Effect Of Build Orientation Research Articles

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

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

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

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

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

In this study, 316L stainless steel Laser Powder Bed Fusion (LPBF) samples were manufactured under three different building orientations (0°, 45°, and 90°). Mechanical, microstructural, tribological and corrosion resistance properties were analyzed for all samples. The results demonstrate that the build orientation significantly influences the microstructure, resulting in variations in grain size, texture and defect distribution. Specifically, 0° (Horizontal) samples exhibited excellent mechanical properties, including ultimate tensile strength of 784 MPa and a hardness of 292 HV, while the vertical (90°) samples showed enhanced wear resistance, characterized by reduction in the coefficient of friction. Corrosion resistance was found to be highest in the 0° samples, with a corrosion current density of 0.650 μA/cm2, compared to 1.580 μA/cm2 in the 90° samples. The results from this study show the non-linear effects of build orientation for certain properties and indicates that individual studies are not sufficient to predict the performance of LPBF parts. Therefore, combined studies are required for orientation-based optimization of the mechanical, tribological and corrosion properties of LPBF parts. This study offers valuable insights into the relationship between build orientation and material properties, providing a pathway to tailor the properties of LPBF parts for specific applications.

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

The ultrasonic fatigue tests on laser-powder bed fused (L-PBF) Ti-6Al-4V specimens manufactured at 0°, 45°, and 90° building orientations were conducted. It is found that the very high cycle fatigue (VHCF) lives decrease with the building orientation from 0°, 45°, to 90°. All the fatigue cracks initiate from internal pores or Lack of Fusion defects. Mode Ι cracks grow perpendicular to the direction of the maximum opening stress, regardless of the building orientation. The maximum prospective defect evaluated by the extreme value statistics (EVS) method is used as the typical defect for VHCF life prediction. A modified Smith-Waston-Topper (SWT) model was proposed and combined with the Critical Distance Method to predict ultra-high cycle fatigue life. The life prediction accuracy was validated by using both experimental data obtained from the experiments conducted in this paper and experimental data taken from the literature. The results show that 84% of the predicted fatigue lives are within a scatter band of 2 standard deviation, and 16% of the predicted lives are outside a scatter band of 2 standard deviation and within a scatter band of 3 standard deviation.

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

This study explores the influence of build orientation on the microstructural and mechanical properties of Wire Arc Additive Manufactured (WAAM) Grade 91 Steel and Monel 400 bimetallic components, which are used in combined thermal and corrosion resistance applications. Microstructural analysis was conducted using techniques such as Optical Microscopy (OM), Field Emission Scanning Electron Microscopy (FE-SEM), and Transmission Electron Microscopy (TEM). The research specifically examines how different orientations (0°, 45°, and 90°) affect the as-built properties of these bimetallic components. Mechanical properties were evaluated through tensile testing, revealing significant variations: Grade 91 steel displayed a tensile strength of 1235.2 ± 12 MPa at a 0° orientation and 1314.7 ± 5 MPa at 90°, indicating anisotropic characteristics. Similarly, Monel 400 exhibited an increase in tensile strength from 491.5 ± 12 MPa at 0° to 517.7 ± 14 MPa at 45°. Fractographic analysis indicates a predominantly ductile fracture mechanism. The results of the study are important for using WAAM to create bimetallic components for environments that combine strength, thermal resistance, and resistance to corrosion.

Tensile anisotropy of powder bed fusion steel 316L: A practical study on the effect of build orientation

This study investigated the tensile anisotropy of steel 316L fabricated via laser powder bed fusion (L-PBF), built at different orientations. Tensile tests were performed on as-built L-PBF specimens produced at 0°, 15°, 30°, 45°, 60° and 90° angles. The yield strength, ultimate tensile strength and elasticity modulus experienced a decrease with an increasing build angle. Conversely, elongation at fracture increased as the build angle increased. The Elasticity modulus was found to be substantially lower than the nominal values reported in the material data sheet of the L-PBF equipment manufacturer. Fractography performed via Scanning Electron Microscopy (SEM) has found indications of porosity and lack of fusion that may have contributed to lower Elasticity modulus and an overall impacted mechanical performance. A complementary powder quality analysis has offered further insights on this and provided indications on the powder recycling impact.

Correction: The effect of building orientation on energy efficiency

Correction: The effect of building orientation on energy efficiency

Effect of building orientation on the in vitro corrosion of biomedical Zn-Cu alloys prepared by selective laser melting

Zn-Cu alloys as biodegradable materials have been successfully fabricated by selective laser melting (SLM) method. XRD, EBSD, electrochemical and immersion tests have been conducted to investigate the effect of building direction on microstructure and in vitro degradation behaviors. Finer grains and more CuZn5 precipitates are found on vertically built Zn-Cu alloy, which results in a higher degradation rate than horizontally built one in both electrochemical and immersion tests. The corrosion mode includes general corrosion and pitting. The moderate corrosion rates of SLM Zn-Cu make them suitable for cardiovascular stents and the corrosion rate is controllable by fabricating methods.

