Interior Fill Research Articles

Precision Enhancement in Tough Polylactic Acid Material Extrusion: A Systematic Response Surface Investigation for Sustainable Manufacturing

<div>This research systematically explores the significant impact of geometrical dimensions within fused deposition modeling (FDM), with a focus on the influence of raster angle and interior fill percentage. Through meticulous experimentation and the application of response surface modeling (RSM), the influence on critical parameters such as weight, length, width at ends, width at neck, thickness, maximum load, and elongation at tensile strength is thoroughly analyzed. The study, supported by ANOVA, highlights the notable effects of raster angle and interior fill percentage, particularly on width at ends, width at neck, and thickness. During the optimization phase, specific parameters—precisely, a raster angle of 31.68 and an interior fill percentage of 27.15—are identified, resulting in an exceptional desirability score of 0.504. These insights, substantiated by robust statistical data, fill a critical gap in the understanding of 3D-printed parts, offering practical recommendations for superior mechanical performance across diverse applications.</div>

Fused deposition modeling three-dimensional printing of flexible polyurethane intravaginal rings with controlled tunable release profiles for multiple active drugs

We designed and engineered novel intravaginal ring (IVR) medical devices via fused deposition modeling (FDM) three-dimensional (3D) printing for controlled delivery of hydroxychloroquine, IgG, gp120 fragment (encompassing the CD4 binding site), and coumarin 6 PLGA-PEG nanoparticles (C6NP). The hydrophilic polyurethanes were utilized to 3D-print reservoir-type IVRs containing a tunable release controlling membrane (RCM) with varying thickness and adaptable micro porous structures (by altering the printing patterns and interior fill densities) for controlled sustained drug delivery over 14 days. FDM 3D printing of IVRs were optimized and implemented using a lab-developed Cartesian 3D printer. The structures were investigated by scanning electron microscopy (SEM) imaging and in vitro release was performed using 5 mL of daily-replenished vaginal fluid simulant (pH 4.2). The release kinetics of the IVR segments were tunable with various RCM (outer diameter to inner diameter ratio ranging from 1.12 to 2.61) produced from FDM 3D printing by controlling the printing perimeter to provide daily zero-order release of HCQ ranging from 23.54 ± 3.54 to 261.09 ± 32.49 µg/mL/day. IgG, gp120 fragment, and C6NP release rates demonstrated pattern and in-fill density-dependent characteristics. The current study demonstrated the utility of FDM 3D printing to rapidly fabricate complex micro-structures for tunable and sustained delivery of a variety of compounds including HCQ, IgG, gp120 fragment, and C6NP from IVRs in a controlled manner.Graphical abstract

Deterioration of the Mechanical Properties of FFF 3D-Printed PLA Structures

Poly(lactic acid) (PLA) is a biodegradable polymer material used for the fabrication of objects by fused filament fabrication (FFF) 3D printing. FFF 3D printing technology has been quickly spreading over the past few years. An FFF-3D-printed object is formed from melted polymer extruded from a nozzle layer-by-layer. The mechanical properties of the object, and the changes in those properties as the object degrades, differ from the properties and changes observed in bulk objects. In this study we evaluated FFF-3D-printed objects by uniaxial tensile tests and four-point flexural tests to characterize the changes of three mechanical properties, namely, the maximum stress, elastic modulus, and breaking energy. Eight types of test pieces printed directly by an FFF 3D printer using two scan patterns and two interior fill percentages (IFPs) were tested by the aforesaid methods. The test pieces were immersed in saline and kept in an incubator at 37 °C for 30, 60, or 90 days before the mechanical testing. The changes in the mechanical properties differed largely between the test piece types. In some of the test pieces, transient increases in strength were observed before the immersion degraded the strength. Several of the test piece types were found to have superior specific strength in the tests. The results obtained in this research will be helpful for the design of PLA structures fabricated by FFF 3D printing.

An Impact Crater Origin for the InSight Landing Site at Homestead Hollow, Mars: Implications for Near Surface Stratigraphy, Surface Processes, and Erosion Rates

