Use Of Rapid Prototyping Technology Research Articles

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.

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.

Tapping the potential of rapid prototyping techniques in creating a paradigm shift in the fabrication of occlusal splints

PurposeThis study aims to cover the overall gamut of rapid prototyping processes and biomaterials used for the fabrication of occlusal splints in a comprehensive manner and elucidate the characteristics of the materials, which are essential in determining their clinical efficacy when exposed to oral surroundings.Design/methodology/approachA collective analysis of published articles covering the use of rapid prototyping technologies in the fabrication of occlusal splints, including manufacturing workflow description and essential properties (mechanical- and thermal-based) evaluation of biocompatible splinting materials, was performed.FindingsWithout advances in rapid prototyping processes and materials engineering, occlusal splints would tend to underperform clinically due to biomechanical limitations.Social implicationsThree-dimensional printing can improve the process capabilities for commercial customization of biomechanically efficient occlusal splints.Originality/valueRapid technological advancement in dentistry with the extensive utilization of rapid prototyping processes, intra-oral scanners and novel biomaterial seems to be the potential breakthrough in the fabrication of customized occlusal splints which have endorsed occlusal splint therapy (OST) as a cornerstone of orthodontic treatment.

Application of rapid prototyping technology in pump engineering

The article presents the results of the use of rapid prototyping technology when modifying the impeller of a centrifugal pump in order to increase efficiency. As a result of the implementation of the technology, the influence of parameters such as the printing speed of the main layers, the printing speed of the current layers, the thickness of the layers on the geometric accuracy of printed products was studied. According to the results of experiments, it was revealed the effect of the feed rate on the OZ axis, an increase in speed will lead to lower surface quality, higher roughness. The distance between the layers is 0,15 mm/s, getting a roughness of Ra 6,3 microns, and in the right case we used a distance of 0,05 mm/s between the layers, getting a roughness of Ra1,6 microns. The article presents the results of the analysis of the effect of exposure time and exposure time in the UV chamber on the hardness of printed products. The article presents a method for determining and compensating the geometry of prototypes based on reverse engineering technology based on the use of an optical scanner. The tests of a centrifugal pump with a prototype of a modified wheel confirm the need for such innovations as rapid prototyping to shorten the design cycle of new products, as well as reduce the cost of their development.

Manufacturing challenges and technological solutions for microwave ablation (MWA) probe prototyping

In this paper, the manufacturing challenges and related technological solutions concerning the prototyping of microwave ablation (MWA) probes are addressed. In particular, the intertwined aspects pertaining probe design, fabrication and target performance are tackled. The development of a 14G MWA probe prototype, working at a frequency of 2.45 GHz, is proposed as a case study, describing design efforts and the use of rapid prototyping technologies combined with other manufacturing processes. A specific focus is dedicated to the insulating part of the probe radiating section, featuring high aspect ratio and complex shape, which was fabricated by means of Digital Light Processing (DLP) and by using a biocompatible material, the EnvisionTEC E-Shell® 300. Furthermore, the probe handling, properly designed to arrange cables and tubes routing, was fabricated by means of Fused Deposition Modeling (FDM) technology. Finally, ex vivo experiments conducted on bovine liver showed satisfactory treatment performance and structural reliability of the 14G MWA probe prototype. Besides being characterized by a good impedance matching ( S11 = −25 dB), prototype performance were also in good agreement with design simulations and even satisfying if compared to other results available in literature as, with an input radiation power of 40 W, the ablated zone after a 10 min treatment exhibited a ratio of the radial and longitudinal axis of 0.66.

3D Printing in Veterinary Medicine

The use of 3D printing technology in the field of medicine, which started with the millennium, continues to increase today. Depending on the technological developments in this field, the use of rapid prototyping technology in the field of veterinary medicine is becoming widespread with the development of 3D printers, increasing material variety, cheaper printing costs and being more accessible. Additive manufacturing is used in veterinary education and training, experimental research and clinical studies, and its area of use is expanding day by day. In this review, both the current usage potential will be evaluated and the expected developments in the near future will be revealed.

