Prototype Manufacturing Research Articles

The process‐structure–property relationship of 3D printed G‐Polymer using fused filament fabrication technique

AbstractThe ever‐increasing demand for additive manufacturing (AM) is driven by the technology's rapid prototyping and flexible manufacturing benefits. Among the various AM techniques, fused filament fabrication (FFF) is one of the most commonly used techniques, in which thermoplastic polymer filaments are deposited layer by layer to create the final part. This technique has been used extensively in various sectors. However, new materials have yet to be developed for use in FFF. This research aims to introduce a new biodegradable highly amorphous polyvinyl alcohol (HAVOH), commercially known as G‐Polymer (GP), into the scope of FFF, to propose a process window for the fabrication of parts with enhanced mechanical properties and to discover the process‐structure–property relationship for this material. This study investigates the effect of five key parameters in GP FFF, including raster angle, number of contours, nozzle temperature, build platform temperature, and print speed. The results of the chemical, thermal, and thermo‐mechanical analysis of the filaments before and after hot extrusion of the 3D printer nozzle showed a significant increase in the mechanical properties of the hot‐extruded filaments. In addition, the mechanical characterization of 3D printed parts showed that increasing the number of contours can improve the mechanical properties of parts, while the raster angle can have a complex effect. The mechanical properties of the parts are also improved by reducing the temperature of the nozzle and the build platform. Printing speed, as an essential parameter in AM, was related to the previously mentioned parameters, and the results showed that increasing the printing speed could improve the UTS and Young's modulus of the 3D printed part.Highlights A novel biodegradable polymer (HAVOH) was introduced into the scope of FFF. The hot extruded G‐Polymer filament from the nozzle showed improved mechanical properties. 180°C nozzle and room temperature platform resulted in improved mechanical properties. 3D printed parts with +45°/−45° raster angle show improved mechanical properties 110 mm/s print speed results in higher mechanical strength than 70 mm/s print speed.

Key technologies of manufacturing and testing for the ITER blanket shield block

The SB is one of the main in-vessel components manufactured with SS316L(N)-IG to play a major role in neutron shielding, to support the FW panels and to supply the FW panel with cooling water. Cooling channels are located inside of the SB to remove the neutron heat deposition while keeping the structure temperature to acceptable levels. The water coolant is routed first through the plasma-facing first wall panel which is attached to the SB and then through the SB. A number of deep slits are introduced into the SB to disrupt eddy current loops and reduce the Electro-Magnetic (EM) loads on the support system and VV. Water headers are machined on the side of the module with 7–10 mm welded cover plates. A Procurement Arrangements (PAs) for the manufacturing and testing of the SBs have been signed with Korea (50 %) and China (50 %).As part of the PA in Korean Domestic Agency (KODA), Process Qualification (PQ) to ensure the manufacturing and testing ability of the SB was completed successfully through manufacture of a Full Scale Prototype (FSP) as an essential step before starting series production. This paper reports key technologies, such as machining, welding, NDE and hot helium leak testing, of manufacturing and testing for the ITER SB series production in Korea toward successful completion of the missions.

Additive manufacturing of sensor prototype based on 3D-extrusion-printed zirconia ceramics

Additive manufacturing of ceramics has attracted large interest due to its unique ability to rapidly prototype, low cost, and increased geometric complexity. Material extrusion technique is often considered for processing and shaping fine and dense ceramic structures because of the high solid loading in ink. In this work, 8 mol.% yttria-stabilized zirconia ink with 70 wt% ceramic loadings was prepared to print zirconia samples in horizontal and vertical directions, following two different filament orientations: 0/90° and ±45°. The study's main objective was to evaluate printing design influences on mechanical properties. This was assessed through flexural testing and digital image correlation analysis. Experimental findings showed that samples printed horizontally with ±45° filament orientation displayed the highest strength. A detailed inspection of fracture surfaces revealed that printing defects were the critical failure location sites formed after sintering and intimately related to printing design issues. After that, a conductive sensor was integrated into the surfaces of 3D-printed specimens by screen-printing silver-based conductive ink to analyze the structural health of zirconia samples. The sensing capabilities of printed conductive patterns were investigated using the four-point bending tests. The results demonstrated that the electrical resistance of the printed silver patterns increased as the applied load on zirconia substrates rose. It indicates that hybrid material extrusion and screen printing techniques are favored ways to manufacture sensors for structural detection of advanced 3D-printed ceramics.

