Rapid Prototyping Technology Research Articles

Evaluating process parameters of SLS part of polyamide-12 recycled powder using RSM

Abstract Selective laser sintering (SLS) is a highly flexible rapid prototyping (RP) technology which can use a wide range of powdered materials to generate high quality complex geometries directly from digital models. The SLS process uses a laser to sinter selected areas of powdered materials to produce solid objects layer by layer, according to the 2D data obtained from CT scan or MRI imaging techniques. This paper presents research work for evaluating the effect of process parameters on impact toughness and surface roughness of the part manufactured on Farsoon SS402P SLS from recycled ageing FS 3300PA which is PA-12 based powder and standard operating parameters using Response Surface Methodology (RSM) design of experiments. Impact tests have been performed as per the ASTM D6110 standard using recommendations from ISO 179-2. According to the results, effect of process parameters are successfully analyzed by employing impact toughness and surface roughness tests. Based on the results of the ANOVA analysis, impact toughness increases with increasing laser power (4.467 j/cm2 at 72.5 watts). Similarly, it is also clear from the results that the region with the lowest laser power, high layer thickness, and 90-degree orientation had the lowest surface roughness (3.46 μm).

Optimizing revision arthroplasty: the role of customized articulating spacers

Introduction The advancement of surgery is set against a backdrop of continuous development and surgical innovations have transformed the way clinical care is delivered. Revision surgery might be required to address complications of primary arthroplasty. The first stage of revision arthroplasty would involve removal of an implant and placement of an antibiotic-impregnated cement spacer to maintain the joint space and stability, prevent soft tissue retraction, provide local antibiotic release and preserve bone tissue for revision implantation at the final stage of revision. Custom-made articulating spacers are a promising tool for optimizing the first stage of revision arthroplasty.The objective was to summarize the current data and present comprehensive information about spacers used in two-stage revision arthroplasty including manufacturing techniques, physical and chemical properties, clinical applications, the possibility of customization within the first stage of revision arthroplasty, current and promising directions for research.Material and methods The original literature search was conducted on key resources including Scientific Electronic Library (www.elibrary.ru), the National Library of Medicine (www.pubmed.org), the Cochraine Library (www.cochranelibrary.com) between 2018 and 2023 using search words and phrases: total arthroplasty, complications, revision arthroplasty, articulating spacer, periprosthetic joint infection, additive manufacturing, 3D printing.Results A comparative analysis of factory supplied, home-made, dynamic and static spacer models showed that the choice of articulating spacers for revision arthroplasty of major joints is of great relevance. Advantages of factory-made spacers include standardized range of sizes, the reliability and availability for medical institutions. They are characterized by limited use in repair of severe bone defects.Discussion Custom-made articulating spacers enable specific tailoring to accommodate individual defects. Despite high expectations from custom-made spacers, development of optimal technologies for rapid prototyping is essential. Investments in research and development in this area have the potential to create innovative solutions that can significantly improve the results of revision arthroplasty.Conclusion The paper explores the importance of systemization of knowledge about spacers and the role of new research in improving the design and functionality. Progress in the field of materials science, additive technologies and a personalized approach to spacer manufacturing can expand possibilities of revision arthroplasty and the effectiveness. Personalized approaches and improved methods of local drug delivery that provide controlled release of antibiotics can improve the results of treatment of periprosthetic joint infections.

Rapid Prototyping Technology: A Driving Force in Product Design Innovation

Abstract: This paper explores the transformative impact of rapid prototyping on product design processes across various industries. Rapid prototyping, characterized by its ability to quickly create physical models from digital designs, significantly enhances the iterative design phase, facilitating early testing and validation of concepts. RP includes the integration of technologies such as 3D printing, computer-aided design (CAD), and additive manufacturing in accelerating product iterations, reducing time-to-market, and fostering innovation. Rapid prototyping (RP) has emerged as a transformative approach in product development, significantly enhancing design processes across various industries. Sectors including automotive, consumer electronics and healthcare show how rapid prototyping streamlines communication among stakeholders, enhances user feedback incorporation, and reduces production costs

Interpretable Machine Learning-Based Influence Factor Identification for 3D Printing Process-Structure Linkages.

