Fused Deposition Modeling Type Research Articles

4D Printing of novel poly(ethylene-vinyl acetate) / poly(butyl methacrylate-co-isobutyl methacrylate) shape memory polymer blends

4D printing is a technology that combines additive manufacturing with shape memory polymers, aiming to enhance the functionality of 3D printed structures. Filaments made from thermoplastic polymers are commonly used in Fused Deposition Modeling (FDM), which is one of the most prevalent types of 3D printing. Here, novel heat-responsive shape memory polymer blends were produced from ethylene-vinyl acetate copolymer (EVA) and poly(butyl methacrylate-co-isobutyl metacrylate) polymers. The effect of blend composition on the morphological, thermal, mechanical, and shape memory properties was investigated. The blend (60E-40B) containing 60 % by weight EVA and 40 % by weight BMA-co-iBMA exhibited optimum shape memory performance with a shape fixing (Rf) of 94.1 % and a shape recovery (Rr) of 94.5 % at a shape transition temperature (Ttrans) of 55 °C. Filament for the 60E-40B blend was produced for FDM type 3D printers, and 4D parts for various applications were printed using this filament. These 4D printed parts, designed for robotic grippers, self-assemble rivets, movable cog-wheel teeth, surface traps, and finger splints, displayed shape recovery characteristics in both hot oven and hot water environments.

ОПТИМИЗАЦИЯ РЕЖИМА 3-D ПЕЧАТИ ТУРБИННОЙ МЕШАЛКИ ДЛЯ ДИСПЕРГИРОВАНИЯ РАСТВОРОВ ПОЛИМЕРНЫХ КОМПОЗИТОВ

The design of the turbine stirrer is characterized by a rather complex shape of working surfaces and during its manufacture by traditional methods unique molds are required for each type of stirrer, increased material and labor costs are required. The use of 3D printing allows you to obtain products with a complex surface configuration, with minimal costs and which do not require subsequent machining. Analysis was carried out and selection of 3D printing type and material of turbine stirrer intended for mixing of elastomeric nanocomposite solutions components was carried out. FDM (Fused Deposition Modeling) is the most suitable type of 3D printing for solving design and technological problems in the manufacture of turbine stirrers. Plastics of the brands ABS, PLA and PETG have become very widespread in this type of 3D printing. The highest mechanical properties, chemical resistance and the lowest price of the materials under consideration are PETG plastic, which was chosen for the manufacture of a turbine stirrer designed to mix and disperse solutions of elastomeric nanocomposites. An active experiment was implemented according to the В2 plan. The samples are PETG plastic plates printed on a Flying Bear Ghost 5 3D printer. The main mode parameters of 3D printing by FDM type, which determine the strength of samples and printing performance, are: the number of concentric lines that make up the wall of the printed product and the line width. A regression model of the dependence of strength of samples made of PETG plastic on the number and width of lines in 3D printing was obtained. The optimal 3D printing mode of the turbine stirrer is set, providing high strength of the product and performance of the technology.

Stereolitografi ve eriyik yığma modellemesi eklemeli imalat yöntemleriyle üretilen numunelerin mekanik özelliklerinin karşılaştırılması

Additive manufacturing (AM) technology has attracted significant attention with the rapid fabri-cation of 3D parts for various applications. With fused deposition modeling (FDM) and stereo-lithography (SLA), the most used methods in this technology, it is possible to produce functional parts with complex shapes quickly and cheaply. Determining the mechanical properties of the parts produced by these methods is important in terms of efficient operation in the relevant fields. This study, 45 test specimens were fabricated using three different polymer materials (UVR, PLA, and ABS) in SLA and FDM type 3D printers, including tensile, compression, and 3-point bending tests. Samples are printed at a 75% fill rate according to ASTM standards. Experimental studies were carried out to determine the mechanical properties of the samples. Among the samples, the highest strength values in tensile, compression and bending test samples made of UVR material were 60.39 MPa, 127.74 MPa and 118.35 MPa, respectively. In addition to mechanical properties, hardness, and SEM analyses were performed to examine the surface roughness, surface topography, and composition of the samples. As a result, the effects on the mechanical properties of the samples fabricated by the UVR-based SLA method and the PLA-ABS-based FDM method were examined and compared.

