3D Printing for Manufacturing Antique and Modern Musical Instrument Parts

Professional musicians today often invest in obtaining antique or vintage instruments. These pieces can be used as collector items or more practically, as performance instruments to give a unique sound of a past music era. Unfortunately, these relics are rare, fragile, and particularly expensive to obtain for a modern day musician. The opportunity to reproduce the sound of an antique instrument through the use of additive manufacturing (3D printing) can make this desired product significantly more affordable. 3D printing allows for duplication of unique parts in a low cost and environmentally friendly method, due to its minimal material waste. Additionally, it allows complex geometries to be created without the limitations of other manufacturing techniques. This study focuses on the primary differences, particularly sound quality and comfort, between saxophone mouthpieces that have been 3D printed and those produced by more traditional methods. Saxophone mouthpieces are commonly derived from a milled blank of either hard rubber, ebonite or brass. Although 3D printers can produce a design with the same or similar materials, they are typically created in a layered pattern. This can potentially affect the porosity and surface of a mouthpiece, ultimately affecting player comfort and sound quality. To evaluate this, acoustic tests will be performed. This will involve both traditionally manufactured mouthpieces and 3D prints of the same geometry created from x-ray scans obtained using a ZEISS Xradia Versa 510. The scans are two dimensional images which go through processes of reconstruction and segmentation, which is the process of assigning material to voxels. The result is a point cloud model, which can be used for 3D printing. High quality audio recordings of each mouthpiece will be obtained and a sound analysis will be performed. The focus of this analysis is to determine what qualities of the sound are changed by the manufacturing method and how true the sound of a 3D printed mouthpiece is to its milled counterpart. Additive manufacturing can lead to more inconsistent products of the original design due to the accuracy, repeatability and resolution of the printer, as well as the layer thickness. In order for additive manufacturing to be a common practice of mouthpiece manufacturing, the printer quality must be tested for its precision to an original model. The quality of a 3D print can also have effects on the comfort of the player. Lower quality 3D prints have an inherent roughness which can cause discomfort and difficulty for the musician. This research will determine the effects of manufacturing method on the sound quality and overall comfort of a mouthpiece. In addition, we will evaluate the validity of additive manufacturing as a method of producing mouthpieces.

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Microstructured Surface Plasmon Resonance Sensor Based on Inkjet 3D Printing Using Photocurable Resins with Tailored Refractive Index

Polymers ◽

10.3390/polym13152518 ◽

2021 ◽

Vol 13 (15) ◽

pp. 2518

Author(s):

Nunzio Cennamo ◽

Lorena Saitta ◽

Claudio Tosto ◽

Francesco Arcadio ◽

Luigi Zeni ◽

...

Keyword(s):

Surface Plasmon Resonance ◽

3D Printing ◽

Surface Plasmon ◽

Plasmon Resonance ◽

Optical Sensor ◽

Low Cost ◽

3D Print ◽

Spr Sensor ◽

Resonance Sensor ◽

3D Printed

In this work, a novel approach to realize a plasmonic sensor is presented. The proposed optical sensor device is designed, manufactured, and experimentally tested. Two photo-curable resins are used to 3D print a surface plasmon resonance (SPR) sensor. Both numerical and experimental analyses are presented in the paper. The numerical and experimental results confirm that the 3D printed SPR sensor presents performances, in term of figure of merit (FOM), very similar to other SPR sensors made using plastic optical fibers (POFs). For the 3D printed sensor, the measured FOM is 13.6 versus 13.4 for the SPR-POF configuration. The cost analysis shows that the 3D printed SPR sensor can be manufactured at low cost (∼15 €) that is competitive with traditional sensors. The approach presented here allows to realize an innovative SPR sensor showing low-cost, 3D-printing manufacturing free design and the feasibility to be integrated with other optical devices on the same plastic planar support, thus opening undisclosed future for the optical sensor systems.

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An Initial Effort to Create a Superficial Femoral Artery Ultrasound Phantom Using 3-Dimensional Printing

Journal for Vascular Ultrasound ◽

10.1177/1544316720911490 ◽

2020 ◽

Vol 44 (2) ◽

pp. 69-73

Author(s):

Paul D. Bishop ◽

Thomas Fultz ◽

Lisa Smith ◽

Ryan S. Klatte ◽

Francis Loth ◽

...