Three-dimensional printing technology is a rapid prototyping technology that has been widely used in manufacturing. However, the printing parameters in the 3D printing process have an important impact on the printing effect, so these parameters need to be optimized to obtain the best printing effect. In order to further understand the impact of 3D printing parameters on the printing effect, make theoretical explanations from the dimensions of mathematical models, and clarify the rationality of certain important parameters in previous experience, the purpose of this study is to predict the impact of 3D printing parameters on the printing effect by using machine learning methods. Specifically, we used four machine learning algorithms: SVR (support vector regression): A regression method that uses the principle of structural risk minimization to find a hyperplane in a high-dimensional space that best fits the data, with the goal of minimizing the generalization error bound. Random forest: An ensemble learning method that constructs a multitude of decision trees and outputs the class that is the mode of the classes (classification) or mean prediction (regression) of the individual trees. GBDT (gradient boosting decision tree): An iterative ensemble technique that combines multiple weak prediction models (decision trees) into a strong one by sequentially minimizing the loss function. Each subsequent tree is built to correct the errors of the previous tree. XGB (extreme gradient boosting): An optimized and efficient implementation of gradient boosting that incorporates various techniques to improve the performance of gradient boosting frameworks, such as regularization and sparsity-aware splitting algorithms. The influence of the print parameters on the results under the feature importance and SHAP (Shapley additive explanation) values is compared to determine which parameters have the greatest impact on the print effect. We also used feature importance and SHAP values to compare the importance impact of print parameters on results. In the experiment, we used a dataset with multiple parameters and divided it into a training set and a test set. Through Bayesian optimization and grid search, we determined the best hyperparameters for each algorithm and used the best model to make predictions for the test set. We compare the predictive performance of each model and confirm that the extrusion expansion ratio, elastic modulus, and elongation at break have the greatest influence on the printing effect, which is consistent with the experience. In future, we will continue to delve into methods for optimizing 3D printing parameters and explore how interpretive machine learning can be applied to the 3D printing process to achieve more efficient and reliable printing results.

Influence of carrier gas flow rate and particle size of AISI M2 in the laser-directed energy deposition process

ABSTRACT Additive manufacturing (AM) is a rapid prototyping technology that offers many advantages over conventional manufacturing processes. However, to make the most of the AM advantages, some requirements need to be met, such as the adjustment of process parameters and quality of the feedstock. This work assessed the influence of carrier gas flow rate and particle size of AISI M2 in the laser-directed energy deposition process (L-DED). Different carrier gas flow rates were tested for two powders with particle size of 53–150 µm (larger range) and 20–53 µm (lower range). The variation of carrier gas flow rate and particle size was assessed in single lines and layers. The results show that increasing the carrier gas flow rate provides better powder convergence in the region where there is interaction with the laser beam and faster particle velocity. The lower range tends to have greater efficiency in the deposition of single lines and layers. Regarding geometric characteristics, the aspect ratio did not show a well-defined trend as a function of the carrier gas flow rate and particle size, however, the layer height tends to be greater for the lower range, while the dilution tends to be greater for the larger range.

Design, modeling, and experiment of a multi-degree-of-freedom pneumatic soft bionic actuator

Drawing on the driving mechanism of biological muscles and combining the nonlinear hyperelastic characteristics of silicone rubber, a multi-degree-of-freedom pneumatic soft bionic actuator is designed, which can be used as the executing mechanism for soft robots and robotic arms. Using response surface analysis and numerical simulation algorithms, the optimal combination of structural dimensions parameters is determined with the maximum bending and torsion angles output by the actuator as the optimization objectives. Based on the idea of flexible mechanism Piecewise Constant Curvature (PCC) modeling, the kinematics equation of the actuator is derived. Analyze the equivalent motion structure of the actuator and establish a dynamic model of the actuator based on the Lagrange method. The physical model of the actuator is manufactured using rapid prototyping technology. Finally, experimental testing and analysis are conducted on the physical model to obtain the motion and dynamic characteristics curves and empirical formulas of the actuator, which are compared with theoretical and simulation results to verify that the pneumatic soft bionic actuator is feasible and effective. The above research methods, processes, and results can provide reference and inspiration for the research and implementation of pneumatic and hydraulic soft robots and gripping actuators for soft robotic arms.

