Application Of Additive Technologies Research Articles

Features of the use of additive technologies in operative orthopaedics

Background. Additive technologies are increasingly making their way from university laboratories and high-tech industries into routine clinical practice and even into our everyday lives. Any enthusiast, having a PC and a 3D printer at his or her disposal, can create any physical object — from children’s toys to works of art. The presence on the market of a wide range of software pro-ducts, equipment, and consumables along with the data from mo-dern diagnostic methods, a high level of training and cooperation between doctors and engineers provide practical medicine with unprecedented opportunities. We are finally able to fully customize our treatment and diagnostic procedures: to perform precise preoperative planning; to draw up a detailed plan of the operation; to rehearse the intervention on full-scale anatomical prototypes using a standard tool; to conduct the surgery as quickly and atraumatically as possible; to minimize risks; to ensure the optimal functional result and to manufacture and install customized implants in the most difficult cases. The purpose was to draw the attention of our distinguished colleagues to the aspects of application of additive technologies in modern orthopaedic practice, to introduce them into the history and current state of medical prototyping, as well as to share technological nuances with them. Materials and methods. While writing this article, we incorporated the data of recent publications in specialized domestic and foreign periodicals, several monographs, materials from thematic conferences, the results of informal conversations with colleagues in the operating rooms, at the computer and production site, as well as our own experience (over 200 cases of prototyping). Conclusions. The availability of equipment, software, and consumables allows for the introduction of additive technology into the everyday practice of nearly every modern orthopaedic and trauma clinic.

Пути повышения свойств заготовок деталей ГТД из жаропрочных титановых сплавов, полученных методом прямого лазерного выращивания

Today, additive technologies for the production of billets from heat-resistant titanium alloys are used in aircraft engine building and the aerospace industry. However, the mechanisms of structure formation and the level of mechanical properties in such blanks are poorly understood and are of interest. Currently, available data are not sufficient for the confident application of additive technologies in the production of aircraft engines. This paper evaluates the microstructure and substantiates the possibility of improving the mechanical properties of workpieces of GTE parts made of VT20 titanium alloy, obtained by laser-powder additive surfacing. For research, workpieces with a size of 215x120x4 mm 120x85x14 mm were grown. As a "building" material, a powder of spherical shape of particles was used, the chemical composition of which corresponds to the alloy VT20. The research results showed that during laser-powder growth in the VT20 alloy, the formation of "hardening" structures is observed, due to the accelerated heat removal into the previously formed layer of cast metal. In this regard, the strength of the alloy sharply increases, and its impact toughness and relative narrowing decrease. Note that stress relief annealing after growing (T = 750 ± 10 ° C, holding time - 1.5 ... 2.0 h.) does not significantly affect the level of mechanical properties. When the annealing temperatures rise to critical levels, significant structural changes are observed in the VT20 alloy, which in turn affects its mechanical properties. Based on the analysis of microstructures and the results of mechanical tests after distinct types of heat treatment (800 ° C, 850 ° C, 920 ° C, holding time - 60...75 min.), it was found that an increase in the plastic properties of the VT20 alloy is observed when the samples are heated to temperatures close to the temperature of the polymorphic transformation (960...1000 ° C). Annealing of workpieces after surfacing according to mode T = 920 ± 10 ° C, holding time - 60...75 min. allows to somewhat reduce the strength characteristics of the VT20 alloy, while increasing its impact strength and relative narrowing.

The Conceptual Design of a Smart Wrist Orthosis and Functional Performance - Project Overview

The idea of the project was to find a conceptual design of a multi-functional smart orthosis for wrist fixation. The application of additive technologies presents the potential in designing a customised orthosis for every patient individually. By using pre-generated 3d models of various hand shapes it is possible to prepare models for several shapes and sizes of forearms and hands. The conceptual design provides a possible solution for a two-part orthosis bound around the forearm and a modular extension to stabilize the wrist without additional compression. The multi-functionality occurs with the development of a small pre-defined electronic plate located in the bottom part of the orthosis. The temperature and heart rate are constantly monitored and displayed wirelessly on a smartphone. The target group are the patients active in sports or patients with minor injuries. Moreover, the orthosis can be used for body temperature and heart function monitoring during recovery period.

