Implementation of Fused Filament Fabrication in Dentistry

Additive manufacturing is becoming an increasingly important technique for the production of dental restorations and assistive devices. The most commonly used systems are based on vat polymerization, e.g., stereolithography (SLA) and digital light processing (DLP). In contrast, fused filament fabrication (FFF), also known under the brand name fused deposition modeling (FDM), is rarely applied in the dental field. This might be due to the reduced accuracy and resolution of FFF compared to vat polymerization. However, the use of FFF in the dental sector seems very promising for in-house production since it presents a cost-effective and straight forward method. The manufacturing of nearly ready-to-use parts with only minimal post-processing can be considered highly advantageous. Therefore, the objective was to implement FFF in a digital dental workflow. The present report demonstrates the production of surgical guides for implant insertion by FFF. Furthermore, a novel approach using a temperature-sensitive filament for bite registration plates holds great promise for a simplified workflow. In combination with a medical-grade filament, a multi-material impression tray was printed for optimized impression taking of edentulous patients. Compared to the conventional way, the printed thermoplastic material is pleasant to model and can allow clean and fast work on the patient.

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Material Flow Rate Estimation in Material Extrusion Additive Manufacturing

10.51843/measure.13.1.5 ◽

2021 ◽

Vol 13 (1) ◽

pp. 46-56

Author(s):

G.P. Greeff

Keyword(s):

Additive Manufacturing ◽

Flow Rate ◽

Material Flow ◽

Fused Deposition Modeling ◽

Volumetric Flow Rate ◽

Cost Effective ◽

Fused Filament Fabrication ◽

Material Extrusion ◽

Fused Deposition ◽

G Code

The additive manufacturing of products promises exciting possibilities. Measurement methodologies, which measure an in-process dataset of these products and interpret the results, are essential. However, before developing such a level of quality assurance several in-process measurands must be realized. One of these is the material flow rate, or rate of adding material during the additive manufacturing process. Yet, measuring this rate directly in material extrusion additive manufacturing presents challenges. This work presents two indirect methods to estimate the volumetric flow rate at the liquefier exit in material extrusion, specifically in Fused Deposition Modeling or Fused Filament Fabrication. The methods are cost effective and may be applied in future sensor integration. The first method is an optical filament feed rate and width measurement and the second is based on the liquefier pressure. Both are used to indirectly estimate the volumetric flow rate. The work also includes a description of linking the G-code command to the final print result, which may be used to create a per extrusion command model of the part.

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Effects of Rice Straw Powder (RSP) Size and Pretreatment on Properties of FDM 3D-Printed RSP/Poly(Lactic Acid) Biocomposites

Molecules ◽

10.3390/molecules26113234 ◽

2021 ◽

Vol 26 (11) ◽

pp. 3234

Author(s):

Wangwang Yu ◽

Lili Dong ◽

Wen Lei ◽

Yuhan Zhou ◽

Yongzhe Pu ◽

...

Keyword(s):

Lactic Acid ◽

Rice Straw ◽

Fused Deposition Modeling ◽

Flexural Modulus ◽

Tensile Modulus ◽

Cost Effective ◽

Poly Lactic Acid ◽

Fused Deposition ◽

Interfacial Compatibility ◽

3D Printed

To develop a new kind of environment-friendly composite filament for fused deposition modeling (FDM) 3D printing, rice straw powder (RSP)/poly(lactic acid) (PLA) biocomposites were FDM-3D-printed, and the effects of the particle size and pretreatment of RSP on the properties of RSP/PLA biocomposites were investigated. The results indicated that the 120-mesh RSP/PLA biocomposites (named 120#RSP/PLA) showed better performance than RSP/PLA biocomposites prepared with other RSP sizes. Infrared results showed that pretreatment of RSP by different methods was successful, and scanning electron microscopy indicated that composites prepared after pretreatment exhibited good interfacial compatibility due to a preferable binding force between fiber and matrix. When RSP was synergistically pretreated by alkaline and ultrasound, the composite exhibited a high tensile strength, tensile modulus, flexural strength, and flexural modulus of 58.59, 568.68, 90.32, and 3218.12 MPa, respectively, reflecting an increase of 31.19%, 16.48%, 18.75%, and 25.27%, respectively, compared with unmodified 120#RSP/PLA. Pretreatment of RSP also improved the thermal stability and hydrophobic properties, while reducing the water absorption of 120#RSP/PLA. This work is believed to provide highlights of the development of cost-effective biocomposite filaments and improvement of the properties of FDM parts.

