influenced the mechanical behavior of the 3D-printed prototypes. The samples that were fabricated parallel to the applied load had higher compressive strength compared with those printed perpendicular to the load. The results of the finite element analysis agreed with the results of the experimental mechanical testing.Research limitations/implicationsThe mechanical behavior was studied for the material and the 3D-printing machine used in this research. If one were to use another material formulation or machine, the printing parameters would have to be set accordingly.Practical implicationsThis work aimed to re-tune the control factors of an existing rapid prototyping process for the given machine. The authors achieved these goals without major changes in the already developed hardware and software architecture.Originality/valueThe results can be used as guidelines to set the printing parameters and a model to predict the mechanical properties of 3D-printed objects for the development of patient- and site-specific scaffolds.

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Density variation in binder jetting 3D-printed and sintered Ti-6Al-4V

Additive Manufacturing ◽

10.1016/j.addma.2018.06.017 ◽

2018 ◽

Vol 22 ◽

pp. 746-752 ◽

Cited By ~ 8

Author(s):

Erica Stevens ◽

Samantha Schloder ◽

Eric Bono ◽

David Schmidt ◽

Markus Chmielus

Keyword(s):

Density Variation ◽

3D Printed ◽

Binder Jetting

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Predictive Modeling of Polymer Saturation in Porous 3D Printed Matrix

Volume 3: Biomedical and Biotechnology Engineering ◽

10.1115/imece2019-10988 ◽

2019 ◽

Author(s):

Adam Mihalko ◽

Robert Michael ◽

Davide Piovesan

Keyword(s):

Additive Manufacturing ◽

Physical Properties ◽

Composite Ceramic ◽

Medical Industry ◽

Solid Matrix ◽

Complex Geometries ◽

Adhesive Binder ◽

3D Printed ◽

Binder Jetting ◽

Accuracy Speed

Abstract Due to the accuracy, speed, and ability to produce controllable complex geometries, additive manufacturing has gained traction in the medical industry. Additive manufacturing based on powder binder-jetting allows fabricating composite ceramic artifacts to mimic the physical properties of cortical bone. Given the porous nature of the artifacts their physical properties can be manipulated based on the percentage of solid matrix and adhesive binder. It has been demonstrated that a reduction of porosity via infiltration greatly increases the mechanical properties of the artifact. In this paper experiments are presented investigating the post processing of porous materials using different adhesives to infiltrate the artifact. The resulting saturation and porosity profiles of the produced composite are analyzed.

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The effect of zinc oxide doping on mechanical and biological properties of 3D printed calcium sulfate based scaffolds

Journal of Applied Biomedicine ◽

10.1016/j.bbe.2017.08.007 ◽

2017 ◽

Vol 37 (4) ◽

pp. 733-741 ◽

Cited By ~ 6

Author(s):

Betül Aldemir Dikici ◽

Serkan Dikici ◽

Ozan Karaman ◽

Hakan Oflaz

Keyword(s):

Zinc Oxide ◽

Calcium Sulfate ◽

Biological Properties ◽

3D Printed

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Analysis of thermal history effects on mechanical anisotropy of 3D-printed polymer matrix composites via in situ X-ray tomography

Journal of Materials Science ◽

10.1007/s10853-017-1339-4 ◽

2017 ◽

Vol 52 (20) ◽

pp. 12185-12206 ◽

Cited By ~ 9

Author(s):

J. C. E. Mertens ◽

K. Henderson ◽

N. L. Cordes ◽

R. Pacheco ◽

X. Xiao ◽

...

Keyword(s):

Polymer Matrix ◽

Thermal History ◽

Polymer Matrix Composites ◽

Mechanical Anisotropy ◽

Matrix Composites ◽

X Ray ◽

History Effects ◽

3D Printed

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Mechanical assessment and odontogenic behavior of a 3D-printed mesoporous calcium silicate/calcium sulfate/poly-ε-caprolactone composite scaffold

Journal of the Formosan Medical Association ◽

10.1016/j.jfma.2021.06.025 ◽

2021 ◽

Author(s):

Chun-Liang Yeh ◽

Rupali Bhorade ◽

Tuan-Ti Hsu ◽

Cheng-Yu Chen ◽

Chun-Pin Lin

Keyword(s):

Calcium Silicate ◽

Calcium Sulfate ◽

Composite Scaffold ◽

3D Printed

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The synergistic effects of quercetin-containing 3D-printed mesoporous calcium silicate/calcium sulfate/poly-ε-caprolactone scaffolds for the promotion of osteogenesis in mesenchymal stem cells

Journal of the Formosan Medical Association ◽

10.1016/j.jfma.2021.01.024 ◽

2021 ◽

Author(s):

Kuo-Hao Huang ◽

Cheng-Yu Chen ◽

Chun-Yao Chang ◽

Yi-Wen Chen ◽

Chun-Pin Lin

Keyword(s):

Stem Cells ◽

Mesenchymal Stem Cells ◽

Calcium Silicate ◽

Calcium Sulfate ◽

Synergistic Effects ◽

3D Printed

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Method for characterization and enhancement of 3D printing by binder jetting applied to the textures quality

Assembly Automation ◽

10.1108/aa-01-2016-007 ◽

2017 ◽

Vol 37 (2) ◽

pp. 162-169 ◽

Cited By ~ 7

Author(s):

Julien Gardan

Keyword(s):

Image Processing ◽

3D Printing ◽

Computer Aided Design ◽

Product Life Cycle ◽

Content Type ◽

Powder Bed ◽

3D Printed ◽

Aided Design ◽

Binder Jetting

Purpose This paper aims to present a technical approach to evaluate the quality of textures obtained by an inkjet during binder jetting in 3D printing on a powder bed through contours detection to improve the quality of the surface printed according to the result of the assembly between the inkjet and a granular product. Design/methodology/approach The manufacturing process is based on the use of computer-aided design and a 3D printer via binder jetting. Image processing measures the edge deviation of a texture on the granular surface with the possibility of implementing a correction in an active assembly through a “design for manufacturing” (DFM) approach. Example application is presented through first tests. Findings This approach observes a shape alteration of the printed image on a 3D printed product, and the work used the image processing method to improve the model according to the DFM approach. Originality/value This paper introduces a solution for improving the texture quality on 3D printed products realized via binder jetting. The DFM approach proposes an active assembly by compensating the print errors in upstream of a product life cycle.

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3D Printed Sand Tools for Thermoforming Applications of Carbon Fiber Reinforced Composites—A Perspective

Materials ◽

10.3390/ma14164639 ◽

2021 ◽

Vol 14 (16) ◽

pp. 4639

Author(s):

Daniel Günther ◽

Patricia Erhard ◽

Simon Schwab ◽

Iman Taha

Keyword(s):

Shell Structures ◽

Reinforced Composites ◽

Fiber Reinforced ◽

Small Series ◽

Innovative Idea ◽

Carbon Fiber Reinforced Composites ◽

3D Printed ◽

Conventional Machining ◽

Binder Jetting ◽

Reduced Time

Tooling, especially for prototyping or small series, may prove to be very costly. Further, prototyping of fiber reinforced thermoplastic shell structures may rely on time-consuming manual efforts. This perspective paper discusses the idea of fabricating tools at reduced time and cost compared to conventional machining-based methods. The targeted tools are manufactured out of sand using the Binder Jetting process. These molds should fulfill the demands regarding flexural and compressive behavior while allowing for vacuum thermoforming of fiber reinforced thermoplastic sheets. The paper discusses the requirements and the challenges and presents a perspective study addressing this innovative idea. The authors present the idea for discussion in the additive manufacturing and FRP producing communities.

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