Application of Additive Technologies for Manufactoring Non-Electronic Components of Microsystems

It is problematic to apply traditional microtechnologies for the manufacturing three-dimensional (3D) components of microsystems due to a number of inherent disadvantages. It is much more promising to use additive technologies for these purposes. In present paper various additive technologies used for manufacturing non-electronic components of microsystems as well as various non-electronic components manufactured using these technologies are considered. The peculiarities of the implementation of additive technologies in the manufacture of non-electronic microcomponents are discussed. More than 20 types of additive technologies characterized by different principles for the implementation of 3D printing processes are presented and their brief description is given. Most of these technologies allow manufacturing the components with micrometer feature sizes and some of them — with nanometer feature sizes. Microcomponents produced by additive technologies are intended for use in micromechanics, microoptics and microfluidics. Many examples of such microcomponents are given with indication of their typical feature sizes. Additive technologies make it possible to create both individual parts of microdevices and completely finished micro-devices. Microcomponents are mainly made from photopolymers and thermoplastics, as well as metals. Among additive technologies those that provide the multi-material 3D printing as well as the embedding of discrete components into printed microdevices are especially promising. It is expected that in near future additive technologies will be widely used in the production of various non-electronic components of microsystems.

Extrusion-Based 3D Printing for Highly Porous Alginate Materials Production.

Three-dimensional (3D) printing is a promising technology for solving a wide range of problems: regenerative medicine, tissue engineering, chemistry, etc. One of the potential applications of additive technologies is the production of highly porous structures with complex geometries, while printing is carried out using gel-like materials. However, the implementation of precise gel printing is a difficult task due to the high requirements for “ink”. In this paper, we propose the use of gel-like materials based on sodium alginate as “ink” for the implementation of the developed technology of extrusion-based 3D printing. Rheological studies were carried out for the developed alginate ink compositions. The optimal rheological properties are gel-like materials based on 2 wt% sodium alginate and 0.2 wt% calcium chloride. The 3D-printed structures with complex geometry were successfully dried using supercritical drying. The resulting aerogels have a high specific surface area (from 350 to 422 m2/g) and a high pore volume (from 3 to 3.78 cm3/g).

Cranioplasty of post-trepanation skull defects using additive 3D printing technologies

Introduction. Every year, there is an increase in the number of operations performed using personalized cranioplasts, which are made with additive 3D printing technologies. They allow surgical intervention, taking into account the characteristics of the shape of the patient's skull. This is especially important when closing large and complex defects extending from the cranial vault to the bones of the facial skeleton. One of the innovative applications of additive technologies in cranioplasty is the creation of implants, preformed based on individual 3D-printed models. However, no preliminary estimates of the results of treatment of patients using the traditional methods of cranial implants and individualized modeling methods were found in the available literary sources.The study objective is to compare the results of treatment using cranioplasts, preformed based on individual 3D-printed skull models and using traditional intraoperative modeling.Materials and methods. A study of 50 patients with post-craniotomy defects of the skull. All patients have undergone cranioplasty. Depending on the technique of individualization of the cranial implants, patients were divided into 2 groups: 1st - using individual 3D-printed models (n = 32), 2nd - traditional intraoperative modeling (n = 18).Results. Statistically, the groups differed significantly in terms of the duration of the intraoperative stage of cranioplasty, postoperative and total hospital stay, indicators of symmetry and financial costs. No differences were found in the duration of the preoperative hospital stay, the number of implant fixation points, the volume of intraoperative blood loss and the quality of life according to the SF-36. The first group (6.25 %) in comparison with the second (16.7 %) had a smaller number of postoperative complications.Conclusion. Modern 3D printing technologies recreate bone models based on patients' individual characteristics, thereby providing time for careful planning of the operation, even at the outpatient stage. The results of the study showed that the usage of cranioplasts preformed with 3D-printed models provides precise closure of post-craniotomy defects, better restoration of the skull contours, and a significant reduction in the duration of the cranioplasty stage. The use of the technology does not lead to a significant increase in the cost of treatment using traditional intraoperative modeling.

About Using Composite Materials when Restoring High-Resource Details with Application of Additive Technologies are Given

The process of restoration of high-resource parts of equipment for various purposes using AM technologies is considered. This method can save significantly the material of the formed coating, while providing the necessary efficiency in increasing the wear resistance of the restored parts. The causes of the leakage from the resulting coatings are residual stresses. Using a regression analysis apparatus, recommendations for the selection of technological modes from coatings are determined. The kinematic features of the recovery process are taken into account, dynamic relationships for determining stresses in the formed coating are determined. To find the volume of work, a worn surface is scanned. Further creation of the composite coating is carried out, taking into account the degree of wear from each section, separately. The influence of technological parameters on the micro-hardness and thickness of the applied composite coatings is investigated. Recommendations are given on the development of production technology, using 3-D printing of composite metal coatings, that can increase the wear resistance of high-resource parts.

