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Bennett C, Sojithamporn P, Thanakulwattana W, Wattanutchariya W, Leksakul K, Nakkiew W, Jantanasakulwong K, Rachtanapun P, Suhr J, Sawangrat C. Optimization of 3D Printing Technology for Fabrication of Dental Crown Prototype Using Plastic Powder and Zirconia Materials. MATERIALS (BASEL, SWITZERLAND) 2022; 15:8618. [PMID: 36500111 PMCID: PMC9738052 DOI: 10.3390/ma15238618] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/16/2022] [Revised: 11/26/2022] [Accepted: 11/29/2022] [Indexed: 06/17/2023]
Abstract
This research was aimed at developing a dental prototype from 3D printing technology using a synthetic filament of polylactic acid (PLA) and zirconium dioxide (ZrO2) with glycerol and silane coupling agent as a binder. A face-centered central composite design was used to study the effects of the filament extrusion parameters and the 3D printing parameters. Tensile and compressive testing was conducted to determine the stress-strain relationship of the filaments. The yield strength, elongation percentage and Young's modulus were also calculated. Results showed the melting temperature of 193 °C, ZrO2 ratio of 17 wt.% and 25 rpm screw speed contributed to the highest ultimate tensile strength of the synthetic filament. A Nozzle temperature of 210 °C and an infill density of 100% had the most effect on the ultimate compressive strength whilst the printing speed had no significant effects. Differential scanning calorimetry (DSC) was used to study the thermal properties and percentage of crystallinity of PLA filaments. The addition of glycerol and a silane coupling agent increased the tensile strength and filament size. The ZrO2 particles induced the crystallization of the PLA matrix. A higher crystallization was also obtained from the annealing treatment resulting in the greater thermal resistance performance of the dental crown prototype.
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Affiliation(s)
- Chonlada Bennett
- Agriculture and Bio Plasma Technology Centre (ABPlas), Science and Technology Park, Chiang Mai University, Chiang Mai 50100, Thailand
| | - Phanumas Sojithamporn
- Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
| | - Warinthorn Thanakulwattana
- Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
| | - Wassanai Wattanutchariya
- Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
- Advanced Manufacturing and Management Technology Research Center, Chiang Mai University, Chiang Mai 50200, Thailand
| | - Komgrit Leksakul
- Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
| | - Wasawat Nakkiew
- Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
| | - Kittisak Jantanasakulwong
- Department of Agro-Industry, Faculty of Agro-Industry, Chiang Mai University, Chiang Mai 50100, Thailand
- Cluster of Agro Bio-Circular-Green Industry (Agro BCG), Chiang Mai University, Chiang Mai 50100, Thailand
| | - Pornchai Rachtanapun
- Department of Agro-Industry, Faculty of Agro-Industry, Chiang Mai University, Chiang Mai 50100, Thailand
- Cluster of Agro Bio-Circular-Green Industry (Agro BCG), Chiang Mai University, Chiang Mai 50100, Thailand
| | - Jonghwan Suhr
- School of Mechanical Engineering, Sungkyunkwan University 2066 Seobu-ro, Jangan-gu, Suwon-si, Gyeonggi-do 16419, Republic of Korea
| | - Choncharoen Sawangrat
- Agriculture and Bio Plasma Technology Centre (ABPlas), Science and Technology Park, Chiang Mai University, Chiang Mai 50100, Thailand
- Department of Industrial Engineering, Faculty of Engineering, Chiang Mai University, Chiang Mai 50200, Thailand
- Advanced Manufacturing and Management Technology Research Center, Chiang Mai University, Chiang Mai 50200, Thailand
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2
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Additive Manufacturing of Polyolefins. Polymers (Basel) 2022; 14:polym14235147. [PMID: 36501543 PMCID: PMC9740552 DOI: 10.3390/polym14235147] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/11/2022] [Revised: 11/21/2022] [Accepted: 11/23/2022] [Indexed: 11/30/2022] Open
Abstract
