+TUO project: low cost 3D printers as helpful tool for small communities with rheumatic diseases

2015 ◽  
Vol 21 (5) ◽  
pp. 491-505 ◽  
Author(s):  
Francesca Ostuzzi ◽  
Valentina Rognoli ◽  
Jelle Saldien ◽  
Marinella Levi
Keyword(s):  
Rheumatic Diseases ◽  
Low Cost ◽  
Assistive Devices ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Small Communities ◽  
Entry Level ◽  
Fused Deposition ◽  
Innovative Products ◽  
3D Printers

Purpose – This paper aims to present a pilot study’s aims to identify opportunities and limits deriving from the use of low-cost 3D printing (3DP), fused deposition modelling (FDM), open-source technologies in co-design and co-production processes involving persons with rheumatic diseases (RDs). Design/methodology/approach – In the paper, the authors outline why the use of low-cost, entry-level FDM can be meaningful for this scenario, implying a complete sharing of the design and the production phases of small assistive devices. The +TUO process is composed of several stages, among which the generative session represents the core. Findings – This study highlights as the introduction of this low-cost technology in co-generative processes with people with RDs is a real challenge that can lead to new products and solutions, and that can sustain a social and local manufacturing approach for people facing a specific disablement. Research limitations/implications – This research is a first step of a broader research, new researches are going to explore further details related with the technology and of the adopted method. Practical implications – Involving actively, the end user during the creation process can bring advantages such as meeting more precisely their needs and create innovative products, as shown in the text. Social implications – For people living with RDs, an occupation is important to sustain a process of empowerment. Adopting assistive devices supports daily activities and facilitates the occupation. Originality/value – +TUO is a pilot study that explore a topic already discussed in the scientific arena, without focusing on the specific use of low-cost 3DP technologies.

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.

Effects of Build Orientations on Tensile Properties of PLA Material Processed by FDM

2014 ◽  
Vol 1044-1045 ◽  
pp. 31-34 ◽  
Author(s):  
Mst Faujiya Afrose ◽  
S.H. Masood ◽  
Mostafa Nikzad ◽  
Pio Iovenitti
Keyword(s):  
Tensile Properties ◽  
Low Cost ◽  
Testing Machine ◽  
Extrusion Process ◽  
Fused Deposition Modelling ◽  
Tensile Testing Machine ◽  
Thermoplastic Material ◽  
Fused Deposition ◽  
Dog Bone ◽  
3D Printers

Fused Deposition Modelling (FDM) of thermoplastic materials is generally a well-known technology among all additive manufacturing (AM) technologies and therefore, it is essential to investigate the mechanical properties of such FDM processed materials. Several open-source and low cost AM machines, known as 3D Printers, have recently been developed using thermoplastic extrusion process based on the original FDM technology. Many of these 3D Printers use Polylactic Acid (PLA) plastic for building parts. The main objective of this paper is to investigate the tensile properties of the PLA thermoplastic material processed by the Cube-2 3D Printer. In this study, the dog-bone sized PLA specimens are printed in different build orientations and a Zwick Z010 tensile testing machine is used to determine the tensile properties of PLA in different build orientation.

scholarly journals Impact of additive manufacturing on engineering education – evidence from Italy

2015 ◽  
Vol 21 (5) ◽  
pp. 535-555 ◽  
Author(s):  
Paolo Minetola ◽  
Luca Iuliano ◽  
Elena Bassoli ◽  
Andrea Gatto
Keyword(s):  
Additive Manufacturing ◽  
Product Design ◽  
Mechanical Engineering ◽  
Additive Technologies ◽  
Direct Access ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Entry Level ◽  
Fused Deposition ◽  
The Impact

