Printing with mechanically interlocked extrudates using a custom bi-extruder for fused deposition modelling

2018 ◽  
Vol 24 (6) ◽  
pp. 921-934 ◽  
Author(s):  
Mohammad Abu Hasan Khondoker ◽  
Asad Asad ◽  
Dan Sameoto
Keyword(s):  
Cross Sections ◽  
Acrylonitrile Butadiene Styrene ◽  
Easy Access ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Immiscible Polymers ◽  
Fused Deposition ◽  
Functionally Gradient ◽  
Different Sources ◽  
Butadiene Styrene

Purpose This paper aims to target to print functionally gradient materials (FGM) devices made of immiscible polymers in multi-material fused deposition modelling (FDM) systems. The design is intended to improve adhesion of dissimilar thermoplastics without the need for chemical compatibilization so that filaments from many different sources can be used effectively. Therefore, there is a need to invent an alternative solution for printing multiple immiscible polymers in an FDM system with the desired adhesion. Design/methodology/approach In this study, the authors have developed a bi-extruder for FDM systems which can print two thermoplastics through a single nozzle with a static intermixer to enhance bonding between input materials. The system can also change the composition of extrudates continuously. Findings The uniqueness of this extruder is in its easy access to the internal channel so that a static intermixer can be inserted, enabling deposition of mechanically interlocked extrudates composed of two immiscible polymers. Without this intermixer, the bi-extruder extrudes with simple side-by-side co-extrusion having no mechanical interlocking. The bi-extruder was characterized by printing objects using pairs of materials including polylactic acid, acrylonitrile butadiene styrene and high impact polystyrene. Microscope images of the cross-sections of the extrudates confirm the ability of this bi-extruder to control the composition as desired. It was also found that the mechanically interlocked extrudates composed of two immiscible polymers substantially reduces adhesion failures within and between filaments. Originality/value In this study, the first-ever FDM extruder with a mechanical blending feature next to the nozzle has been designed and used to successfully print FGM objects with improved mechanical properties.

scholarly journals Geometric accuracy of an acrylonitrile butadiene styrene canine tibia model fabricated using fused deposition modelling and the effects of hydrogen peroxide gas plasma sterilisation

2020 ◽  
Vol 16 (1) ◽  
Author(s):  
Chi-Pin Hsu ◽  
Chen-Si Lin ◽  
Chun-Hao Fan ◽  
Nai-Yuan Chiang ◽  
Ching-Wen Tsai ◽  
...  
Keyword(s):  
Hydrogen Peroxide ◽  
Cross Sections ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
3D Ct ◽  
Geometric Accuracy ◽  
Fused Deposition ◽  
Gas Plasma ◽  
Butadiene Styrene

Abstract Background Three-dimensional (3D) printing techniques have been used to produce anatomical models and surgical guiding instruments in orthopaedic surgery. The geometric accuracy of the 3D printed replica may affect surgical planning. This study assessed the geometric accuracy of an acrylonitrile butadiene styrene (ABS) canine tibia model printed using fused deposition modelling (FDM) and evaluated its morphological change after hydrogen peroxide (H2O2) gas plasma sterilisation. The tibias of six canine cadavers underwent computed tomography for 3D reconstruction. Tibia models were fabricated from ABS on a 3D printer through FDM. Reverse-engineering technology was used to compare morphological errors (root mean square; RMS) between the 3D-FDM models and virtual models segmented from original tibia images (3D-CT) and between the models sterilised with H2O2 gas plasma (3D-GAS) and 3D-FDM models on tibia surface and in cross-sections at: 5, 15, 25, 50, 75, 85, and 95% of the tibia length. Results The RMS mean ± standard deviation and average positive and negative deviation values for all specimens in EFDM-CT (3D-FDM vs. 3D-CT) were significantly higher than those in EGAS-FDM (3D-GAS vs. 3D-FDM; P < 0.0001). Mean RMS values for EFDM-CT at 5% bone length (proximal tibia) were significantly higher than those at the other six cross-sections (P < 0.0001). Mean RMS differences for EGAS-FDM at all seven cross-sections were nonsignificant. Conclusions The tibia models fabricated on an FDM printer had high geometric accuracy with a low RMS value. The surface deviation in EFDM-CT indicated that larger errors occurred during manufacturing than during sterilisation. Therefore, the model may be used for surgical rehearsal and further clinically relevant applications in bone surgery. Graphical abstract

scholarly journals Shape accuracy of an acrylonitrile butadiene styrene canine tibia model fabricated using fused deposition modelling and the effects of hydrogen peroxide gas plasma sterilisation

