Effect Of Build Orientation Research Articles

Effect of Building Orientation on Tensile Properties of Hastelloy X alloy Manufactured by Laser Powder Bed Fusion

In this study, the effect of build orientation on the mechanical properties of Hastelloy X fabricated by laser powder bed fusion (LPBF) process was investigated. Initial microstructural analysis revealed an equiaxed grain structure with random crystallographic orientation and annealing twins. Intragranular precipitates identified as Cr-rich M23C6 and Mo-rich M6C carbides were observed, along with a dense dislocation network and localized dislocation accumulation around the carbides. Mechanical testing showed negligible variation in yield strength with respect to build orientation; however, both ultimate tensile strength and elongation exhibited a clear increasing trend with higher build angles. Notably, the specimen built at 90° exhibited approximately 22% higher tensile strength and more than twice the elongation compared to the 0° specimen.

Effect of Build Orientation on the Fatigue Limit of CX Steel by Laser Powder Bed Fusion

ABSTRACTThe effect of part build orientation on the fatigue properties of additively manufactured parts has been demonstrated to be highly influenced by the type or composition of the raw material. In this study, an experimental campaign was carried out to investigate this effect in the case of CX maraging steel processed by laser powder bed fusion. For this purpose, specimens were manufactured with vertical, horizontal, and 45° inclined orientations. First, the dimensional accuracy, surface finishing, density, and hardness of specimens were characterized to determine the role of part build orientation. Then, the specimens were tested to determine the fatigue curve and limit. Finally, the fracture region was observed via scanning electron microscope. The results reveal that the effect of build orientation on the fatigue strength in the finite life domain is not statistically significant. Conversely, the build orientation affects the achievable surface finishing of parts after machining and, consequently, the fatigue limit of the material. The highest fatigue resistance is observed in specimens inclined at 45°, while vertical specimens showed the lowest limit.

Effect of Building Orientation on Fracture Toughness and Fatigue Crack Growth Properties of Ti-6Al-4V Alloy by Selective Laser Melting

Effect of Building Orientation on Fracture Toughness and Fatigue Crack Growth Properties of Ti-6Al-4V Alloy by Selective Laser Melting

Effects of DLP printing orientation and postprocessing regimes on the properties of 3D printed denture bases.

The variety of recommended postprocessing techniques and printing parameters makes it challenging to determine the best approach to 3-dimensionally (3D) printed dentures. The purpose of this in vitro study was to assess the effect of printing orientations (0, 45, and 90 degrees) and postprocessing treatments (ultraviolet [UV], heat, or combination) on the mechanical and surface properties of 3D printed denture base resin. Three-dimensionally printed denture base resin specimens were fabricated at 0-, 45-, and 90-degree printing orientations, followed by 4 postprocessing techniques (UV, Heat, UV+Heat, and control). Microhardness was assessed using a Vickers microhardness tester. Additionally, the flexural strength (FS) and modulus of elasticity (MoE) were analyzed using a 3-point bend test. Wettability was measured according to the sessile drop test. The fractured surfaces were observed under scanning electron microscopy (SEM). FS was significantly greater (P<.001) at a print orientation of 90 degrees (73.7MPa) compared with 0 and 45 degrees (55.2 and 61.8MPa). No significant difference in FS was found among postprocessing treatments (all complied with the International Organization for Standardization [ISO] requirements). The UV group had the highest MoE (up to 2061MPa), followed by the heat-treated groups (up to 1412MPa). The 45-degree print orientation showed the highest contact angle (CA) in almost all groups (CA=117.6±11.7), and UV led to higher hydrophilicity (CA=33.9±12.0). The effect of build orientation on the microhardness depended on the postprocessing technique with the highest value (23.4 ±1.3) achieved by UV postprocessing in combination with the 90-degree orientation. The optimal FS of 3D printed denture base resin is achieved when it is printed in a vertical orientation (90 degrees relative to the platform base). Thermal annealing as a postprocessing technique combined with UV can effectively enhance FS, induce favorable wettability, and reduce stiffness.

