Deriving Infill Design of Fused Deposition Modelled Parts From Predicted Stress Profiles

2016 ◽  
Author(s):  
James A. Gopsill ◽  
Ben J. Hicks
Keyword(s):  
Process Time ◽  
Fused Deposition Modelling ◽  
Stress Profile ◽  
3 Dimensional ◽  
Fused Deposition ◽  
Industrial Sectors ◽  
Pattern Structures ◽  
Initial Work ◽  
Bending Loads ◽  
Multiple Materials

The use of Fused Deposition Modelling (FDM) is increasing rapidly in both the commercial and industrial sectors as a means of rapidly prototyping geometrically complex parts. Particular affordances of FDM include the reduction of waste material during manufacture, the use of multiple materials within a single manufacturing process and the ability to manipulate the internal geometry of a part. The latter of which has seen the generation of many 2-dimensional repeating pattern structures such as square, rectilinear and hexagonal, as well as an emerging field of 3-dimensional structures. Although these patterns have provided stiffness and rigidity whilst reducing the production time of FDM prototypes, many do not consider the actual loading conditions of the part in-situ, where it is argued that further significant gains in the performance could be achieved. This includes further reduction in process time and increased part functionality. Thus, this paper presents initial work into the generation of an infill that is derived from the predicted stress profile for the part. This has been achieved through the post-processing of Finite Element (FE) models to identify the stress profile. Interpolation across these profiles leads to a set of aligned Bézier splines that enable the transmission of force and are also able to be manufactured using FDM. These splines are embedded within the typical slicing procedure of a part ahead of being manufactured on a FDM machine. Initial results from parts designed to support three-point bending loads show a 79% increase in the stiffness of the part alongside a consistent and repeatable mode of failure when compared to the commonly used honeycomb infill design.

scholarly journals Designing a delta tripod based robot fused deposition modelling 3 dimensional printer using an open-source Arduino development platform

2018 ◽  
Vol 184 ◽  
pp. 02013
Author(s):  
Tamás Templom ◽  
Timotei István Erdei ◽  
Zsolt Molnár ◽  
Edwin Shaw ◽  
Géza Husi
Keyword(s):  
3D Printing ◽  
Rapid Prototyping ◽  
Open Source ◽  
Fused Deposition Modelling ◽  
3 Dimensional ◽  
Development Platform ◽  
Fused Deposition

The pinnacle of 3D printing is its effect on the field of rapid prototyping. The major advantage comes from the fact that designers can quickly materialize a part or object, which then could be tested in practice, and can be effortlessly modified if needed. This obviously cuts the development expenses and time by a significant percent. Moreover, it’s possible to create complex and precise shapes with the technology, which would take more time and would be resource intensive if done by older methods, for example manual or automatic machining.

scholarly journals Development of a 3-dimensional printed tube thoracostomy task trainer: An improved methodology

2021 ◽  
Vol 6 (1) ◽  
pp. 109-113
Author(s):  
Wen Hao Chen ◽  
Shairah Radzi ◽  
Li Qi Chiu ◽  
Wai Yee Yeong ◽  
Sreenivasulu Reddy Mogali
Keyword(s):  
3D Printing ◽  
Chest Tube ◽  
Fused Deposition Modelling ◽  
3 Dimensional ◽  
Fused Deposition ◽  
Simulation Based ◽  
3D Printed ◽  
Medical Educators ◽  
Based Instruction ◽  
Training Modalities

Introduction: Simulation-based training has become a popular tool for chest tube training, but existing training modalities face inherent limitations. Cadaveric and animal models are limited by access and cost, while commercial models are often too costly for widespread use. Hence, medical educators seek a new modality for simulation-based instruction. 3D printing has seen growing applications in medicine, owing to its advantages in recreating anatomical detail using readily available medical images. Methods: Anonymised computer tomography data of a patient’s thorax was processed using modelling software to create a printable model. Compared to a previous study, 3D printing was applied extensively to this task trainer. A mixture of fused deposition modelling and material jetting technology allowed us to introduce superior haptics while keeping costs low. Given material limitations, the chest wall thickness was reduced to preserve the ease of incision and dissection. Results: The complete thoracostomy task trainer costs approximately SGD$130 (or USD$97), which is significantly cheaper compared to the average commercial task trainer. It requires approximately 118 hours of print time. The complete task trainer simulates the consistencies of ribs, intercostal muscles and skin. Conclusion: By utilising multiple 3D printing technologies, this paper aims to outline an improved methodology to produce a 3D printed chest tube simulator. An accurate evaluation can only be carried out after we improve on the anatomical fidelity of this prototype. A 3D printed task trainer has great potential to provide sustainable simulation-based education in the future.

scholarly journals Hybrid Manufacturing and Experimental Testing of Glass Fiber Enhanced Thermoplastic Composites

2019 ◽  
Vol 3 (4) ◽  
pp. 96 ◽  
Author(s):  
Javaid Butt ◽  
Yasasween Hewavidana ◽  
Vahaj Mohaghegh ◽  
Shabnam Sadeghi-Esfahlani ◽  
Hassan Shirvani
Keyword(s):  
Tensile Strength ◽  
Glass Fiber ◽  
Tensile Testing ◽  
Experimental Testing ◽  
Microstructural Analysis ◽  
Optimal Number ◽  
Fused Deposition Modelling ◽  
Gfrp Composites ◽  
Fused Deposition ◽  
Industrial Sectors