Design and Experiment of Ordinary Tea Profiling Harvesting Device Based on Light Detection and Ranging Perception

Due to the complex shape of the tea tree canopy and the large undulation of a tea garden terrain, the quality of fresh tea leaves harvested by existing tea harvesting machines is poor. This study proposed a tea canopy surface profiling method based on 2D LiDAR perception and investigated the extraction and fitting methods of canopy point clouds. Meanwhile, a tea profiling harvester prototype was developed and field tests were conducted. The tea profiling harvesting device adopted a scheme of sectional arrangement of multiple groups of profiling tea harvesting units, and each unit sensed the height information of its own bottom canopy area through 2D LiDAR. A cross-platform communication network was established, enabling point cloud fitting of tea plant surfaces and accurate estimation of cutter profiling height through the RANSAC algorithm. Additionally, a sensing control system with multiple execution units was developed using rapid control prototype technology. The results of field tests showed that the bud leaf integrity rate was 84.64%, the impurity rate was 5.94%, the missing collection rate was 0.30%, and the missing harvesting rate was 0.68%. Furthermore, 89.57% of the harvested tea could be processed into commercial tea, with 88.34% consisting of young tea shoots with one bud and three leaves or fewer. All of these results demonstrated that the proposed device effectively meets the technical standards for machine-harvested tea and the requirements of standard tea processing techniques. Moreover, compared to other commercial tea harvesters, the proposed tea profiling harvesting device demonstrated improved performance in harvesting fresh tea leaves.

Digital fabrication of custom tracheostomy appliances: A clinical report.

The use of rapid prototyping technology has revolutionized the fabrication of intraoral prostheses. With the advancement of digital technology, its applications have expanded to extraoral prostheses and appliances to replace a variety of head and neck defects. The following clinical report illustrates the use of a new technique that allows the digital replication and recontouring of a stock tracheostomy tube to improve patient fit, comfort, and esthetics.

A Review on 3D Printing Processes in Pharmaceutical Engineering and Tissue Engineering: Applications, Trends and Challenges

AbstractAs a 3D rapid prototyping technology, 3D printing (3DP) technology has been widely applied in medical research, fabricating various medical devices or implants. With the development of biomaterials and cell‐related technologies, 3DP, especially bioprinting technology, is quietly bringing great changes and opportunities in the medical industry. Beyond surgical models, medical devices, and implants, traditional 3DP, cell‐based 3D bioprinting, and emerging 4D printing (4DP) have significantly aided in the advancement and manufacture of pharmaceuticals and biological alternatives for tissue engineering. It is envisioned that future healthcare systems, based on evolving 3DP technology and precision medicine, will deliver customized solutions that cater to the unique differences and needs of each patient. In this review work, several mainstream 3D bioprinting technologies are presented, with a focus on recent advances in 3DP for pharmaceutical engineering and important tissue engineering, including vascular and bone tissue engineering. Challenges and future prospects of 3DP for drug discovery, drug delivery systems, artificial blood vessels, vascular and bone tissue engineering scaffolds, and practical applications are also covered. Finally, the differences between 3DP and 4DP, as well as the advantages and disadvantages of different stimulus response mechanisms in 4DP and their potential applications are summarized.

Research and Implementation of Pneumatic Amphibious Soft Bionic Robot

To meet the requirements of amphibious exploration, ocean exploration, and military reconnaissance tasks, a pneumatic amphibious soft bionic robot was developed by taking advantage of the structural characteristics, motion forms, and propulsion mechanisms of the sea lion fore-flippers, inchworms, Carangidae tails, and dolphin tails. Using silicone rubber as the main material of the robot, combined with the driving mechanism of the pneumatic soft bionic actuator, and based on the theory of mechanism design, a systematic structural design of the pneumatic amphibious soft bionic robot was carried out from the aspects of flippers, tail, head–neck, and trunk. Then, a numerical simulation algorithm was used to analyze the main executing mechanisms and their coordinated motion performance of the soft bionic robot and to verify the rationality and feasibility of the robot structure design and motion forms. With the use of rapid prototyping technology to complete the construction of the robot prototype body, based on the motion amplitude, frequency, and phase of the bionic prototype, the main execution mechanisms of the robot were controlled through a pneumatic system to carry out experimental testing. The results show that the performance of the robot is consistent with the original design and numerical simulation predictions, and it can achieve certain maneuverability, flexibility, and environmental adaptability. The significance of this work is the development of a pneumatic soft bionic robot suitable for amphibious environments, which provides a new idea for the bionic design and application of pneumatic soft robots.

