Making 3D printing of machine parts more efficient

BackgroundThree-dimensional (3D) printing is a growing practice in the medical community for patient care and trainee education as well as production of equipment and devices. The development of functional models to replicate physiologic systems of human tissue has also been explored, although to a lesser degree. Specifically, the design of 3D printed phantoms that possess comparable biomechanical properties to human cervical vertebrae is an underdeveloped area of spine research. In order to investigate the functional uses of cervical 3D printed models for replicating the complex physiologic and biomechanical properties of the human subaxial cervical spine, our institution has created a prototype that accurately reflects these properties and provides a novel method of assessing spinal canal dimensions using simulated myelography. To our knowledge, this is the first 3D printed phantom created to study these parameters.Materials and methodsA de-identified cervical spine computed tomography imaging file was segmented using threshold modulation in 3D Slicer software. The subaxial vertebrae (C3-C7) of the scan were individualized by separating the facet joint spaces and uncovertebral joints within the software in order to create individual stereolithography (STL) files. Each individual vertebra was printed on an Ultimaker S5 dual-extrusion printer using white “tough” polylactic acid filament. A human cadaveric subaxial cervical spine was harvested to provide a control for our experiment. Both models were assessed and compared in flexion and extension dynamic motion grossly and fluoroscopically. The maximum angles of deformation on X-ray imaging were recorded using DICOM (Digital Imaging and Communications in Medicine) viewing software. In order to compare the ability to assess canal dimensions of the models using fluoroscopic imaging, a myelography simulation was designed.ResultsThe cervical phantom demonstrated excellent ability to resist deformation in flexion and extension positions, attributed to the high quality of initial segmentation. The gross and fluoroscopic dynamic movement of the phantom was analogous to the cadaver model. The myelography simulator adequately demonstrated the canal dimensions in static and dynamic positions for both models. Pertinent anatomic landmarks were able to be effectively visualized for assessment of canal measurements for sagittal and transverse dimensions.ConclusionsBy utilizing the latest technologies in DICOM segmentation and 3D printing, our institution has created the first cervical myelography phantom for biomechanical evaluation and trainee instruction. By combining new technologies with anatomical knowledge, quality 3D printing shows great promise in becoming a standard player in the future of spinal biomechanical research.

The Manufacturing Automation course in the Mechanical Engineering program at the University of Connecticut (UConn) was one of the most popular courses in the ME curriculum. The students’ benefits from the course were already described in the companion paper [1]. In this paper the advantages of prototyping and part production through Subtractive Manufacturing (SM) and Additive Manufacturing (AM) are described. The paper discusses parts fabrication done as subtractive and additive manufacturing operations. This was done in the scope of the UConn Engineering i.e. in the ME and MEM programs where Manufacturing Automation and Senior Design courses are taught. Such operations were possible thanks to the equipment available at UConn School of Engineering and thanks to the cooperation with the creator of the Mastercam software - CNC Software Inc and aircraft engines and equipment manufacturer - Pratt & Whitney of East Hartford. The integration of design and manufacturing in the course was done through putting together the operations of conceptual design, geometric design and modeling of the parts designed during the course. The models of parts done by AM were created using 3D printing in ME Laboratory out of acrylonitrile butadiene styrene and different kinds of plastic and in PW/UConn laboratory using laser and electron beam AM machines. To demonstrate further integration of design and machining automation, the students were introduced to complicated problems of surfaces crossing, connections of surfaces and edges of cross sections of the tops and valleys. Thanks to the support and cooperation of the CNC Software, Inc., it was possible to show the students how to cut complicated surfaces on different computer numerically controlled (CNC) machines that ranged from three to nine degrees of freedom specifically designed for accurate and repeatable metal working. In addition, the additive manufacturing (AM) capabilities were introduced in the course thanks to the support of Pratt & Whitney/UConn Additive Manufacturing Laboratory located on the UConn campus. The AM machines are Arcam and laser machines that use electron and laser beams to meld titanium powder. The fabricated parts of high strengths are useful as rapid prototypes or in some cases as substitution parts in an existing mechanical systems. Thanks to the UConn Engineering program and support of the corporations: CNC Software, Inc. and P&W, students were introduced to the spectrum of modern Rapid Prototyping and part sintering operations going through subtractive and additive manufacturing. The process details of the theory, practice of operations, and recommendation for use of the technologies discussed above, as well as possibilities of further applications, are described in this paper. After learning the fundamentals of these processes, students are prepared to design and analyze parts as well as the process required for different machining capabilities. Methods to introduce students to the concepts of using laser and electron beams AM machine as well the prototype machining are described in the paper. Conclusions recommending the teaching methods of product SM and AM machining concepts and lessons learned are also pointed out.