Keyword(s):

3D Printing ◽

Femoral Artery ◽

Superficial Femoral Artery ◽

Low Cost ◽

Duplex Ultrasound ◽

3D Print ◽

Stl File ◽

Calcified Plaque ◽

3D Printed ◽

Artery Geometry

Three-dimensional (3D) printing of anatomical structures has yielded valuable models for simulation, education, and surgical planning applications. Applications for 3D printing have continued to expand to include some ultrasound applications. The goal of this effort was to evaluate if a 3D printed model of a superficial femoral artery (SFA) would have realistic ultrasound characteristics. A computed tomography scan was 3D reconstructed and segmented using TeraRecon Aquarius Intuition software (TeraRecon, Foster City, California) to obtain an atherosclerotic SFA geometry. Both the lumen geometry and calcified plaque geometry of the SFA were exported as a stereolithographic (STL) file. The STL file was printed with An Object350 Connex 3D System using 2 different materials selected based on published elastic modulus data. VeroWhite was selected for the calcified plaque and TangoPlus Clear was selected for the artery wall. After printing, the SFA model was imaged in a water bath with a Phillips IU22 duplex ultrasound console and L12-9 ultrasound probe. Ultrasound imaging of the SFA model yielded grayscale views of artery geometry. Lumen geometry of the SFA model was similar to the actual artery geometry. Ultrasound was able to discern between the 3D print materials and visualize regions with stenosis. Suboptimal ultrasound parameters of echogenicity and wave velocity noted to differ from biological tissue. Total 3D print material cost was estimated at below $20. Although the 3D printed model did not have fully accurate ultrasound characteristics, it still provided realistic imaging. With further research, 3D printed models may offer a low-cost alternative for ultrasound phantoms.

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Design and Manufacturing of a Metal 3D Printed kW Scale Axial Turboexpander

Volume 8: Microturbines, Turbochargers, and Small Turbomachines; Steam Turbines ◽

10.1115/gt2019-91822 ◽

2019 ◽

Author(s):

Vaclav Novotny ◽

Monika Vitvarova ◽

Michal Kolovratnik ◽

Barbora Bryksi Stunova ◽

Vaclav Vodicka ◽

...

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Surface Quality ◽

High Efficiency ◽

Cost Effective ◽

Manufacturing Cost ◽

Machining Processes ◽

Manufacturing Method ◽

Design And Manufacturing ◽

3D Printed

Abstract Greater expansion of distributed power and process systems based on thermodynamic cycles with single to hundred kW scale power output is limited mainly there are not available cost-effective expanders. Turboexpanders have a perspective of high efficiency and flexibility concerning operating parameters even for the micro applications. However, they suffer from a high manufacturing cost and lead time in the development of traditional technologies (such as casting and machining processes). Additive manufacturing provides a possibility to overcome some of the issues. Manufacturing parts with complicated shapes by this technology, combining multiple components into a single part or rapid production by 3D printing for development purposes are among the prospective features with this potential. On the other hand, the 3D printing processes come with certain limitations which need to be overcome. This paper shows a design and manufacturing process of a 3 kW axial impulse air turbine working with isenthalpic drop 30 kJ/kg. Several samples to verify printing options and the turbine itself has been manufactured from stainless steel by the DMLS additive manufacturing method. Manufactured are two turbine variations regarding blade size and 3D printer settings while maintaining their specific dimensions. The turboexpanders testing method and rig is outlined. As the surface quality is an issue, several methods of post-processing of 3D printed stator and rotor blading to modify surface quality are suggested. Detailed experimental investigation is however subject of future work.

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Fused Filament Fabrication, a New Fabrication Paradigm for 3D Printing Capacitive Sensors: Design, Fabrication, and Characterization for Liquid Level Measurements.

10.21203/rs.3.rs-875418/v1 ◽

2021 ◽

Author(s):