Custom Triflange Acetabular Implants for Complex Hip Revisions: A Case Series.

Revision total hip arthroplasty (THA) presents a formidable challenge when addressing extensive acetabular defects, particularly in severe cases classified under Paprosky types 3A and 3B and American Academy of Orthopaedic Surgeons types 3 and 4. Traditional methods often fall short, prompting the potential use of custom triflange acetabular components or patient-specific acetabular implants (PSAIs). These implants are specifically designed to conform to an individual's anatomy, aiming to enhance defect reconstruction and pelvic stabilization. This case series describes the utilization of advanced 3-dimensional printing and rapid prototyping technologies to construct customized acetabular components, which can be instrumental in enabling precise preoperative planning and surgical execution for these difficult acetabular cases and potentially leading to improved surgical outcomes.

The application and significance of 3D printing technology in biomedicine

3D printing technology, also known as rapid prototyping technology, is an emerging production and manufacturing method. Medical researchers can create various medical devices for patients' bodies with greater accuracy by converting 3D digital graphics from computer-aided design into physical entities and printing 3D objects layer by layer. Thriving as medicine is, 3D printing, being a widely used and promising technology, will make significant contributions to the progress of biomedical science in multiple directions. The fundamental principle of this technology is akin to building blocks, where small parts are assembled into a comprehensive structure, utilizing materials such as plastic, metal, ceramics, etc. In the production of medical equipment under traditional manufacturing methods, a significant amount of manual debugging is sometimes necessary, which often results in the waste of considerable time and resources. Nonetheless, the manufacturing technique of 3D printing can rapidly and precisely create intricate instruments, as well as produce implants or tissue models. The main focus of this article is to analyze recent progress, applications and restriction prospects of 3D printing in medical applications. The advancement that 3D technology gains across different domains and levels is poised to significantly influence future medical treatment. The significance is to clarify the application and significance of 3D printing technology in the biomedical field. Through the review and analysis of relevant literature, a comprehensive understanding of the research progress and existing problems on 3D printing in the biomedical domain be gained, providing references and inspiration for future research.

REVERSE ENGINEERING AND PROTOTYPING OF DISC BRAKE CALIPER

Disc brake calipers are the components which plays a vital role in automotive braking systems, which are responsible for slowing down or stopping the vehicle. This project aims to understand the design and functionality of a disc brake caliper through Reverse engineering and create a new, improved prototype. We will disassemble an existing disc brake caliper, analyse its components, and understand its working principles. Using techniques such as 3D scanning and CAD modelling we will create a digital representation of the caliper. This digital model will serve as the basis for our prototyping phase, where we will leverage rapid prototyping technologies to create a physical model of the disc brake caliper. The goal of this project is not only to replicate the existing design but also to identify potential areas for improvement and innovation. By integrating reverse engineering and prototyping, we aim to enhance the performance and efficiency of disc brake calipers. Keywords: Disc Brake Caliper, Rapid Prototyping, Reverse Engineering, 3D Scanning, Calibry Nest Software.

Analysis of 3D printing technology research status

Three dimensional printing (3DP) is a kind of rapid prototyping technology, also known as additive manufacturing, it is a digital model file based on the use of powder metal or plastic and other adhesive materials, through layer by layer printing to construct the object technology. The complicated process can also be a problem. For products with complex structure, it is necessary to collect various structural information and correct printing equipment. And the material needs to be proved too. Nowadays its material is too normal. The high cost and non-replicability are also one of the important reasons for the cost increase. 3D printing technology has a wide range of application prospects and great significance, it can make personalized products, fast original manufacturing, reduce material waste. At the same time, it has a good design curve, and has far-reaching influence in many fields such as industry, medical care, education, and architecture. Through searching the data, this article understands the definition, principle, main process, application in different fields, significance and future development of 3D printing technology to understand 3D printing technology.

