scholarly journals Manufacturing a First Upper Molar Dental Forceps Using Continuous Fiber Reinforcement (CFR) Additive Manufacturing Technology with Carbon-Reinforced Polyamide

Polymers ◽  
2021 ◽  
Vol 13 (16) ◽  
pp. 2647
Author(s):  
Roland Told ◽  
Gyula Marada ◽  
Szilard Rendeki ◽  
Attila Pentek ◽  
Balint Nagy ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Medical Devices ◽  
Fiber Reinforcement ◽  
Strong Impact ◽  
Vertical Force ◽  
Continuous Fiber ◽  
Fused Filament Fabrication ◽  
Sem Images ◽  
3D Printed ◽  
Upper Molar

3D printing is an emerging and disruptive technology, supporting the field of medicine over the past decades. In the recent years, the use of additive manufacturing (AM) has had a strong impact on everyday dental applications. Despite remarkable previous results from interdisciplinary research teams, there is no evidence or recommendation about the proper fabrication of handheld medical devices using desktop 3D printers. The aim of this study was to critically examine and compare the mechanical behavior of materials printed with FFF (fused filament fabrication) and CFR (continuous fiber reinforcement) additive manufacturing technologies, and to create and evaluate a massive and practically usable right upper molar forceps. Flexural and torsion fatigue tests, as well as Shore D measurements, were performed. The tensile strength was also measured in the case of the composite material. The flexural tests revealed the measured force values to have a linear correlation with the bending between the 10 mm (17.06 N at 5000th cycle) and 30 mm (37.99 N at 5000th cycle) deflection range. The findings were supported by scanning electron microscopy (SEM) images. Based on the results of the mechanical and structural tests, a dental forceps was designed, 3D printed using CFR technology, and validated by five dentists using a Likert scale. In addition, the vertical force of extraction was measured using a unique molar tooth model, where the reference test was carried out using a standard metal right upper molar forceps. Surprisingly, the tests revealed there to be no significant differences between the standard (84.80 N ± 16.96 N) and 3D-printed devices (70.30 N ± 4.41 N) in terms of extraction force in the tested range. The results also highlighted that desktop CFR technology is potentially suitable for the production of handheld medical devices that have to withstand high forces and perform load-bearing functions.

Fused Filament Fabrication 3D Printed Polylactic Acid Electroosmotic Pumps

Lab on a Chip ◽  
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...

scholarly journals Continuous Fiber Angle Topology Optimization for Polymer Composite Deposition Additive Manufacturing Applications

Fibers ◽  
2019 ◽  
Vol 7 (2) ◽  
pp. 14 ◽  
Author(s):  
Delin Jiang ◽  
Robert Hoglund ◽  
Douglas Smith
Keyword(s):  
Mechanical Properties ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Polymer Composite ◽  
Fiber Reinforcement ◽  
Fiber Direction ◽  
Optimization Approach ◽  
Continuous Fiber ◽  
Fiber Angle

Mechanical properties of parts produced with polymer deposition additive manufacturing (AM) depend on the print bead direction, particularly when short carbon-fiber reinforcement is added to the polymer feedstock. This offers a unique opportunity in the design of these structures since the AM print path can potentially be defined in a direction that takes advantage of the enhanced stiffness gained in the bead and, therefore, fiber direction. This paper presents a topology optimization approach for continuous fiber angle optimization (CFAO), which computes the best layout and orientation of fiber reinforcement for AM structures. Statically loaded structures are designed for minimum compliance where the adjoint variable method is used to compute design derivatives, and a sensitivity filter is employed to reduce the checkerboard effect. The nature of the layer-by-layer approach in AM is given special consideration in the algorithm presented. Examples are provided to demonstrate the applicability of the method in both two and three dimensions. The solution to our two dimensional problem is then printed with a fused filament fabrication (FFF) desktop printer using the material distribution results and a simple infill method which approximates the optimal fiber angle results using a contour-parallel deposition strategy. Mechanical stiffness testing of the printed parts shows improved results as compared to structures designed without accounting for the direction of the composite structure. Results show that the mechanical properties of the final FFF carbon fiber/polymer composite printed parts are greatly influenced by the print direction, and optimized material orientation tends to align with the imposed force direction to minimize the compliance.

scholarly journals Effect of Porosity and Crystallinity on 3D Printed PLA Properties

Polymers ◽  
2019 ◽  
Vol 11 (9) ◽  
pp. 1487 ◽  
Author(s):  
Yuhan Liao ◽  
Chang Liu ◽  
Bartolomeo Coppola ◽  
Giuseppina Barra ◽  
Luciano Di Maio ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Polylactic Acid ◽  
Complex Geometry ◽  
Fused Filament Fabrication ◽  
3D Printed ◽  
Physical Changes ◽  
Crystalline Forms