Features of Use of Rapid Prototyping Technology in the Manufacture of Wax Models of GTE Turbine Blades

The paper presents the main results related to the peculiarities of using 3D printing technology and methods of rapid prototyping in the manufacture of wax models of blades of a GTE turbine. The main design solutions that must be used in the design of a blade blank are presented in detail: the total shrinkage coefficient, equidistant rolling of the airfoil profile, allowance along tract surfaces, radial fillets, and a number of others. The results of control of geometric dimensions of the turbine blade blanks at the corresponding stages of the technological process showed deviations from the nominal value within the tolerance range for the executable dimensions, and the statistical information from the measurement of an experimental batch of wax models of blade blanks showed stability of the silicone tooling and ability to manufacture a series of wax models of the blades in the amount of 100 pieces when using one mold.

Use of rapid prototyping technology in complex plastic structures. Part II. Impact of operating conditions on functional properties of polymer harmonic drives

The influence of operating conditions on physical and mechanical properties of tooth surface in the flexspline of a harmonic drive was investigated. 3D printed test models were made from poly(acrylonitrile--co-butadiene-co-styrene) (ABS) copolymer and from poly(lactic acid) (PLA) and subjected to the accelerated UV aging test and to bench tests. Measurements of hardness, Vicat softening point and atomic force microscopy (AFM) analysis were performed in order to determine the properties of the teeth surface in the gear wheels. Furthermore, the degree of degradation of the plastics was determined with IR spectroscopy. It was found, that the ambient conditions and exploitation of harmonic drives do not affect the value of softening point and hardness. On the other hand, the AFM analysis indicated that the sides of teeth were smoother as a result of their cooperation. The values of Ra parameter in the areas examined decreased from 110.0 to 54.6 nm and from 23.9 to 17.0 nm for the gear wheels made of ABS and PLA, respectively. Furthermore, the Derjaguin--Muller-Toporov modulus (DMT) of surfaces was also decreased from 10.0 to 3.0 GPa and from 4.5 to 2.2 GPa in the gear wheels made of ABS and PLA, respectively. The AFM imaging provide evidence for destructive effects of UV radiation and elevated humidity, confirmed by IR spectroscopy.

Creation of prototype 3D models using RAPID PROTOTYPING

The article deals with creating 3D models using RAPID PROTOTYPING technology. At present, we are witnessing the integration of new technologies into ordinary life. A good example is the use of FDM (fused deposition modeling) technology that primarily uses thermoplastics to create 3D models. A few years ago, the use of rapid prototyping technology was a prerogative of companies, research institutes and a narrow group of universities. Technologies such as FDM and STL (Stereolithography) have become affordable in the past few years for smaller businesses and individuals. The specific segment is the replicating rapid prototype RepRap (replicating rapid prototype), the extended version of which is the Prusa i3 printer.

Use of rapid prototyping technology in complex plastic structures. Part I. Bench testing and numerical calculations of deformations in harmonic drive made from ABS copolymer

In the study, measurements of 3D deformations of the flexspline in harmonic drive were performed by applying a digital image correlation (DIC) method. The tests were carried out with the use of physical 3D printed models made of ABS copolymer (acrylonitrile-butadiene-styrene), which ensured sufficient capacity andrigidity of the structures. The findings related to deformations in flexspline, obtained through bench testing, were compared to the results of calculations conducted using the finite element method (FEM). Significant convergence in the findings obtained using the two methods was shown, yet deformations measured in the real-life model were characterized by greater irregularity compared to the corresponding solutions obtained with the numerical method. The results obtained through optical measurement confirm that physical models made of plastics, built using rapid prototyping technology, can justifiably be appliedin bench testing of prototype gear transmissions.

