Additive manufacturing and injection molding process for mass-production of face shields during COVID-19 pandemic: A comparative study

Abstract Face shield is a personal protective equipment required for healthcare professionals to decrease the risk of contamination during the COVID-19. Fused deposition modeling (FDM) is the most applied process of additive manufacturing due to its usability and low-cost. The injection molding (IM) is the fastest process for mass industrial production. The comparison between the FDM and IM process to produce plastic parts is well known, but this study is the first to perform a qualitative comparison of these processes for mass-production and distribution of face shields in a pandemic. The design of the face shield was developed in three prototyping cycles based on requirements of medical, Brazilian regulatory standards, manufacturing, and production. The FDM manufacturing of 35,000 face shields was carried out by a volunteer network using low-cost 3D printer and the IM manufacturing of 80,000 was carried out by partner companies. With the production of face shields through the FDM process, it was possible to make daily deliveries of small batches to local hospitals. A total of 80,000 face shields was produced in larger batches by the IM process and delivered to remote regions in Brazil. Considering the manufacturing resilience of the processes (quality, costs, and production time), in a situation such as the current COVID-19 pandemic with disturbances and uncertainties, both FDM and IM processes are suitable for mass production of face shields. The FDM process promotes a fast-daily production once a committed network of volunteers is formed in strategic regions. The IM process was the best option for large scale production of face shields and delivery to remote regions without the availability of 3D printers.

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Mass-production and Distribution of Medical Face Shields Using Additive Manufacturing and Injection Molding Process for Healthcare System Support During COVID-19 Pandemic in Brazil

10.21203/rs.3.rs-63872/v1 ◽

2020 ◽

Cited By ~ 1

Author(s):

Maria Elizete Kunkel ◽

Mayra Torres Vasques ◽

João Aléssio Juliano Perfeito ◽

Nataly Rabelo Mina Zambrana ◽

Tainara dos Santos Bina ◽

...

Keyword(s):

Additive Manufacturing ◽

Injection Molding ◽

Mass Production ◽

Large Scale ◽

Fused Deposition Modeling ◽

Public Hospitals ◽

Injection Molding Process ◽

Scale Production ◽

Molding Process ◽

Fused Deposition

Abstract Face shields have been adopted worldwide as personal protective equipment for healthcare professionals during the COVID-19 pandemic. This device provides a transparent facial physical barrier reducing the exposure to aerosol particles. The fused deposition modeling (FDM) is the most applied process of additive manufacturing due to its usability and low-cost. The injection molding (IM) is the fastest process for mass production. This study is the first to perform a qualitative comparison between the use of FDM and IM processes for mass production and rapid distribution of face shields in a pandemic. The design of the face shield and tests were conducted in prototyping cycles based on requirements of medical, Brazilian standards, manufacturing, and production. The FDM face shields manufacturing was carried out by a volunteer network, and the IM manufacturing was carried out by companies. The volunteers produced 35,000 medical face shields through the FDM process with daily delivery to several hospitals. A total of 80,000 face shields was produced by the IM process and delivered to remote Brazilian regions. The mass production of 115,000 face shields protected health professionals from public hospitals in all states of Brazil. In a pandemic, both FDM and IM processes are suitable for mass production of face shields. Once a committed network of volunteers is formed in strategic regions, the FDM process promotes a fast daily production. The IM process is the best option for large scale production of face shields and delivery to remote areas where access to 3D printing is reduced.

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Environmental and Economic Analysis of FDM, SLS and MJF Additive Manufacturing Technologies

Materials ◽

10.3390/ma12244161 ◽

2019 ◽

Vol 12 (24) ◽

pp. 4161 ◽

Cited By ~ 4

Author(s):

Vincenzo Tagliaferri ◽

Federica Trovalusci ◽

Stefano Guarino ◽

Simone Venettacci

Keyword(s):

Additive Manufacturing ◽

High Performance ◽

Large Scale ◽

Fused Deposition Modeling ◽

Production Capacity ◽

Optimal Choice ◽

Scale Production ◽

Fused Deposition ◽

Manufacturing Technologies ◽

The Impact

In this study, the authors present a comparative analysis of different additive manufacturing (AM) technologies for high-performance components. Four 3D printers, currently available on the Italian national manufacturing market and belonging to three different AM technologies, were considered. The analysis focused on technical aspects to highlight the characteristics and performance limits of each technology, economic aspects to allow for an assessment of the costs associated with the different processes, and environmental aspects to focus on the impact of the production cycles associated with these technologies on the ecosystem, resources and human health. This study highlighted the current limits of additive manufacturing technologies in terms of production capacity in the case of large-scale production of plastic components, especially large ones. At the same time, this study highlights how the geometry of the object to be developed greatly influences the optimal choice between the various AM technologies, in both technological and economic terms. Fused deposition modeling (FDM) is the technology that exhibits the greatest limitations hindering mass production due to production times and costs, but also due to the associated environmental impact.