Multi-material laser powder bed fusion: effects of build orientation on defects, material structure and mechanical properties

Multi-Material Laser Powder Bed Fusion (MM-LPBF) offers a novel approach for fabricating high-resolution components with both spatially tailored material properties and design by leveraging selective powder deposition (SPD) in conventional LPBF processing. This study analyzes the effect of build orientation as a contributing factor to material compatibility, process-induced defects, and interfacial formation mechanisms to elucidate the process-structure-property framework for MM-LPBF. New MM-LPBF capabilities are demonstrated through a complex gyroid structure (904L stainless steel and bronze) for unique MM-LPBF signatures (e.g., melt pool characteristics, grain morphology, defects, and mechanical properties). Fracture mechanisms in MM-LPBF are investigated through multi-scale domain techniques, including flexural testing supported by digital image correlation (DIC), finite element analysis (FEA), and intermittent micro-CT. Findings from this study demonstrate the current technological opportunities and challenges in the adoption of MM-LPBF for a wide range of applications such as thermo-fluidic surfaces, solid-state energy storage, and biodegradable implants.

Experimental evaluation of build orientation effects on the microstructure, thermal, mechanical, and shape memory properties of SLA 3D-printed epoxy resin

Experimental evaluation of build orientation effects on the microstructure, thermal, mechanical, and shape memory properties of SLA 3D-printed epoxy resin

Effect of Build Orientation on Thermal Expansion of LPBF Printed Ti-6Al-4V

Ti-6Al-4V is a widely adopted alloy for components produced by Laser Powder Bed Fusion (LPBF). Due to its high strength-to-weight ratio, its excellent corrosion resistance, and biocompatibility, it is used in a wide range of applications in the aerospace, chemical and process engineering, energy, and biomedical sector. While conventionally produced Ti-6Al-4V typically features an α+β microstructure, additively manufactured Ti-6Al-4V is well known to develop an acicular martensitic α′ structure with often pronounced anisotropic properties resulting from the hexagonally closest packed (hcp) structure of α′. This study investigates the effect of the build direction of an LPBF printed Ti-6Al-4V (Grade 23) alloy on the resulting thermal expansion behaviour up to 1100 °C. Vertically built samples show a distinctly positive step in the apparent thermal expansion between approximately 850 °C and 1000 °C, while that of horizontally built specimen exhibit a dip. This is shown to be associated with (1) the alignment of prior β grains growing epitaxially with ⟨001⟩β along the direction of the thermal gradient that is related (but not parallel) to the build direction, (2) the Burgers orientation relationship and crystallographic variant selection causing acicular α′ laths to grow at approximately 40 deg to the primary axis of prior β grains, and (3) the strain occurring during the α′→β transformation. The apparent anisotropy of the thermal expansion of the as-printed Ti-6Al-4V is expected to have a relevant impact on the residual stress state after heat-treatment of LPBF components.

Effect of building orientation, thickness, and contouring on the microstructure and mechanical properties of AlSi10Mg via laser powder bed fusion

Effect of building orientation, thickness, and contouring on the microstructure and mechanical properties of AlSi10Mg via laser powder bed fusion

Evaluation of the fabrication trueness and internal fit of additively manufactured two-piece zirconia abutments with different build orientations compared to subtractively manufactured abutments

Evaluation of the fabrication trueness and internal fit of additively manufactured two-piece zirconia abutments with different build orientations compared to subtractively manufactured abutments

Effect of Build Orientation on Tensile Properties and Fractography of Additive Manufactured Inconel 718 Alloy

Effect of Build Orientation on Tensile Properties and Fractography of Additive Manufactured Inconel 718 Alloy

Effect of build orientation on trueness and adaptation of intaglio surface of maxillary complete denture metal frameworks fabricated by selective laser melting.