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Precision Model of Predicting FDM Rapid Prototype Based on BP Neural Network

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.392-394.891 ◽

2008 ◽

Vol 392-394 ◽

pp. 891-897

Author(s):

G.Q. Shang ◽

C.H. Sun ◽

X.F. Chen ◽

J.H. Du

Keyword(s):

Neural Network ◽

Bp Neural Network ◽

Fused Deposition Modeling ◽

Rapid Prototype ◽

Fused Deposition ◽

Novel Approach ◽

Deposition Modeling ◽

Hidden Layer ◽

Parts Manufacturing ◽

Bp Neural Network Model

Fused deposition modeling (FDM) has been widely applied in complex parts manufacturing and rapid tooling and so on. The precision of prototype was affected by many factors during FDM, so it is difficult to depict the process using a precise mathematical model. A novel approach for establishing a BP neural network model to predict FDM prototype precision was proposed in this paper. Firstly, based on analyzing effect of each factor on prototyping precision, some key parameters were confirmed to be feature parameters of BP neural networks. Then, the dimensional numbers of input layer and middle hidden layer were confirmed according to practical conditions, and therefore the model structure was fixed. Finally, the structure was trained by a great lot of experimental data, a model of BP neural network to predict precision of FDM prototype was constituted. The results show that the error can be controlled within 10%, which possesses excellent capability of predicting precision.

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EFFECT OF EXTRUSION PROCESS PARAMETERS ON MECHANICAL PROPERTIES OF 3D PRINTED PLA PRODUCT

Journal of Mechanical Engineering and Mechatronics ◽

10.33021/jmem.v6i2.1573 ◽

2021 ◽

Vol 6 (2) ◽

pp. 119

Author(s):

Nanang Ali Sutisna ◽

Rakha Amrillah Fattah

Keyword(s):

Mechanical Properties ◽

Additive Manufacturing ◽

Fused Deposition Modeling ◽

Extrusion Process ◽

Experimental Procedure ◽

Fused Deposition ◽

Novel Approach ◽

Deposition Modeling ◽

3D Printed ◽

3D Digital Models

The method of producing items through synchronously depositing material level by level, based on 3D digital models, is named Additive Manufacturing (AM) or 3D-printing. Amongs many AM methods, the Fused Deposition Modeling (FDM) technique along with PLA (Polylactic acid) material is commonly used in additive manufacturing. Until now, the mechanical properties of the AM components could not be calculated or estimated until they've been assembled and checked. In this work, a novel approach is suggested as to how the extrusion process affects the mechanical properties of the printed component to obtain how the parts can be manufactured or printed to achieve improved mechanical properties. This methodology is based on an experimental procedure in which the combination of parameters to achieve an optimal from a manufacturing experiment and its value can be determined, the results obtained show the effect of the extrusion process affects the mechanical properties.

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How Accurate Is Oral Implant Installation Using Surgical Guides Printed from a Degradable and Steam-Sterilized Biopolymer?

Journal of Clinical Medicine ◽

10.3390/jcm9082322 ◽

2020 ◽

Vol 9 (8) ◽

pp. 2322 ◽

Cited By ~ 1

Author(s):

Stefano Pieralli ◽

Benedikt Christopher Spies ◽

Valentin Hromadnik ◽

Robert Nicic ◽

Florian Beuer ◽

...

Keyword(s):

Fused Deposition Modeling ◽

Reference Group ◽

Second Molar ◽

Surgical Workflow ◽

Surgical Guide ◽

Fused Deposition ◽

Implant Placement ◽

Surgical Guides ◽

Oral Implant ◽

Observational Group

3D printed surgical guides are used for prosthetically-driven oral implant placement. When manufacturing these guides, information regarding suitable printing techniques and materials as well as the necessity for additional, non-printed stock parts such as metal sleeves is scarce. The aim of the investigation was to determine the accuracy of a surgical workflow for oral implant placement using guides manufactured by means of fused deposition modeling (FDM) from a biodegradable and sterilizable biopolymer filament. Furthermore, the potential benefit of metal sleeve inserts should be assessed. A surgical guide was designed for the installation of two implants in the region of the second premolar (SP) and second molar (SM) in a mandibular typodont model. For two additive manufacturing techniques (stereolithography [SLA]: reference group, FDM: observational group) n = 10 surgical guides, with (S) and without (NS) metal sleeves, were used. This resulted in 4 groups of 10 samples each (SLA-S/NS, FDM-S/NS). Target and real implant positions were superimposed and compared using a dedicated software. Sagittal, transversal, and vertical discrepancies at the level of the implant shoulder, apex and regarding the main axis were determined. MANOVA with posthoc Tukey tests were performed for statistical analyses. Placed implants showed sagittal and transversal discrepancies of <1 mm, vertical discrepancies of <0.6 mm, and axial deviations of ≤3°. In the vertical dimension, no differences between the four groups were measured (p ≤ 0.054). In the sagittal dimension, SLA groups showed decreased deviations in the implant shoulder region compared to FDM (p ≤ 0.033), whereas no differences in the transversal dimension between the groups were measured (p ≤ 0.054). The use of metal sleeves did not affect axial, vertical, and sagittal accuracy, but resulted in increased transversal deviations (p = 0.001). Regarding accuracy, biopolymer-based surgical guides manufactured by means of FDM present similar accuracy than SLA. Cytotoxicity tests are necessary to confirm their biocompatibility in the oral environment.