Additive Manufacturing (AM) is gaining enormous attention from academic and industrial sectors for product development using different materials. Fused Deposition Modelling (FDM) is a popular AM method that works with thermoplastics. This process offers benefits of customisation both in terms of hardware and software in the case of desktop-based FDM systems. Enhancement of mechanical properties for the traditional thermoplastic material is a widely researched area and various materials have been added to achieve this goal. This paper focuses on the manufacture of glass fiber reinforced plastic (GFRP) composites using Hybrid Fused Deposition Modelling (HFDM). Commonly available polylactic acid or polylactide (PLA) material was inter-laced with 0.03 mm thick glass fiber sheets to manufacture GFRP products followed by tensile testing. This was done to investigate whether adding more layers increases the tensile strength of the GFRP products or not. Furthermore, the maximum number of glass fiber layers that can be added to the 4 mm thick specimen was also identified. This was done to demonstrate that there is an optimal number of glass fiber layers that can be added as after this optimal number, the tensile strength start to deteriorate. Microstructural analysis was undertaken after tensile testing followed by ultrasonic testing to assess the uniformity of the GFRP composites.

scholarly journals New fabrication method using additive manufacturing technologies for the pattern of pressed lithium disilicate onlay restorations

2017 ◽  
Vol 20 (4) ◽  
pp. 149
Author(s):  
Marta Revilla-Leon ◽  
Marina Olea-Vielba ◽  
Ana Esteso-Díaz ◽  
Iñaki Martinez-Klemm ◽  
Jose Manuel Reuss Rodriguez-Vilaboa ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modelling ◽  
3 Dimensional ◽  
Material Extrusion ◽  
Fused Deposition ◽  
Direct Light ◽  
Accuracy And Precision ◽  
Manufacturing Technologies ◽  
Dental Applications ◽  
Am Processes

<p>There are 7 categories for the additive manufacturing (AM) technologies and a wide variety of materials that can be used to build a computer aided designed (CAD) 3-Dimensional (3D) object. The present article reviews the main AM processes for polymers for dental applications: stereolithography (SLA), direct light processing (DLP), material jetting (MJ) and material extrusion (ME). The manufacturing process, accuracy and precision of these methods will be reviewed, as well as, their prosthodontic applications.</p><p> </p><p><strong>Keywords: </strong>3D printing; Additive manufacturing technologies; Direct light processing; Fused deposition modelling; Material extrusion; Material jetting; Multijet printing; Prosthodontics; Stereolitography.</p>

Evaluation of geometrical benchmark artifacts containing multiple overhang lengths fabricated using material extrusion technique

2020 ◽  
Vol 14 (3) ◽  
pp. 7296-7308
Author(s):  
Siti Nur Humaira Mazlan ◽  
Aini Zuhra Abdul Kadir ◽  
N. H. A. Ngadiman ◽  
M.R. Alkahari
Keyword(s):  
3D Model ◽  
Laser Scanner ◽  
Dimensional Accuracy ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Layer Technique ◽  
Subtractive Manufacturing ◽  
Manufacturing Features ◽  
Layer Problem

Fused deposition modelling (FDM) is a process of joining materials based on material entrusion technique to produce objects from 3D model using layer-by-layer technique as opposed to subtractive manufacturing. However, many challenges arise in the FDM-printed part such as warping, first layer problem and elephant food that was led to an error in dimensional accuracy of the printed parts especially for the overhanging parts. Hence, in order to investigate the manufacturability of the FDM printed part, various geometrical and manufacturing features were developed using the benchmarking artifacts. Therefore, in this study, new benchmarking artifacts containing multiple overhang lengths were proposed. After the benchmarking artifacts were developed, each of the features were inspected using 3D laser scanner to measure the dimensional accuracy and tolerances. Based on 3D scanned parts, 80% of the fabricated parts were fabricated within ±0.5 mm of dimensional accuracy as compared with the CAD data. In addition, the multiple overhang lengths were also successfully fabricated with a very significant of filament sagging observed.

scholarly journals Current State and Challenges of Natural Fibre-Reinforced Polymer Composites as Feeder in FDM-Based 3D Printing

Polymers ◽  
2021 ◽  
Vol 13 (14) ◽  
pp. 2289
Author(s):  
Nishata Royan Rajendran Royan ◽  
Jie Sheng Leong ◽  
Wai Nam Chan ◽  
Jie Ren Tan ◽  
Zainon Sharmila Binti Shamsuddin
Keyword(s):  
Mechanical Properties ◽  
Natural Fibre ◽  
Critical Discussion ◽  
Fused Deposition Modelling ◽  
Preparation Methods ◽  
Fused Deposition ◽  
Current State ◽  
Future Challenges ◽  
Raster Angle ◽  
Fibre Reinforced Polymer

As one of the fastest-growing additive manufacturing (AM) technologies, fused deposition modelling (FDM) shows great potential in printing natural fibre-reinforced composites (NFRC). However, several challenges, such as low mechanical properties and difficulty in printing, need to be overcome. Therefore, the effort to improve the NFRC for use in AM has been accelerating in recent years. This review attempts to summarise the current approaches of using NFRC as a feeder for AM. The effects of fibre treatments, composite preparation methods and addition of compatibilizer agents were analysed and discussed. Additionally, current methods of producing feeders from NFRCs were reviewed and discussed. Mechanical property of printed part was also dependent on the printing parameters, and thus the effects of printing temperature, layer height, infill and raster angle were discussed, and the best parameters reported by other researchers were identified. Following that, an overview of the mechanical properties of these composites as reported by various researchers was provided. Next, the use of optimisation techniques for NFRCs was discussed and analysed. Lastly, the review provided a critical discussion on the overall topic, identified all research gaps present in the use of NFRC for AM processes, and to overcome future challenges.

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