We aimed to evaluate the trueness and adaptation of the intaglio surfaces of complete denture metal frameworks fabricated using selective laser melting (SLM) with different building orientations (0°, 45°, and 90°). Cobalt-chromium maxillary complete denture metal frameworks were fabricated at 0°, 45°, and 90° using SLM. Trueness measurements were conducted using the best-fit alignment method of three-dimensional inspection software, and adaptation was evaluated using the silicone replica technique. Nonparametric Kruskal-Wallis and Bonferroni tests were performed to determine differences among the groups (P = 0.05). No significant differences were observed in the root mean square (RMS), positive, and negative deviation values between 0° and 45° group (P > 0.05), and the median, first quartile, and third quartile of each were considered clinically acceptable. For the 90° group, the RMS, positive deviation, and negative deviation values were significantly higher than those of the other groups (P < 0.05). The overall adaptation of the 45° group was better than that of the 0° and 90° groups (P < 0.05), whereas the 0° and 90° groups showed no significant difference (P > 0.05). The trueness and adaptation of the intaglio surface of cobalt-chromium maxillary complete denture metal frameworks were affected by the building orientation through SLM. Considering both trueness and adaptation, 45° is recommended as the most efficient build orientation for clinical applications.

Effect of Build Orientation on Mechanical and Physical Properties of Additively Manufactured Resins Using Digital Light Processing Technology in Dentistry: A Systematic Review.

The aim of this systematic review was to evaluate the effect of build orientation on the mechanical and physical properties of additively manufactured resin using digital light processing (DLP). The properties of 3D-printed materials are influenced by various factors, including the type of additive manufacturing (AM) system and build orientation. There is a scarcity of literature on the effect of build orientation on the mechanical and physical properties of additively manufactured resins using DLP technology in dentistry. This study followed the preferred reporting items for systematic reviews and meta-analyses (PRISMA) guidelines and was registered in PROSPERO. The formulated population, intervention, comparison, outcome (PICO) question was "What is the effect of build orientation on the mechanical and physical properties of additively manufactured resins produced using DLP in dentistry." The search strategy used three main electronic databases and an additional manual search was done until February 2024. All the studies that evaluated the correlation of build orientation and the properties of printed resin using DLP were included. Two different analysis was used for in vivo and in vitro studies to assess the risk of bias. On search 237 studies were yielded for systematic review, out of which 13 studies were included for the systematic review evaluation. On evaluation and reviewing the included studies, though the build orientation angle influenced the properties of printed resins the results obtained were varied as 90° angle had increased compressive strength, low surface roughness, and best accuracy. The 0° angle had better wear resistance, tensile strength, and high flexural strength. There was no influence of build orientation on microhardness, shear bond strength, gloss and color difference. The studies on denture base showed that 45° build angle showed the truest with best accuracy. The build orientation angle effects on both the mechanical and physical properties of the additively manufactured resin but varies with each property. The build orientation can be chosen based on the type of properties to be achieved based on the treatment modality. Based on the systematic review results the specific build orientation angle should be used during fabrication of any denture designs, crowns, and bridges as it is correlated with the properties to be achieved by particular designs. How to cite this article: Paranna S, Thosar N, Kanitkar A. Effect of Build Orientation on Mechanical and Physical Properties of Additively Manufactured Resins Using Digital Light Processing Technology in Dentistry: A Systematic Review. J Contemp Dent Pract 2024;25(9):891-903.

Build Orientation-Driven Anisotropic Fracture Behaviour in Polymer Parts Fabricated by Powder Bed Fusion

Additive manufacturing (AM) enables fabricating intricate objects with complex geometries previously unattainable through conventional methods. This process encompasses various techniques, including powder bed fusion (PBF), such as selective laser sintering (SLS) and multi-jet fusion (MJF). These techniques involve selectively melting powdered polymer material, predominantly utilizing engineering thermoplastics layer by layer to create solid components. Although their mechanical properties have been extensively characterised, very few works have addressed the influence of additive manufacturing on fracture behaviour. In this context, we present our work demonstrating the presence of anisotropy in fracture behaviour due to the build orientation as well as the PBF methods. To evaluate this anisotropy, the fracture behaviour of polyamide 12 polymer manufactured by SLS and MJF were investigated with experiments and numerical modelling of Mode I compact tension (CT) specimens. Experiments were monitored by digital image correlation (DIC) and infra-red thermography (IRT). Additionally, the fractured surfaces are analysed using scanning electron microscopy. Comparative analyses between SLS and MJF technologies unveiled dissimilar trends in mechanical strength, build-orientation effects, and fracture properties.

