Extrusion-Based 3D Printing of CuSn10 Bronze Parts: Production and Characterization

The interest in producing cost-effective 3D printed metallic materials is increasing day by day. One of these methods, which has gained much attention recently, is the fused deposition modelling (FDM) method. The parameters used in the FDM method have significant effects on the printed part properties. In this study, CuSn10 bronze alloy was successfully produced. The printing speed and layer thickness were investigated as the printing process parameters, and their effect on morphological properties was characterized by using SEM. As a result, it was observed that the formation of printing-induced voids was prevented by applying a layer thickness of 0.2 mm. Additionally, by increasing printing speed, a slight decrease in product density was observed. Following determination of 3D printing parameters which give the highest printed part density, the parts were debound in hexane solution via solvent debinding. Finally, the parts were sintered at 850, 875 and 900 °C for 5 h to examine effect of sintering temperature on density, porosity, shape deformation and mechanical properties. Although partial slumping started to form over 875 °C, the highest density (94.19% of theoretical density) and strength (212 ± 17.72 MPa) were obtained by using 900 °C as the sintering temperature.

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FDM 3D printing method utility assessment in small RC aircraft design

Aircraft Engineering and Aerospace Technology ◽

10.1108/aeat-07-2018-0189 ◽

2019 ◽

Vol 91 (6) ◽

pp. 865-872 ◽

Cited By ~ 4

Author(s):

Igor Skawiński ◽

Tomasz Goetzendorf-Grabowski

Keyword(s):

3D Printing ◽

Aircraft Design ◽

Cost Effective ◽

Fused Deposition Modelling ◽

Thin Wall ◽

Good Reliability ◽

Content Type ◽

Fused Deposition ◽

Wall Structures ◽

3D Printed

Purpose The purpose of this paper is to investigate the possibility of manufacturing fused deposition modelling (FDM) 3D printed structures such as wings or fuselages for small remote control (RC) air craft and mini unmaned aerial vehicles (UAVs). Design/methodology/approach Material tests, design assumptions and calculations were verified by designing and manufacturing a small radio-controlled motor-glider using as many printed parts as possible and performing test flights. Findings It is possible to create an aircraft with good flight characteristics using FDM 3D printed parts. Current level of technology allows for reasonably fast manufacturing of 3D printed aircraft with good reliability and high success ratio of prints; however, only some of the materials are suitable for printing thin wall structures such as wings. Practical implications The paper proves that apart from currently popular small RC aircraft structural materials such as composites, wood and foam, there is also printed plastic. Moreover, 3D printing is highly competitive in some aspects such as first unit production time or production cost. Originality/value The presented manufacturing technique can be useful for quick and cost-effective creating scale prototypes of the aircraft for performing test flights.

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Pengaruh Setting Parameter pada Slicing Software terhadap Surface Roughness Objek 3D Printing menggunakan Metode Taguchi

Jurnal Rekayasa Mesin ◽

10.32497/jrm.v16i3.2519 ◽

2021 ◽

Vol 16 (3) ◽

pp. 319

Author(s):

Hasdiansah Hasdiansah ◽

Sugiyarto Sugiyarto

Keyword(s):