Using of additive manufacturing (AM) in construction economics – shortcomings, advantages, prospects

The article considers the topic which is currently relevant for the construction industry – competitiveness growth of construction companies in the market by application of additive technologies. 3D technologies open up new ground for the construction industry as their application allows them to construct buildings of almost any shape, therefore, designers and architects will get more freedom to implement their creative plans and ideas. Upgrading of construction technologies will reduce quantity of waste and provide higher safety level on construction sites. Innovativeness of Additive Manufacturing (additive technologies) is based on application of special equipment - a 3D printer. Intensive development of Additive Manufacturing significantly changes ratio of economic factors in construction. The author believes that profitability of companies in a new competitive context will depend not on scale of production but on quality and originality of ideas. Philosophy of the economy after the third industrial revolution will base on development of original projects and not on products manufacturing.

Parameters Evaluation in 3D Spare Parts Printing

Future trends in maritime technology include the application of additive technology in spare parts management. Nowadays, 3D printing has become an integral technology in many fields. Maritime industry is one of the fields where 3D printing has become a focus of research. To prepare Electro-technical Officers (ETOs) for the future, it is necessary to investigate parameters which help with deciding whether to use additive technology or to order a spare part. This paper aims to research parameters influencing spare parts printing as a job carried out by ETOs aboard ships. Conclusions about the filament density and quality of the printed parts are derived and presented. Suggestions for future work and possible applications are given.

Использование лазерного сканирования для неразрушающего контроля качества деталей, изготовленных по технологии 3D печати

The article identifies promising areas of application of additive technologies in the production of parts and elements of aviation equipment (AT), the main tasks that need to be solved when implementing them (during the implementation process). The features of the application of laser scanning for non-destructive quality control of aircraft parts manufactured using modern additive technologies are considered. The possibility of controlling deviations in the shape and size of parts of aircraft manufactured using 3D printing technology from their 3D models by stationary and portable scanners (for example, an adapter for the air conditioning and ventilation system of an aircraft) is shown.(is represented) The article presents the main operations of the technological process of laser scanning using modern technical and software tools, the process of laser scanning of the AT part using the FARO Arm mobile CMM is implemented.

Advanced aluminum alloys for aircraft brazed structures

Review of domestic and foreign scientific and technical literature in the fi eld of application of aluminum alloys for brazed structures of aircraft heat exchangers manufactured by high-temperature vacuum brazing is provided. Prospective developments of domestic aluminum alloys for application as base material for clad sheets for brazed structures of heat exchangers are presented. The possibilities for increasing of the corrosion resistance of heat transfer surfaces are considered. The possibilities for application of additive technologies for the manufacture of aluminum heat exchangers alloys are considered.

Application of Additive Technologies in Improving Instrumental Equipment of Space Simulators.

The paper considers: additive technologies and their practical application in solving problems of operation, testing and modernization of space simu-lators in the framework of digital transformation policy of the Russian space industry; software and hardware and the experimental setups; prac-tical recommendations and suggestions for using the advantages of 3D modeling and FDM 3D printing technologies for prototyping products ap-plied in simulator construction and operation of technical means for train-ing cosmonauts.

Application of additive technologies for manufacturing a wear-resistant steel pipe outlet

The paper analyzes the problems of exploitation of pipe outlets for the oil and gas industry and describes the special design of the outlet’s vane, which allows to extend its service life. However, this special shape of the vane requires new manufacturing technologies. The paper lists the technical requirements for the finished model of the outlet and the method of its manufacture. Based on them, an analysis was carried out, and has been proposed the application of additive technologies for the manufacture of a steel pipe outlet with the vane, namely, the method of Selective Laser Melting (SLM). The advantages and particularities of the method’s application are described, as well as the stages of the manufacturing process for manufacturing an outlet with a special shape of the vane.