The effect of build orientation on the mechanical properties of a variety of polymer AM-created triply periodic minimal surface structures

The effect of build orientation on the mechanical properties of a variety of polymer AM-created triply periodic minimal surface structures

Build angle effect on 3D-printed dental crowns marginal fit using digital light-processing and stereo-lithography technology: an in vitro study

BackgroundThe effect of 3D printing technology and build angle on the marginal fit of printed crowns is unclear. The objective of this research was to use digital light processing (DLP) and stereo-lithography (SLA)-based 3D printing to construct single restorations with varied build angles and to analyze the crowns′ marginal fit.MethodsA prepared resin first molar was scanned utilizing an optical scanner. Three build orientations were used to construct the specimens: 0, 45, and 90º. DLP and SLA technology were used to produce the casting patterns. A digital microscope was used to measure the marginal gaps. The effect of build orientation was statistically analyzed by using Two-way ANOVA followed by pair-wise Tukey test.ResultsTwo-way ANOVA revealed a significant effect of printer technology and build angle on the marginal discrepancy of 3D printed crowns (p < 0.001). One-way ANOVA revealed that SLA printers (55.6 [± 13.59]) showed significantly better mean [± SD] marginal discrepancy in µm than DLP printers (72 [± 13.67]) (p < 0.001). Regarding build angle, one-way ANOVA revealed significant differences between the different angles. Tukeys post-hoc test revealed that 0° (48.5 [± 9.04]) had the significantly smallest marginal discrepancy followed by 45° (62.5 [± 8.05]) then 90° (80.5 [± 8.99]) (p < 0.001).ConclusionThe build orientation affects the marginal discrepancy of single crowns manufactured utilizing DLP and SLA.

Effect of build orientation on the fracture resistance and marginal quality of 3D-printed anatomic provisional crowns: An in-vitro study

IntroductionComputer-aided design and computer-aided manufacturing (CAD/CAM) technologies have been increasingly used to fabricate provisional restorations in recent years. This study assessed how build orientation influences the fracture resistance and marginal quality of 3D-printed crowns compared with milled provisional crowns. MethodsThe test group included 3D-printed crowns (Freeprint temp Shade A2, Detax, Ettlingen, Germany), which were further subdivided based on print orientation (0°, 45°, and 90°; n = 10 for each subgroup). The control group (n = 10) included milled crowns (Coratemp, White Peaks, Germany) with the same design as those of the test group. The margin quality of each crown was assessed at 60 × magnification using a digital stereomicroscope. A load-to-fracture test was performed by applying a force at a rate of 2 mm/min to assess fracture resistance. One sample from each subgroup was also subjected to scanning electron microscope (SEM) analysis. ResultsThe milled group exhibited the highest fracture resistance and marginal quality. Within the printed subgroups, the 0° group showed the best mean marginal quality, whereas the 90° group showed the lowest mean marginal quality (p < 0.05). Within the test groups, the 90° group had the highest mean fracture resistance (p < 0.05). In the SEM analysis, the milled group exhibited the most homogenous boundaries, whereas among the 3D-printed subgroups, the samples printed at 0° had the best margin quality. ConclusionThe manufacturing method significantly influences the marginal quality and fracture resistance. Milled crowns demonstrated superior marginal quality and fracture resistance compared to those of 3D printed crowns. Furthermore, the print orientation of 0° led to the best marginal quality, whereas printing at 90° led to the highest fracture resistance.

Effect of build orientation and heat treatment on the microstructure, mechanical and corrosion performance of super duplex stainless steels fabricated via laser powder bed fusion

Correction for ‘Effect of build orientation and heat treatment on the microstructure, mechanical and corrosion performance of super duplex stainless steels fabricated via laser powder bed fusion’ by Karl Peter Davidson et al., Mater. Adv., 2024, 5, 8177–8198, https://doi.org/10.1039/D4MA00448E.

Effect of build orientation and heat treatment on the microstructure, mechanical and corrosion performance of super duplex stainless steels fabricated via laser powder bed fusion

Build orientation in PBF-L manipulates microstructures, thus tuning the mechanical and corrosion properties of duplex stainless steel before and after heat treatment.

Effect of build orientation on the wear resistance and hardness of denture teeth fabricated using digital light processing: An in vitro study.