Pengaruh Parameter Proses 3D Printing Terhadap Kuat Bentur Menggunakan Fiamen Polycarbonate

The existence of this 3D printing technology in manufacturing has brought big companies to the world of industry. One of the rapid prototyping technologies that are often found in the market today is the FDM type of technology. Fused Deposition Modeling (FDM) technology is a printing technique used to print products using fibrous materials, printed products have ideal geometric characteristics. Impact test is a method used to determine the strength, hardness and ductility of a material. In this impact test, rapid loading is used. The method used is Taguchi and this study aims to obtain optimal process parameters in the impact test. Printing was carried out with a 3D printing machine Creality Ender 3 which printed 81 specimens. Then the impact test was carried out so that the highest average value of the impact test results was in experiment number 27 with a value of 0.00392 joules and for the lowest impact test value was in experiment number 1 with a value of 0.00291 Joules. The method used in this process parameter optimization research is the Taguchi L9 OA method. for the factors used, namely printing speed, infill layer thickness, wall thickness, print temperature. . the results of the research that has been carried out show the optimum parameter values ​​and parameters that influence the impact test successively, namely printing speed (40mm/s), infill layer thickness (0.2mm), wall thickness (2.0mm), print temperature (250 ℃), bed temperature(250℃), infill overlap(30mm), raft extra margin(7.5mm), wall printing speed(22.5mm/s). It was found that the highest average value of the impact test results was in experiment number 2 with a value of 0.031 joules and the lowest impact test value was in experiment number 7 with a value of 0.026 Joules.

3D Printing Model of Abdominal Cavity of Liver Transplantation Recipient to Prevent Large-for-Size Syndrome.

The application of three-dimensional (3D) printing has been increasing and we invented cost-effective and time-saving 3D printed model of intra-abdominal cavity which was utilized in liver transplantation (LT) to prevent large-for-size syndrome. 3D printings were performed on potential adult recipients with small cavity and pediatric patients scheduled for transplantation during July 2020 - September 2021. Based on the computed tomography of the recipient, the inner surface of the abdominal cavity was outlined. The line was marked with a distance of 1 - 3 cm. Then, the outlined data were reconstructed as a 3D model and printed by a fused deposition modeling type 3D printer with a thickness of 2 mm. Pillars and footings for holding the lines were printed and assembled altogether. During deceased donor organ procurement, the size of the graft was compared to that of the printed model. For living donor LT, preoperatively planned liver graft was printed and was physically placed into the 3D printed abdominal cavity. All the 16 cases with 3D printed abdominal cavity showed appropriate fitting of the donor's liver graft to both the 3D printed model and actual recipient's abdominal cavity with no large-for-size syndrome after LT. Median time for manufacturing the model was 576 min (IQR 434 - 680) and estimated median cost for the filament was US$ 1.6 (IQR 1.2 - 1.7). The 3D printed abdominal cavity model can be manufactured in <10 h and was useful for preventing large-for-size syndrome in small-sized recipients.

Motion Control of the Robot Arm Manufactured with a Three-Dimensional Printer and Hardness Detection of Objects

In the study, a robotic arm was produced using a Fused Deposition Modeling (FDM) printer, one of the 3D printing technologies. Tactile sensing and motion planning of the produced robot arm was investigated by using image processing techniques and machine learning algorithms. This study aims to investigate and apply innovative approaches using image processing techniques and deep learning algorithms to prevent uncontrolled force application of the robotic arm and to solve tactile grip problems. In this study, solid models of the parts were designed by CAD program and manufactured using FDM type three-dimensional printer. The control system of the robotic hand consists of a Raspberry Pi control card, servo motors, pressure sensors, and a camera. Tactile sensing was performed by measuring the hardness of the product with pressure sensors placed on each fingertip of the robotic arm. Raspberry pi control card is receive the data from the sensors are process them, after that the appropriate motion and clutch pressure information is sent to the servo motors. A reference data set for the robotic arm was prepared with the possible movements of the human hand obtained using the camera. Image processing is provided by using the Gaussian filtering method on the images of the data set. In addition, the angular position of the robotic arm's motion was optimized using machine learning algorithms on the data set, and the motion planning of the robot arm was classified with 90% accuracy using HitNet, CNN, Capsule Networks, and Naive Bayes deep learning models. Among the deep learning models which were very successful are compared each other according to the performance evaluation criteria, for the motion planning of the robotic arm; The accuracy rate was 97.23% with the HitNET algorithm, 97.48% with CNN, 98.58% with the Capsnet algorithm and 98.61% with the Naive Bayes model. As a result of the performance evaluation criteria; It has been observed that the Naive Bayes model gives more successful results than other models with 98.61% accuracy, 98.63% specificity, 98.65% sensitivity, 1.39 error rate, and 68.64% F-measure value.