DLP printed 3D gyroid structure: Mechanical response at meso and macro scale

Rapid prototyping (RP) technology enables the fabrication of complex geometries, making lattice structures increasingly popular. Lattice structures, known as cellular materials, have garnered significant attention over the past two decades due to their ability to optimise mass distribution in components. These structures excel in mechanical properties, catering to energy absorption (bending-dominated structures) and structural performance (stretch-dominated structures). In this paper, we investigate the behaviour of stretch-dominated lattice structures using periodic surface models, specifically focusing on sheet-based Gyroid cells, to allow for a more efficient macroscale modelling. We study cells and scaffolds of different sizes, considering various triply periodic minimal surface thicknesses and relative densities ranging from approximately 0.2 to 0.65. We explore load applications in directions different from the unit cell's principal axes and analyse the strain rate effect on both bulk and cellular material. The lattice structures are manufactured using epoxy resin and digital light processing (DLP) technology. In the range of relative density investigated, both in quasi-static and dynamic conditions, a linear trend is observed for Young's modulus and compression yield strength. To extend the quasi-static results to the dynamic regime, we employ a more generalized normalization technique. This approach divides Young's modulus and compression yield strength by the behaviour of the base material at a specific strain rate, facilitating the correlation of mechanical properties across the two loading regimes. Based on experimental findings, we implemented and calibrated a bi-linear material model for describing, in macroscale, triply periodic minimal surface (TPMS) Gyroid structures. The model coefficients are parameterized with respect to relative density. In addition, the presented material law was compared with that proposed by Gibson-Ashby. Furthermore, we evaluated the anisotropy of both the base material and the unit cell. The first one is done by testing the 3D printed samples in directions different from the printing one, the latter by using the Zener factor. The anisotropy evaluation confirmed the isotropic behaviour of the unit cell within the range of relative density and test conditions investigated. Finally, we perform linear elastic 3D macroscopic and mesoscopic model simulations for combined shear-compression tests using the implemented bi-linear material model and the anisotropic stiffness matrix (obtained through the homogeneous formulation) for the macroscale, and the base material for the mesoscopic one. The results demonstrate the suitability of the proposed equivalent material model for studying the TPMS Gyroid structure in the elastic regime, both in quasi-static and dynamic states. This allows for an efficient FE modelling process of complex lattice structures.

Nature as a Technological Paradigm: The Case of “Moisture-Responsive Wrinkling Dynamic Footwear”

The forces of nature have shaped the form of matter, and similarly, human creations are also driven by natural forces. This makes biology a key source of inspiration for solving engineering problems. With the rapid advancement of digital and robotic technologies, rapid prototyping technology has made it possible to manufacture complex parts, creating a new body of knowledge and a novel approach to design known as generative design. This paper focuses on applying biology and related life science technologies to the paradigm of generative design and how this paradigm influences the concepts, strategies, and practices in the design field. The article also specifically examines the project “Moisture-Responsive Wrinkling Dynamic Footwear,” a pedagogical design research initiative, demonstrating how it integrates formative design methods based on composite materials, computational strategies, and emerging manufacturing technologies.

Bottom-Illuminated Photothermal Nanoscale Chemical Imaging with a Flat Silicon ATR in Air and Liquid.

We demonstrate a novel approach for bottom-illuminated atomic force microscopy and infrared spectroscopy (AFM-IR). Bottom-illuminated AFM-IR for measurements in liquids makes use of an attenuated total reflection setup where the developing evanescent wave is responsible for photothermal excitation of the sample of interest. Conventional bottom-illuminated measurements are conducted using high-refractive-index prisms. We showcase the advancement of instrumentation through the introduction of flat silicon substrates as replacements for prisms. We illustrate the feasibility of this technique for bottom-illuminated AFM-IR in both air and liquid. We also show how modern rapid prototyping technologies enable commercial AFM-IR instrumentation to accept these new substrates. This new approach paves the way for a wide range of experiments since virtually any established protocol for Si surface functionalization can be applied to this sample carrier. Furthermore, the low unit cost enables the rapid iteration of experiments.