Additive manufacturing (AM) is a promising technology for the rapid tooling and fabrication of complex geometry components. Among all AM techniques, fused filament fabrication (FFF) is the most widely used technique for polymers. However, the consistency and properties control of the FFF product remains a challenging issue. This study aims to investigate physical changes during the 3D printing of polylactic acid (PLA). The correlations between the porosity, crystallinity and mechanical properties of the printed parts were studied. Moreover, the effects of the build-platform temperature were investigated. The experimental results confirmed the anisotropy of printed objects due to the occurrence of orientation phenomena during the filament deposition and the formation both of ordered and disordered crystalline forms (α and δ, respectively). A heat treatment post-3D printing was proposed as an effective method to improve mechanical properties by optimizing the crystallinity (transforming the δ form into the α one) and overcoming the anisotropy of the 3D printed object.

Enhanced Bonding via Additive Manufacturing-Enabled Surface Tailoring of 3D Printed Continuous-Fiber Composites

2018 ◽  
Vol 20 (12) ◽  
pp. 1800691 ◽  
Author(s):  
Edem Dugbenoo ◽  
Muhamad F. Arif ◽  
Brian L. Wardle ◽  
Shanmugam Kumar
Keyword(s):  
Additive Manufacturing ◽  
Fiber Composites ◽  
Continuous Fiber ◽  
3D Printed

scholarly journals Fused Filament Fabrication of Polymers and Continuous Fiber-Reinforced Polymer Composites: Advances in Structure Optimization and Health Monitoring

Polymers ◽  
2021 ◽  
Vol 13 (5) ◽  
pp. 789
Author(s):  
Fatemeh Mashayekhi ◽  
Julien Bardon ◽  
Vincent Berthé ◽  
Henri Perrin ◽  
Stephan Westermann ◽  
...  
Keyword(s):  
Health Monitoring ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fused Filament Fabrication ◽  
Thermoplastic Matrix ◽  
Fiber Reinforced Polymer Composites ◽  
3D Printed ◽  
Printed Materials ◽  
Monitoring Technologies

3D printed neat thermoplastic polymers (TPs) and continuous fiber-reinforced thermoplastic composites (CFRTPCs) by fused filament fabrication (FFF) are becoming attractive materials for numerous applications. However, the structure of these materials exhibits interfaces at different scales, engendering non-optimal mechanical properties. The first part of the review presents a description of these interfaces and highlights the different strategies to improve interfacial bonding. The actual knowledge on the structural aspects of the thermoplastic matrix is also summarized in this contribution with a focus on crystallization and orientation. The research to be tackled to further improve the structural properties of the 3D printed materials is identified. The second part of the review provides an overview of structural health monitoring technologies relying on the use of fiber Bragg grating sensors, strain gauge sensors and self-sensing. After a brief discussion on these three technologies, the needed research to further stimulate the development of FFF is identified. Finally, in the third part of this contribution the technology landscape of FFF processes for CFRTPCs is provided, including the future trends.

scholarly journals A Review on Reinforcement Methods for Polymeric Materials Processed Using Fused Filament Fabrication (FFF)

Polymers ◽  
2021 ◽  
Vol 13 (22) ◽  
pp. 4022
Author(s):  
Juan Pratama ◽  
Sukmaji I. Cahyono ◽  
Suyitno Suyitno ◽  
Muhammad A. Muflikhun ◽  
Urip A. Salim ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fiber Reinforcement ◽  
Polymeric Materials ◽  
Short Fiber ◽  
Continuous Fiber ◽  
Fused Filament Fabrication ◽  
Automotive Components ◽  
The Poor ◽  
Powder Addition ◽  
Processed Products

Over the last few years, fused filament fabrication (FFF) has become one of the most promising and widely used techniques for the rapid prototyping process. A number of studies have also shown the possibility of FFF being used for the fabrication of functional products, such as biomedical implants and automotive components. However, the poor mechanical properties possessed by FFF-processed products are considered one of the major shortcomings of this technique. Over the last decade, many researchers have attempted to improve the mechanical properties of FFF-processed products using several strategies—for instance, by applying the short fiber reinforcement (SFR), continuous fiber reinforcement (CFR), powder addition reinforcement (PAR), vibration-assisted FFF (VA-FFF) methods, as well as annealing. In this paper, the details of all these reinforcement techniques are reviewed. The abilities of each method in improving tensile, flexural, and compressive strength are discussed.