A fully digital approach to replacing an obturator prosthesis using a 3D printed closed hollow bulb: Α dental technique

The replacement of an obturator prosthesis using conventional methods has multiple issues. Standard tessellation language files generated from the superimposition of an accurate intraoral scanning of the maxillary defect and direct data acquisition of the existing hollow bulb obturator can facilitate the precise design of the prosthesis, requiring only minor adjustments. Rapid prototyping manufacturing techniques seem to ensure precise control of the integrity of the prosthetic component completion. The success of the technique is the simplicity and repeatability of designing and fabricating a retrievable and easily repairable obturator.

Developing cyber-physical system and digital twin for smart manufacturing: Methodology and case study of continuous clarification

Biopharmaceutical production has recently begun transitioning toward the construction of highly advanced, digitalised production facilities, as per Industry Revolution 4.0 or smart manufacturing. Clarification is the bridging step in biotherapeutics continuous production, and this study proposes a Digital twin (DT) and a cyber-physical system (CPS) for the Cadence™ Acoustic Wave Separator (CAS), that uses the novel acoustic wave separation (AWS) technology for clarification of Chinese hamster ovary (CHO) cells. While the CPS - DT serves as the core, a real-time model based on the empirical and mechanistic relationship has been implemented in tandem to present a highly reliable hybrid model so as to improve the adaptability of the model. The framework employs a distributed control system (DCS), the heart of the CPS architecture, that updates the parameters of the physical system in real-time, thereby simplifying process control. To evaluate the hybrid-model predictive control strategy in real time, three case studies were conducted, which involved introducing abrupt turbidity pulses of high, low, and multi values. The sudden deviation in the turbidity of the feed sample was controlled by adjusting the acoustic power of the chamber (the control variable). The use of the proposed controller resulted in a 5 % mean deviation from the setpoint in the first chamber, while a > 33 % mean deviation resulted in the absence of the controller. The study's outcome demonstrates the high effectiveness of hybrid model-based CPS - DT control in consistently achieving high cell separation efficiency (> 90 %) and integrating the unit operation in a continuous processing train to establish a smart manufacturing prototype for the biopharmaceutical industry.

Development of a Compact Phase Shifter for the Decimeter Wavelength Range

This paper presents the results of a study aimed at miniaturizing a microstrip phase shifter with switched transmission lines. Two compact phase shifters have been obtained — one in which the classic section of the transmission line is replaced by a low-pass filter, and the second in which the power supply filters are made on SMD elements. When comparing the theoretical and experimental characteristics of phase shifters, a discrepancy has been discovered between them, which is associated with the difference in the dielectric constant of the substrates in the model and the prototype, as well as due to differences in the values of lumped elements and tolerances in the manufacture of prototypes.

Magnet Technology and Design of Superconducting Magnets for Heavy Ion Gantry for Hadron Therapy

Various initiatives in Europe have been launched to study superconducting magnets for a rotatable gantry suitable to deliver up to 440 MeV/A carbon ions for hadron therapy. One initiative is led by INFN inside an agreement with CERN, CNAO, and MedAustron aiming at designing and manufacturing a strongly curved cos θ dipole rated for 4 T central field and with a ramp rate of 0.15-0.4 T/s. Here we explore the suitability of dipole technology derived from HEP collider for a rotatable gantry that poses severe conditions on the thermal design (indirectly cooled coils). A second one is in the frame of the European program H2020-HITRIplus-WP8, aimed at exploring the feasibility of using the novel Canted Cosine Theta (CCT) concept to produce a superconducting dipole with similar characteristics. The scope is to design and built one or two prototypes with Nb-Ti rope, to see if this route could be a viable alternative. Finally in the European collaboration H2020-I. FAST-WP8 we are exploring both CCT in combined function design (dipole + quadrupole, in Nb-Ti) and the use of HTS (REBCO tapes) with CCT dipole layout, pursuing the design manufacture of small prototypes with European Industry. If HTS will be found successful, it will be a great benefit for the cryogenic design of the magnet system.

