Effect of build orientation in 3D printing production for material extrusion, material jetting, binder jetting, sheet object lamination, vat photopolymerisation, and powder bed fusion

Additive manufacturing (AM, 3D printing) is used in many fields and different industries. In the medical and dental field, every patient is unique and, therefore, AM has significant potential in personalized and customized solutions. This review explores what additive manufacturing processes and materials are utilized in medical and dental applications, especially focusing on processes that are less commonly used. The processes are categorized in ISO/ASTM process classes: powder bed fusion, material extrusion, VAT photopolymerization, material jetting, binder jetting, sheet lamination and directed energy deposition combined with classification of medical applications of AM. Based on the findings, it seems that directed energy deposition is utilized rarely only in implants and sheet lamination rarely for medical models or phantoms. Powder bed fusion, material extrusion and VAT photopolymerization are utilized in all categories. Material jetting is not used for implants and biomanufacturing, and binder jetting is not utilized for tools, instruments and parts for medical devices. The most common materials are thermoplastics, photopolymers and metals such as titanium alloys. If standard terminology of AM would be followed, this would allow a more systematic review of the utilization of different AM processes. Current development in binder jetting would allow more possibilities in the future.

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Multi-Objective Build Orientation Optimization for Powder Bed Fusion by Laser

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4037570 ◽

2017 ◽

Vol 139 (11) ◽

Cited By ~ 22

Author(s):

Salah Eddine Brika ◽

Yaoyao Fiona Zhao ◽

Mathieu Brochu ◽

Justin Mezzetta

Keyword(s):

Mechanical Properties ◽

Surface Roughness ◽

Integrated Approach ◽

Powder Bed Fusion ◽

Powder Bed ◽

Build Orientation ◽

Multi Objective ◽

Build Time ◽

Process Factors ◽

Experimental Data Analysis

This paper proposes an integrated approach to determine optimal build orientation for powder bed fusion by laser (PBF-L), by simultaneously optimizing mechanical properties, surface roughness, the amount of support structure (SUPP), and build time and cost. Experimental data analysis has been used to establish the objective functions for different mechanical properties and surface roughness. Geometry analysis of the part has been used to estimate the needed SUPP and thus evaluate the build time and cost. Normalized weights are assigned to different objectives depending on their relative importance allowing solving the multi-objective optimization problem using a genetic optimization algorithm. A study case is presented to demonstrate the capabilities of the developed system. The major achievements of this work are the consideration of multiple objectives and the establishment of objective function considering different load direction and heat treatments. A user-friendly graphical user interface was developed allowing to control different optimization process factors and providing different visualization and evaluation tools.

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Synergistic application of continuous granulation and selective laser sintering 3D printing for the development of pharmaceutical dosage forms with enhanced dissolution rates and physical properties

10.1101/2021.02.13.430988 ◽

2021 ◽

Cited By ~ 1

Author(s):

Rishi Thakkar ◽

Yu Zhang ◽

Jiaxiang Zhang ◽

Mohammed Maniruzzaman

Keyword(s):