Surface Roughness ◽

3D Printing ◽

Layer Thickness ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

Cooling Speed ◽

G Code ◽

Nozzle Temperature ◽

Printing Speed

Teknologi FDM (Fused Deposition Modelling) merupakan salah satu teknologi yang digunakan untuk membuat objek 3D. FDM sering disebut sebagai teknologi yang sudah mampu mengubah dunia manufaktur dewasa ini. Namun teknologi FDM memiliki kelemahan karena teknologi ini menggunakan proses building per layer membuat permukaan yang dihasilkan terlihat memiliki garis yang menunjukan batas antar layer sehingga mempengaruhi kekasaran pada permukaan produk cetak. Penelitian ini menggunakan filamen Super Tough PLA (ST.PLA). Tujuan penelitian ini adalah untuk mengetahui pengaruh parameter proses terhadap kekasaran permukaan objek cetak dan untuk mengetahui seting parameter proses yang menghasilkan kekasaran permukaan terbaik dari parameter proses yang digunakan. Penelitian ini menggunakan metode Taguchi dengan matriks ortogonal L25(56). Parameter proses yang akan dipilih dan dianalisis dalam penelitian ini adalah layer thickness, printing speed, nozzle temperature, orientation, flowrate, cooling speed dan respon yang diamati adalah kekasaran permukaan objek cetak. Untuk mengatasi permasalahan noise (gangguan) maka dicetak masing-masing tiga kali replikasi Selanjutnya parameter proses tersebut akan dianalisis menggunakan Analisis Varian (ANOVA). Berdasarkan data hasil pengukuran kekasaran permukaaan objek cetak, maka diperoleh parameter proses yang memberikan pengaruh paling besar terhadap kekasaran permukaan objek cetak dengan menggunakan filamen ST-PLA adalah layer thickness dengan nilai F hitung sebesar 129,96, flowrate dengan nilai F hitung sebesar 6 dan orientation dengan nilai F hitung sebesar 3,03. Seting parameter proses yang menghasilkan nilai kekasaran permukaan terbaik objek cetak adalah 0,10 mm yaitu pada eksperimen nomor lima (Exp. No. 5) dengan rata-rata 12,61 µm, dengan pengaturan layer thickness, 45 mm/s pada pengaturan printing speed, 210˚C pada nozzle temperature, 0˚ pada orientation, 110% pada pengaturan flowrate dan 40% pada pengaturan cooling speed. Seluruh parameter proses tersebut disetting pada slicing software ideamaker 3.6.1. dalam menghasilkan G-Code objek cetak.

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Pengaruh Geometri Infill terhadap Kekuatan Tarik Spesimen Uji Tarik ASTM D638 Type IV Menggunakan Filamen PLA+ Sugoi

Jurnal Rekayasa Mesin ◽

10.32497/jrm.v16i2.2343 ◽

2021 ◽

Vol 16 (2) ◽

pp. 140

Author(s):

Hasdiansah Hasdiansah ◽

Zaldy Sirwansyah Suzen

Keyword(s):

Surface Roughness ◽

3D Printing ◽

Layer Thickness ◽

Travel Speed ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

Type Iv ◽

Bed Temperature ◽

Nozzle Temperature ◽

Printing Speed

Pengaturan parameter proses 3D Printing berteknologi Fused Deposition Modelling (FDM) sangat mempengaruhi kualitas produk cetak baik dalam hal akurasi dimensi, surface roughness, dan kekuatan tariknya. Dua material yang paling sering digunakan para praktisi 3D Printing adalah PLA dan ABS masih memerlukan pengaturan parameter proses pada slicing software untuk menghasilkan produk cetak paling kuat ditinjau dari kuat tariknya. Penelitian ini memvariasikan bentuk geometri infill yang tersedia pada Ultimaker Cura 4.8.0 dalam mencetak spesimen uji tarik ASTM D638 Type IV. Ada 13 (tiga belas) bentuk infill yang digunakan dengan infill density 100%. Ada 3 (tiga) variasi nozzle temperature yaitu 205°C, 215°C, dan 225°C. Parameter proses yang tetap seperti layer thickness 0,2 mm, printing speed 50 mm/s, travel speed 100 mm/s, dan bed temperature 60°C. Spesimen uji tarik dicetak masing-masing tiga buah pada 39 (tiga puluh sembilan) eksperimen dan rata-rata hasil uji tarik dihitung kemudian selanjutnya dianalisis. Nilai kekuatan tarik tertinggi diperoleh pada pengaturan nozzle temperature 205°C dengan bentuk infill concentric atau terdapat pada eksperimen nomor 9 dengan nilai 32,40 MPa. Sedangkan nilai kekuatan tarik diperoleh pada pengaturan nozzle temperature 225°C dan dengan bentuk infill cross atau pada eksperimen nomor 37 dengan nilai 19,10 MPa. Sehingga dapat disimpulkan bahwa bentuk geometri infill pada proses 3D Printing FDM sangat mempengaruhi kekuatan tarik produk cetak.