Service-oriented industrial internet of things gateway for cloud manufacturing

Three-dimensional (3D) printing offers several advantages, including flexible design, faster production, cost-effectiveness, suitability for small-batch production and reduction of carbon emissions. In particular, by optimizing the structure of oilfield equipment and adjusting the microstructure of metal 3D printed parts, high-performance components can be manufactured for complex working conditions in the oilfield. Taking the hydrocyclone as an example, the preparation process is as follows. Firstly, the optimization of the hydrocyclone's structure. The response surface design was combined with computational fluid dynamics to optimize the type and parameters of the hydrocyclone. Secondly, the selection of 3D printing material. Maraging stainless steel was chosen as the 3D printing material based on the performance requirements of the hydrocyclone. Thirdly, determining the 3D printing process parameters. Parameters were selected based on the microstructures, mechanical properties, wear resistance, and corrosion performance of the 3D printed parts. Ultimately, a novel hydrocyclone was 3D printed, and its separation performance was evaluated using a laboratory testing system. Results show a variable pitch hydrocyclone structure with high separation efficiency was designed and a high-density hydrocyclone part was successfully printed. Heterogeneous microstructures present in 3D printing stainless steel lead to excellent strength (tensile strength, σb = 1184 MPa), toughness (impact energy, Wt = 149 J) and wear and corrosion resistance. The 3D-printed complex hydrocyclone features greatly improved separation efficiency (99.38%, which is 0.58% higher than that of the conventional structure). Based on the above results, an innovative mindset based on 3D printing for cost reduction and efficiency enhancement was formed, and a comprehensive technical system, from structural design to manufacturing, microstructure characterization and performance evaluation, was developed. The challenges and prospects of applying 3D printing in the oilfield were analyzed, with a focus on the research and development of key oilfield equipment. This research promotes applications of 3D printing in the petroleum industry and advocates for the intelligent manufacturing of high-end petroleum equipment.

This paper introduces briefly China’s development plan for intelligent manufacturing, and combining with the present situation of design, manufacture and maintenance of pressure equipment, puts forward the development directions for the digitization, networking and intelligentization of pressure equipment at present and in the next decade from three aspects. The first aspect is digital control of shape and performance of pressure equipment. Taking the furnace tube as an example, the Material Genome technology is recommended for establishing the relationship between the microstructure and macroscopic performance of its material and achieve the target macroscopic performance by the adjustment of composition, phase and microstructure; then the additive manufacturing (3D printing) technology can be used to control the resulting shape of certain special structures so as to achieve the integrated shape and performance and significant improvement of its service life. The second aspect is digitization and network-based interconnection of production factors such as materials, equipment and personnel in the pressure vessel production workshop to realize intelligent manufacturing. Taking the transportable pressure vessel for instance, the real-time identification, diagnosis and control of abnormal conditions can be realized by information and communication technology during the key production processes such as baiting, cutting, forming, welding, heat treatment, and non-destructive testing; and if necessary, the suitable manufacturing resources across different enterprises and regions can be organized to achieve the flexible production and collaborative manufacturing of the components such as heads and flanges, etc. The third aspect is to achieve the real-time online integrity assurance of pressure equipment in process industries (e.g., petrochemical and electric power, etc.) by digitization and networking of risk-based inspection (RBI), fitness-for-service (FFS) assessment technologies and their corresponding database, in combination with real-time monitoring technology based on the characteristic safety parameters. Taking the reactor effluent air cooler (REAC) system as an example, this technology would enable not only the safety warning of critical characteristic parameters, but also the self-limiting and self-prevention of the flow-induced corrosion failure by linking with the distributed control system (DCS).