2020 ◽  
Author(s):  
Chi-Pin Hsu ◽  
Chen-Si Lin ◽  
Chun-Hao Fan ◽  
Nai-Yuan Chiang ◽  
Ching-Wen Tsai ◽  
...  
Keyword(s):  
Hydrogen Peroxide ◽  
Cross Sections ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
3D Ct ◽  
Shape Accuracy ◽  
Fused Deposition ◽  
Gas Plasma ◽  
Butadiene Styrene

Abstract Background Three-dimensional (3D) printing techniques have been used for anatomical models and surgical guiding instruments in orthopaedic surgery. The accuracy of these surgical guiding tools is important for obtaining good clinical outcomes. This study assessed the shape accuracy of an acrylonitrile butadiene styrene (ABS) canine tibia model printed using fused deposition modelling (FDM) and evaluated its morphological change after hydrogen peroxide (H2O2) gas plasma sterilisation. The tibias of six canine cadavers underwent computed tomography for 3D reconstruction. Tibia models were fabricated from ABS on a 3D printer through FDM. Reverse-engineering technology was used to compare morphological errors (root mean square; RMS) between the 3D-FDM models and virtual models segmented from original tibia images (3D-CT) and between the models sterilised with H2O2 gas plasma (3D-GAS) and 3D-FDM models on tibia surface and in cross-sections at: 5%, 15%, 25%, 50%, 75%, 85%, and 95% of the tibia length. Results The RMS mean ± standard deviation and average positive and negative deviation values for all specimens in G1 (3D-FDM vs. 3D-CT) were significantly higher than those in G2 (3D-GAS vs. 3D-FDM; P < 0.0001). Mean RMS values for G1 at 5% bone length (proximal tibia) were significantly higher than those at the other six cross-sections (P < 0.0001). Mean RMS differences for G2 at all seven cross-sections were nonsignificant. Conclusions Our tibia model fabricated on an FDM printer had high shape accuracy with a low RMS value. The surface deviation in G1 indicated that larger errors occurred during manufacturing than during sterilisation. Therefore, the model may be clinically acceptable for bone surgery and surgical rehearsal.

Optimal assembling of 3D printed features by modulation of interfacial behaviour

2019 ◽  
Vol 25 (1) ◽  
pp. 13-21
Author(s):  
Justin Favero ◽  
Sofiane Belhabib ◽  
Sofiane Guessasma ◽  
Hedi Nouri
Keyword(s):  
Design Methodology ◽  
Acrylonitrile Butadiene Styrene ◽  
Interfacial Phenomena ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Fused Deposition ◽  
Interfacial Behaviour ◽  
3D Printed ◽  
Practical Implications ◽  
Butadiene Styrene

Purpose Assembling items to achieve bigger parts seems to be the solution to counterbalance the dimension limits of 3D printing. This work aims to propose an approach to achieve optimal assembling. Design/methodology/approach Acrylonitrile butadiene styrene polymer samples were printed using fused deposition modelling (FDM). These samples were assembled and the precise contribution of interfacial shearing and tension was measured using simple tensile experiments. Findings The results achieved show the correlation between the printing orientation and the assembling angle. It could be proved that rupture by an interfacial decohesion mechanism of glued parts can be avoided by simple adaptation of the assembling junction. Practical implications Design of large parts using FDM is no more a limitation if assembling configurations are adapted based on the knowledge gained about the interfacial phenomena occurring at the junction position. Originality/value The unbalanced contribution of shearing and tension at the interface defines new assembling profiles that exclude flat junctions.

scholarly journals Geometric accuracy of an acrylonitrile butadiene styrene canine tibia model fabricated using fused deposition modelling and the effects of hydrogen peroxide gas plasma sterilisation