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3D Printing of Thermo-Sensitive Drugs

Pharmaceutics ◽

10.3390/pharmaceutics13091524 ◽

2021 ◽

Vol 13 (9) ◽

pp. 1524

Author(s):

Sadikalmahdi Abdella ◽

Souha H. Youssef ◽

Franklin Afinjuomo ◽

Yunmei Song ◽

Paris Fouladian ◽

...

Keyword(s):

3D Printing ◽

Three Dimensional ◽

Fused Deposition Modelling ◽

Future Directions ◽

Digital Light Processing ◽

Fused Deposition ◽

Printing Technique ◽

3D Printed ◽

Semi Solid ◽

Selection Of

Three-dimensional (3D) printing is among the rapidly evolving technologies with applications in many sectors. The pharmaceutical industry is no exception, and the approval of the first 3D-printed tablet (Spiratam®) marked a revolution in the field. Several studies reported the fabrication of different dosage forms using a range of 3D printing techniques. Thermosensitive drugs compose a considerable segment of available medications in the market requiring strict temperature control during processing to ensure their efficacy and safety. Heating involved in some of the 3D printing technologies raises concerns regarding the feasibility of the techniques for printing thermolabile drugs. Studies reported that semi-solid extrusion (SSE) is the commonly used printing technique to fabricate thermosensitive drugs. Digital light processing (DLP), binder jetting (BJ), and stereolithography (SLA) can also be used for the fabrication of thermosensitive drugs as they do not involve heating elements. Nonetheless, degradation of some drugs by light source used in the techniques was reported. Interestingly, fused deposition modelling (FDM) coupled with filling techniques offered protection against thermal degradation. Concepts such as selection of low melting point polymers, adjustment of printing parameters, and coupling of more than one printing technique were exploited in printing thermosensitive drugs. This systematic review presents challenges, 3DP procedures, and future directions of 3D printing of thermo-sensitive formulations.

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Use of polymer concrete for large-scale 3D printing

Rapid Prototyping Journal ◽

10.1108/rpj-12-2019-0316 ◽

2021 ◽

Vol 27 (3) ◽

pp. 465-474

Author(s):

Martin Krčma ◽

David Škaroupka ◽

Petr Vosynek ◽

Tomáš Zikmund ◽

Jozef Kaiser ◽

...

Keyword(s):

3D Printing ◽

Large Scale ◽

Mechanical Performance ◽

Construction Material ◽

Polymer Concrete ◽

Fused Deposition Modelling ◽

Cast State ◽

Content Type ◽

Fused Deposition ◽

3D Printed

Purpose This paper aims to focus on the evaluation of a polymer concrete as a three-dimensional (3D) printing material. An associated company has developed plastic concrete made from reused unrecyclable plastic waste. Its intended use is as a construction material. Design/methodology/approach The concrete mix, called PolyBet, composed of polypropylene and glass sand, is printed by the fused deposition modelling process. The process of material and parameter selection is described. The mechanical properties of the filled material were compared to its cast state. Samples were made from castings and two different orientations of 3D-printed parts. Three-point flex tests were carried out, and the area of the break was examined. Computed tomography of the samples was carried out. Findings The influence of the 3D printing process on the material was evaluated. The mechanical performance of the longitudinal samples was close to the cast state. There was a difference in the failure mode between the states, with cast parts exhibiting a tougher behaviour, with fractures propagating in a stair-like manner. The 3D-printed samples exhibited high degrees of porosity. Originality/value The results suggest that the novel material is a good fit for 3D printing, with little to no degradation caused by the process. Layer adhesion was shown to be excellent, with negligible effect on the finished part for the longitudinal orientation. That means, if large-scale testing of buildability is successful, the material is a good fit for additive manufacturing of building components and other large-scale structures.