Gianni Stano ◽

Attilio Di Nisio ◽

Anna Maria Lanzolla ◽

Mattia Ragolia ◽

Gianluca Percoco

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Flexible Substrate ◽

Capacitive Sensor ◽

Single Step ◽

Liquid Level ◽

Capacitive Sensors ◽

Fused Filament Fabrication ◽

3D Print ◽

3D Printed

Abstract In recent years, the exploitation of Additive Manufacturing technologies for the fabrication of different kinds of sensors has abruptly increased: in particular, a growing interest for extrusion-based techniques has emerged. This research proposes the exploitation of Fused Filament Fabrication (FFF) process and two commercial materials (one flexible and one conductive) for the monolithic fabrication of a bendable, coplanar capacitive sensor. The whole sensor, consisting of a flexible substrate and two electrodes, has been fabricated in a single-step printing cycle: Design for Additive Manufacturing approach was used, setting out a methodology to direct 3D print thin and close tracks with conductive materials, in order to obtain high capacitance values measurable by common measurement instrumentations. Despite a huge exploitation of FFF technology for piezoresistive-based sensors, this manufacturing process has never been used for the fabrication of coplanar capacitive sensors since the manufacture of thin and close conductive tracks (key requirement in coplanar capacitive sensors) is a challenging task, mainly due to low manufacturability of extruded conductive beads with a high level of detail. Two versions of the sensor were developed: the first one with an embedded 3D printed coverage (ready to use) and the second one which requires a further manual post-processing to seal the electrodes. The main benefits related to the exploitation of FFF technology for these sensors are: i) the reduction of the number of different manufacturing processes employed, from at least two in traditional manufacturing approach up to one, ii) the exploitation of a cost-effective technology compared to traditional high-cost technologies employed (i.e. lithography, inkjet etc.) iii) the reduction of manual and assembly tasks (one of the proposed versions does not require any further task) , and iv) the cost-effectiveness of the sensors (in a range between 0.27 € and 0.38 €). The two developed prototypes have been tested demonstrating all their potentialities in the field of liquid level sensing, showing results consistent with the ones found in scientific literature: good sensitivity and high linearity and repeatability were proved when different liquids were employed. These 3D printed liquid level sensors have these features: i) flexible sensor, ii) the length is limited only by the machine workspace, iii) they can be either applied outside of the traditional reservoirs or embedded into the reservoirs (by 3D printing both the reservoir and sensor in the same manufacturing cycle), and iv) simple calibration.Finally, the bendability of these sensors paves the way toward their application for liquid level sensing into tanks with non-conventional shapes and for other application fields (i.e. soft robotics, non-invasive monitoring for biomedical applications).

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Evaluation of Dimensional Accuracy of 3D printed mandibular model using two different Additive Manufacturing Techniques based on Cone Beam Computed Tomography scan data (A Diagnostic Accuracy Study)

10.21203/rs.2.9866/v1 ◽

2019 ◽

Author(s):

Noha Hamada Mohamed ◽

Hossam Kandil ◽

Iman Ismail Dakhli

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Low Cost ◽

Dimensional Accuracy ◽

3D Models ◽

The Body ◽

Reference Standard ◽

Linear Measurements ◽

3D Printed ◽

Manufacturing Techniques

Abstract In dentistry, 3D printing already has diverse applicability, and holds a great deal of promise to make possible many new and exciting treatments and approaches to manufacturing dental restorations. Better availability, shorter processing time, and descending costs have resulted in the increased use of RP. Concomitantly the development of medical applications is expanding. (Zaharia et al., 2017)Many different printing technologies exist, each with their own advantages and disadvantages. Unfortunately, a common feature of the more functional and productive equipment is the high cost of the equipment, the materials, maintenance, and repair, often accompanied by a need for messy cleaning, difficult post-processing, and sometimes onerous health and safety concerns (Dawood et al., 2015)Low-cost 3D printers represent a great opportunity in the dental and medical field, as they could allow surgeons to use 3D models at a very low cost and, therefore, democratize the use of these 3D models in various indications. However, efforts should be made to establish a unified validation protocol for low-cost RP 3D printed models, including accuracy, reproducibility, and repeatability tests. Asaumi et al., suggested that dimensional changes may not affect the success of surgical applications if such changes are within a 2% variation .However, the proposed cut-off of 2% should be furthermore discussed, as the same accuracy may be not required for all types of indications. (Silva et al., 2008; Maschio et al., 2016)This aim of the present study is to evaluate the dimensional accuracy of the 3D printed mandibular models fabricated by two different additive manufacturing techniques, using highly precise one as selective laser sintering (SLS) and a low-cost one as fused filament fabrication and whether they are both comparable in terms of precision. In addition to evaluation of dimensional accuracy of linear measurements of the mandible in CBCT scans.7 mandibular models will be recruited. Radio-opaque markers of gutta-percha balls will be applied on the model to act as guide pointsTen linear measurements (5 long distances: Inter-condylar, inter-coronoidal, inter-mandibular notch, length of left ramus, length of right ramus; as well as 5 short distances: Length of the body of the mandible at midline, length of the body of the mandible in the area of last left molar, as well as that of the last right molar, the distance between the tip of right condyle to the tip of the right coronoid, as well as that of their left counterparts) will be obtained using digital calliper, to act as the reference standard later. Scanning of the model by CBCT will be next , 3D printing of the scanned image using SLS and FFF printers will be done. Recording of same linear measurment will be done on printed models. Comparison of the recorded values vs reference standard is the last step

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Towards Distributed Recycling with Additive Manufacturing of PET Flake Feedstocks

Materials ◽

10.3390/ma13194273 ◽

2020 ◽

Vol 13 (19) ◽

pp. 4273

Author(s):

Helen A. Little ◽

Nagendra G. Tanikella ◽

Matthew J. Reich ◽

Matthew J. Fiedler ◽

Samantha L. Snabes ◽

...