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Typography-Like 3D-Printed Templates for the Lithography-Free Fabrication of Microfluidic Chips

SLAS TECHNOLOGY Translating Life Sciences Innovation ◽

10.1177/2472630319867903 ◽

2019 ◽

Vol 25 (1) ◽

pp. 82-87

Author(s):

Wenqiong Su ◽

Yulong Li ◽

Lulu Zhang ◽

Jiahui Sun ◽

Shuopeng Liu ◽

...

Keyword(s):

Processing Time ◽

Fused Deposition Modeling ◽

Three Dimensional ◽

Cost Effective ◽

Microfluidic Channels ◽

3D Printer ◽

Microfluidic Chips ◽

Fused Deposition ◽

Deposition Modeling ◽

3D Printed

Typography-like templates for polydimethylsiloxane (PDMS) microfluidic chips using a fused deposition modeling (FDM) three-dimensional (3D) printer are presented. This rapid and fast proposed scheme did not require complicated photolithographic fabrication facilities and could deliver resolutions of ~100 μm. Polylactic acid (PLA) was adopted as the material to generate the 3D-printed units, which were then carefully assembled on a glass substrate using a heat-melt-curd strategy. This craft of bonding offers a cost-effective way to design and modify the templates of microfluidic channels, thus reducing the processing time of microfluidic chips. Finally, a flexible microfluidic chip to be employed for cell-based drug screening was developed based on the modularized 3D-printed templates. The lithography-free, typography-like, 3D-printed templates create a modularized fabrication process and promote the prevalence of integrated microfluidic systems with minimal requirements and improved efficiency.

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Investigation of Electromechanical Properties on 3-D Printed Piezoelectric Composite Scaffold Structures

Materials ◽

10.3390/ma14205927 ◽

2021 ◽

Vol 14 (20) ◽

pp. 5927

Author(s):

Tutu Sebastian ◽

Miriam Bach ◽

Andreas Geiger ◽

Tony Lusiola ◽

Lucjan Kozielski ◽

...

Keyword(s):

Fused Deposition Modeling ◽

Composite Scaffold ◽

Piezoelectric Composite ◽

Electromechanical Properties ◽

Destructive Testing ◽

Fused Filament Fabrication ◽

Pore Former ◽

Piezoelectric Composites ◽

Fused Deposition ◽

Acoustic Transducer

Piezoelectric composites with 3-3 connectivity gathered attraction due to their potential application as an acoustic transducer in medical imaging, non-destructive testing, etc. In this contribution, piezoelectric composites were fabricated with a material extrusion-based additive manufacturing process (MEX), also well-known under the names fused deposition modeling (FDM), fused filament fabrication (FFF) or fused deposition ceramics (FDC). Thermoplastic filaments were used to achieve open and offset printed piezoelectric scaffold structures. Both scaffold structures were printed, debinded and sintered successfully using commercial PZT and BaTiO3 powder. For the first time, it could be demonstrated, that using the MEX processing method, closed pore ferroelectric structure can be achieved without pore-former additive. After ceramic processing, the PZT scaffold structures were impregnated with epoxy resin to convert them into composites with 3-3 connectivity. A series of composites with varying ceramic content were achieved by changing the infill parameter during the 3D printing process systematically, and their electromechanical properties were investigated using the electromechanical aix PES device. Also, the Figure of merit (FOM) of these composites was calculated to assess the potential of this material as a candidate for transducer applications. A maximum for the FOM at 25 vol.% of PZT could be observed in this study.

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3D printers in dentistry: a review of additive manufacturing techniques and materials

Clinical and Laboratorial Research in Dentistry ◽

10.11606/issn.2357-8041.clrd.2021.188502 ◽

2021 ◽

Author(s):

Leonardo Portilha Gomes da Costa ◽

Stephanie Isabel Díaz Zamalloa ◽

Fernando Amorim Mendonça Alves ◽

Renan Spigolon ◽

Leandro Yukio Mano ◽

...

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Fused Deposition Modeling ◽

Dental Materials ◽

Clinical Results ◽

Digital Light Processing ◽

Fused Deposition ◽

3D Printers ◽

Manufacturing Techniques ◽

Printed Materials

3D printers manufacture objects used in various dental specialties. Objective: This literature review aims to explore different techniques of current 3D printers and their applications in printed materials for dental purposes. Methods: The online PubMed databases were searched aiming to find applications of different 3D printers in the dental area. The keywords searched were 3D printer, 3D printing, additive manufacturing, rapid prototyping, 3D prototyping, dental materials and dentistry. Results: From the search results, we describe Stereolithography (SLA), Digital Light Processing (DLP), Material Jetting (MJ), Fused Deposition Modeling (FDM), Binder Jetting (BJ) and Dust-based printing techniques. Conclusion: 3D printing enables different additive manufacturing techniques to be used in dentistry, providing better workflows and more satisfying clinical results.