Purpose – The purpose of this paper is to evaluate how the direct access to additive manufacturing (AM) systems impacts on education of future mechanical engineers, within a Master’s program at a top Italian University. Design/methodology/approach – A survey is specifically designed to assess the relevance of entry-level AM within the learning environment, as a tool for project development. The survey is distributed anonymously to three consecutive cohorts of students who attended the course of “computer-aided production (CAP)”, within the Master of Science Degree in Mechanical Engineering at Politecnico di Torino. The course includes a practical project, consisting in the design of a polymeric product with multiple components and ending with the production of an assembled prototype. The working assembly is fabricated by the students themselves, who operate a fused deposition modelling (FDM) machine, finish the parts and evaluate assemblability and functionality. The post-course survey covers diverse aspects of the learning process, such as: motivation, knowledge acquisition, new abilities and team-working skills. Responses are analyzed to evaluate students’ perception of the usefulness of additive technologies in learning product design and development. Among the projects, one representative case study is selected and discussed. Findings – Results of the research affirm a positive relationship of access to AM devices to perceived interest, motivation and ease of learning of mechanical engineering. Entry-level additive technologies offer a hands-on experience within academia, fostering the acquisition of technical knowledge. Research limitations/implications – The survey is distributed to more than 200 students to cover the full population of the CAP course over three academic years. The year the students participated in the CAP course is not tracked because the instructor was the same and there were no administrative differences. For this reason, the survey administration might be a limitation of the current study. In addition to this, no gender distinction is made because historically, the percentage of female students in Mechanical Engineering courses is about 10 per cent or lower. Although the answers to the survey are anonymous, only 37 per cent of the students gave a feedback. Thus, on the one hand, impact assessment is limited to a sample of about one-third of the complete population, but, on the other hand, the anonymity ensures randomization in the sample selection. Practical implications – Early exposure of forthcoming designers to AM tools can turn into a “think-additive” approach to product design, that is a groundbreaking conception of geometries and product functionalities, leading to the full exploitation of the possibilities offered by additive technologies. Social implications – Shared knowledge can act as a springboard for mass adoption of AM processes. Originality/value – The advantages of adopting AM technologies at different levels of education, for diverse educational purposes and disciplines, are well assessed in the literature. The innovative aspect of this paper is that the impact of AM is evaluated through a feedback coming directly from mechanical engineering students.

scholarly journals Filament Advance Detection Sensor for Fused Deposition Modelling 3D Printers

2018 ◽  
Author(s):  
Enrique Soriano Heras ◽  
Fernando Blaya Haro ◽  
José María de Agustín del Burgo ◽  
Manuel Islán Marcos ◽  
Roberto d´Amato
Keyword(s):  
Low Cost ◽  
Normal Function ◽  
Primary Objective ◽  
Normal Operation ◽  
Fused Deposition Modelling ◽  
Optical Encoder ◽  
Design Concepts ◽  
Fused Deposition ◽  
3D Printers ◽  
The Cost

The main purpose of this paper is to present a system to detect extrusion failures in Fused Deposition Modelling (FDM) 3D printers by sensing that the filament is moving forward properly. After several years using these kind of machines, authors detected that there is not any system to detect the main problem in FDM machines. Authors thought in different sensors and used the Weighted Objectives Method, one of the most common evaluation methods, for comparing design concepts based on an overall value per design concept. Taking into account the obtained scores of each specification, the best choice for this work is the optical encoder. Once the sensor is chosen, it is necessary to design de part where it will be installed without interfering with the normal function of the machine. To do it, photogrammetry scanning methodology was employed. The developed device perfectly detects the advance of the filament without affecting the normal operation of the machine. Also, it is achieved the primary objective of the system, avoiding loss of material, energy and mechanical wear, keeping the premise of making a low-cost product that does not significantly increase the cost of the machine. This development has made it possible to use the printer with remains coil filament, which were not spent because they were not sufficient to complete an impression and also printing models in two colours with only one extruder.

Plate auto-level system for fused deposition modelling (FDM) 3D printers

2017 ◽  
Vol 23 (2) ◽  
pp. 401-413 ◽  
Author(s):  
Enrique Soriano Heras ◽  
Fernando Blaya Haro ◽  
José María de Agustín del Burgo ◽  
Manuel Enrique Islán Marcos
Keyword(s):  
Design Methodology ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Open Hardware ◽  
Fused Deposition ◽  
Sensing System ◽  
3D Printers ◽  
The Cost ◽  
Ultrasound Sensing ◽  
Practical Implications