Polyolefins are semi-crystalline thermoplastic polymers known for their good mechanical properties, low production cost, and chemical resistance. They are amongst the most commonly used plastics, and many polyolefin grades are regarded as engineering polymers. The two main additive manufacturing techniques that can be used to fabricate 3D-printed parts are fused filament fabrication and selective laser sintering. Polyolefins, like polypropylene and polyethylene, can, in principle, be processed with both these techniques. However, the semi-crystalline nature of polyolefins adds complexity to the use of additive manufacturing methods compared to amorphous polymers. First, the crystallization process results in severe shrinkage upon cooling, while the processing temperature and cooling rate affect the mechanical properties and mesoscopic structure of the fabricated parts. In addition, for ultra-high-molecular weight polyolefins, limited chain diffusion is a major obstacle to achieving proper adhesion between adjunct layers. Finally, polyolefins are typically apolar polymers, which reduces the adhesion of the 3D-printed part to the substrate. Notwithstanding these difficulties, it is clear that the successful processing of polyolefins via additive manufacturing techniques would enable the fabrication of high-end engineering products with enormous design flexibility. In addition, additive manufacturing could be utilized for the increased recycling of plastics. This manuscript reviews the work that has been conducted in developing experimental protocols for the additive manufacturing of polyolefins, presenting a comparison between the different approaches with a focus on the use of polyethylene and polypropylene grades. This review is concluded with an outlook for future research to overcome the current challenges that impede the addition of polyolefins to the standard palette of materials processed through additive manufacturing.
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3
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Predicting mechanical properties of material extrusion additive manufacturing-fabricated structures with limited information. Sci Rep 2022; 12:14736. [PMID: 36042368 PMCID: PMC9427823 DOI: 10.1038/s41598-022-19053-3] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/27/2022] [Accepted: 08/23/2022] [Indexed: 11/11/2022] Open
Abstract
Mechanical properties of additively manufactured structures fabricated using material extrusion additive manufacturing are predicted through combining thermal modeling with entanglement theory and molecular dynamics approaches. A one-dimensional model of heat transfer in a single road width wall is created and validated against both thermography and mechanical testing results. Various model modifications are investigated to determine which heat transfer considerations are important to predicting properties. This approach was able to predict tear energies on reasonable scales with minimal information about the polymer. Such an approach is likely to be applicable to a wide range of amorphous and low crystallinity thermoplastics.
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4
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FDM Printability of PLA Based-Materials: The Key Role of the Rheological Behavior. Polymers (Basel) 2022; 14:polym14091754. [PMID: 35566923 PMCID: PMC9104839 DOI: 10.3390/polym14091754] [Citation(s) in RCA: 6] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/10/2022] [Revised: 04/23/2022] [Accepted: 04/25/2022] [Indexed: 12/03/2022] Open
Abstract
Fused deposition modeling (FDM) is one of the most commonly used commercial technologies of materials extrusion-based additive manufacturing (AM), used for obtaining 3D-printed parts using thermoplastic polymers. Notwithstanding the great variety of applications for FDM-printed objects, the choice of materials suitable for processing using AM technology is still limited, likely due to the lack of rapid screening procedures allowing for an efficient selection of processable polymer-based formulations. In this work, the rheological behavior of several 3D-printable, commercially available poly(lactic acid)-based filaments was accurately characterized. In particular, each step of a typical FDM process was addressed, from the melt flowability through the printing nozzle, to the interlayer adhesion in the post-deposition stage, evaluating the ability of the considered materials to fulfill the criteria for successful 3D printing using FDM technology. Furthermore, the rheological features of the investigated materials were related to their composition and microstructure. Although an exhaustive and accurate evaluation of the 3D printability of thermoplastics must also consider their thermal behavior, the methodology proposed in this work aimed to offer a useful tool for designing thermoplastic-based formulations that are able to ensure an appropriate rheological performance in obtaining 3D-printed parts with the desired geometry and final properties.