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Ultrasonic measurement of clamping force for injection molding machine

Journal of Polymer Engineering ◽

10.1515/polyeng-2018-0268 ◽

2019 ◽

Vol 39 (4) ◽

pp. 388-396 ◽

Cited By ~ 6

Author(s):

Peng Zhao ◽

Yao Zhao ◽

Jianfeng Zhang ◽

Junye Huang ◽

Neng Xia ◽

...

Keyword(s):

Injection Molding ◽

Measurement Method ◽

Large Scale ◽

Force Measurement ◽

Low Cost ◽

Ultrasonic Method ◽

Injection Molding Process ◽

Propagation Time ◽

Clamping Force ◽

Molding Process

AbstractAn online and feasible clamping force measurement method is important in the injection molding process and equipment. Based on the sono-elasticity theory, anin situclamping force measurement method using ultrasonic technology is proposed in this paper. A mathematical model is established to describe the relationship between the ultrasonic propagation time, mold thickness, and clamping force. A series of experiments are performed to verify the proposed method. Experimental findings show that the measurement results of the proposed method agree well with those of the magnetic enclosed-type clamping force tester method, with difference squares less than 2 (MPa)2and errors bars less than 0.7 MPa. The ultrasonic method can be applied in molds of different thickness, injection molding machines of different clamping scales, and large-scale injection cycles. The proposed method offers advantages of being highly accurate, highly stable, simple, feasible, non-destructive, and low-cost, providing significant application prospects in the injection molding industry.

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A Ceramic Tubular Probe For Online Substance Concentration Measurement, Manufactured By Ceramic Injection Molding

International Symposium on Microelectronics ◽

10.4071/isom-2012-wa32 ◽

2012 ◽

Vol 2012 (1) ◽

pp. 000604-000608

Author(s):

Matthias Hartmann ◽

Bertram Schmidt

Keyword(s):

Injection Molding ◽

Zirconium Oxide ◽

Large Scale ◽

Low Cost ◽

Tetragonal Zirconia ◽

Scale Production ◽

Ceramic Injection Molding ◽

Substance Concentration ◽

Sensor Effect ◽

Concentration Measurements

The current research presents recent respective to the work development of a ceramic tubular probe for online substance concentration measurements. The aim was to develop a robust and acid-resistant sensor device, which can be easily included in existing procedural pipeline systems. To archive those goals a lot of factors had to be checked. For the substance concentration measurements a capacitive sensor effect was chosen. With this method even low substance concentrations down to one-tenth of a per cent can be indentified. For the package material zirconium oxide (tetragonal zirconia polycrystal – TZP) was used. Zirconium oxide is a technical ceramic which is wear-resistant, acid-resistant, has a low thermal conductivity, is electrically isolating and can be uses in a ceramic injection molding (CIM) process. In the phase of the sensor design process multiple geometries for the sensor effect and integration space for the evaluation electronics had to be considered. A standardized DN 10 DIN 32676 flanged joint was also added for an unproblematic connection to the pipelines. All these needed geometries had to be integrated into one ceramic element. As a result of these requirements a 3D CAD model of the sensor element was designed. The CAD-file has shown that there was only the CIM technology left to comprehend developed sensor geometry. CIM is a low cost process for large-scale production which is distinguished by high size accuracy. In the CIM process the material shrinkage, this is caused by the needed debindering and sintering steps, had to be considered. The developed ceramic tubular probe was successfully tested in multiple fluidic systems. It has left the test phase and is now ready for maturity phase.

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Low-Cost Additive Manufacturing Techniques Applied to the Design of Planar Microwave Circuits by Fused Deposition Modeling

Polymers ◽

10.3390/polym12091946 ◽

2020 ◽

Vol 12 (9) ◽

pp. 1946 ◽

Cited By ~ 1

Author(s):

Héctor García-Martínez ◽

Ernesto Ávila-Navarro ◽

Germán Torregrosa-Penalva ◽

Alberto Rodríguez-Martínez ◽

Carolina Blanco-Angulo ◽

...