Effect of build orientation on the fabrication trueness of additively manufactured implant-supported complete arch interim fixed prostheses.

To evaluate how build orientation affects the fabrication trueness of additively manufactured implant-supported complete arch prostheses by comparing them to subtractively manufactured high-impact polymer-based prostheses. An edentulous maxillary model with four implants at canine and first molar regions bilaterally was digitized (ATOS Core 80 5MP) to design a reference implant-supported complete arch prosthesis standard tessellation language file (RF-STL). The STL file was used to manufacture prostheses additively in five different orientations according to the build platform (AM-0, 0-degree; AM-15, 15-degree; AM-30, 30-degree; AM-45, 45-degree; AM-90, 90-degree) or subtractively (SM-HIP, control) (n = 10). The prostheses were digitized with an intraoral scanner (Trios 3) to generate their STLs (TF-STL). After superimposing TF-STLs over the RF-STL with a metrology-grade analysis software program (Geomagic Control X), surface deviations at four regions (overall, occlusal, overall without occlusal, and abutments), linear deviations at each abutment site, and interimplant distance deviations (canine-to-molar, canine-to-canine, and molar-to-molar) were calculated. One-way analysis of variance and Tukey HSD tests were used for the statistical analyses (α = 0.05). AM-90 mostly had the highest surface deviations, while AM-0 had the lowest overall, and lowest overall without occlusal region deviations (p ≤ 0.022). SM-HIP had the lowest occlusal region deviations (p < 0.001). AM-90 had the highest linear deviations (p < 0.001). AM-15 had higher canine-to-molar deviations than SM-HIP (p = 0.042). SM-HIP had the highest canine-to-canine deviations, while AM-90 had higher deviations than AM-0 and AM-30 (p ≤ 0.026). AM-45 and AM-90 had the highest and AM-0 had the lowest molar-to-molar deviations (p ≤ 0.013). AM-0 mostly had higher trueness and AM-90 mostly had lower trueness within tested outcomes. Additively manufactured prostheses mostly had lower canine-to-molar distances and higher molar-to-molar distances, whereas SM-HIP prostheses consistently had higher distances than the design file.

Effect of build orientation on all additively manufactured polyvinylidene fluoride with electrical poling for strain sensing and energy-harvesting application

The development of highly sensitive and flexible strain sensors is critical for applications in wearable technology, structural health monitoring, and energy-harvesting. Additive manufacturing (AM) presents a promising solution due to its ability to create sensors with complex geometries and tailored microstructures. However, optimizing the fabrication parameters to enhance the performance of these sensors remains a challenge. This study focuses on the fabrication of polyvinylidene fluoride (PVDF)-based piezoelectric strain sensors using the material extrusion (ME) process, investigating how different printing orientations and poling methods affect their mechanical and piezoelectric properties. PVDF was selected for its strong piezoelectric characteristics and was extruded and printed in three flat orientations: 0°, 45°, and 90°. To improve the β-phase content and enhance piezoelectric performance, two poling methods contact poling and corona poling were applied to the printed samples. Mechanical testing showed that the 45° printing orientation resulted in the highest Young's modulus (131.17 ± 2.25 MPa) and ultimate tensile strength (23.57 ± 0.76 MPa). However, strain-sensing tests revealed that the sample printed in the 0° orientation and subjected to corona poling exhibited superior performance, achieving a maximum output voltage of 11 V, a short circuit current of 0.9 µA, and a power output of 5.5 µW under 20% strain. This work demonstrates that the 0° printing orientation, combined with corona poling, optimizes the sensor's performance, offering both high sensitivity and effective energy-harvesting capabilities. The novelty of this research presents the systematic exploration of orientation and poling effects, advancing the understanding of AM in sensor fabrication and providing a foundation for developing more efficient and responsive piezoelectric devices. These findings not only contribute to the literature on AM of sensors but also open new avenues for the creation of multifunctional devices that can simultaneously act as sensors and energy harvesters, broadening their potential applications.