A Review of 3D Printing and Surgical Planning

Three-Dimensional Printing (3DP), also known as rapid prototyping or additive manufacturing, has revolutionized the field of medicine, particularly in preoperative planning. By transforming intricate Two-Dimensional (2D) medical imaging data into tangible, patient-specific Three-Dimensional (3D) models, 3DP enhances surgical precision and patient care. This technology facilitates detailed preoperative visualization, enabling surgeons to interact with accurate anatomical models, plan complex procedures, and anticipate potential challenges. The evolution of 3DP, driven by advances in Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA), has democratized access to affordable and sophisticated 3D printers, spurring innovation in medical applications. In this study, a comprehensive review of the literature on the integration of 3DP technology into preoperative planning is conducted. Applications across various surgical disciplines, including cardiovascular, orthopedic, craniofacial, neurosurgical, oncological, transplant, and pediatric surgeries are examined. Benefits of 3DP in providing tactile feedback, creating patient-specific surgical guides and implants, and enhancing surgical simulation and training are evaluated. Additionally, challenges associated with the high costs, time-intensive processes, and material limitations of 3DP are assessed. Findings demonstrate that 3DP significantly reduces operative times, improves surgical outcomes, and lowers complication rates. The study highlights the transformative impact of 3DP on surgical practice and underscores its potential for future advancements. With ongoing research and innovation in materials science, bioprinting, artificial intelligence, and augmented reality, 3DP is poised to further revolutionize preoperative planning, offering more personalized, precise, and patient-centered healthcare solutions.

Development of an Automatic Tree Coating Machine Based on Cooperative Functioning of Multiple Nozzles

Background: At present, the tree whitewashing in China is mainly based on the traditional manual whitewashing method, which has the shortcomings of high labor intensity, low efficiency, excessive wastage of paint, danger to human health, and poor adaptability to the strong seasonality of tree whitewashing. Objective: To reduce the sunburn and water evaporation of trees, prevent the invasion of diseases and pests, and to enhance the disease resistance of trees, the tree trunk coating mainly uses a traditional manual method. However, this mainstream manual whitewashing approach is labor- intensive and inefficient. To resolve the issue, an automatic spraying device for tree coating based on multisprinkler cooperative operation is designed. It can meet the requirements of tree whitening and replace manual operation. To some extent, this machine can reduce labor intensity and promote the healthy growth of trees. Methods: Through literature review and field research, the technical requirements and research status of tree whitewashing have been explored. The three-dimensional Software Solidworks has been used to model the rack assembly, device moving assembly, up and down moving assembly, nozzle moving support assembly, and spraying assembly, and then the three-dimensional assembly of the whole machine has been carried out. According to the simulation optimization results, the initial three-dimensional model is modified, and then the engineering drawing is drawn through the threedimensional model for prototype processing, manufacturing, and assembly. The schematic diagram and PCB pattern of the circuit board of the electronic control system have been drawn, the program of the controller k60dn512 single chip microcomputer has been written, simulation and debugging have been conducted, and the control system has been designed. Laboratory and field tests on the prototype have been conducted, and the device has been improved according to the test data. Results: Experiments show that the device can accurately spray trees with a trunk circumference of 50-125cm. When the trunk circumference is greater than 125 cm, repeated spraying can meet the spraying requirements. The trunk circumference is in the range of 50-80 cm, and the opening and closing angle is in the range of 80-100°. The spraying effect is good, and the average spraying coverage can reach 97.73%. The trunk perimeter is in the range of 80-125 cm, and the opening and closing angle is in the range of 100-120°. The spraying effect is the best, and the average spraying coverage can reach 98.06%. During the experiment, the spraying efficiency of the device can reach 100 trees/hour, which is significantly higher than the efficiency of manual operation. Conclusion: The device improves the efficiency and quality of tree spraying, reduces the labor intensity of operation, and realizes the high-efficiency spraying for tree coating.

