Liquid Resin Infusion Process Validation through Fiber Optic Sensor Technology

In the proposed work, a fiber-optic-based sensor network was employed for the monitoring of the liquid resin infusion process. The item under test was a panel composed by a skin and four stringers, sensorized in such a way that both the temperature and the resin arrival could be monitored. The network was arranged with 18 Fiber Bragg Gratings (FBGs) working as temperature sensors and 22 fiber optic probes with a modified front-end in order to detect the resin presence. After an in-depth study to find a better solution to install the sensors without affecting the measurements, the system was investigated using a commercial Micron Optics at 0.5 Hz, with a passive split-box connected in order to be able to sense all the sensors simultaneously. The obtained results in terms of resin arrival detection at different locations and the relative temperature trend allowed us to validate an infusion process numerical model, giving us better understanding of what the actual resin flow was and the time needed to dry preform filling during the infusion process.

Cavity vat photopolymerisation for additive manufacturing of polymer-composite 3D objects

Vat photopolymerisation describes resin-based additive manufacturing processes in which ultraviolet light is used to layer-wise solidify liquid resin into a desired 3D shape. If the starting resin is a dual-curing formulation the object is also thermally cured to attain its final properties, obtaining either an elastomer or a thermoset. Here, we introduce cavity vat photopolymerisation, in which one photopolymer resin produces a composite material of an elastomer and thermoset. Cavities of any geometry are purposefully designed in the solid object and then filled with liquid resin during printing due to negative pressure. Thermal curing then solidifies the resin in the cavities into an elastomer, forming a distinct interface held together by strong covalent bonds. Hybrid specimens indicate improved damping, reduced fragmentation upon fracture and increased local elasticity, and we suggest several hard-shell/soft-core applications that might benefit.

Chipboards as raw material of furniture

The problem of using wood materials in residential premises is closely related to the issues of forestry. This is due to the fact that the wood subsequently processed into materials and products emits a gas harmful to humans - formaldehyde. In Russia, there are strict requirements for the permissible level of formaldehyde in the air (0.01 mg/m3) both in residential premises and in the atmosphere. The environmentally friendly wood emits formaldehyde. The emission of formaldehyde may exceed the permissible level up to 10 times when obtaining chipboards using urea-formaldehyde and phenol-formaldehyde resins. Such an excess of the permissible level of formaldehyde is especially characteristic for chipboards. Moreover, a much larger amount of formaldehyde is emitted from urea-formaldehyde and phenol-formaldehyde resins during their hot curing than it is in the liquid resin in its free form. Therefore, much attention in this work is paid to the curing process of urea-formaldehyde and phenol-formaldehyde resins in relation to the manufacturing conditions of chipboards. The study of this process was based on the models related to the manufacturing conditions of chipboards using the microscopy method. It was found that some formaldehyde is preserved in vapor-gas bubbles and eventually moves out the chipboards.

Continuous 3D printing from one single droplet

3D printing has become one of the most promising methods to construct delicate 3D structures. However, precision and material utilization efficiency are limited. Here, we propose a one-droplet 3D printing strategy to fabricate controllable 3D structures from a single droplet ascribing to the receding property of the three-phase contact line (TCL) of the resin droplet. The well-controlled dewetting force of liquid resin on the cured structure results in the minimization of liquid residue and the high wet and net material utilization efficiency in forming a droplet into a 3D structure. Additionally, extra curing induced protruding or stepped sidewalls under high printing speed, which require high UV intensity, can be prevented. The critical is the free contact surface property of the droplet system with the introduction of the receding TCL, which increased the inner droplet liquid circulation and reduces the adhesion properties among the liquid resin, cured resin, and resin vat.

A Review of Stereolithography: Processes and Systems

Being the earliest form of additive manufacturing, stereolithography (SLA) fabricates 3D objects by selectively solidifying the liquid resin through a photopolymerization reaction. The ability to fabricate objects with high accuracy as well as a wide variety of materials brings much attention to stereolithography. Since its invention in the 1980s, SLA underwent four generations of major technological innovation over the past 40 years. These innovations have thus resulted in a diversified range of stereolithography systems with dramatically improved resolution, throughput, and materials selection for creating complex 3D objects and devices. In this paper, we review the four generations of stereolithography processes, which are scanning, projection, continuous and volumetric stereolithography. For each generation, representative stereolithography system configurations are also discussed in detail. In addition, other derivative technologies, such as scanning–projection, multi-material, and magnetically assisted stereolithography processes, are also included in this review.

Surface Characteristics of Milled and 3D Printed Denture Base Materials Following Polishing and Coating: An In-Vitro Study

(1) Background: To date, no information on the polishability of milled and 3D-printed complete denture bases has been provided, which is relevant in terms of plaque accumulation. (2) Methods: three groups (n = 30) were manufactured using the cold-polymerization polymethilmethacrilate, milling (SM) and 3D printing (AM). 10 specimens of each group were left untreated (reference). 10 more specimens were pre-polished (intermediate polishing) and 10 final specimens were highgloss polished. An additional 20 specimens were 3D printed and coated with the liquid resin (coated), 10 of which were additionally polished (coated + polished). For each group Ra and Rz values, gloss value and REM images were obtained. (3). The “highgloss-polished” specimens showed statistically lower Ra and Rz values in the SM, followed by AM and conventional groups. In the AM group statistically lower surfaces roughness was revealed for highgloss-polished, “coated + polished”, and “coated” specimens, respectively. (4) Conclusions: The milled specimens demonstrated superiors surface characteristics than 3D printed and conventionally produced after polishing. The polished specimens demonstrated superior surface characteristics over coated specimens. However, the surface roughness by both polished and coated specimens was within the clinically relevant threshold of 0.2 µm.