Effect of build orientation on the accuracy and internal porosity of removable partial denture metal frameworks

This study aimed to investigate whether the accuracy and internal porosity of removable partial denture frameworks differ depending on the build direction in the selective laser melting method. Methods: A partially edentulous maxillary study model was scanned, and the anterior-posterior palatal bar was then digitally designed. The angles formed between the z-axis and the path of the insertion and removal were divided into five groups: -60°, -30°, 0°, 30°, and 60°. For each group, three removable partial denture metal frameworks were fabricated and used as specimens. The inner surface of each sample was scanned and superimposed on the design file to obtain the root mean square (RMS) value, and the average RMS value of each group was measured. One sample was randomly selected from each group, and the equivalent diameter and sphericity of the pores were analyzed using industrial X-ray threedimensional computed tomography. To compare statistical differences between groups, the Kruskal-Wallis test of SPSS Statistics ver. 27.0 (IBM) was used (α=0.05). The average RMS values of the whole inner surface accuracy of the specimens were in the order of -60°<0°<-30°<30°<60° (p<0.05). The equivalent diameter and sphericity of internal pores were significantly different among groups (p<0.001). The build orientation of the selective laser melting method influences the accuracy and internal porosity of removable partial denture frameworks.

Mechanical, tribological, and corrosion behavior of laser powder-bed fusion 316L stainless steel parts: Effect of build orientation

Mechanical, tribological, and corrosion behavior of laser powder-bed fusion 316L stainless steel parts: Effect of build orientation

Effect of building orientation on weld characteristics of additively manufactured 316L stainless steel: Microstructure and mechanical properties

In this study, the influence of building orientation of additively manufactured 316L stainless steel (SS) welded joints was investigated. Laser powder bed fusion (LPBF) technique was employed to print 316L SS plates in three different building orientations (BO): horizontal, inclined at 45°, and vertical directions. Subsequently, the welding processing of the printed 316L plates were conducted in various directions to the building orientations, i.e., the weld directions were perpendicular to the built layer (W90D) in horizontal specimens, parallel (W0D) in the vertical specimens, and oriented with 45° (W45D) to the inclined layers. The microstructure features were characterized using electron backscattered diffraction (EBSD) and laser confocal scanning microscopy (LCSM). The mechanical properties were evaluated through tension tests and hardness measurements. Fracture mode after tensile testing was examined by scanning electron imaging.The microstructural analysis revealed that the fusion zone (FZ) consisted of a predominantly austenitic matrix with the presence of 1–4% δ-ferrite. The FZ of the W0D joints exhibited fine grain structure and lowest dendrites arm spacing as compared to W90D and W45D. The hardness measurements in the FZ of W90D and W45D are 143 ± 5 and 155 ± 6 HV, respectively. These values were lower than the hardness of W0D joints, which measured 180 ± 7 HV. During tensile testing, the W90D and W45D joints were observed to fracture at the FZ, recording ultimate tensile strength (UTS) of 531 and 548 MPa, respectively. In contrast, the W0D joints fractured outside the FZ, displaying a lower UTS of 492 MPa. Furthermore, the welded joints displayed a ductile fracture mode, while W0D joints showed a very fine dimple structure, indicative of a different failure mechanism.

A modified SWT model for very high cycle fatigue life prediction of L-PBF Ti-6Al-4V alloy based on Single Defect: Effect of building orientation

A modified SWT model for very high cycle fatigue life prediction of L-PBF Ti-6Al-4V alloy based on Single Defect: Effect of building orientation

Effect of build orientation on the microstructure and mechanical properties of wire arc additive manufactured grade 91 steel/monel 400 bimetallic components

Effect of build orientation on the microstructure and mechanical properties of wire arc additive manufactured grade 91 steel/monel 400 bimetallic components