Review on Recent Advance of 3DP-Based Pediatric Drug Formulations.

Three-dimensional printing (3DP) has emerged as a game-changing technology in the pharmaceutical industry, providing novel formulation development in the pharmaceutical sector as a whole, which improved patients' individualized therapy. The pediatric population is among the key targets for individualized therapy. Children are a diverse group that includes neonates, infants, and toddlers, each with unique physiological characteristics. Treatment adherence has a significant impact on safe and effective pharmacotherapy in the pediatric population. Improvement of therapeutic dosage forms that provide for the special demands of the pediatric population is a significant challenge for the pharmaceutical industry. Scientists have actively explored 3DP, a quick prototype manufacturing method that has emerged in recent years from many occupations due to its benefits of modest operation, excellent reproducibility, and vast adaptability. This review illuminates the most widely used 3DP technology and its application in the development of pediatric-friendly drug formulations. This 3DP technology allows optimization of pediatric dosage regimens and cases that require individualized treatment, such as geriatrics, renal impairment, liver impairment, critically ill, pregnancy populations, and drugs with nonlinear pharmacokinetics. The fast evolution of 3DP expertise, in addition to the introduction of pharmaceutical inks, has enormous promise for patient dosage form customization.

Development of Character Makeup Learning Videos for the Makeup and Beauty Department Students

Character Make-up is one of the materials consists of theory and practice. Based on the results of observations, it shows that Students have difficulty in determining the theme of character makeup which is the final project in this material. Based on these problems, this study aims to develop learning video on character makeup material. This video can be used as a reference for students looking for character makeup themes to complete assignments in character makeup courses. The method in this research is R&D method, with the Ploomp development model. The stages of the Ploomp model are initial investigation, development and manufacture of prototypes and the assessment phase. The conclusion of the research shows that the resulting character makeup learning video is valid which is shown in the results of the media expert validation test is 0.85 and the material expert validation is 0.88, while the practicality of the lecturers is 82% with practical criteria and the practicality of the students is 93.9% with very practical criteria. The resulting learning video is also effectively used, which is indicated by the difference in the value of student learning outcomes when the posttest is higher than the value of the pretest learning outcomes.

Advanced Strategies for the Fabrication of Multi-Material Anatomical Models of Complex Pediatric Oncologic Cases.

The printing and manufacturing of anatomical 3D models has gained popularity in complex surgical cases for surgical planning, simulation and training, the evaluation of anatomical relations, medical device testing and patient-professional communication. 3D models provide the haptic feedback that Virtual or Augmented Reality (VR/AR) cannot provide. However, there are many technologies and strategies for the production of 3D models. Therefore, the aim of the present study is to show and compare eight different strategies for the manufacture of surgical planning and training prototypes. The eight strategies for creating complex abdominal oncological anatomical models, based on eight common pediatric oncological cases, were developed using four common technologies (stereolithography (SLA), selectie laser sinterning (SLS), fused filament fabrication (FFF) and material jetting (MJ)) along with indirect and hybrid 3D printing methods. Nine materials were selected for their properties, with the final models assessed for application suitability, production time, viscoelastic mechanical properties (shore hardness and elastic modulus) and cost. The manufacturing and post-processing of each strategy is assessed, with times ranging from 12 h (FFF) to 61 h (hybridization of FFF and SLS), as labor times differ significantly. Cost per model variation is also significant, ranging from EUR 80 (FFF) to EUR 600 (MJ). The main limitation is the mimicry of physiological properties. Viscoelastic properties and the combination of materials, colors and textures are also substantially different according to the strategy and the intended use. It was concluded that MJ is the best overall option, although its use in hospitals is limited due to its cost. Consequently, indirect 3D printing could be a solid and cheaper alternative.