Cooperation of the Research Centers of the European Union and Ukraine in the implementation of additive technologies for biomedicine products

Abstract. The need to save material resources and reduce the cost of production requires that manufacturers and processors of raw materials improve existing technologies for shaping products and introduce new highly effective solutions. Recently, in such hightech industries as mechanical engineering, the aerospace industry, there has been a significant intensification of research on the development of new technological approaches for obtaining expensive parts using additive technologies (3D printing technologies). This approach is based on layer-by-layer formation of objects, when at the initial stage each new layer of the future part is a powder fraction consisting of identical or different particles of a structural material in shape and size. Additive technologies (AT) are significantly ahead and evolve faster than other technological processes of product manufacturing. Today, a significant proportion of industries use traditional technologies, so in the near future they can become potential consumers of AT. Examples of application of additive technologies are considered, allowing to solve difficult tasks on creation of products of biomedical purpose of domestic production thanks to experience of European countries, and the will to adjust the own production. The rapid growth of 3D printing confirms the high potential of this technology. The unification of scientific groups in creating an effective competitive environment for the development of JSC will allow a technological breakthrough for Ukraine in the future.

СТРУКТУРА И СВОЙСТВА ДЕТАЛЕЙ, ПОЛУЧЕННЫХ СЕЛЕКТИВНЫМ ЛАЗЕРНЫМ СПЛАВЛЕНИЕМ ПОСЛЕ ИСПЫТАНИЯ НА МАЛОЦИКЛОВУЮ УСТАЛОСТЬ

Results of low cycle fatigue (LCF) testing, investigation of microstructure, and fractures of specimens, which was, obtain by selective laser melting process (SLM) of the powders from Inconel 718 alloy have been carried out in the present article. Chemical composition of the considered specimens, microstructure before and after testing, results at room and elevated temperatures, which were built in XY direction (horizontal), were carrying-out. The specimens in the as-build state were exposed by hot isostatic pressing (HIP) with subsequent inherent Inconel 718 heat treatment. It was established that in specimens in as-built state observe accurately expressed zones of layer-by-layer smelting with 100 μm height. After HIP with subsequent heat treatment strengthening of the considered alloy provides by intermetallic γ'' – Ni3Nb phase, γ'-phase and carbides, also was identified lamellar δ-phase in the microstructure. LCF-testing was conducted in a so-called «soft» cycle of loading with a predetermined interval of the strain for providing of fatigue life in 103, 5х103, 104 cycles. The obtained data was built logarithmic curve in coordinates «Strain σ – Number of cycles N», that allows, with sufficient reliability, determine a rational strain level at LCF-testing for providing a predetermined number of cycles. The following ratios of σ – N were established (Rσ=0, υ=1 Hz): for providing N=103, σ≤1020 МPа, N=5х103, σ=931…961 МPа, N= 104, σ≤941 МPа. Results of the fractures investigation after LCF-testing at 20°С and 550°С shows that during the cyclic elastoplastic deformation at room temperature multicentricity of crack initiations zones observes. Mainly fixed a viscous pattern of fracture with a fatigue grooves presence, which size increases in the process of crack advance to the zone of fracture area. At elevated temperature in the zones of fatigue crack initiation and spreading quasi-brittle character of destruction observes, and turns in viscous in the zone of fracture area. Authors should be pointed out that the application of additive technologies in the manufacture of aerospace parts requires extensive R&D works, and testing efforts to confirm the repeatability of alloy characteristics.

Usage of additive technologies in the Arctic region

The article considers the use of additive technologies in the Arctic region as a tool that contributes to the sustainable development of the Arctic territories. The Arctic region is rich in deposits of minerals, hydrocarbons and other strategically important resources for the Russian Federation. In the article described the current use of additive technologies and a classification of additive technologies according to the following criteria: method of layer formation, method of the powder conversion and on the materials being processed. The types of additive technologies for each classification criterion are considered. A conceptual approach of analyzing the capabilities of additive technologies in the Arctic is proposed, it is based on the classification of the Russian Arctic area into subspaces and consideration of the capabilities of additive technologies for each subspace. Due to the fact that human activity in the Arctic is heterogeneous, the entire region can be divided into subspaces for functional purposes. The article presents the results of the analysis of the possibility of using additive technologies in the following Arctic subspaces: base cities, mobile rotational camps, mineral resource extraction territories, recreational territories, fishing territories, the Northern sea route, and infrastructure for the protection of safe existence. The article describes the application of additive technologies taking into account the functional features of each subspace of the region, describes advantages and limitations of using this technology of its use.