Training Higher School Students in Rapid Prototyping Technology as a Final Stage of Their Preparation for Innovative Activities

Introduction. The methodological systems of preparation for innovative engineering activity involve the involvement of students in all stages of the innovation cycle, including obtaining an intangible innovative product. However, the inability to obtain in students a material innovative product reduces the effectiveness of the preparation of these systems. The purpose of this study is to create a methodical system for preparing students for innovative research activities based on their involvement in all stages of obtaining a material innovative product using additive technologies. Materials and Methods. For writing the article the authors used the main points of the integrated approach to learning (integration of theoretical and practical training of innovative research activities and interdisciplinary integration of various branches of science (pedagogy, mathematical modeling, 3D modeling, additive technologies, innovation). Results. The methodical system of training students of technical higher education institution has been created and implemented, ensuring their involvement in all stages of the innovation cycle due to the use of rapid prototyping technologies. The effectiveness of technologies is confirmed by the results of the pedagogical experiment. Discussion and Conclusions. The performed researches allowed to create a methodical system for training students of technical universities of innovative research activities based on rapid prototyping technologies. This method significantly improves the effectiveness of training. It ensures the participation of students in all stages of obtaining a material innovative product: during the study of the course, and during classroom sessions. This method was developed and tested for the implementation at National Research Ogarev Mordovia State University. It provides the practical significance of the study considered in the article. Further development of the material presented in the article can be related to the expansion of the infrastructure of the Rapid Pro university center for designing and prototyping and attracting students to manufacturing industrial products.

Test Stand for the Experimental Investigation of Turbochargers with 3D Printed Components

Abstract The paper discusses the universal test stand which allows determining the characteristics of turbochargers. Currently, there are works carried out in the world aimed to develop innovative fluid-flow machines, made partly with the use of rapid prototyping technology. This type of manufacturing technology allows reducing production time and costs in comparison to conventional methods of prototyping. This article also discusses start-up tests of the experimental test stand using a commercial turbocharger and the comparison between calculated and experimental results. In this paper, there are also described some modifications of the test stand, made prior to the start-up test, which were necessary to get more accurate characteristics of turbochargers. This work is an introduction to the investigation on turbomachines, whose elements were manufactured using the rapid prototyping technology.

Experimental testing and numerical analysis of FDM multi-cell inserts and hybrid structures

Modern transportation systems require light materials with an increased level of protection thus thin walled structures are in the focus of structural engineers. The latest developments in the field of manufacturing processes allow the use of Rapid Prototyping technologies for custom safety devices and Additive Manufacturing is a candidate that already captured some attention. In this work Fused Deposition Modelling method was used to manufacture samples for material characterization and multi-cell insert designed as safety devices and the material is ABS. Traction tests were performed and some SEM images complete the specimens’ analysis. From this analysis, in order to define a simple material model for numerical analysis, a stacking configuration -45°/0°/45°/90° was selected. A model for material damage is also presented in this paper. Circular structures with rectangular multi-cell were manufactured and tested in compression. In order to improve the performances a hybrid structure was investigated. Aluminium tubes were added in order to enhance the performances of the printed structures. For each step of the experimental work a numerical companion is presented. Modelling techniques and parameters are presented and discussed in this paper. By adding the aluminium tube there is an increase in the performances of the structure. A progressive profile for the crushing force is obtained. By adjusting the support (outer aluminium tube) and designing multi-cell insert, structures for safety enhancement can be developed.

A novel diamond anvil cell for x-ray diffraction at cryogenic temperatures manufactured by 3D printing.