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5
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Xu Y, Huang M, Schlarb AK. Print path‐dependent contact temperature dependency for
3D
printing using fused filament fabrication. J Appl Polym Sci 2022. [DOI: 10.1002/app.52337] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Yao Xu
- Chair of Composite Engineering (CCe) Technische Universität Kaiserslautern (TUK) Kaiserslautern Germany
| | - Miaozi Huang
- Chair of Composite Engineering (CCe) Technische Universität Kaiserslautern (TUK) Kaiserslautern Germany
| | - Alois K. Schlarb
- Chair of Composite Engineering (CCe) Technische Universität Kaiserslautern (TUK) Kaiserslautern Germany
- Research Center OPTIMAS Technische Universität Kaiserslautern (TUK) Kaiserslautern Germany
- Qingdao University of Science & Technology Qingdao China
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6
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Thézé A, Guinault A, Régnier G, Richard S, Macquaire B. Fused filament fabrication process window for good interlayer bonding: Application to highly filled polymers in metallic powder*. POLYM ENG SCI 2022. [DOI: 10.1002/pen.25781] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Affiliation(s)
- Alexis Thézé
- PIMM Laboratory Arts et Métiers Institute of Technology, CNAM, CNRS, HESAM Université Paris France
- Safran Tech, Materials and Processes Chateaufort France
| | - Alain Guinault
- PIMM Laboratory Arts et Métiers Institute of Technology, CNAM, CNRS, HESAM Université Paris France
| | - Gilles Régnier
- PIMM Laboratory Arts et Métiers Institute of Technology, CNAM, CNRS, HESAM Université Paris France
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Chaka KT. Fused deposition modeling of polypropylene-aluminium silicate dihydrate microcomposites. E-POLYMERS 2022. [DOI: 10.1515/epoly-2022-0014] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
Abstract
Abstract
Polypropylene (PP) undergoes fast crystallization and resulting in rigorous shrinkage when it is subjected to high temperature likewise of the fused deposition modeling (FDM) process. This research study focuses on the investigation of the processing parameters and factors that decrease the warpage of PP during the FDM process. Aluminium silicate dihydrate (K) microparticles of different ratios were melt blended with PP by a twin-screw extruder, and filaments of about 1.7 mm diameter were extruded in a single screw extruder. Then, the extruded filaments were used to fabricate the dumbbells structure through the FDM process. The effects of optimizing the fused deposition temperature, coating the chamber with thick papers/fabrics, and coating a printer bed with PP material were also investigated in this study. Scanning and transmission electron microscopy, differential scanning calorimetry, melt flow, and mechanical properties testing instruments are used to analyze the microparticles dispersion, crystallization, flow, and mechanical properties of resulting samples. Uniformly dispersed filler and increased printing chamber temperature result in an increase of crystallization temperature and improve the dimensional accuracy of fused deposited specimens. The fused deposited PP-K10 wt% composite showed an improvement of up to 32% in tensile modulus compared to the neat PP.