教育用途 FDM 型 3D プリンターから作成した機械部品の簡易的3次元計測による品質評価法

In recent years, commercial mass production of mechanical parts has been realized using powder 3D printers. However, the FDM (Fused Deposition Modeling) type 3D printers used in industrial education are often used only to roughly confirm the actual shape. This is due to suffering from decrease in molding accuracy owing to such as distortion caused by the thermal expansion characteristics of the material and the effects of the relative humidity. In other words, the problem is that machine parts designed with 3D CAD often do not faithfully reproduce the actual shape. Therefore, evaluation of molding accuracy is necessary to ensure the function of the machine itself in case that the machine parts created by the FDM type 3D printer are combined to produce a machine. In this paper, we propose a method to evaluate the quality of mechanical parts by means of a machine learning that uses the results of simple shape measurements and strength tests.

Applicability of the Specimens Fabricated by Fused Deposition Modeling for Evaluating Acoustic Emission Measurement Systems

The authors have been conducting studies on standard specimens for the acoustic emission (AE) method that realize the quantitative discussion about the performance of measurement systems, including both instruments and engineers’ skills, in the environment equivalent to the practical situation. In this study, the applicability to standard specimens was examined for those fabricated by the fused deposition modeling type 3D printer. The behavior of AE generation was monitored during the four-point bending test using a desktop-type loading instrument for the specimen laminated toward the longitudinal direction and having a conical surface defect. It was shown that multiple delaminations associating AE signals occur on the extensional line of the cone tip. This fact implies that the intended actual AE events are generated intermittently at specific locations. Hence, it was found that the specimen has potential as standard specimens for the AE method with low cost and convenience of use.

3D Printing-Assisted Soft Capacitive Inclinometers for Simultaneous Monitoring of Tilt Angles and Directions

This study presents capacitive-type inclinometers composed of flexible polymer pillars and dome-shaped roof frames that were manufactured using the three-dimensional (3D) printing method. Polylactic acid (PLA) filaments and acrylonitrile butadiene styrene (ABS) filaments were printed by the fused deposition modeling type 3D printer to fabricate the dome-shaped roof frames and the polymer curing molds, respectively. The operating principle of the inclinometer was to detect the change in capacitance between the helix-shaped electrode coiled around the polymer pillar and the built-in electrode in the roof frame. When the inclinometer was tilted, the polymer pillar was bent, and the physical distance between each electrode was changed with respect to the tilt angle and direction. Therefore, the tilt angles and directions were simultaneously estimated by distinguishing the capacitance and peak capacitance, respectively. The results of the experiments revealed that the inclinometer using the polymer pillar that was electrically connected to a standard weight and the roof frame with a roof angle of 45° exhibited a higher sensitivity (1.391 pF at a tilt angle of 40°) compared to those using roof angles of 90° and 135°. This study supports the use of 3D printing technology for the facile manufacturing of inclinometers that can detect tilt angles and directions simultaneously, which is not achievable with conventional inclinometers.

Modeling and analysis of flexural strength with fuzzy logic technique for a fused deposition modeling ABS components

Fused Deposition Modeling (FDM) is an additive manufacturing technique used for prototype, physical modeling, and end-of-line production. Proper parameter selection is essential for producing high-quality items with suitable mechanical properties, such as flexural strength. Four critical process variables, such as layer thickness, raster width, raster angle, and orientation angle, are investigated in this study. The link between these factors and the flexural strength of the Acrylonitrile Butadiene Styrene (ABS) printed components are analysed using analysis of variance. The fuzzy logic (FL) approaches were used to develop a prediction model. The test samples are made on a 3D forge dreamer II printing machine of the FDM type. In Minitab software, the Taguchi mixed L18 orthogonal design technique was used to organize the trials. The result showed that the raster angle has the most significant parameter affecting flexural strength when compere with layer thickness, raster width and orientation angle. The fuzzy logic models provided high accuracy prediction of flexural strength with the maximum percentage error of 3.62%, and this revealed that the model and the experimental data were in good agreement.

COMPARISON OF OPTIMIZATION METHODS FOR ADDITIVE MANUFACTURING AND MACHINING METHODS

Thanks to the developing technology and softwares, analysis and optimization of the engineering parts can be done through computer programs nowadays. Softwares play an active role not only in analysis but also in reducing the material cost as a result of lightening the part with changes in design. Manufacturing methods and comparisons of these methods with each other have always been the subject of research. Choosing the methods of manufacturing of material has a great importance for enterprise. The loads and strength of the designed part under operating conditions are very important for the manufacturer. The pros and cons of both production methods which are additive manufacturing and machining have been investigated and these methods have been compared for the use of Pet-G material. An FDM (Fused Deposition Modeling) type 3D (three-dimensional) printer has been used in the additive manufacturing method and CNC Router (Computer Numerical Control Router) has been used for the machining method. A part design created in accordance with the mentioned manufacturing methods and its mechanical properties after its twice optimization have been examined and compared. After the optimizations, the targeted reduction on the mass of production has been achieved. After the optimization process, the sample has reduced by about 63% in volume and mass according to the design program. The mass of the sample, which is approximately 300 grams, has been reduced to 100 grams. As a result of the tests, it has been observed that the strength values of the samples manufactured by machining are higher.