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Enhancing 3D Printing Producibility in Polylactic Acid Using Fused Filament Fabrication Fused Deposition Modelling and Machine Learning

10.21203/rs.3.rs-131006/v1 ◽

2020 ◽

Author(s):

Mahmoud Moradi ◽

M. Saleh Meiabadi ◽

Mojtaba Karami Moghadam ◽

Sina Ardabili ◽

Shahab S. Band ◽

...

Keyword(s):

Neural Network ◽

Machine Learning ◽

Production Cost ◽

Fused Deposition Modeling ◽

Deformation Property ◽

Fused Filament Fabrication ◽

Fused Deposition ◽

Surface Method ◽

Deposition Modeling ◽

Part Thickness

Abstract Polylactic Polylactic acid (PLA) is one of the high applicable material which is used in the 3D printers due to some significant features like its deformation property and affordable costacid (PLA) is brittle in nature with extensive deformation property. For improvement of the end-use quality, it is of significant importance to enhance the quality of Fused Filament Fabrication (FFF)fused deposition modeling (FDM)-printed objects in PLA. The purpose of this investigation is to boost toughness and to reduce the production cost of the FDMFFF-printed tensile test samples with the desired part thickness. Due to prevent from many numerous and idle printing samples the response Surface Method (RSM) is used.To attain the research purpose number of experiments are designed and analyzed by the Response Surface Method (RSM). The statistical analysis is performed to deal with this concern considering extruder temperature (ET), infill percentage (IP), and layer thickness (LT) as controlled factors. The tensile test specimens are printed based on the designed experiments, and the tensile strength tests are conducted by SANTAM 150 universal testing machine based on ASTM D638. The pattern for filling is designed based on honeycomb which is applied to produce lightweight and high-strength specimens. The area under Force- Extension curve up to fracture is acquired as the toughness of the printed specimens. This study also developed a modeling process using artificial neural network (ANN) and artificial neural network- genetic algorithm (ANN-GA) techniques to develop an accurate estimation for toughness, part thickness, and production cost dependent variables. Results were evaluated by correlation coefficient and RMSE values. According to the modeling results, ANN-GA as a hybrid machine learning (ML) technique could could successfully improveenhances the accuracy of modeling about 7.5, 11.5 and 4.5 % for toughness, part thickness, and production cost, respectively, in comparison with those for the single ANN method. On the other side, the optimization results confirm that the optimized specimen is cost-effective and able to comparatively undergo deformation, which enables the usability of printed PLA objects. The research is accomplished under the constraints of PLA compatibility with existing Fused Filament Fabrication fused deposition modeling installation, in the absence of the functional assistant of the machine in the absence of the functional assistant of the machine. Although the mechanical properties and dimensional accuracy of PLA have already been studied, there is little literature on the toughness of the printed PLA with honeycomb internal fill pattern.

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Applications of 3D-Printed PEEK via Fused Filament Fabrication: A Systematic Review

Polymers ◽

10.3390/polym13224046 ◽

2021 ◽

Vol 13 (22) ◽

pp. 4046

Author(s):

Rupak Dua ◽

Zuri Rashad ◽

Joy Spears ◽

Grace Dunn ◽

Micaela Maxwell

Keyword(s):

Systematic Review ◽

Fused Deposition Modeling ◽

Chemical Properties ◽

Organic Polymer ◽

Current Status ◽

Fused Filament Fabrication ◽

Fused Deposition ◽

Polyether Ether Ketone ◽

Deposition Modeling ◽

3D Printed

Polyether ether ketone (PEEK) is an organic polymer that has excellent mechanical, chemical properties and can be additively manufactured (3D-printed) with ease. The use of 3D-printed PEEK has been growing in many fields. This article systematically reviews the current status of 3D-printed PEEK that has been used in various areas, including medical, chemical, aerospace, and electronics. A search of the use of 3D-printed PEEK articles published until September 2021 in various fields was performed using various databases. After reviewing the articles, and those which matched the inclusion criteria set for this systematic review, we found that the printing of PEEK is mainly performed by fused filament fabrication (FFF) or fused deposition modeling (FDM) printers. Based on the results of this systematic review, it was concluded that PEEK is a versatile material, and 3D-printed PEEK is finding applications in numerous industries. However, most of the applications are still in the research phase. Still, given how the research on PEEK is progressing and its additive manufacturing, it will soon be commercialized for many applications in numerous industries.

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