Design and Manufacture of Modular Robotic Cell prototype for application in different production processes

This work presents the design and development of a two-axis robotic cell with a modular and versatile approach for industrial applications. The aim is to enhance efficiency in industrial production through process automation. The modular design allows for future adaptations without significant structural changes. The results demonstrate an increase in production speed, a reduction in errors and waste, and greater consistency in product quality. The investment in this robotic cell is economically justified by its benefits. Safety measures have been implemented to ensure the integrity of operators. Additionally, various applications have been presented, such as the automation of manufacturing processes, painting, and parts organization. This project opens up opportunities for future research, such as process optimization, the integration of artificial intelligence, applications in Industry 4.0, and sustainability

Modeling and Sizing of a Y-Shaped Laminar Flow Micro-Fluidic Fuel Cell

The high demand for portable and desktop electronic devices requires mobile energy sources. Electronic devices, in general, are small when they are portable and require autonomy, sustainability, efficiency, and large enough periods of operability. In that sense, microtechnology, a type of technology related to the manufacture of prototypes or three-dimensional high-precision products in various materials ranging in size from tenths of microns to a few millimeters, has reached a boom in microfabrication of devices that are not exclusively electronic. Applications in several fields show that micro-energy sources are a focal point for commercializing prototypes in the mobility sector.The energy demand to supply micro-devices has been increasing in recent years. Considering the power output of the laminar flow microfluidic fuel cell (LFFC), it is a suitable solution to provide the required electrical energy in small devices. The absence of electrolytes and no requirement of platinum as catalytic material are two of the most important advantages of this type of fuel cell. The current study provides detailed information about the design and characteristics of an LFFC. A complete analysis of the different channel shapes is considered in this study, with the Y-shaped channel being selected as the best option. The impact of the inclination degree for the inlet channels has been considered to evaluate the average velocity the flow acquires in the channel. In addition, the voltage-current behavior considering the materials, fuel/oxidant, and design characteristics has been obtained through modeling approaches. Figure 1. Velocity profile and Reynolds number in the mid-plane of the Y-channel design Figure 1

Design of a large format printing platform that allows the extrusion of composite materials based on pellets and continuous fibers.

Commonly additive manufacturing (AM) through the technique of extrusion of molten material is used to manufacture prototypes. This is mainly because the materials commonly used in these technologies are thermoplastics of low mechanical performance. That is why this project seeks the development of an extrusion head that uses polymeric matrix composite materials in the form of pellets and reinforcements of natural or synthetic continuous fibers in order to be used in a large format MA system, which allows the manufacture of objects with better functional and mechanical performance than those found conventionally. For this purpose, different stages were carried out for the development of the project, starting with the design and construction of the printing platform; followed by the design of an extrusion head that allows the integration of a polymeric matrix and continuous fibers. As a result, printed traces were obtained using PLA pellets and glass fiber, resulting in a total coating of the fiber on the printed material.

Development of E-Module Based on Flip Book Media to Improve Students’ Speaking Skills

This research aims to develop E-module teaching materials based on Flip Book media to improve students' speaking skills. This research method used research and development with the Plomp model consisting of three stages: preliminary analysis phase, development or manufacture of prototypes, and assessment. The research instrument used a questionnaire, while the data analysis technique was quantitative. Based on the results of the media product feasibility test validation, the value was 85.62%, while the media feasibility test percentage was 89.58%. Next, the practicality test with a percentage of 0.86%, the results of the feasibility test and practicality test showed that the flip book-based e-module product developed was in the very valid category and suitable for use without revision. Meanwhile, the results of the N-gain score test for increasing students' speaking skills each semester towards increasing speaking skills are in the medium category, so it can be concluded that using e-modules based on Flip Book media can improve students' speaking skills.