Keyword(s):

Additive Manufacturing ◽

Manufacturing Process ◽

Fused Deposition Modeling ◽

Low Cost ◽

Microwave Frequency ◽

Microwave Circuits ◽

Fused Deposition ◽

Microwave Electronic ◽

Deposition Modeling ◽

Manufacturing Techniques

This work presents a study on the implementation and manufacturing of low-cost microwave electronic circuits, made with additive manufacturing techniques using fused deposition modeling (FDM) technology. First, the manufacturing process of substrates with different filaments, using various options offered by additive techniques in the manufacture of 3D printing parts, is described. The implemented substrates are structurally analyzed by ultrasound techniques to verify the correct metallization and fabrication of the substrate, and the characterization of the electrical properties in the microwave frequency range of each filament is performed. Finally, standard and novel microwave filters in microstrip and stripline technology are implemented, making use of the possibilities offered by additive techniques in the manufacturing process. The designed devices were manufactured and measured with good results, which demonstrates the possibility of using low-cost 3D printers in the design process of planar microwave circuits.

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3D Printed Fully Recycled TiO2-Polystyrene Nanocomposite Photocatalysts for Use against Drug Residues

Nanomaterials ◽

10.3390/nano10112144 ◽

2020 ◽

Vol 10 (11) ◽

pp. 2144

Author(s):

Maria Sevastaki ◽

Mirela Petruta Suchea ◽

George Kenanakis

Keyword(s):

Tio2 Nanoparticles ◽

Large Scale ◽

Fused Deposition Modeling ◽

Low Cost ◽

Real Life ◽

3D Printer ◽

Alternative Route ◽

Fused Deposition ◽

Deposition Modeling ◽

3D Printed

In the present work, the use of nanocomposite polymeric filaments based on 100% recycled solid polystyrene everyday products, enriched with TiO2 nanoparticles with mass concentrations up to 40% w/w, and the production of 3D photocatalytic structures using a typical fused deposition modeling (FDM)-type 3D printer are reported. We provide evidence that the fabricated 3D structures offer promising photocatalytic properties, indicating that the proposed technique is indeed a novel low-cost alternative route for fabricating large-scale photocatalysts, suitable for practical real-life applications.

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Development of a Low-Cost Parallel Kinematic Machine for Multidirectional Additive Manufacturing

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4028897 ◽

2015 ◽

Vol 137 (2) ◽

Cited By ~ 61

Author(s):

Xuan Song ◽

Yayue Pan ◽

Yong Chen

Keyword(s):

Additive Manufacturing ◽

Fused Deposition Modeling ◽

Low Cost ◽

Work Piece ◽

Test Cases ◽

Constraint Checking ◽

Fused Deposition ◽

System A ◽

Deposition Modeling ◽

Tool Motion

Most additive manufacturing (AM) processes are layer-based with three linear motions in the X, Y, and Z axes. However, there are drawbacks associated with such limited motions, e.g., nonconformal material properties, stair-stepping effect, and limitations on building-around-inserts. Such drawbacks will limit AM to be used in more general applications. To enable 6-axis motions between a tool and a work piece, we investigated a Stewart mechanism and the feasibility of developing a low-cost 3D printer for the multidirectional fused deposition modeling (FDM) process. The technical challenges in developing such an AM system are discussed including the hardware design, motion planning and modeling, platform constraint checking, tool motion simulation, and platform calibration. Several test cases are performed to illustrate the capability of the developed multidirectional AM system. A discussion of future development on multidirectional AM systems is also given.

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Sustainable Natural Bio Composite for FDM Feedstocks

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.607.65 ◽

2014 ◽

Vol 607 ◽

pp. 65-69 ◽

Cited By ~ 8

Author(s):

M. Ibrahim ◽

N.S. Badrishah ◽

Nasuha Sa'ude ◽

Mohd Halim Irwan Ibrahim

Keyword(s):

Flexural Strength ◽

Injection Molding ◽

Fused Deposition Modeling ◽

Wood Flour ◽

Injection Molding Process ◽

Molding Process ◽

Weight Percentage ◽

Fused Deposition ◽

Plastic Composite ◽

Deposition Modeling

This paper presents the development of a new Wood Plastic Composite (WPC) material for Fused Deposition Modeling (FDM) feedstocks. In this study, a biodegradable polymer matrix (POLYACTIDE, PLA) was mixed with natural wood flour (WF) by Brabender mixer, and the samples produced by injection molding machine. The effect of wood was investigated as a filler material in composite FDM feedstock and the detailed formulations of compounding ratio by weight percentage. Based on results obtained, it was found that, compounding ratio of PLA80%:WF20% has a goods result on the tensile strength and PLA60% : WF40% gave a higher value of flexural strength. An increment of 20% to 40% WF filler affected the flexural strength, and hardness results. The highly filled WF content in PLA composites increases the mechanical properties of PMC material through the injection molding process. The potential of development of a sustainable composite material will be explored as the FDM feedstocks in the rapid prototyping process.