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Affiliation(s)
- Kilole Tesfaye Chaka
- Ethiopian Institute of Textile and Fashion Technology, Bahir Dar University , Bahir Dar , Ethiopia
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8
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Mechanical performance and supermolecular morphology of void free polypropylene manufactured by fused filament fabrication. J Appl Polym Sci 2021. [DOI: 10.1002/app.51409] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
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9
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Vaes D, Coppens M, Goderis B, Zoetelief W, Van Puyvelde P. The Extent of Interlayer Bond Strength during Fused Filament Fabrication of Nylon Copolymers: An Interplay between Thermal History and Crystalline Morphology. Polymers (Basel) 2021; 13:polym13162677. [PMID: 34451217 PMCID: PMC8401508 DOI: 10.3390/polym13162677] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/21/2021] [Revised: 08/04/2021] [Accepted: 08/06/2021] [Indexed: 11/16/2022] Open
Abstract
One of the main drawbacks of Fused Filament Fabrication is the often-inadequate mechanical performance of printed parts due to a lack of sufficient interlayer bonding between successively deposited layers. The phenomenon of interlayer bonding becomes especially complex for semi-crystalline polymers, as, besides the extremely non-isothermal temperature history experienced by the extruded layers, the ongoing crystallization process will greatly complicate its analysis. This work attempts to elucidate a possible relation between the degree of crystallinity attained during printing by mimicking the experienced thermal history with Fast Scanning Chip Calorimetry, the extent of interlayer bonding by performing trouser tear fracture tests on printed specimens, and the resulting crystalline morphology at the weld interface through visualization with polarized light microscopy. Different printing conditions are defined, which all vary in terms of processing parameters or feedstock molecular weight. The concept of an equivalent isothermal weld time is utilized to validate whether an amorphous healing theory is capable of explaining the observed trends in weld strength. Interlayer bond strength was found to be positively impacted by an increased liquefier temperature and reduced feedstock molecular weight as predicted by the weld time. An increase in liquefier temperature of 40 °C brings about a tear energy value that is three to four times higher. The print speed was found to have a negligible effect. An elevated build plate temperature will lead to an increased degree of crystallinity, generally resulting in about a 1.5 times larger crystalline fraction compared to when printing occurs at a lower build plate temperature, as well as larger spherulites attained during printing, as it allows crystallization to occur at higher temperatures. Due to slower crystal growth, a lower tie chain density in the amorphous interlamellar regions is believed to be created, which will negatively impact interlayer bond strength.
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Affiliation(s)
- Dries Vaes
- Department of Chemical Engineering, KU Leuven, Celestijnenlaan 200J Box 2424, 3001 Leuven, Belgium; (D.V.); (M.C.)
| | - Margot Coppens
- Department of Chemical Engineering, KU Leuven, Celestijnenlaan 200J Box 2424, 3001 Leuven, Belgium; (D.V.); (M.C.)
| | - Bart Goderis
- Department of Chemistry, KU Leuven, Celestijnenlaan 200F Box 2404, 3001 Leuven, Belgium;
| | - Wim Zoetelief
- DSM Additive Manufacturing, Urmonderbaan 22, 6167 RD Geleen, The Netherlands;
| | - Peter Van Puyvelde
- Department of Chemical Engineering, KU Leuven, Celestijnenlaan 200J Box 2424, 3001 Leuven, Belgium; (D.V.); (M.C.)
- Correspondence:
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10
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Fang L, Yan Y, Agarwal O, Seppala JE, Migler KD, Nguyen TD, Kang SH. Estimations of the effective Young's modulus of specimens prepared by fused filament fabrication. SCRIPTA MATERIALIA 2021; 42:10.1016/j.addma.2021.101983. [PMID: 38487257 PMCID: PMC10938458 DOI: 10.1016/j.addma.2021.101983] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 03/17/2024]
Abstract
The elastic response of homogeneous isotropic materials is most commonly represented by their Young's modulus (E), but geometric variability associated with additive manufacturing results in materials that are neither homogeneous nor isotropic. Here we investigated methods to estimate the effective elastic modulus ( E eff ) of samples fabricated by fused filament fabrication. We conducted finite element analysis (FEA) on printed samples based on material properties and CT-scanned geometries. The analysis revealed how the layer structure of a specimen altered the internal stress distribution and the resulting E eff . We also investigated different empirical methods to estimate E eff as guides. We envision the findings from our study can provide guidelines for modulus estimation of as-printed specimens, with the potential of applying to other extrusion-based additive manufacturing technologies.