Mini modular plant design for ethylene production using Martian atmosphere on Mars

A main shift in the competitive landscape of technology development is in 3D printing of complex articles made of variety of materials due to faster manufacturing and less human error in the production. In fact, it seems to be a viable candidate for the construction of structures for terrestrial and extraterrestrial life in future. Thus, new or damaged equipment in space explorations could be replaced instantly, and habitats could be manufactured using 3D printing in varying gravitational fields in the solar system. Among 3D printing materials, HDPE is commonly used in the projects, such as a prototype manufacturing or pipes or damp-proof membrane. This study initially focused on the preliminary design of the self-sustaining mini ethylene production plant from Martian atmosphere with scale-out architecture. UniSIM® was integrated with MATLAB® via CAPE-OPEN extension to design mini-ethylene production plant at low gravity. Ethylene capacity was found as 17.71 tons/year for 100 modules.

Hydrodynamic behaviour improvement of check valves through CFD analysis

In this article, the computer assisted design, flow simulation, optimization of production parameters and unique design prototype manufacturing of a check valve with 16 bar pressure, 5 m/s flow rate and 52000 m3/h flow coefficients, which have never been achieved before in the valve sector, were presented to the attention of the readers. Check valves have a critical role that do not allow reverse flow of the fluid passing through them and are generally designed to secure the pipeline. A small mistake in design may cause great damage in the system. For this reason, a new product of which the disc material exposed to 5 m/s fluid velocity, the body subjected to 16 bar pressure and the system with a flow coefficient of 52000 m3/h were designed by the Solidworks, the flow was simulated with CFD (Computational Fluid Dynamics), and the mechanical resistance was analysed by FEA (Finite Element Analysis). Fluent, CFD and mechanical modules of ANSYS were used to define the parameters of the design. The manufactures of the products designed in the computer environment have been produced by casting method with a 45% ferritic microstructure and impact resistance twice as high as the standard requirements have been implemented.

The use of soluble resin for additive manufacturing of automotive industry prototypes

The article describes the method of producing car parts using the Freeform method (FIM). The injection process into a mold obtained by 3D printing was simulated and the surface condition of the finished product made of high-strength PEEK was assessed.

Development of biodegradable filaments based on agro‐industrial waste and evaluation of process parameters in final properties

AbstractAdditive manufacturing, which has become popular in recent years, is the process of joining materials through the deposition of layers to form parts based on data from a 3D model and fused deposition modeling. The search for biodegradable materials for the production of filaments for 3D printing is increasing and opening up possibilities for the development of new sustainable products, including the use of lignocellulosic waste in the formulation. Therefore, the present work aims to develop polymeric filaments based on polybutylene adipate terephthalate and low content (2.5 and 5 wt%) of peanut and soybean shells and evaluate their potential for 3D printing. The charges were characterized in terms of chemical composition. Tensile and dimensional variation tests were performed on samples manufactured from two different filling orientations: −45/45° and 0/90°. The printability of the filament was based on the manufacture of prototypes of agricultural tubes that were also characterized by thermogravimetry and their morphology through scanning electron and optical microscopy. Both natural residues significantly (p < 0.05) affected the sample dimensions and mechanical properties. However, the filling orientation difference was insignificant (p > 0.05). The filaments produced showed good processability, thermal and dimensional stability. The samples produced showed a satisfactory surface finish without exposing load agglomerates. These results demonstrate the feasibility of using lignocellulosic fillers, such as peanut and soybean shells, in additive manufacturing and indicate the possibility of producing parts with varied geometries.Highlights Use of lignocellulosic residues in biodegradable filaments. The filament produced with fillers of peanut and soybean shells showed good processability. Filament fracture depends on the raster angle. It was possible to produce tubes with good surface quality and mechanical properties.