Purpose The purpose of this paper is to present a solution for the levelling plate of fused deposition modelling (FDM) additive manufacturing (AM) systems. This automatic levelling system is presented as an evolution of actual systems, which uses a new ultrasound sensing system. Design/methodology/approach After obtaining a prototype, different tests were conducted for getting a system which solves the level plate problem and can be mounted in any FDM AM machine. Several benchmark models were obtained and compared with current equipment concepts for the validity of the product. Findings All tests were performed with high accuracy, enabling the production of geometries that could not have been achieved without this novel system. Practical implications This development will enable experienced users to set aside the problems of calibration and focus on the purpose of this type of machines, making prototypes. Originality/value A system architecture has been developed and integrated into an open hardware AM system, allowing real-time adjustment of the plate during each layer, thus eliminating the need of levelling the plate, allowing to achieve easier printing, and without increasing the cost significantly.

scholarly journals On the 3D printing of recycled ABS, PLA and HIPS thermoplastics for structural applications

2018 ◽  
Vol 2 (2) ◽  
pp. 115-137 ◽  
Author(s):  
Ranvijay Kumar ◽  
Rupinder Singh ◽  
Ilenia Farina
Keyword(s):  
Low Cost ◽  
Acrylonitrile Butadiene Styrene ◽  
Functionally Graded ◽  
Parameters Optimization ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Fused Deposition ◽  
Structural Applications ◽  
Composite Form ◽  
Material Printing

Purpose Three-dimensional printing (3DP) is an established process to print structural parts of metals, ceramic and polymers. Further, multi-material 3DP has the potentials to be a milestone in rapid manufacturing (RM), customized design and structural applications. Being compatible as functionally graded materials in a single structural form, multi-material-based 3D printed parts can be applied in structural applications to get the benefit of modified properties. Design/methodology/approach The fused deposition modelling (FDM) is one of the established low cost 3DP techniques which can be used for printing functional/ non-functional prototypes in civil engineering applications. Findings The present study is focused on multi-material printing of primary recycled acrylonitrile butadiene styrene (ABS), polylactic acid (PLA) and high impact polystyrene (HIPS) in composite form. Thermal (glass transition temperature and heat capacity) and mechanical properties (break load, break strength, break elongation, percentage elongation at break and Young’s modulus) have been analysed to observe the behaviour of multi-material composites prepared by 3DP. This study also highlights the process parameters optimization of FDM supported with photomicrographs. Originality/value The present study is focused on multi-material printing of primary recycled ABS, PLA and HIPS in composite form.

scholarly journals A dynamic model for nozzle clog monitoring in fused deposition modelling

2017 ◽  
Vol 23 (2) ◽  
pp. 391-400 ◽  
Author(s):  
Yedige Tlegenov ◽  
Yoke San Wong ◽  
Geok Soon Hong
Keyword(s):  
Dynamic Model ◽  
Low Cost ◽  
Vibration Sensor ◽  
Fused Deposition Modelling ◽  
Process Conditions ◽  
Nozzle Clogging ◽  
Content Type ◽  
Fused Deposition ◽  
Unique Method ◽  
Different Diameters

Purpose Fused deposition modelling (FDM) is one of the most popular additive manufacturing processes, and is widely used for prototyping and fabricating low-cost customized parts. Current FDM machines have limited techniques to monitor process conditions to minimize process errors, such as nozzle clogging. Nozzle clogging is one of the most significant process errors in current FDM machines, and may cause serious consequences such as print failure. This paper aims to present a physics-based dynamic model suitable for monitoring nozzle clogging in FDM machines. Design/methodology/approach Liquefier mount of an FDM extruder is analysed as a beam excited by a uniform loading distributed over a partial length. Boundary conditions and applied loads for a direct-type FDM extruder are identified and discussed. Simulation of nozzle clogging was performed by using nozzles of different diameters from 0.5 to 0.2 mm, in step change of 0.1 mm. Sets of experiments were carried out by measuring vibrations of the liquefier block mount during FDM extrusion. Findings The mount of a liquefier block in an FDM extruder can be used to place a vibration sensor to monitor process errors such as nozzle clogging. Liquefier block mount’s transverse vibration amplitudes increase non-linearly when nozzle starts to block. Practical implications The proposed model can be effectively used for monitoring nozzle clogging in FDM machines, as it is based on the physics relating the FDM process parameters and the nozzle blockage. Originality/value The novelty of this paper is the unique method of modelling the FDM process dynamics that can be used for monitoring nozzle clogging.