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Affiliation(s)
- Lichen Fang
- Department of Mechanical Engineering and Hopkins Extreme Materials Institute, Johns Hopkins University, Baltimore, MD 21218, USA
| | - Yishu Yan
- Department of Mechanical Engineering and Hopkins Extreme Materials Institute, Johns Hopkins University, Baltimore, MD 21218, USA
| | - Ojaswi Agarwal
- Department of Mechanical Engineering and Hopkins Extreme Materials Institute, Johns Hopkins University, Baltimore, MD 21218, USA
| | - Jonathan E. Seppala
- Materials Science and Engineering Division, National Institute of Standards and Technology, Gaithersburg, MD 20899, USA
| | - Kalman D. Migler
- Materials Science and Engineering Division, National Institute of Standards and Technology, Gaithersburg, MD 20899, USA
| | - Thao D. Nguyen
- Department of Mechanical Engineering and Hopkins Extreme Materials Institute, Johns Hopkins University, Baltimore, MD 21218, USA
| | - Sung Hoon Kang
- Department of Mechanical Engineering and Hopkins Extreme Materials Institute, Johns Hopkins University, Baltimore, MD 21218, USA
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11
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Candal MV, Calafel I, Fernández M, Aranburu N, Aguirresarobe RH, Gerrica-Echevarria G, Santamaría A, Müller AJ. Study of the interlayer adhesion and warping during material extrusion-based additive manufacturing of a carbon nanotube/biobased thermoplastic polyurethane nanocomposite. POLYMER 2021. [DOI: 10.1016/j.polymer.2021.123734] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/16/2022]
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12
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Fused Filament Fabrication of Polymers and Continuous Fiber-Reinforced Polymer Composites: Advances in Structure Optimization and Health Monitoring. Polymers (Basel) 2021; 13:polym13050789. [PMID: 33806621 PMCID: PMC7961789 DOI: 10.3390/polym13050789] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/11/2021] [Revised: 02/26/2021] [Accepted: 02/26/2021] [Indexed: 02/07/2023] Open
Abstract
3D printed neat thermoplastic polymers (TPs) and continuous fiber-reinforced thermoplastic composites (CFRTPCs) by fused filament fabrication (FFF) are becoming attractive materials for numerous applications. However, the structure of these materials exhibits interfaces at different scales, engendering non-optimal mechanical properties. The first part of the review presents a description of these interfaces and highlights the different strategies to improve interfacial bonding. The actual knowledge on the structural aspects of the thermoplastic matrix is also summarized in this contribution with a focus on crystallization and orientation. The research to be tackled to further improve the structural properties of the 3D printed materials is identified. The second part of the review provides an overview of structural health monitoring technologies relying on the use of fiber Bragg grating sensors, strain gauge sensors and self-sensing. After a brief discussion on these three technologies, the needed research to further stimulate the development of FFF is identified. Finally, in the third part of this contribution the technology landscape of FFF processes for CFRTPCs is provided, including the future trends.
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13
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Abouzaid K, Bassir D, Guessasma S, Yue H. Modelling the Process of Fused Deposition Modelling and the Effect of Temperature on the Mechanical, Roughness, and Porosity Properties of Resulting Composite Products. MECHANICS OF COMPOSITE MATERIALS 2021; 56:805-816. [PMCID: PMC7809226 DOI: 10.1007/s11029-021-09925-6] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/06/2020] [Accepted: 08/04/2020] [Indexed: 04/03/2024]
Abstract
Advances in the additive manufacturing (AM) processes have opened up the possibilities of widely using them in various structural sectors. Since 1980s this technology has been in permanent mutations. The ramification of the AM technology makes it difficult to obtain a clear impression of its potentialities. Predicting and controlling the mechanical characteristics of printed products is crucial for their final practical use. This study mainly aims to characterize the impact of printing parameters on the characteristics of printed articles and to evaluate their significance.