This in vitro study investigated the effect of build orientation on the wear resistance and hardness of denture teeth fabricated using digital light processing (DLP) compared to other denture tooth materials. Disc-shaped specimens were prepared using denture tooth monomers and DLP devices in three build orientations: 0°, 45°, and 90°. Specimens of the same shape were fabricated using denture tooth materials for subtractive manufacturing, commercially available polymethylmethacrylate (PMMA) resin, and composite resin. The wear resistance was evaluated as the wear volume loss after 50,000 wear cycles using a ball-on-disc wear device in water for two-body wear and poppy seed slurry for three-body wear. The Vickers hardness values of the materials were measured. Two-way and one-way analyses of variance were performed for wear resistance and hardness, respectively, followed by Tukey's honest significance test. The interaction between the denture tooth resins and maximum wear volume was significant (P < 0.01). The 0° build orientation exhibited the lowest wear volume in the three-body wear test and the highest hardness among the three build orientations. The 0° DLP-fabricated specimens demonstrated significantly less wear volume than that of the PMMA specimens and a wear volume comparable to that of the milled specimens. However, the 0° DLP-fabricated specimens showed significantly lower hardness than that of the milled and PMMA specimens. The composite resin specimens exhibited the highest wear resistance and hardness. A 0° build orientation is recommended for DLP-fabricated denture teeth compared to 45° and 90° orientations to achieve greater wear resistance and hardness.

The effect of building orientation on energy efficiency

The effect of building orientation on energy efficiency

Effect of Build Orientation and Heat Treatment on Erosion Behavior of Al10SiMg Fabricated Using Laser Powder Bed Fusion

Laser Powder Bed Fusion (LPBF) is a form of additive manufacturing that can directly make metal components and has begun to be employed in a variety of industrial situations. Moreover, the erosion characteristics of SLM-produced items have been documented relatively infrequently. In the current work, the erosion behavior of a heat-treated Al-Si-10% Mg alloy generated via laser powder bed fusion (LPBF) has been investigated. The samples were printed in three directions (horizontal (0o), vertical (90o), and inclined (45o) on the build platform using the Direct Metal Laser Sintering (DMLS) system (EOS M 290) machine. Al%Si-10%Mg samples were given treatment (T5, T6). Optical and scanning electron microscopes (SEM) were used to examine the microstructure under both printed and heat-treated conditions. Energy Dispersive Spectroscopy (EDS) and X-ray Diffraction (XRD) were used to investigate the alloy's elemental composition and compound production. The erosion test was executed in each of the three orientations, plus heat-treated samples and as-printed samples. The selected input parameters were impingement angle and flow velocity. The erosion rate was examined and contrasted across orientations for printed and heat-treated conditions to establish the best orientation. The post-eroded surface was analysed using SEM, EDS, and XRD to evaluate possible erosion processes. The key findings were: T5 heat-treated samples sustain well and have the least mass loss; Horizontal (0°) oriented samples undergo less erosion compared to other orientations; T6 heat-treated samples show maximum erosion on printed samples, and hence it is not recommended. T5 heat treatment is proven to be superior in providing high erosion resistance, followed by printed and T6 heat-treatment, respectively. The heat treatment effects are more significant than the orientation effects in determining the erosion resistance of the Al10SiMg alloy. The erosion mechanisms, such as ploughing, melting, and cratering, were identified.

Additive manufacturing of short carbon filled fiber nylon: effect of build orientation on surface roughness and viscoelastic behavior

Additive manufacturing of short carbon filled fiber nylon: effect of build orientation on surface roughness and viscoelastic behavior

Effect of build orientation on the green tribological properties of multi-jet fusion manufactured PA12 parts

Additive manufacturing (AM) is a newly developed technology for manufacturing parts from three-dimensional (3D) computer-aided design (CAD) models by depositing a material layer on layer. Multi-jet fusion (MJF) is one of the AM technologies that can be used for manufacturing functional parts like gear, linear, bearing, etc., by polymers. In various applications, technical processes, design of tribological systems, optimum lubrication, and reduction of wear and friction are significant performance criteria to provide energy and material conservation. The development of green tribological applications offers essential solutions to problems of ecosystem pollution and energy from a global point of view to increase sustainability. In this article, the green tribological behavior of Polyamide 12 (PA12) parts, manufactured by MJF with different build orientations was evaluated by ball-on-disc tribological tests under different normal loads and lubricated environments. Mechanical profilometer and digital microscope were used to evaluate surface quality and morphology. Scanning electron microscope (SEM) was used to determine the samples’ wear characteristics. The maximum surface roughness was measured for the part having a build orientation of 45°. The maximum coefficient of friction value was determined as 0.355 for the sample with 45° orientation under 5 N load and dry environment. The maximum wear rate value was determined as 2.3249 × 10−4 mm3/Nmm for the sample with 0° orientation under 10 N load and dry state. The differences between build orientations should be considered when evaluating tribological properties. This article provides a new perspective to researchers and practitioners toward green tribology of polymer AM parts.