The effect of UV irradiation on polyamide 6/carbon-fiber composites based on three-dimensional printing

In this research, we demonstrate the effect of ultraviolet-C (UV-C) irradiation of Polyamide 6/carbon-fiber (PA6/CF) composites. The PA6 and PA6/CF composites were fabricated using a fused deposition modeling type 3D printer with a single spool. These specimens were exposed for 0, 1, 3, 5, and 7 days under UV-C light irradiation. After exposure, the specimens were observed and characterized with contact angle measurements, Fourier transform infrared analysis, 3D fluorescence spectroscopy analysis, tensile tests, and scanning electron microscopy. As a result, PA6 was found to be more photo-oxidative degraded than PA6/CF. Furthermore, the 3D fluorescence images and emission spectra were shown to successfully coincide with the results of the photo-oxidative degradation reactions of PA6 and PA6/CF. In addition, the tensile test results showed a dramatic decrease in PA6 while PA6/CF did not decrease much, indicating that CF is useful not only as a reinforcement of the composite but also for UV protection.

Patient-Specific 3-Dimensional Printed Models for Planning Nasal Osteotomy to Correct Nasal Deformities Due to Trauma.

Nasal deformities due to trauma are more challenging to correct with rhinoplasty than nasal deformities of nontraumatic causes. Nasal osteotomy is an essential procedure for bone deviations. Preoperative planning is vital in these cases, but it is challenging to comprehend 3-dimensional (3D) structures of the nasal bone on 2-dimensional facial photographs and computed tomography images. We used a 3D-printing technique to fabricate real-size facial bone models with similar physical properties and texture as the actual bone. Furthermore, we established a precise surgical plan using simulated osteotomy on the 3D-printed model. Fused deposition modeling–type desktop 3D printer with polylactic acid filaments was used. A surgical plan was established using simulated osteotomy in 11 cases, and the actual surgery was performed as planned in 10 cases (90.9%). The 3D-printed model and stimulated osteotomy were useful for precise planning of osteotomy to correct nasal deformities due to trauma.

Process capability analysis of a 3D printing process

3D printing processes (3DP) are getting wider applications in manufacturing, medical and socio-cultural sectors. Owing to involvement of various controllable and uncontrollable factors, many challenges are faced in terms of dimensions and shape of the object. In order to maintain quality under control, performance capability analysis (PCA) is used as a popular statistical tool in 3DP to ascertain how well the process meets a set of specification limits. The process under scanner is fused deposition modeling (FDM) type of 3DP. In PCA, process capability indices (PCI) are used to determine the quality that the process is delivering practically by calculating the deviation of the process mean from the target mean. This work employs PCA on FDM type 3DP by computing six PCIs in order to determine deviation of the process mean from target mean. This will help in determining the stability and the capability of the process. So, this work is an attempt to employ PCA to improve the quality of the 3DP process. Consideration of six PCIs is the novelty of the work.

Drawing Electrochemical Sensors Using a 3D Printing Pen

This communication demonstrates that a 3D printing pen, commercially-available as a toy for kids, can be used to draw thermoplastic electrochemical sensors using conductive filaments over any desirable format and substrate. A polylactic acid filament containing graphene or carbon black was passed through the 3D pen that works as a handheld 3D printer (fused deposition modeling type). As proof-of-concepts, we select three designs, the first one analogous to a conventional carbon-paste electrode, the second one containing the three electrodes in a cylindrical tube and the third one similar to commercial screen-printed electrodes. The 3D pen was used to draw the thermoplastic electrodes inside the pockets of all devices until reaching the copper wires to establish electric contact. Customized 3D printed substrates were used to guide the application of the 3D pen. The fabricated electrodes were applied for the detection of dopamine and trace metals as well as to generate electrochemically a Prussian Blue modified sensor. Many other designs, conductive filaments and substrates can be combined with a 3D pen to draw electrochemical sensors as well as other electrochemical devices, with applications ranging from medical point-of-care platforms, energy-storage devices as well as for teaching purpose.