3D printing has been heralded as a innovative technology that will revolutionize industry. it is already used in aerospace, defense, art, and design, which becoming a popular subject in surgery. Digital advancements, smart biomaterials, and enhanced cell culture, in combination with 3D printing, give promising ground for patient-tailored therapies. Dental applications for three-dimensional (3D) printing in various departments range from prosthodontics, oral and maxillofacial surgery, and oral implantology through orthodontics, endodontics, and periodontology. The uses of 3D printing in prosthodontics can help provide patients with lower-cost, more customized services and ease the complicated workflow associated with the manufacturing of all dental equipment due to its quick production, high precision, and personal customization. The technique comprises intraoral or model scanning and designing, 3D printing, and post-processing and is used to fabricate surgical guides, removable, fixed, and maxillofacial prostheses.They can also have drawbacks, such as expensive and lengthy postprocessing. This study gives a practical and scientific overview of 3D printing technologies, which will be the future of digital dentistry, due to the development of new materials and technology.

This article contains an overview of global skills in the application of additive knowledge in the construction industry. Concrete 3D printing allows for the implementation of architectural projects of any complexity, lower production waste, less lack of housing stock, and lower labor, material, and energy costs associated with construction. The primary technologies for printing buildings and other structures are covered in the article, along with their unique characteristics. The issue of materials used for the manufacture of building mixtures has also been studied. Particular attention is paid to assessing the current state of 3D printing of concrete in the world. A review of construction companies, equipment manufacturers, and research centers, which are the main market participants, was carried out. The review also discusses ongoing research, emerging trends, and potential future developments in 3D printing concrete technology. Sustainability aspects, environmental impact, and considerations of standardization and regulations within the context of 3D printing concrete in construction are thoroughly examined. As 3D printing of concrete continues to revolutionize the construction landscape, this review serves as a comprehensive resource for researchers, practitioners, and industry stakeholders seeking a deeper understanding of the current state and future directions of this innovative technology.

On Demand Additive Manufacturing of a Basic Surgical Kit

Additive manufacturing (AM), is also known as rapid prototyping, is considered as a revolution in field of manufacturing and fabrications and boosted the development in biomedical fabrication. The 3D printing technique is mostly utilized in the field of medical for the manufacturing of medical equipment and surgical equipment, especially 3D biomedical printing which means 3D printing of substance which are biologically compatible to human body, blood and cells in the field of tissue fabrications. The main aim of tissue fabrications and engineering is to produce the artificial organ which is functional and viable. To fulfill this objective, investigation of various manufacturing techniques and materials is required. The process is difficult as it includes multiple aspects of human physiology, like types of multiple cell culturing, vasculature, nerve innervation, and interactions with nearby cells. This paper objective is to find the suitable material, is difficult task and, need in-depth focus on why it is difficult & what are the factors influencing the negative role of effective utilization of 3D printing tissue engineering. Also, this paper focuses on comparative study of materials in economic perspective human organ manufacturing. At the end, the conclusion elaborates about the applications and challenges of additive manufacturing in medical field and the alternative materials for organ tissue manufacturing.