A new miniature high-pressure diamond anvil cell was designed and constructed using 3D micro laser sintering technology. This is the first application of the use of rapid prototyping technology to construct high-pressure apparatus. The cell is specifically designed for use as an X-ray diffraction cell that can be used with commercially available diffractometers and open-flow cryogenic equipment to collect data at low temperature and high pressure. The cell is constructed from stainless steel 316L and is about 9 mm in diameter and 7 mm in height, giving it both small dimensions and low thermal mass, and it will fit into the cooling envelope of a standard CryostreamTM cooling system. The cell is clamped using a customized miniature buttress thread of diameter 7 mm and pitch of 0.5 mm enabled by 3D micro laser sintering technology; such dimensions are not attainable using conventional machining. The buttress thread was used as it has favourable uniaxial load properties allowing for higher pressure and better anvil alignment. The clamp can support the load of at least 1.5 kN according to finite element analysis (FEA) simulations. FEA simulations were also used to compare the performance of the standard thread and the buttress thread, and demonstrate that stress is distributed more uniformly in the latter. Rapid prototyping of the pressure cell by the laser sintering resulted in a substantially higher tensile yield strength of the 316L stainless steel (675 MPa compared to 220 MPa for the wrought type of the same material), which increased the upper pressure limit of the cell. The cell is capable of reaching pressures of up to 15 GPa with 600 μm diameter culets of diamond anvils. Sample temperature and pressure changes on cooling were assessed using X-ray diffraction on samples of NaCl and HMT-d12.

Cost, resources, and energy efficiency of additive manufacturing

Additive manufacturing (AM) is the process of joining materials to make objects from Computer Aided Design (CAD) model data, usually layer upon layer, as opposed to using subtractive manufacturing methods. The use of rapid prototyping technologies has increased significantly in recent years. These new techniques, while still evolving, are projected to exert a profound impact on manufacturing. They can reduce energy use and time to market and offer industry new design flexibility. We include a brief study on the cost and energy efficiency of selected methods of additive manufacturing compared to traditional methods of manufacturing parts. One common claim is that 3D printers are more energy-efficient than other manufacturing technologies. We present energy efficiency and time requirements for producing a typical mechanical part and a very complicated element, using both traditional manufacturing and rapid prototyping methods. This paper represents an attempt to answer the questions of when 3D printing can be used efficiently and of choosing the appropriate technology on the basis of batch size, element size, complexity, and material requirements.

Rapid Prototyping: An Educational Extension of Anatomy Coloring Textbooks

Access to cadaveric specimens, which is dependent on donation and heavy equipment, is still a limiting factor in the study of anatomy. As there are many spatially challenging structures throughout the human body for which physical support is beneficial, new strategies are always needed to implement new interactive teaching techniques to help students more efficiently grasp the complex organization of the human body. In this report, the author reveals the use of rapid prototyping technology to create an innovative and anatomically accurate teaching tool to engage students and help them build threedimensional (3D) mental maps of the human heart. The model consists of polylactic acid (PLA) thermoplastic deposited layer by layer on a platform in a pattern that corresponds to a digital Standard Tessellation Language (.stl) file. Printing a hollow human heart with a 1:1 ratio was rapid (<5 hrs) and affordable (approximatively US$5 per model). Given access to the appropriate printable digital files, students could print their own model and could subsequently paint them appropriately to give them an anatomically correct representation. This studentcentered activity is an extension of the current anatomy coloring textbooks, with the benefit of building an accurate 3D representation of the human body.

3DP Technology for the Manufacture of Molds for Pressure Casting

Abstract The paper presents the use of rapid prototyping technology of three dimensional printing (3DP) to make a prototype shell casting mold. In the first step, for identification purposes, a mold was prepared to enable different alloys to be cast. All molds being cast were designed in a universal CAD environment and printed with the zp151 composite material (Calcium sulfate hemihydrate) with a zb63 binder (2-pyrrolidone). It is designated to be used to prepare colourful models presenting prototypes or casting models and molds. The usefulness of 3DP technology for use with copper alloys, aluminum and zinc was analyzed. The strength of the mold during casting was assumed as a characteristic comparative feature in the material resistance to high temperature, the quality of the resulting casting and its surface roughness. Casting tests were carried out in vacuum – pressure casting. The casting programs applied, significantly increased the quality of castings and enabled precise mold submergence. Significant improvement was noted in the quality compared to the same castings obtained by gravity casting.