scholarly journals Fabrication of High-Performance CNT Reinforced Polymer Composite for Additive Manufacturing by Phase Inversion Technique

Polymers ◽  
2021 ◽  
Vol 13 (22) ◽  
pp. 4007
Author(s):  
Pooyan Parnian ◽  
Alberto D’Amore
Keyword(s):  
Additive Manufacturing ◽  
Electrical Properties ◽  
Phase Inversion ◽  
High Performance ◽  
Inversion Method ◽  
Fused Filament Fabrication ◽  
Phase Inversion Technique ◽  
Key Factor ◽  
3D Printed ◽  
Thermal And Electrical Properties

Additive Manufacturing (AM) of polymer composites has enabled the fabrication of highly customized parts with notably mechanical properties, thermal and electrical conductivity compared to un-reinforced polymers. Employing the reinforcements was a key factor in improving the properties of polymers after being 3D printed. However, almost all the existing 3D printing methods could make the most of disparate fiber reinforcement techniques, the fused filament fabrication (FFF) method is reviewed in this study to better understand its flexibility to employ for the proposed novel method. Carbon nanotubes (CNTs) as a desirable reinforcement have a great potential to improve the mechanical, thermal, and electrical properties of 3D printed polymers. Several functionalization approaches for the preparation of CNT reinforced composites are discussed in this study. However, due to the non-uniform distribution and direction of reinforcements, the properties of the resulted specimen do not change as theoretically expected. Based on the phase inversion method, this paper proposes a novel technique to produce CNT-reinforced filaments to simultaneously increase the mechanical, thermal, and electrical properties. A homogeneous CNT dispersion in a dilute polymer solution is first obtained by sonication techniques. Then, the CNT/polymer filaments with the desired CNT content can be obtained by extracting the polymer’s solvent. Furthermore, optimizing the filament draw ratio can result in a reasonable CNT orientation along the filament stretching direction.

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

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).

Regulating 3D-printed medical products

2018 ◽  
Vol 10 (461) ◽  
pp. eaan6521 ◽  
Author(s):  
Laura M. Ricles ◽  
James C. Coburn ◽  
Matthew Di Prima ◽  
Steven S. Oh
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Medical Devices ◽  
Three Dimensional ◽  
Emerging Technology ◽  
3D Object ◽  
Medical Products ◽  
3D Printed ◽  
Regulatory Landscape ◽  
The U.S

Additive manufacturing [also known as three-dimensional (3D) printing] is the layer-wise deposition of material to produce a 3D object. This rapidly emerging technology has the potential to produce new medical products with unprecedented structural and functional designs. Here, we describe the U.S. regulatory landscape of additive manufactured (3D-printed) medical devices and biologics and highlight key challenges and considerations.

scholarly journals Mechanical Recyclability of Polypropylene Composites Produced by Material Extrusion-Based Additive Manufacturing

Polymers ◽  
2019 ◽  
Vol 11 (8) ◽  
pp. 1318 ◽  
Author(s):  
Martin Spoerk ◽  
Florian Arbeiter ◽  
Ivan Raguž ◽  
Clemens Holzer ◽  
Joamin Gonzalez-Gutierrez
Keyword(s):  
Additive Manufacturing ◽  
Chain Scission ◽  
Fused Filament Fabrication ◽  
Polypropylene Composites ◽  
Material Extrusion ◽  
Wide Range ◽  
Tremendous Amount ◽  
3D Printed ◽  
The Impact

Due to a lack of long-term experience with burgeoning material extrusion-based additive manufacturing technology, also known as fused filament fabrication (FFF), considerable amounts of expensive material will continue to be wasted until a defect-free 3D-printed component can be finalized. In order to lead this advanced manufacturing technique toward cleaner production and to save costs, this study addresses the ability to remanufacture a wide range of commercially available filaments. Most of them either tend to degrade by chain scission or crosslinking. Only polypropylene (PP)-based filaments appear to be particularly thermally stable and therefore suitable for multiple remanufacturing sequences. As the extrusion step exerts the largest influence on the material in terms of temperature and shear load, this study focused on the morphological, rheological, thermal, processing, tensile, and impact properties of a promising PP composite in the course of multiple consecutive extrusions as well as the impact of additional heat stabilizers. Even after 15 consecutive filament extrusions, the stabilized additively manufactured PP composite revealed an unaltered morphology and therefore the same tensile and impact strength as the initial material. As the viscosity of the material of the 15th extrusion was nearly identical to that of the 1st extrusion sequence, the processability both in terms of extrusion and FFF was outstanding, despite the tremendous amount of shear and thermal stress that was undergone. The present work provides key insights into one possible step toward more sustainable production through FFF.

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