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Mechanical Properties of Diamond Schwarzites: From Atomistic Models to 3D-Printed Structures

MRS Advances ◽

10.1557/adv.2020.175 ◽

2020 ◽

Vol 5 (33-34) ◽

pp. 1775-1781 ◽

Cited By ~ 1

Author(s):

Levi C. Felix ◽

Vladimir Gaál ◽

Cristiano F. Woellner ◽

Varlei Rodrigues ◽

Douglas S. Galvao

Keyword(s):

Mechanical Properties ◽

3D Printing ◽

Uniaxial Compression ◽

Chemical Vapour ◽

Md Simulations ◽

Atomic Model ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

Structural Applications ◽

3D Printed

ABSTRACTTriply Periodic Minimal Surfaces (TPMS) possess locally minimized surface area under the constraint of periodic boundary conditions. Different families of surfaces were obtained with different topologies satisfying such conditions. Examples of such families include Primitive (P), Gyroid (G) and Diamond (D) surfaces. From a purely mathematical subject, TPMS have been recently found in materials science as optimal geometries for structural applications. Proposed by Mackay and Terrones in 1991, schwarzites are 3D crystalline porous carbon nanocrystals exhibiting a TPMS-like surface topology. Although their complex topology poses serious limitations on their synthesis with conventional nanoscale fabrication methods, such as Chemical Vapour Deposition (CVD), schwarzites can be fabricated by Additive Manufacturing (AM) techniques, such as 3D Printing. In this work, we used an optimized atomic model of a schwarzite structure from the D family (D8bal) to generate a surface mesh that was subsequently used for 3D-printing through Fused Deposition Modelling (FDM). This D schwarzite was 3D-printed with thermoplastic PolyLactic Acid (PLA) polymer filaments. Mechanical properties under uniaxial compression were investigated for both the atomic model and the 3D-printed one. Fully atomistic Molecular Dynamics (MD) simulations were also carried out to investigate the uniaxial compression behavior of the D8bal atomic model. Mechanical testings were performed on the 3D-printed schwarzite where the deformation mechanisms were found to be similar to those observed in MD simulations. These results are suggestive of a scale-independent mechanical behavior that is dominated by structural topology.

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Ten guidelines for the design of non-assembly mechanisms: The case of 3D-printed prosthetic hands

Proceedings of the Institution of Mechanical Engineers Part H Journal of Engineering in Medicine ◽

10.1177/0954411918794734 ◽

2018 ◽

Vol 232 (9) ◽

pp. 962-971 ◽

Cited By ~ 8

Author(s):

Juan Sebastian Cuellar ◽

Gerwin Smit ◽

Amir A Zadpoor ◽

Paul Breedveld

Keyword(s):

Developing Countries ◽

3D Printing ◽

Fused Deposition Modelling ◽

Prosthetic Hand ◽

Prosthetic Devices ◽

Hand Prosthesis ◽

Fused Deposition ◽

Prosthetic Hands ◽

Design Considerations ◽

3D Printed

In developing countries, prosthetic workshops are limited, difficult to reach, or even non-existent. Especially, fabrication of active, multi-articulated, and personalized hand prosthetic devices is often seen as a time-consuming and demanding process. An active prosthetic hand made through the fused deposition modelling technology and fully assembled right after the end of the 3D printing process will increase accessibility of prosthetic devices by reducing or bypassing the current manufacturing and post-processing steps. In this study, an approach for producing active hand prosthesis that could be fabricated fully assembled by fused deposition modelling technology is developed. By presenting a successful case of non-assembly 3D printing, this article defines a list of design considerations that should be followed in order to achieve fully functional non-assembly devices. Ten design considerations for additive manufacturing of non-assembly mechanisms have been proposed and a design case has been successfully addressed resulting in a fully functional prosthetic hand. The hand prosthesis can be 3D printed with an inexpensive fused deposition modelling machine and is capable of performing different types of grasping. The activation force required to start a pinch grasp, the energy required for closing, and the overall mass are significantly lower than body-powered commercial prosthetic hands. The results suggest that this non-assembly design may be a good alternative for amputees in developing countries.