Performance of Low-Cost 3D Printer in Medical Application

2021 ◽  
Author(s):  
Nor Aiman Sukindar ◽  
Azib Azhari Awang Dahan ◽  
Sharifah Imihezri Syed Shaharuddin ◽  
Nor Farah Huda Abd Halim
Keyword(s):  
Low Cost ◽  
Medical Application ◽  
Fused Deposition Modelling ◽  
3D Printer ◽  
Layer By Layer ◽  
Total Deformation ◽  
Element Analysis ◽  
Porosity Level ◽  
Fused Deposition ◽  
Printing Parameters

Abstract Fused Deposition Modelling (FDM) is an additive manufacturing (AM) process that produces a physical object directly from a CAD design using layer-by-layer deposition of the filament material that is extruded via a nozzle. In industry, FDM has become one of the most used AM processes for the production of low batch quantity and functional prototypes, due to its safety, efficiency, reliability, low cost, and ability to process manufacturing-grade engineering thermoplastic. Recently, the market is flooded with the availability of low-cost printers produced by numerous companies. This research aims to investigate the effect of different porosity levels on a scaffold structure produced using a low-cost 3D printer. Comparisons of these porous structures were made in terms of Von-Mises strain, total deformation, as well as compressive stress. Various porosity levels were created by varying printing parameters, including layer height, infill density, and shell thickness by slicing the initial solid CAD file using Repetier Host 3D printing software. Finite Element Analysis (FEA) simulation was then performed on the created scaffold structures by using Ansys Workbench 19.2. The simulation result indicates that the greater porosity level will result in higher total deformation of the structure. Meanwhile, the compression test shows that the minimum strength value obtained was favourable at 22 MPa and had exceeded that of the trabecular femur (15 MPa). However, its porosity level (maximum at 52%) was still below that of the minimum threshold of porosity level of 70 percent. However, the printing parameters currently used can be adjusted in the future. Therefore, it was deduced that the low-cost 3D printer offers promising potential to fabricate different porosity structures with multiple outcomes.

Animal orthosis fabrication with additive manufacturing – a case study of custom orthosis for chicken

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Wiktoria Maria Wojnarowska ◽  
Jakub Najowicz ◽  
Tomasz Piecuch ◽  
Michał Sochacki ◽  
Dawid Pijanka ◽  
...  
Keyword(s):  
Veterinary Medicine ◽  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Fused Deposition ◽  
Secondary Objective ◽  
Traditional Manufacturing ◽  
Aided Design

Purpose Chicken orthoses that cover the ankle joint area are not commercially available. Therefore, the main purpose of this study is to fabricate a customised temporary Ankle–Foot Orthosis (AFO) for a chicken with a twisted ankle using computer-aided design (CAD) and three-dimensional (3D) printing. The secondary objective of the paper is to present the specific application of Additive Manufacturing (AM) in veterinary medicine. Design/methodology/approach The design process was based on multiple sketches, photos and measurements that were provided by the owner of the animal. The 3D model of the orthosis was made with Autodesk Fusion 360, while the prototype was fabricated using fused deposition modelling (FDM). Evaluation of the AFO was performed using the finite element method. Findings The work resulted in a functional 3D printed AFO for chicken. It was found that the orthosis made with AM provides satisfactory stiffen and a good fit. It was concluded that AM is suitable for custom bird AFO fabrication and, in some respects, is superior to traditional manufacturing methods. It was also concluded that the presented procedure can be applied in other veterinary cases and to other animal species and other parts of their body. AM provides veterinary with a powerful tool for the production of well-fitted and durable orthoses for animals. Research limitations/implications The study does not include the chicken's opinion on the comfort or fit of the manufactured AFO due to communication issues. Evaluation of the final prototype was done by the researchers and the animal owner. Originality/value No evidence was found in the literature on the use of AM for chicken orthosis, so this study is the first to describe such an application of AM. In addition, the study demonstrates the value of AM in veterinary medicine, especially in the production of devices such as orthoses.

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.

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