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Thermal Characterization ◽

3D Print ◽

Wide Range ◽

3D Printed ◽

Sequential Combination ◽

Future Work ◽

The Impact ◽

First Time

This study explores the potential to reach a circular economy for post-consumer Recycled Polyethylene Terephthalate (rPET) packaging and bottles by using it as a Distributed Recycling for Additive Manufacturing (DRAM) feedstock. Specifically, for the first time, rPET water bottle flake is processed using only an open source toolchain with Fused Particle Fabrication (FPF) or Fused Granular Fabrication (FGF) processing rather than first converting it to filament. In this study, first the impact of granulation, sifting, and heating (and their sequential combination) is quantified on the shape and size distribution of the rPET flakes. Then 3D printing tests were performed on the rPET flake with two different feed systems: an external feeder and feed tube augmented with a motorized auger screw, and an extruder-mounted hopper that enables direct 3D printing. Two Gigabot X machines were used, each with the different feed systems, and one without and the latter with extended part cooling. 3D print settings were optimized based on thermal characterization, and both systems were shown to 3D print rPET directly from shredded water bottles. Mechanical testing showed the importance of isolating rPET from moisture and that geometry was important for uniform extrusion. The mechanical strength of 3D-printed parts with FPF and inconsistent flow is lower than optimized fused filament, but adequate for a wide range of applications. Future work is needed to improve consistency and enable water bottles to be used as a widespread DRAM feedstock.

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Validation and Development of Discharge Equations for 3D Printed Flumes for Flow Monitoring

Transactions of the ASABE ◽

10.13031/trans.14365 ◽

2021 ◽

Vol 64 (6) ◽

pp. 1921-1928

Author(s):

Farhana Akhter ◽

John McMaine ◽

Alex J. McLemore ◽

Morghan J. Hurst

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Goodness Of Fit ◽

Low Cost ◽

Information Criteria ◽

Measurement Tool ◽

List Type ◽

Flow Monitoring ◽

3D Printed ◽

Hydrologic Monitoring

HighlightsTwo different configurations of 3D printed flumes of two different materials were tested for accuracy and variability.Discharge equations were developed for 3D printed 0.122 m HS and 0.102 m Palmer-Bowlus flumes.3D flumes are accurate and show no statistical variability between prints, providing a low-cost flow measurement tool.Abstract. Flumes are specially shaped, engineered structures that have been used widely for measuring flow. Flumes are typically fabricated from aluminum or fiberglass; however, these types of flumes can be costly if purchased commercially and may lack machine precision if custom fabricated. This limits availability for widespread monitoring by smaller municipalities, engineering firms, or researchers with limited budgets. Using 3D printing technology (additive manufacturing) to produce flumes is very cost-effective, but variability between flumes and materials has not been tested, and discharge equations have not been developed for 3D printed flumes. In this study, a laboratory-scale setup was used to develop discharge equations for two types of 3D printed flumes (0.122 m HS flume and 0.102 m Palmer-Bowlus flume) made from two 3D printing materials: polylactic acid (PLA) and polyethylene terephthalate glycol modified (PETG). Variability between the same type of flume and between different materials for the same type of flume was analyzed to evaluate the consistency of the discharge equation with flumes of the same type. Eight models were developed to fit each dataset (PLA, PETG, and combined PLA and PETG) for both flume types and evaluated for goodness-of-fit and information criteria (AIC and BIC for model parsimony) to select the discharge equation for each flume type. Discharge equations were consistent for the same type of flume across each print and across different print materials. The discharge equations of 3D printed 0.122 m HS flumes and 0.102 m Palmer-Bowlus flumes are Q = 0.45624 × H2.351 and Q = 0.0001176 + 1.309 × (H - 0.0174625)2.235, respectively. The discharge equations of both flume types had R2adj values greater than 97% for the measured data of each individual flume. Both 3D printed flumes were consistent in measuring flow and are suitable for hydrologic monitoring. Keywords: 3D printing, Additive manufacturing, Discharge equation, Flume, Hydrologic monitoring.