Solid State ◽

3D Printing ◽

Physical Properties ◽

Dosage Forms ◽

Flow Properties ◽

Printing Process ◽

Powder Bed ◽

Printing Processes ◽

Binder Jetting ◽

Physical Mixtures

AbstractThis study demonstrated the first case of combining novel continuous granulation with powder-based pharmaceutical 3-dimensional (3D) printing processes to enhance the dissolution rate and physical properties of a poorly water-soluble drug. Powder bed fusion (PBF) and binder jetting 3D printing processes have gained much attention in pharmaceutical dosage form manufacturing in recent times. Although powder bed-based 3D printing platforms have been known to face printing and uniformity problems due to the inherent poor flow properties of the pharmaceutical physical mixtures (feedstock). Moreover, techniques such as binder jetting currently do not provide any solubility benefits to active pharmaceutical ingredients (APIs) with poor aqueous solubility (>40% of marketed drugs). For this study, a hot-melt extrusion-based versatile granulation process equipped with UV-Vis process analytical technology (PAT) tools for the in-line monitoring of critical quality attributes (i.e., solid-state) of indomethacin was developed. The collected granules with enhanced flow properties were mixed with vinylpyrrolidone-vinyl acetate copolymer and a conductive excipient for efficient sintering. These mixtures were further characterized for their bulk properties observing an excellent flow and later subjected to a PBF-3D printing process. The physical mixtures, processed granules, and printed tablets were characterized using conventional as well as advanced solid-state characterization. These characterizations revealed the amorphous nature of the drug in the processed granules and printed tablets. Further, the in vitro release testing of the tablets with produced granules as a reference standard depicted a notable solubility advantage (100% drug released in 5 minutes at >pH 6.8) over the pure drug and the physical mixture. Our developed system known as DosePlus combines innovative continuous granulation and PBF-3D printing process which can potentially improve the physical properties of the bulk drug and formulations in comparison to when used in isolation. This process can further find application in continuous manufacturing of granules and additive manufacturing of pharmaceuticals to produce dosage forms with excellent uniformity and solubility advantage.Abstract Figure

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Characterization of channels made by laser powder bed fusion and binder jetting using X-ray CT and image analysis

Additive Manufacturing ◽

10.1016/j.addma.2020.101445 ◽

2020 ◽

Vol 36 ◽

pp. 101445

Author(s):

T. Dahmen ◽

C.G. Klingaa ◽

S. Baier-Stegmaier ◽

A. Lapina ◽

D.B. Pedersen ◽

...

Keyword(s):

Image Analysis ◽

Powder Bed Fusion ◽

Laser Powder Bed Fusion ◽

Powder Bed ◽

X Ray ◽

Binder Jetting

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Effects of build orientation and heat treatment on the evolution of microstructure and mechanical properties of alloy Mar-M-509 fabricated via laser powder bed fusion

International Journal of Plasticity ◽

10.1016/j.ijplas.2019.06.002 ◽

2019 ◽

Vol 121 ◽

pp. 116-133 ◽

Cited By ~ 16

Author(s):

Nicholas C. Ferreri ◽

Saeede Ghorbanpour ◽

Shubhrodev Bhowmik ◽

Ryan Lussier ◽

Jonathan Bicknell ◽

...

Keyword(s):

Mechanical Properties ◽

Heat Treatment ◽

Powder Bed Fusion ◽

Laser Powder Bed Fusion ◽

Powder Bed ◽

Build Orientation ◽

Microstructure And Mechanical Properties ◽

Evolution Of Microstructure

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Exploring Additive Manufacturing Processes for Direct 3D Printing of Copper Induction Coils

Volume 2: Advanced Manufacturing ◽

10.1115/imece2017-71685 ◽

2017 ◽

Cited By ~ 2

Author(s):

John D. Martin

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Electron Beam Melting ◽

Energy Deposition ◽

Manufacturing Processes ◽

Powder Bed Fusion ◽

Laser Melting ◽

Powder Bed ◽

Computer Aided ◽

Directed Energy

A number of additive manufacturing processes were analyzed and compared in regards to the direct 3D printing of copper induction coils. The purpose of this study was to narrow in on 3D printing technologies that would best be suited for the manufacture of copper inductions coils. The main focus of the study was to look at how all the available additive processes could specifically be successful at creating parts made of copper pure enough to effectively conduct electricity and also geometries complex enough to meet the demands of various induction coil designs. The results of this study led to three main categories of additive manufacturing that were deemed good choices for producing copper induction coils, these included: powder bed fusion, sheet lamination, and directed energy deposition. Specific processes identified within these categories were powder bed fusion using electron beam melting and laser melting; ultrasonic additive manufacturing; and directed energy deposition utilizing laser melting and electron beam melting using both wire and powder material delivery systems. Also discussed was additional benefits that using 3D printing technology could provide beyond the physical manufacturing portion by opening doors for coupling with computer aided drafting (CAD) and computer aided engineering (CAE) software in order to create a seamless design-to-production process.

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