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Affiliation(s)
- K. Abouzaid
- INRAE, Avignon University, UMR EMMAH, F-84000 Avignon, France
| | - D. Bassir
- CNRS/UMR 5060, / Univ. Bourgogne Franche Comté (UBFC)-UTBM, France, France
- Borelli Center, UMR 9010, ENS Cachan, Université Paris-Saclay, 94235 Cachan, France
| | - S. Guessasma
- INRA, UR1268 Biopolymères Interactions Assemblages, F-44300 Nantes, France
| | - H. Yue
- FRDISI, National and High School of Electricity and Mechanics, Hassan II University, Casablanca, Morocco
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14
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Wang S, D’hooge DR, Daelemans L, Xia H, Clerck KD, Cardon L. The Transferability and Design of Commercial Printer Settings in PLA/PBAT Fused Filament Fabrication. Polymers (Basel) 2020; 12:E2573. [PMID: 33147749 PMCID: PMC7694024 DOI: 10.3390/polym12112573] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/06/2020] [Revised: 10/28/2020] [Accepted: 10/30/2020] [Indexed: 12/03/2022] Open
Abstract
In many fused filament fabrication (FFF) processes, commercial printers are used, but rarely are printer settings transferred from one commercial printer to the other to give similar final tensile part performance. Here, we report such translation going from the Felix 3.0 to Prusa i3 MK3 printer by adjusting the flow rate and overlap of strands, utilizing an in-house developed blend of polylactic acid (PLA) and poly(butylene adipate-co-terephthalate) (PBAT). We perform a sensitivity analysis for the Prusa printer, covering variations in nozzle temperature, nozzle diameter, layer thickness, and printing speed (Tnozzle, dnozzle, LT, and vprint), aiming at minimizing anisotropy and improving interlayer bonding. Higher mass, larger width, and thickness are obtained with larger dnozzle, lower vprint, higher LT, and higher Tnozzle. A higher vprint results in less tensile strain at break, but it remains at a high strain value for samples printed with dnozzle equal to 0.5 mm. vprint has no significant effect on the tensile modulus and tensile and impact strength of the samples. If LT is fixed, an increased dnozzle is beneficial for the tensile strength, ductility, and impact strength of the printed sample due to better bonding from a wider raster structure, while an increased LT leads to deterioration of mechanical properties. If the ratio dnozzle/LT is greater than 2, a good tensile performance is obtained. An improved Tnozzle leads to a sufficient flow of material, contributing to the performance of the printed device. The considerations brought forward result in a deeper understanding of the FFF process and offer guidance about parameter selection. The optimal dnozzle/vprint/LT/Tnozzle combination is 0.5 mm/120 mm s-1/0.15 mm/230 °C.
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Affiliation(s)
- Sisi Wang
- Centre for Polymer and Material Technologies (CPMT), Department of Materials, Textiles and Chemical Engineering, Ghent University, Technologiepark 130, 9052 Zwijnaarde, Belgium;
- College of Engineering, Zhejiang Normal University, Jinhua 321004, China
| | - Dagmar R. D’hooge
- Centre for Textiles Science and Engineering (CTSE), Ghent University, Technologiepark 70A, 9052 Zwijnaarde, Belgium; (D.R.D.); (L.D.); (K.D.C.)
- Laboratory for Chemical Technology (LCT), Department of Materials, Textiles and Chemical Engineering, Ghent University, Technologiepark 125, 9052 Zwijnaarde, Belgium
| | - Lode Daelemans
- Centre for Textiles Science and Engineering (CTSE), Ghent University, Technologiepark 70A, 9052 Zwijnaarde, Belgium; (D.R.D.); (L.D.); (K.D.C.)
| | - Hesheng Xia
- State Key Laboratory of Polymer Materials Engineering, Polymer Research Institute, Sichuan University, Chengdu 610017, China;
| | - Karen De Clerck
- Centre for Textiles Science and Engineering (CTSE), Ghent University, Technologiepark 70A, 9052 Zwijnaarde, Belgium; (D.R.D.); (L.D.); (K.D.C.)