Exploring the frontier of rapid prototyping technologies for plant synthetic biology and what could lie beyond.

Realizing the full potential of plant synthetic biology both to elucidate the relationship between genotype and phenotype and to apply these insights to engineer traits requires rapidly iterating through design-build-test cycles. However, the months-long process of transgenesis, the long generation times, and the size-based limitations on experimentation have stymied progress by limiting the speed and scale of these cycles. Herein, we review a representative sample of recent studies that demonstrate a variety of rapid prototyping technologies that overcome some of these bottlenecks and accelerate progress. However, each of them has caveats that limit their broad utility. Their complementary strengths and weaknesses point to the intriguing possibility that these strategies could be combined in the future to enable rapid and scalable deployment of synthetic biology in plants.

The Influence of Selected Fillers on the Functional Properties of Polycarbonate Dedicated to 3D Printing Applications.

Additive manufacturing is still the fastest-developing technology in the modern world. Three-dimensional printing has become popular due to the method's numerous advantages, such as its short time and low cost, compared to conventional methods such as injection molding. Therefore, the demand for new materials and material systems that will be characterized by the desired functional properties is clearly growing. As part of this work, work was carried out on the development and preparation of new polymer composites dedicated to 3D printing applications, especially in FDM/FFF/MEM technologies. The influence of the content and amount of fillers, such as silica modified with alumina (S) and bentonite modified with a quaternary ammonium salt (B), on the functional properties of a commercially available fiber made of traditional plastic, such as polycarbonate, obtained in the form of a filament (PCF), was determined. It was found that the addition of B significantly increased the fluidity of the polymer, the introduction of a filler in the amount of 1.5% allowed to obtain a result that was 6% higher compared to PCF (16.8 g/10 min), while the amount of 3% was 20% higher. The obtained mass melt flow rate (MFR) results were confirmed by determining the viscosity of the produced polymer composites. Satisfactory results of mechanical properties were obtained, including the following: it was found that the introduced modified fillers increased the elasticity of the material. The introduction of modified silica resulted in a reduction in Young's modulus by 10.02% at the content of 0.5% S and at 1% S by 8.64% compared to the polymer. The introduced modified filler S significantly increased the thermostability of polycarbonate (T5% equal to 449 °C) by 23 °C for PCF/0.5% S and 14 °C for PCF/1% S, respectively. The SEM and WAXS results confirmed the appropriate dispersion of the fillers in the polymer matrix, which indicates well-selected conditions for the homogenization process of the components and the subsequent production of samples. Detailed characterization of the influence of selected fillers on the functional properties of the polymer matrix-polycarbonate allowed for an increase in the range of polymer composites and their use in rapid prototyping technologies, as well as supplementing the literature on databases regarding the characteristics of the obtained materials.

Using Rapid Prototyping to Develop a Cell-Based Platform with Electrical Impedance Sensor Membranes for In Vitro RPMI2650 Nasal Nanotoxicology Monitoring.

Due to advances in additive manufacturing and prototyping, affordable and rapid microfluidic sensor-integrated assays can be fabricated using additive manufacturing, xurography and electrode shadow masking to create versatile platform technologies aimed toward qualitative assessment of acute cytotoxic or cytolytic events using stand-alone biochip platforms in the context of environmental risk assessment. In the current study, we established a nasal mucosa biosensing platform using RPMI2650 mucosa cells inside a membrane-integrated impedance-sensing biochip using exclusively rapid prototyping technologies. In a final proof-of-concept, we applied this biosensing platform to create human cell models of nasal mucosa for monitoring the acute cytotoxic effect of zinc oxide reference nanoparticles. Our data generated with the biochip platform successfully monitored the acute toxicity and cytolytic activity of 6 mM zinc oxide nanoparticles, which was non-invasively monitored as a negative impedance slope on nasal epithelial models, demonstrating the feasibility of rapid prototyping technologies such as additive manufacturing and xurography for cell-based platform development.