Application of polymeric materials for obtaining gears with involute and sinusoidal profile

In the article research related to the increasing in the scope of application of additive technologies in the construction of machines for the production of gears with involute and sinusoidal profile from polymeric materials was presented. The designed original research stand and with its use carried out a series of preliminary fatigue tests of the obtained polymer gears with an involute and sinusoidal profile was show. The tested gears were obtained in the technology of rapid prototyping by the FFF (Fused Filament Fabrication) method from polymer composites obtained in the form of an ABS (acrylonitrile/butadiene/styrene) – based filament. Based on the results obtained, it was noticed that the temperature in the meshing zone of the gears with involute profiles is higher than for sinusoidal profiles, regardless of the type of composite from which the gears were made. It should also be noted that in the range of nominal load, the sound intensity level of the meshing zone is also lower for gears with a sinusoidal profile than for gears with an involute profile. Based on the tests carried out, an increase in sound intensity was noticed in the case of gears obtained from selected composites (Table 2) compared to the gear obtained from unfilled ABS. However, in the case of gears obtained from the tested composite materials, we observe a decrease in the gear operating temperature (Table 2). The most favorable results of these tests were obtained for gears with a sinusoidal profile obtained from ABS + P2 composite, which show the lowest operating temperature of the gear. It should also be mentioned that slightly worse results were obtained for involute gears.

Additive Manufacturing of Polymer Moulds for Small-Batch Injection Moulding

In case of small-batch production, applications of classic technologies and tools, for e.g. injection moulding and classic moulds are not competitive. Application of additive technologies (AT) for direct production of finally parts can partially reduce deficiencies of classic approach, but there are for e.g. limited number of available materials. Potential solution is application of AT in production of so called bridge moulds for small-batch production from originally requested material for final part. This paper presents PolyJet process of AT and its possible application for production of bridge polymer moulds for injection moulding of small quantity of the moulded parts together with design rules for PolyJet bridge moulds.

Obtaining and Research of Additive Products from Electro-Erosive Cobalt-Chrome Powders

The main requirement for powders for additive machines is the spherical shape of the particles. Such particles most compactly fit into a certain volume and provide the “fluidity” of the powder composition in the material supply systems with minimal resistance. Based on the peculiarities of the methods of obtaining spherical powders in order to obtain spherical granules of a regulated grain size, the technology of electroerosive dispersion, which is distinguished by relatively low energy costs and ecological cleanliness of the process, is proposed. The main advantage of the proposed technology is the use of waste as raw materials, which is much cheaper than the pure components used in traditional technologies. In addition, this technology is powder, which allows to obtain powder-alloys. The widespread use of the method of EED for the processing of metal waste into powders for the purpose of their reuse and application in additive technologies is hampered by the lack of complete information in the scientific and technical literature on the influence of the original composition, modes and media on the properties of powders and technologies of practical application. Therefore, the development of technologies for the reuse of EED powders and the evaluation of the effectiveness of their use requires the conduct of comprehensive theoretical and experimental studies. The purpose of this work was to obtain and study additive products from electroerosive cobalt-chromium powders of a specific particle size distribution and to study their microstructure. The granulometry of the obtained powders was determined on a laser analyzer of particle sizes “Analysette 22 NanoTec”. The microstructure of additive samples from cobalt-chromium powders (by transverse polishing) was investigated by optical microscopy on an inverted optical microscope OLYMPUS GX51. On the basis of completed studies, aimed at obtaining and studying additive products from electroerosive cobalt-chrome powders of a specific particle size distribution, and studying their microstructure, it was found that additive samples, obtained from a cobalt-chrome powder with an average particle size of 35,68 microns, have practically no pores.

Application of Additive Technology in Precision Casting

In this paper the surface of the prepared test specimens had been examined with light microscopy and surface roughness measurements. In order to improve the surface smoothness of PLA specimens, application of ethyl acetate was required. After this surface treatment, microscopic images were taken again. The melting and decomposition temperatures of the materials had been determined using derivatography. The chosen method was precision casting with gypsum molding. Also, the plaster molds had been burnt out according to the predefined melting and firing diagram. The measurement series shows that the samples produced by 3D printing can also be used in the field of precision casting. They provide greater freedom of design, more sophisticated pieces, and prototypes can be finished in a shorter amount of time.