2020 ◽  
Author(s):  
Chi-Pin Hsu ◽  
Chen-Si Lin ◽  
Chun-Hao Fan ◽  
Nai-Yuan Chiang ◽  
Ching-Wen Tsai ◽  
...  
Keyword(s):  
Hydrogen Peroxide ◽  
Cross Sections ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
3D Ct ◽  
Geometric Accuracy ◽  
Fused Deposition ◽  
Gas Plasma ◽  
Butadiene Styrene

Abstract Background: Three-dimensional (3D) printing techniques have been used to produce anatomical models and surgical guiding instruments in orthopaedic surgery. The geometric accuracy of the 3D printed replica may affect surgical planning. This study assessed the geometric accuracy of an acrylonitrile butadiene styrene (ABS) canine tibia model printed using fused deposition modelling (FDM) and evaluated its morphological change after hydrogen peroxide (H 2 O 2 ) gas plasma sterilisation. The tibias of six canine cadavers underwent computed tomography for 3D reconstruction. Tibia models were fabricated from ABS on a 3D printer through FDM. Reverse-engineering technology was used to compare morphological errors (root mean square; RMS) between the 3D-FDM models and virtual models segmented from original tibia images (3D-CT) and between the models sterilised with H 2 O 2 gas plasma (3D-GAS) and 3D-FDM models o n tibia surface and in cross-sections at: 5%, 15%, 25%, 50%, 75%, 85%, and 95% of the tibia length. Results: The RMS mean ± standard deviation and average positive and negative deviation values for all specimens in E FDM-CT (3D-FDM vs. 3D-CT) were significantly higher than those in E GAS-FDM (3D-GAS vs. 3D-FDM; P < 0.0001). Mean RMS values for E FDM-CT at 5% bone length (proximal tibia) were significantly higher than those at the other six cross-sections ( P < 0.0001). Mean RMS differences for E GAS-FDM at all seven cross-sections were nonsignificant. Conclusions: The tibia models fabricated on an FDM printer had high geometric accuracy with a low RMS value. The surface deviation in E FDM-CT indicated that larger errors occurred during manufacturing than during sterilisation. Therefore, the model may be used for surgical rehearsal and further clinically relevant applications in bone surgery.

Evaluation of a rapid prototyping application for stomas

2020 ◽  
Vol 26 (9) ◽  
pp. 1525-1533 ◽  
Author(s):  
Jose Manuel Sierra ◽  
Jose Ignacio Rodríguez ◽  
Marta María Villazon ◽  
Jose Luis Cortizo ◽  
Maria del Rocio Fernandez
Keyword(s):  
3D Printing ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Tests ◽  
Fused Deposition Modelling ◽  
Static Loads ◽  
Content Type ◽  
Fused Deposition ◽  
Collection Device ◽  
Low Costs ◽  
Butadiene Styrene

Purpose This paper aims to describe the development of an internal waste-collection device for patients who have undergone a colostomy or ileostomy. Its design is based on devices that have been produced by 3D printing with acrylonitrile butadiene styrene. The aim is to find an alternative to the external bags that these patients currently use and to evaluate the properties of the device produced by additive manufacturing. Design/methodology/approach Software for solid modelling has been used, and virtual models allow its visualization and animation, for evaluation, in a simple and fast way. Subsequently, functional prototypes have been developed by a multidisciplinary team, which includes surgeons and engineers, and have been tested to verify their mechanical properties and suitability for function. Findings The project has developed a functional design that has been patented and is in the clinical trials phase. This study demonstrates how 3D printing technologies are the perfect complement to accelerate the design process and build functional prototypes at low costs. The experimental tests regarding cytotoxicity, printing orientation, dynamic and static loads and temperature resistance have demonstrated the validity of the proposed device. Originality/value A device for internal pouch in colostomized patients has been designed, manufactured by fused deposition modelling and validated.