AbstractThe InSight mission to Mars landed within Homestead hollow on an Early Amazonian lava plain. The hollow is a 27‐m‐diameter, 0.3‐m‐deep quasi‐circular depression that shares morphologic and sedimentologic characteristics to degraded impact craters. Unlike the intercrater plains outside of the hollow, the interior lacks cobbles and is dominated by loose sand, granules, and pebbles. Fresher craters near the landing site exhibit meter‐scale bedforms in their ejecta and on their floors due to sediment trapping. The sedimentology of the interior fill of Homestead hollow suggests similar trapping. The hollow falls along a morphologic continuum that requires low rates of rim degradation and fill. Crater degradation rates (rim erosion plus filling) in the landing site decline nonlinearly through time from 10−2 to 10−4 m/Myr as craters evolve to a hollow‐like form. Rim erosion rates are lower initially, at 10−3 m/Myr, but converge with degradation rates to 10−4 m/Myr. This implies that while filling plays an important role soon after crater formation, it is limited in later stages. Crater statistics indicate that the bulk of the fill occurred in the first ~50 Myr for Homestead hollow. The estimated maximum age of the hollow is ~400 to 700 Myr. This requires near‐zero fill aggradation and long‐term soil stability for the bulk of the crater's history. Fill stability manifests in Homestead hollow as a ~5‐ to 10‐cm‐thick duricrust, formed by exchanges of atmospheric water vapor with soil. The estimated degradation in the hollow requires ~2 to 3 m of sedimentary fill beneath the lander.

Influence of Process Parameters on Rapid Prototype Part Using Response Surface Methodology

In this research the influencing process parameters on fused deposition modelling of Acrylonitrile Butadiene Styrene (ABS) parts were studied. The two process parameters, layer thickness and model interior fill style are studied. The specimens were built, tests carried out to find out the surface roughness quality of the specimens. The results analyzed using Response Surface Methodology (RSM). The result indicates that the specimen Type 1 with the 0.254mm layer thickness and solid model interior fill style is the best specimen among the types of specimens tested.

Influence of Process Parameters on Rapid Prototype Part Using Response Surface Methodology

In this research the influencing process parameters on fused deposition modelling of Acrylonitrile Butadiene Styrene (ABS) parts were studied. The two process parameters, layer thickness and model interior fill style are studied. The specimens were built, tests carried out to find out the surface roughness quality of the specimens. The results analyzed using Response Surface Methodology (RSM). The result indicates that the specimen Type 1 with the 0.254 mm layer thickness and solid model interior fill style is the best specimen among the types of specimens tested.

Modeling diverse responses to filled and outline shapes in macaque V4.

Visual area V4 is an important midlevel cortical processing stage that subserves object recognition in primates. Studies investigating shape coding in V4 have largely probed neuronal responses with filled shapes, i.e., shapes defined by both a boundary and an interior fill. As a result, we do not know whether form-selective V4 responses are dictated by boundary features alone or if interior fill is also important. We studied 43 V4 neurons in two male macaque monkeys ( Macaca mulatta) with a set of 362 filled shapes and their corresponding outlines to determine how interior fill modulates neuronal responses in shape-selective neurons. Only a minority of neurons exhibited similar response strength and shape preferences for filled and outline stimuli. A majority responded preferentially to one stimulus category (either filled or outline shapes) and poorly to the other. Our findings are inconsistent with predictions of the hierarchical-max (HMax) V4 model that builds form selectivity from oriented boundary features and takes little account of attributes related to object surface, such as the phase of the boundary edge. We modified the V4 HMax model to include sensitivity to interior fill by either removing phase-pooling or introducing unoriented units at the V1 level; both modifications better explained our data without increasing the number of free parameters. Overall, our results suggest that boundary orientation and interior surface information are both maintained until at least the midlevel visual representation, consistent with the idea that object fill is important for recognition and perception in natural vision. NEW & NOTEWORTHY The shape of an object's boundary is critical for identification; consistent with this idea, models of object recognition predict that filled and outline versions of a shape are encoded similarly. We report that many neurons in a midlevel visual cortical area respond differently to filled and outline shapes and modify a biologically plausible model to account for our data. Our results suggest that representations of boundary shape and surface fill are interrelated in visual cortex.

The Effects of Build Parameters and Strain Rate on the Mechanical Properties of FDM 3D-Printed Acrylonitrile Butadiene Styrene

In this paper, the effects of build parameters on the mechanical properties of 3D-printed acrylonitrile butadiene styrene (ABS) produced using fused deposition modeling (FDM) are investigated. Full factorial experimental design incorporating a 2-level, 3-factor design with raster angle, layer thickness and interior fill style was carried out. Tensile tests were performed at four different strain rates to determine how the build parameters influence the mechanical properties of the 3-D printed ABS and to assess its strain rate sensitivity under quasi-static loading. It was found that the modulus of toughness of ABS material is most influenced by raster angle, while the interior fill style is the most dominant build parameter that dictates the specimen’s modulus of resilience, yield strength and ultimate tensile strength. At all strain rates, it is further revealed that higher mean values of yield strength, ultimate tensile strength and modulus of resilience were obtained when the interior fill style is solid as opposed to high density. This can be attributed to the denser structure and higher effective cross-sectional area in solid interior fill style in comparison with high density interior fill style. However, the influence of the layer thickness on the investigated mechanical properties was found to be inconsistent. It was noted that specimens built with both 0.254 mm layer thickness and the cross [0°/90°] raster angle had superior mechanical properties when compared to those built with the 0.3302 mm layer thickness and cross [0°/90°] raster angle. This suggests that there is a key interaction between the layer thickness and the raster angle. At any FDM build parameter, it was found that all the mechanical properties investigated in this work exhibited modest sensitivity to strain rates. This study has provided a platform for an appropriate selection of build parameters combinations and strain rates for additive manufacturing of 3D-printed ABS with improved mechanical properties.