Tidy up cryo-EM sample grids with 3D printed tools

Cryo-EM technology has developed to the point of high-throughput structure determination of biological macromolecules embedded in vitreous ice. Nonetheless, challenging targets need extensive sample screening, often of many cryo-EM sample grids prepared under various conditions. We have designed and made tools for manipulating sample grids in storage cases. These tools are made of a plastic fiber using a wide-use 3D printer, a fused deposition modeling type, and polished under acetone gas. A grid case stacker organizes many frozen-hydrated cryo-EM grids and the stackers can be piled up inside a standard 50 mL centrifuge tube. We have also introduced tools that facilitate handling of grid cases under liquid nitrogen and a stocker of the grid retainers contained in a CRYO ARM electron microscope. Blueprints of the tools named CryoGridTools are available from a GitHub site.

Topology Optimization and Additive Manufacturing of Customized Sports Item Considering Orthotropic Anisotropy

Topology optimization is a shape optimization method connected with finite element (FE) structural analysis, and has recently received increasing attention owing to rapid evolution of additive manufacturing (AM). In this study, a rifle support for the sport biathlon is developed by combining three-dimensional (3D) scanning, FE analysis, topology optimization, and AM. Considering that the biathlon requires a stable shooting motion under hard breathing after a distance of cross-country skiing, the rifle support was designed to be fitted to a human body based on 3D scanning data. Topology optimization was then performed to reduce the part weight efficiently, and its structural safety and stiffness were evaluated by FE analyses considering the orthotropic material properties and the relevant printing directions. The optimized design and printing direction were showed 12.7% improvements in the specific stiffness and 23–43% improvements in the structural safety according to the direction. The final design was fabricated using a fused deposition modeling type 3D printer with acrylonitrile butadiene styrene filament. Compression tests were then performed to evaluate its structural safety, and the resulting relative critical force showed a 40% improvement in comparison with the original design.

Additive Manufacturing of SiC Ceramics with Complicated Shapes Using the FDM Type 3D-Printer

Silicon carbide (SiC) ceramics have excellent properties and widely used for high temperature applications. So far, joining techniques have been applied to fabricate large SiC ceramics with complicated shapes. In this work, the additive manufacturing (AM) technique was examined to fabricated SiC ceramics with complicated hollow structures using the Fused Deposition Modeling (FDM) type 3D-printer. To mold the hollow structure for the applications such as heat exchangers, the “support-less” condition must be achieved. Thus, extruded SiC-phenol resin compounds must be cured immediately after molding to keep the molded shapes. To increase the thermal conductivity of the SiC compounds, the combinations of commercial SiC powders with different average diameters were examined for increasing the volume fraction of SiC particles to the phenol resin. SiC compounds with optimized rheological properties for the modified FDM-type 3D-printer were successfully obtained.

Development of Multi-Material 3D Printer

We present development of multi-material Fused deposition modeling (FDM) 3D printer. Most of the FDM type of 3d printers are able to print plastics such as ABS, PLA and Nylon in a single run. In order to overcome this problem, we have developed an affordable multi-material 3D printer that can print an object with a different kind of soft and hard material in a single run. The combination of printing soft and hard materials in a single run will open the doors to various applications such as soft robotics, actuators and sensors. One of the main printing materials for this printer is the conductive based soft filament made by our laboratory “Soft & Wet Matter Engineering Laboratory”, along with other different soft filament and hard plastic filament to create a fully functional, multi-material printer to print objects in a single printing run with greater diversity and lower cost than any other single material printer. We have developed a single screw-based extruder 3D printer extruder type 3D printer that can print both soft and hard materials. Instead of using a filament to 3D print objects, we have used pellets of different materials, including carbon-based conductive composites. Such type of single screw base extruder 3D printer will be a new addition to the additive manufacturing process.

3D printing of electrically conductive hybrid organic–inorganic composite materials

We present preparation, characterization, and 3D printing of electrically conductive acrylonitrile butadiene styrene (ABS) polymer. The conducting ABS prepared by doping carbon fibers (150 μm in length) at 200 °C by using a thermo-plasto mill, with different weight percentage (10–60 wt%) of carbon fibers in ABS polymer matrix. The conductivity was measured by four-point probe that determines percolation threshold occurs at 15 wt%. Conductivity of 0.067 S/m was observed at 50 wt%. Melt extrusion technique was employed in order to fabricate cylindrical filament with a diameter of 1.75 mm. A standard fused deposition modeling type printer (Makerbot) was used to print the developed filament. The developed ABS electrically conductive composite can be potentially used for various applications, such as 3D printing of wires, circuits, sensors, resistors, heaters, robotics, MEMS and active microfluidics devices.