Desktop Fused Deposition Modeling Research Articles

On-Site 3D Printing of Functional Custom Mallet Splints for Mars Analogue Crewmembers

The first off-Earth fused deposition modeling (FDM) 3D printer is investigating acrylonitrile butadiene styrene (ABS) thermoplastic manufacturing applications for long-duration space missions. This study assessed the feasibility of FDM 3D printing ABS thermoplastic customized mallet splints on site for Mars analogue crewmembers. Seven caliper measurements were taken of the right ring finger of 13 healthy Mars Desert Research Station mission crewmembers. These measurements were input into a free 3D modeling software program to create customized digital splint models. These digital files were uploaded to a desktop FDM 3D printer and custom splints were printed on site with ABS thermoplastic. Splint fit was assessed via subject feedback. Joint active range of motion was recorded when the splint was worn briefly. The time it took the software program to digitally render each splint model was less than 2 min and 30 s. The print duration for the splints ranged from 21 to 29 min. All 13 subjects reported that their 3D printed custom mallet splints fit securely and comfortably. All splints permitted full active range of motion of the proximal interphalangeal joint (0-100°) while maintaining the distal interphalangeal joint in extension. It is feasible to 3D print functional ABS thermoplastic custom mallet splints on site for Mars analogue crewmembers. This technology could be used clinically in the future when a custom mallet splint is required in a remote, resource-constrained setting.

Analysis of Applying Ultrasonic Frequency on a Desktop FDM Nozzle

Fused deposition modeling (FDM) is an additive manufacturing (AM) process that has an economical advantage compared to other AM processes. However, its biggest drawback is that it requires post processing to achieve a good surface finish. Ultrasound has been applied in various conventional machining processes and produces a good surface finish. However, the application of ultrasound to AM has not been sufficiently explored. This research aims to investigate the application of using ultrasound technology for a desktop FDM system. The idea is to transmit high vibration from the ultrasonic transducer to the FDM system's nozzle, and the objective is to examine whether the nozzle is able to withstand the high vibration being transmitted. Computer-aided design (CAD) software used to develop the 3D model of the extrusion nozzle component and a computer-aided engineering (CAE) software was used to perform static and vibration analysis. A frequency range of 20 to 30kHz and 30 to 40kHz was applied to the nozzle and it was found that the nozzle was able to withstand frequencies up to 40 kHz of vibration. In addition, the lowest Factor of Safety (FoS) obtained was 18.8975, concluding that the nozzle of FDM can withstand the high vibration transmitted from the ultrasonic transducer.

Experimental Setup for Ultrasonic-Assisted Desktop Fused Deposition Modeling System

Fused deposition modeling (FDM) is an additive manufacturing (AM) process that has been used in various manufacturing fields. However, the drawback of FDM is poor surface finish of parts produced, leading to surface roughness and requires hand finishing. In this study, ultrasonic technology will be integrated into a desktop FDM system.Ultrasound has been applied in various conventional machining processes and shows good machined surface finish. However, very little research regarding the application of ultrasound to AM has been carried out. Our previous research found that the extrusion nozzle of the FDM system could withstand the high vibration transmitted at 40 kHz of frequency from an ultrasonic transducer. The aim of this paper is to discuss three novel setups of using ultrasound devices attached to a desktop FDM system to study its feasibility to improve the surface finish of parts produced. A comparative study was made and it was found that the second setup (Concept 2) was most suitable due to its safety and reliability aspects.