Comparison of strength characteristics of polylactic acid test pieces with low interior fill percentage formed by a 3D-printer

Comparison of strength characteristics of polylactic acid test pieces with low interior fill percentage formed by a 3D-printer

Innovative Foundry Technology and Material Using Fused Deposition Modeling and Polylactic Acid Material in Sand Casing

In sand casting, Fused Deposition Modeling (FDM) printing by using Poly Lactic Acid (PLA) filament is one of the innovative foundry technologies being adopted to substitute traditional pattern making. Several literatures have reported the influence of process parameters such as raster angle and print speed on some mechanical properties of FDM-printed, PLA-prototypes used in other applications. This study investigated the effects of interior fill, top solid layer, and layer height on the compressive strength of rapid patterns for sand casting application. Different values of the process parameters were used to print the pre-defined samples of the PLA-specimens and a compression test was performed on them. The coupled effects of the process parameters on compressive strength were investigated and the optimum values were determined. Interior fill of 36%, layer height of 0.21 mm and top solid layer of 4 were found to produce a FDM-printed, PLApattern that sustained a compaction pressure of 0.61 MPa. A simulation analysis with ANSYS® to compare failure modes of both experiment and model shows a similarity of buckling failure that occurred close to the base of each specimen.

Minimizing voids for a material extrusion-based process

PurposeAfter experimental testing, it was recognized that a component’s strength relationship with respect to the volume material usage is inconsistent and that failures occurred in regions of voids. The purpose of this study is to present an optimal toolpath for a material extrusion process to minimize voids and discontinuities using standard parameters and settings available for any given machine.Design/methodology/approachTo carry out this study, a literature review was performed to understand the influence of the build parameters. Then, an analysis of valid parameter settings to be targeted was performed for a commercial system. Fortus 400 machine build parameters are used for the case studies presented here. Optimal relationships are established based on the geometry and are to be applied on a layer-by-layer or sub-region basis and available machine build options. The component geometry is analyzed and decomposed into build regions. Matlab® is used to determine a standard (available) toolpath parameters with optimal variables (bead height, bead width, raster angle and the airgap) for each layer/build region.FindingsIt was found that the unwanted voids are decreased by up to 8 per cent with the new model. The final component will contain multiple bead widths and overlap conditions, but all are feasible as the available machine solutions are used to seed the model.Practical implicationsUnwanted voids can create failure points. Introducing an optimization solution for a maximized material fill strategy using existing build options will reduce the presence of voids and will eliminate “chimneys” or a void present in every layer of the component. This solution can be implemented using existing machine-toolpath solutions.Originality/valueThis study demonstrates that existing build settings and toolpath strategies can be used to improve the interior fill by performing targeted optimization strategies for the build parameters.

Spin-it

Spinning tops and yo-yos have long fascinated cultures around the world with their unexpected, graceful motions that seemingly elude gravity. We present an algorithm to generate designs for spinning objects by optimizing rotational dynamics properties. As input, the user provides a solid 3D model and a desired axis of rotation. Our approach then modifies the mass distribution such that the principal directions of the moment of inertia align with the target rotation frame. We augment the model by creating voids inside its volume, with interior fill represented by an adaptive multi-resolution voxelization. The discrete voxel fill values are optimized using a continuous, nonlinear formulation. Further, we optimize for rotational stability by maximizing the dominant principal moment. We extend our technique to incorporate deformation and multiple materials for cases where internal voids alone are insufficient. Our method is well-suited for a variety of 3D printed models, ranging from characters to abstract shapes. We demonstrate tops and yo-yos that spin surprisingly stably despite their asymmetric appearance.

Integrated diagnostic analysis of inertial confinement fusion capsule performance

A conceptual model is developed for typical inertial confinement fusion implosion conditions that integrates available diagnostic information to determine the stagnation properties of the interior fill and surrounding shell. Assuming pressure equilibrium at peak compression and invoking radiative and equation-of-state relations, the pressure, density, and electron temperature are obtained by optimized fitting of the experimental output to smooth, global functional forms. Typical observational data that may be used includes x-ray self-emission, directional neutron time-of-flight signals, neutron yield, high-resolution x-ray spectra, and radiographic images. This approach has been validated by comparison with radiation-hydrodynamic simulations, producing semi-quantitative agreement. Model results implicate poor kinetic energy coupling to the hot core as the primary cause of the observed low thermonuclear burn yields.