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Research on Curved Layer Fused Deposition Modeling (CLFDM) With Variable Extruded Filament (VEF)

Volume 4: 23rd Design for Manufacturing and the Life Cycle Conference; 12th International Conference on Micro- and Nanosystems ◽

10.1115/detc2018-85343 ◽

2018 ◽

Cited By ~ 2

Author(s):

Donghua Zhao ◽

Weizhong Guo

Keyword(s):

Additive Manufacturing ◽

Fused Deposition Modeling ◽

Solid Freeform Fabrication ◽

Low Cost ◽

Theoretical Point ◽

Fundamental Study ◽

Strength Performance ◽

Longitudinal Tensile Strength ◽

Fused Deposition ◽

Deposition Modeling

Fused Deposition Modeling (FDM), an Additive Manufacturing (AM) technique, is widely used due to its low-cost and open source. Geometry accuracy and strength performance of the printed parts are closely related to inter-layer bonding between adjacent layers and inter-road bonding in the layer. Because of the limit of layer-based AM, the longitudinal tensile strength of the filaments is much higher than the bonding strength between adjacent filaments, which brings anisotropy of the printed part. While CLFDM is devoted to solve this problem and obtain better geometry accuracy and meanwhile decrease build time by virtue of high continuity of filament, reduced stair-step effect, and lesser number of layers, especially when manufacturing thin and curved parts (shells). However, to the best of our knowledge in the aspects of process modeling of CLFDM, available researches focus mainly on simple curved layer, instead of more intricate ones possessing tiny features, which are more common in manufacturing. Therefore, to realize Solid Freeform Fabrication (SFF), this paper researches CLFDM with VEF (simultaneously changing the direction and the dimension of extruded filament according to manufacturing demand of the curved layer), which would be a fundamental study and a foundation for Advanced Design for Additive Manufacturing (ADFAM), slicing and path planning (extruder path generation) in 3D space. To realize slicing and printing with homogeneous and inhomogeneous extruded filament between consecutive layers and within the layer (flat or curved), models of flat layer FDM and CLFDM with VEF are respectively established. Then, the relationships among key process parameters are analyzed. Finally, graphical simulation of the proposed strategy based on a vase is provided to verify its effectiveness and advantages from a theoretical point of view. In general, variable direction of extruded filament along tangential directions of part surface imparts smoother surfaces, instead of rough exterior appearance resulting from stair-step effects. And variable dimension of extruded filament maximizes material extruded to increase build speed wherever allowed and minimizes deposition size for resolution whenever needed, resulting in curved layer surfaces with uneven layer thickness and having tiny features.

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Surgical Planning of Sacral Nerve Stimulation Procedure in Presence of Sacral Anomalies by Using Personalized Polymeric Prototypes Obtained with Additive Manufacturing Techniques

Polymers ◽

10.3390/polym12030581 ◽

2020 ◽

Vol 12 (3) ◽

pp. 581 ◽

Cited By ~ 2

Author(s):

Inés Rubio-Pérez ◽

Andrés Díaz Lantada

Keyword(s):

Additive Manufacturing ◽

Nerve Stimulation ◽

Sacral Nerve Stimulation ◽

Fused Deposition Modeling ◽

Low Cost ◽

Reference Points ◽

Production Costs ◽

Sacral Nerve ◽

Common Reference ◽

Fused Deposition

Sacral nerve stimulation or sacral neuromodulation involves the implantation of a stimulating electrode lead through the sacral foramina. In patients with anatomical sacral anomalies, it can constitute a challenging procedure due to a lack of common reference points present in the normal anatomy. In this study, we present an innovative application of additive manufacturing for the planning of sacral nerve stimulation techniques and related surgical procedures in complex cases, and we verify that the use of personalized patient models may help to manage the presence of sacral anomalies. The use of two alternative additive manufacturing technologies working with thermoplastic and thermoset polymers, including fused deposition modeling as low-cost alternative and laser stereolithography as industrial gold standard, is compared in terms of viability, precision and overall production costs. They pay special attention to fidelity in terms of the bone microstructure reconstruction, which is necessary for adequately planning electrode insertion. Advantages and limitations of the alternative approaches are discussed and ideas for future developments and for solving current challenges are presented.

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