(1) Background: 3D printable materials with accurately defined iodine content enable the development and production of radiological phantoms that simulate human tissues, including lesions after contrast administration in medical imaging with X-rays. These phantoms provide accurate, stable and reproducible models with defined iodine concentrations, and 3D printing allows maximum flexibility and minimal development and production time, allowing the simulation of anatomically correct anthropomorphic replication of lesions and the production of calibration and QA standards in a typical medical research facility. (2) Methods: Standard printing resins were doped with an iodine contrast agent and printed using a consumer 3D printer, both (resins and printer) available from major online marketplaces, to produce printed specimens with iodine contents ranging from 0 to 3.0% by weight, equivalent to 0 to 3.85% elemental iodine per volume, covering the typical levels found in patients. The printed samples were scanned in a micro-CT scanner to measure the properties of the materials in the range of the iodine concentrations used. (3) Results: Both mass density and attenuation show a linear dependence on iodine concentration (R2 = 1.00), allowing highly accurate, stable, and predictable results. (4) Conclusions: Standard 3D printing resins can be doped with liquids, avoiding the problem of sedimentation, resulting in perfectly homogeneous prints with accurate dopant content. Iodine contrast agents are perfectly suited to dope resins with appropriate iodine concentrations to radiologically mimic tissues after iodine uptake. In combination with computer-aided design, this can be used to produce printed objects with precisely defined iodine concentrations in the range of up to a few percent of elemental iodine, with high precision and anthropomorphic shapes. Applications include radiographic phantoms for detectability studies and calibration standards in projective X-ray imaging modalities, such as contrast-enhanced dual energy mammography (abbreviated CEDEM, CEDM, TICEM, or CESM depending on the equipment manufacturer), and 3-dimensional modalities like CT, including spectral and dual energy CT (DECT), and breast tomosynthesis.

The research explores the possibility of using mobile 3D printing technologies in construction and manufacturing. It is noted that many equipment manufacturers are already utilizing 3D printing for constructing various objects, but one of the limitations has been the lack of mobility. However, new concepts and prototypes of mobile 3D printers are emerging, which allow for construction and manufacturing in different locations without the need for additional transportation equipment. The proposed design of a mobile 3D construction printer-complex, housed on a cargo semi-trailer, is suggested as a mobile and autonomous system for construction purposes.

From pencils to commercial aircraft, every man-made object must be designed and manufactured. When it is cheaper or easier to steal a design or a manufacturing process specification than to invent one's own, the incentive for theft is present. As more and more manufacturing data comes online, incidents of such theft are increasing. In this paper, we present a side-channel attack on manufacturing equipment that reveals both the form of a product and its manufacturing process, i.e., exactly how it is made. In the attack, a human deliberately or accidentally places an attack-enabled phone close to the equipment or makes or receives a phone call on any phone nearby. The phone executing the attack records audio and, optionally, magnetometer data. We present a method of reconstructing the product's form and manufacturing process from the captured data, based on machine learning, signal processing, and human assistance. We demonstrate the attack on a 3D printer and a CNC mill, each with its own acoustic signature, and discuss the commonalities in the sensor data captured for these two different machines. We compare the quality of the data captured with a variety of smartphone models. Capturing data from the 3D printer, we reproduce the form and process information of objects previously unknown to the reconstructors. On average, our accuracy is within 1 mm in reconstructing the length of a line segment in a fabricated object's shape and within 1 degree in determining an angle in a fabricated object's shape. We conclude with recommendations for defending against these attacks.

Summary:The advent of 3-dimensional (3D) printing technology has facilitated the creation of customized objects. The lack of regulation in developing countries renders conventional means of addressing various healthcare issues challenging. 3D printing may provide a venue for addressing many of these concerns in an inexpensive and easily accessible fashion. These may potentially include the production of basic medical supplies, vaccination beads, laboratory equipment, and prosthetic limbs. As this technology continues to improve and prices are reduced, 3D printing has the potential ability to promote initiatives across the entire developing world, resulting in improved surgical care and providing a higher quality of healthcare to its residents.

The integration of digital design and manufacturing technologies has revolutionized sports equipment production, improving efficiency, precision, and customization. This study explores the role of CAD, CAE, and 3D printing in enhancing design accuracy and reducing development cycles, while highlighting intelligent manufacturing’s impact on cost reduction and resource optimization. Personalized equipment production, driven by 3D printing and consumer data, is examined alongside simulation technologies for performance testing and iterative optimization. Furthermore, real-time data feedback and lifecycle management systems demonstrate the potential for sustainable and adaptive designs. These advancements redefine industry standards, fostering innovation, sustainability, and user-centric development in sports equipment manufacturing.

3D printing: An emerging opportunity for soil science