Capric–myristic acid/vermiculite composite as form-stable phase change material for thermal energy storage

Phase change materials (PCMs) can be incorporated with building materials to obtain novel form-stable composite PCM which has effective energy storage performance in latent heat thermal energy storage (LHTES) systems. In this study, capric acid (CA)–myristic acid (MA) eutectic mixture/vermiculite (VMT) composite was prepared as a novel form-stable PCM using vacuum impregnation method. The composite PCM was characterized using scanning electron microscope (SEM) and Fourier transformation infrared (FT-IR) analysis technique. Thermal properties and thermal reliability of the composite PCM were determined by differential scanning calorimetry (DSC) analysis. The CA–MA eutectic mixture could be retained by 20 wt% into pores of the VMT without melted PCM seepage from the composite and therefore, this mixture was described as form-stable composite PCM. Thermal cycling test showed that the form-stable composite PCM has good thermal reliability and chemical stability although it was subjected to 3000 melting/freezing cycling. Thermal conductivity of the form-stable CA–MA/VMT composite PCM was increased by about 85% by introducing 2 wt% expanded graphite (EG) into the composite. The increase in thermal conductivity was confirmed by comparison of the melting and freezing times of the CA–MA/VMT composite with that of CA–MA/VMT/EG composite. The form-stable PCM including EG can be used as energy absorbing building material such as lightweight aggregate for plaster, concrete compounds, fire stop mortar, and component of interior fill for wallboards or hollow bricks because of its good thermal properties, thermal and chemical reliability and thermal conductivity.

Breccia dikes and crater‐related faults in impact craters on Mars: Erosion and exposure on the floor of a crater 75 km in diameter at the dichotomy boundary

Abstract— Environmental conditions on Mars are conducive to the modification and erosion of impact craters, potentially revealing the nature of their substructure. On Earth, postimpact erosion of complex craters in a wide range of target rocks has revealed the nature and distribution of craterrelated fault structures and a complex array of breccia and pseudotachylyte dikes, which range up to tens of meters in width and tens of kilometers in length. We review the characteristics of fault structures, breccia dikes, and pseudotachylyte dikes on Earth, showing that they occur in complex network‐like patterns and are often offset along late‐stage crater‐related faults. Individual faults and dikes can undulate in width and can branch and bifurcate along strike. Detailed geological analyses of terrestrial craters show that faults and breccia dikes form during each of the major stages of the impact‐cratering process (compression, excavation, and modification). We report here on the discovery of prominent, lattice‐like ridge networks occurring on the floor of a highly modified impact crater 75 km in diameter near the dichotomy boundary of the northern lowland and southern upland. Interior fill and crater‐floor units have been exhumed by fluvial and eolian processes to reveal a unit below the crater floor containing a distinctive set of linear ridges of broadly similar width and forming a lattice‐like pattern. Ridge exposures range from ˜1–4 km in length and ˜65–120 m in width, are broadly parallel, straight to slightly curving, and are cross‐cut by near‐orthogonal ridges, forming a box or lattice‐like pattern. Ridges are exposed on the exhumed crater floor, extending from the base of the wall toward the center. On the basis of the strong similarities of these features to terrestrial crater‐related fault structures and breccia dikes, we interpret these ridges to be faults and breccia dikes formed below the floor of the crater during the excavation and modification stages of the impact event, and subsequently exhumed by erosion. The recognition of such features on Mars will help in documenting the nature of impact‐cratering processes and aid in assessment of crustal structure. Faults and breccia dikes can also be used as data for the assessment of post‐cratering depths and degrees of landform exhumation.

Construction and Performance of Two Large Rockfill Embankments

TWO rockfill embankments were constructed as sites for building refinery structures in western Colorado. The fills ranged in maximum thickness from 80‐155 ft (25‐48 m). Test fills were done to develop construction‐method specifications that would produce an economic yet dense fill. It was assumed that if dense fills were constructed, long‐term settlement of the fills could be minimized. The specifications developed called for a maximum 2‐ft (0.6‐m) lift thickness compacted by six passes of a smooth‐drum vibratory compactor. Settlements of the fills were monitored for 44‐70 months after construction. The results of the monitoring indicated that the majority of settlement occurs within nine to 18 months after construction. Interior fill points settled less on a percentage basis than points near the fill crest. Overall, the total settlement of the fills was 0.05‐0.10% of the fill height for interior points and 0.10‐0.20% of the fill height for crest points. The results of the settlement monitoring confirmed that the test‐fill program and method specifications provided for the construction of fills in which long‐term settlements were minimized.