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Development of 3D-printed customized facial padding for burn patients

Rapid Prototyping Journal ◽

10.1108/rpj-09-2017-0179 ◽

2019 ◽

Vol 25 (1) ◽

pp. 55-61 ◽

Cited By ~ 1

Author(s):

Muhammad Aiman Ahmad Fozi ◽

Mohamed Najib Salleh ◽

Khairul Azwan Ismail

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Computer Aided Design ◽

Digital Design ◽

Pressure Measurements ◽

Pressure Therapy ◽

Content Type ◽

Manufacturing Method ◽

Pressure Region ◽

3D Printed

Purpose This paper aims to develop 3D-printed customized padding to increase pressure at the zero pressure region. This padding is specifically intended for facial areas with complex contours in pressure therapy treatment of hypertrophic scars. Design/methodology/approach To carry out this study, a full-face head garment was fabricated by a local occupational therapist, and pressure measurements were conducted to establish the pressure exerted by this head garment and to determine the zero pressure region. Furthermore, an additional manufacturing method was used to construct customized padding, and pressure measurements were performed to measure the pressure exerted after application of this customized padding. Findings The results reveal that 3D-printed customized padding can increase pressure at the zero pressure region, which occurs on complex contour surfaces with a spatial gap because of non-contact of the head garment and facial surfaces. Practical implications This paper suggests that an additive manufacturing method using 3D printing is capable of producing accurate, functional and low-cost medical parts for rehabilitation. Moreover, the 3D-printed padding fabricated by additive manufacturing assists in generating optimal pressure, which is necessary for effective pressure therapy. Originality/value Digital design using 3D scanning, computer-aided design and 3D printing is capable of designing and producing properly fitting, customized padding that functions to increase pressure from zero to an acceptable pressure range required for pressure therapy.

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Fused Filament Fabrication 3D Printed Polylactic Acid Electroosmotic Pumps

Lab on a Chip ◽

10.1039/d1lc00452b ◽

2021 ◽

Author(s):

Liang Wu ◽

Stephen Beirne ◽

Joan-Marc Cabot Canyelles ◽

Brett Paull ◽

Gordon G. Wallace ◽

...

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Polylactic Acid ◽

Fused Filament Fabrication ◽

Flexible Approach ◽

Electroosmotic Pump ◽

3D Printed ◽

Electroosmotic Pumps

Additive manufacturing (3D printing) offers a flexible approach for the production of bespoke microfluidic structures such as the electroosmotic pump. Here a readily accessible fused filament fabrication (FFF) 3D printing...

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Gold, Silver, and Electrum Electroless Plating on Additively Manufactured Laser Powder-Bed Fusion AlSi10Mg Parts: A Review

Coatings ◽

10.3390/coatings11040422 ◽

2021 ◽

Vol 11 (4) ◽

pp. 422

Author(s):

Dana Ashkenazi ◽

Alexandra Inberg ◽

Yosi Shacham-Diamand ◽

Adin Stern

Keyword(s):

Additive Manufacturing ◽

Low Cost ◽

Ion Beam ◽

Surface Finishing ◽

Powder Bed Fusion ◽

Laser Powder Bed Fusion ◽

Powder Bed ◽

Finishing Process ◽

Gold Silver ◽

3D Printed

Additive manufacturing (AM) revolutionary technologies open new opportunities and challenges. They allow low-cost manufacturing of parts with complex geometries and short time-to-market of products that can be exclusively customized. Additive manufactured parts often need post-printing surface modification. This study aims to review novel environmental-friendly surface finishing process of 3D-printed AlSi10Mg parts by electroless deposition of gold, silver, and gold–silver alloy (e.g., electrum) and to propose a full process methodology suitable for effective metallization. This deposition technique is simple and low cost method, allowing the metallization of both conductive and insulating materials. The AlSi10Mg parts were produced by the additive manufacturing laser powder bed fusion (AM-LPBF) process. Gold, silver, and their alloys were chosen as coatings due to their esthetic appearance, good corrosion resistance, and excellent electrical and thermal conductivity. The metals were deposited on 3D-printed disk-shaped specimens at 80 and 90 °C using a dedicated surface activation method where special functionalization of the printed AlSi10Mg was performed to assure a uniform catalytic surface yielding a good adhesion of the deposited metal to the substrate. Various methods were used to examine the coating quality, including light microscopy, optical profilometry, XRD, X-ray fluorescence, SEM–energy-dispersive spectroscopy (EDS), focused ion beam (FIB)-SEM, and XPS analyses. The results indicate that the developed coatings yield satisfactory quality, and the suggested surface finishing process can be used for many AM products and applications.

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