Investigations for partial denture casting by fused deposition modelling-assisted chemical vapour smoothing

2020 ◽  
Vol 40 (5) ◽  
pp. 745-754
Author(s):  
Gurpartap Singh ◽  
Rupinder Singh ◽  
S.S. Bal
Keyword(s):  
Ph Value ◽  
Low Cost ◽  
Chemical Vapour ◽  
Dimensional Accuracy ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
View Point ◽  
Content Type ◽  
Fused Deposition ◽  
Set Up

Purpose The purpose of this study is to investigate dimensional accuracy (Δd), surface roughness (Ra) and micro hardness (HV) of partial dentures (PD) prepared with synergic combination of fused deposition modelling (FDM) assisted chemical vapour smoothing (CVS) patterns and conventional dental casting (DC) from multi-factor optimization view point. Design/methodology/approach The master pattern for PD was prepared with acrylonitrile butadiene styrene (ABS) thermoplastic on FDM set-up (one of the low cost additive manufacturing process) followed by CVS process. The final PD as functional prototypes was casted with nickel–chromium-based (Ni-Cr) alloy by varying Ni% (Z). The other input parameters were powder to water ratio P/W (X) and pH value (Y) of water used. Findings The results of this study suggest that for controlling the Δd and Ra of the PD, most important factor is X, followed by Z. For hardness of PD, the most important factor is Z. But from overall optimization viewpoint, the best settings are X-100/12, Y-10 and Z-61% (in Ni-Cr alloy). Further, based upon X-bar chart (for HV), the FDM-assisted DC process used for preparation of PD is statistically controlled. Originality/value This study highlights that PD prepared with X-100/12, Y-10 and Z-61% gives overall better results from multi-factor optimization view point. Finally, X-bar chart has been plotted to understand the statistical nature of the synergic combination of FDM, CVS and DC.

Parametric Study on Surface Roughness of Metallized Parts Manufactured by Additive Manufacturing

2019 ◽  
Vol 821 ◽  
pp. 137-143 ◽  
Author(s):  
Pavan Kumar Gurrala ◽  
Brijesh Tripathi
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Acrylonitrile Butadiene Styrene ◽  
Etching Time ◽  
Fused Deposition Modelling ◽  
Technological Evolution ◽  
Fused Deposition ◽  
Copper Electroplating ◽  
Optimal Value ◽  
Butadiene Styrene

In the current technological evolution, additive manufacturing is taking a lead role in manufacturing of components for both prototyping as well as finished products. Metallization of the polymer parts has high potential to add value in-terms of metallic luster, improved strength, long shelf-life and better radiation resistance. Standard acid copper plating process has been adopted for deposition of copper on polymer parts manufactured by fused deposition modelling (FDM) technique. The parameters namely the etching time, voltage and the surface finish of the manufactured FDM parts are studied for their influence on the surface quality. Experiments have been designed using design of experiments strategy. Experiments have been conducted and surface roughness has been measured. Influence of each of the three parameters has been discussed in detail. For the reported process the optimal value of etching time of Acrylonitrile Butadiene Styrene (ABS) has been found in the range of 30 to 60 minutes along with applied voltage in the range of 1.5 to 2.5 Volts for copper electroplating.

scholarly journals Modelling and Investigation of Crack Growth for 3D-Printed Acrylonitrile Butadiene Styrene (ABS) with Various Printing Parameters and Ambient Temperatures

Polymers ◽  
2021 ◽  
Vol 13 (21) ◽  
pp. 3737
Author(s):  
Yousef Lafi A. Alshammari ◽  
Feiyang He ◽  
Muhammad A. Khan
Keyword(s):  
3D Printing ◽  
Crack Growth ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
Structural Dynamic ◽  
Fused Deposition ◽  
Nozzle Size ◽  
Printing Parameters ◽  
Butadiene Styrene

Three-dimensional (3D) printing is one of the significant industrial manufacturing methods in the modern era. Many materials are used for 3D printing; however, as the most used material in fused deposition modelling (FDM) technology, acrylonitrile butadiene styrene (ABS) offers good mechanical properties. It is perfect for making structures for industrial applications in complex environments. Three-dimensional printing parameters, including building orientation, layers thickness, and nozzle size, critically affect the crack growth in FDM structures under complex loads. Therefore, this paper used the dynamic bending vibration test to investigate their influence on fatigue crack growth (FCG) rate under dynamic loads and the Paris power law constant C and m. The paper proposed an analytical solution to determine the stress intensity factor (SIF) at the crack tip based on the measurement of structural dynamic response. The experimental results show that the lower ambient temperature, as well as increased nozzle size and layer thickness, provide a lower FCG rate. The printing orientation, which is the same as loading, also slows the crack growth. The linear regression between these parameters and Paris Law’s coefficient also proves the same conclusion.

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