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Printable Prosthetics

10.26686/wgtn.17064389.v1 ◽

2021 ◽

Author(s):

◽

Stuart Baynes

Keyword(s):

Design Research ◽

Cost Effective ◽

Fused Deposition Modelling ◽

Physical And Mental Health ◽

Positive Effects ◽

Fused Deposition ◽

Prosthetic Limbs ◽

The Status ◽

New Material ◽

3D Printed

The practice of fitting and making prosthetic limbs using current techniques leaves little room for innovative research and design. Though market leaders are consistently producing more advanced components, prosthetic technicians are using traditional techniques to fabricate prosthetic limbs. New material and design technologies could enable progressive solutions to historic barriers such as fabrication time and cost. Increasing the amputee’s accessibility to, and enjoyment of exercise may help to advocate and improve their physical and mental health. Design research was used to develop a functional 3D printed swimming prosthesis for lower limb amputees with the use of 3D scanning, parametric software and Fused Deposition Modelling. Using digital technologies has the potential to provide a platform for cost effective specialty prosthetic limbs, enabling and enriching recreational sport for amputees. Prototypes were developed with a unilateral trans-tibial amputee using an iterative process involving material testing and user testing. These prototypes allowed him to walk independently to the pool and produced positive effects on his swimming, including a recreated anthropometric symmetry. As advances in data collection and additive manufacturing continue to be made we will be able to more closely cater to the individual’s needs whilst challenging the status quo in prosthesis craft.

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Printable Prosthetics

10.26686/wgtn.17064389 ◽

2021 ◽

Author(s):

◽

Stuart Baynes

Keyword(s):

Design Research ◽

Cost Effective ◽

Fused Deposition Modelling ◽

Physical And Mental Health ◽

Positive Effects ◽

Fused Deposition ◽

Prosthetic Limbs ◽

The Status ◽

New Material ◽

3D Printed

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Three-dimensional Printing Versus Conventional Machining in the Creation of a Meatal Urethral Dilator: a Cost and Mechanical Strength Analysis

10.21203/rs.3.rs-28817/v1 ◽

2020 ◽

Author(s):

Michael Yue-Cheng Chen ◽

Jacob Skewes ◽

Ryan Daley ◽

Maria Ann Woodruff ◽

Nicholas John Rukin

Keyword(s):

3D Printing ◽

Three Dimensional ◽

Patient Specific ◽

Strength Analysis ◽

Fused Deposition Modelling ◽

3D Printer ◽

Current Time ◽

Fused Deposition ◽

3D Printed ◽

Conventional Machining

Abstract BackgroundThree-dimensional (3D) printing is a promising technology but the limitations are often poorly understood. We compare different 3D printingmethods with conventional machining techniques in manufacturing meatal urethral dilators which were recently removed from the Australian market. MethodsA prototype dilator was 3D printed vertically orientated on a low cost fused deposition modelling (FDM) 3D printer in polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS). It was also 3D printed horizontally orientated in ABS on a high-end FDM 3D printer with soluble support material, as well as on a SLS 3D printer in medical nylon. The dilator was also machined in stainless steel using a lathe. All dilators were tested mechanically in a custom rig by hanging calibrated weights from the handle until the dilator snapped. ResultsThe horizontally printed ABS dilator experienced failure at a greater load than the vertically printed PLA and ABS dilators respectively (503g vs 283g vs 163g, p < 0.001). The SLS nylon dilator and machined steel dilator did not fail. The steel dilator is most expensive with a quantity of five at 98 USD each, but this decreases to 30 USD each for a quantity of 1000. In contrast, the cost for the SLS dilator is 33 USD each for five and 27 USD each for 1000. ConclusionsAt the current time 3D printing is not a replacement for conventional manufacturing. 3D printing is best used for patient-specific parts, prototyping or manufacturing complex parts that have additional functionality that cannot otherwise beachieved.

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