Rapid Prototyping in Humanitarian Aid To Manufacture Last Mile Vehicles Spare Parts: An Implementation Plan

AbstractThis research examines the use of rapid prototyping technologies in the supply chain of spare parts. Spare parts are manufactured in small production lots and distributed in wide areas, eventually requiring short delivery times. The focus of this research is the use of rapid prototyping in humanitarian logistics. The demand of humanitarian aid is large, but it is very difficult to predict and also to supply. The use of rapid prototyping to produce spare parts can greatly increase the availability of scarce resources. In this paper, it is demonstrated that rapid prototyping of spare parts for last mile vehicles can help achieve a cost‐effective solution to increase vehicle availability. Also, a detailed implementation plan is developed to serve as a guideline for any organization to successfully introduce the equipment in their operations.

Rapid prototyping in the intervertebral implant design process

Purpose – The purpose of this paper is to present the methodology of a design process of new lumbar intervertebral disc implants with specific emphasis on the use of rapid prototyping technologies. The verification of functionality of artificial intervertebral discs is also given. The paper describes the attempt and preliminary research to evaluate the properties of the intervertebral disc implant prototypes manufactured with the use of different rapid prototyping technologies, i.e. FDM – fused deposition modelling, 3DP – 3D printing and SLM – selective laser melting. Design/methodology/approach – Based on the computed tomography (CT) scan data, the anatomical parameters of lumbar spine bone tissue were achieved, which were the bases for the design-manufacture process carried out with the use of computer-aided designing/computer-aided engineering/computer-aided manufacturing systems. In the intervertebral disc implant design process, three RP technologies: FDM, 3DP and SLM were used for solving problems related to the reconstruction of geometry and functionality of the disc. Some preliminary tests such as measurement of roughness and structural analyses of material of prototypes made by different prototyping technologies were performed. Findings – This paper allowed the authors to elaborate and patent two new intervertebral disc implants. Because the implant designs are parametrical ones with relation to lumbar bone tissue properties measured on CT scans, they can be also made for individual patients. We also compared some of the properties of intervertebral implants prototypes made with the use of FDM, 3DP and SLM technologies. Originality/value – The paper presents the new intervertebral disc implants and their manufacturing by rapid prototyping. The methodology of designing intervertebral disc implant is shown. Some features of the methodology make it useful for preoperative planning of intervertebral disc surgery, as well.

Digitizing, modelling and 3D printing of skeletal digital models of Palaeoloxodon tiliensis (Tilos, Dodecanese, Greece)

Charkadio Cave, on Tilos Island, is one of the richest Mediterranean fossiliferous sites, preserving remains of the dwarf elephant Palaeoloxodon tiliensis. This species is considered to be the last European elephant. Recent advances in the fields of engineering and imaging technology and their applications in palaeontology have allowed the digitization, modelling and 3D printing of skeletal remains of P. tiliensis for the first time. Taphonomical data were combined with appropriate mathematical methods and allometric analyses in order to determine missing bone measurements and estimate correct relative proportions of skeletal elements. Computed Tomography and non-contact digitization via Laser Scanning were used in order to capture the specimens' surface morphology and create 3D models that are adjusted to the correct dimensions derived from the mathematical analyses. The 3D models were then 3D printed with the use of Rapid Prototyping technologies. A research potential of fossil 3D modeling could be its application in morphological comparisons between different taxa. In this study, atlas 3D models of P. tiliensis and Palaeoloxodon antiquus (Falconer and Cautley, 1847) have been combined in a single 3D model that quantifies morphological differences by a color scale, thus minimizing observation error. 3D models and 3D printed replicas facilitate and enhance inter-institutional scientific interaction, minimizing costs and risks related to the transfer of irreplaceable fossil specimens. Finally, a positive outcome related to the above research could be its application in educational activities hosted in institutes such as schools, universities and museums.