| | - Ludwig Cardon
- Centre for Polymer and Material Technologies (CPMT), Department of Materials, Textiles and Chemical Engineering, Ghent University, Technologiepark 130, 9052 Zwijnaarde, Belgium;
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15
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Optimization and Quality Evaluation of the Interlayer Bonding Performance of Additively Manufactured Polymer Structures. Polymers (Basel) 2020; 12:polym12051166. [PMID: 32438656 PMCID: PMC7284967 DOI: 10.3390/polym12051166] [Citation(s) in RCA: 17] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/06/2020] [Revised: 05/15/2020] [Accepted: 05/16/2020] [Indexed: 11/17/2022] Open
Abstract
The application of additive manufacturing changes from prototypes to series production. In order to fulfill all requirements of series production, the process and the material characteristics must be known. The machine operator of additive manufacturing systems is both a component and a material producer. Nevertheless, there is no standardized procedure for the manufacturing or testing of such materials. This includes the high degree of anisotropy of additively manufactured polymers via material extrusion. The interlayer bonding performance between two layers in the manufacturing direction z is the obvious weakness that needs to be improved. By optimizing this interlayer contact zone, the overall performance of the additively manufactured polymer is increased. This was achieved by process modification with an infrared preheating system (IPS) to keep the temperature of the interlayer contact zone above the glass transition temperature during the manufacturing process. Combining destructive and non-destructive testing methods, the process modification IPS was determined and evaluated by a systematic approach for characterizing the interlayer bonding performance. Thereby, tensile tests under quasi-static and cyclic loading were carried out on short carbon fiber-reinforced polyamide (SCFRP). In addition, micro-computed tomography and microscopic investigations were used to determine the process quality. The IPS increases the ultimate interlayer tensile strength by approx. 15% and shows a tendency to significantly improved the fatigue properties. Simultaneously, the analysis of the micro-computed tomography data shows a homogenization of the void distribution by using the IPS.
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16
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New Business Models for Sustainable Spare Parts Logistics: A Case Study. SUSTAINABILITY 2020. [DOI: 10.3390/su12083071] [Citation(s) in RCA: 19] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
Abstract
Additive manufacturing of spare parts significantly impacts industrial, social, and environmental aspects. However, a literature review shows that: (i) academic papers on the adoption of additive manufacturing have focused mainly on large companies; (ii) the methods required by SMEs to adopt new technologies differ from those employed by large companies; and (iii) recent studies suggest that a suitable way to help small- and medium-sized enterprises (SMEs) to adopt new additive manufacturing technologies from the academic world is by presenting case studies in which SMEs are involved. Given the increasing number of global SMEs (i.e., SMEs that manufacture locally and sell globally), we claim that these companies need to be assisted in adopting spare-parts additive manufacturing for the sake of resource and environmental sustainability. To bridge this gap, the purpose of this article is to present a case study approach that shows how a digital supply chain for spare parts has the potential to bring about changes in business models with significant benefits for both global SMEs (more effective logistic management), customers (response time), and the environment (reduced energy, emissions, raw materials, and waste).
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17
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Bachtiar EO, Erol O, Millrod M, Tao R, Gracias DH, Romer LH, Kang SH. 3D printing and characterization of a soft and biostable elastomer with high flexibility and strength for biomedical applications. J Mech Behav Biomed Mater 2020; 104:103649. [PMID: 32174407 PMCID: PMC7078069 DOI: 10.1016/j.jmbbm.2020.103649] [Citation(s) in RCA: 28] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/01/2019] [Revised: 12/26/2019] [Accepted: 01/20/2020] [Indexed: 01/09/2023]
Abstract
Recent advancements in 3D printing have revolutionized biomedical engineering by enabling the manufacture of complex and functional devices in a low-cost, customizable, and small-batch fabrication manner. Soft elastomers are particularly important for biomedical applications because they can provide similar mechanical properties as tissues with improved biocompatibility. However, there are very few biocompatible elastomers with 3D printability, and little is known about the material properties of biocompatible 3D printable elastomers. Here, we report a new framework to 3D print a soft, biocompatible, and biostable polycarbonate-based urethane silicone (PCU-Sil) with minimal defects. We systematically characterize the rheological and thermal properties of the material to guide the 3D printing process and have determined a range of processing conditions. Optimal printing parameters such as printing speed, temperature, and layer height are determined via parametric studies aimed at minimizing porosity while maximizing the geometric accuracy of the 3D-printed samples as evaluated via micro-CT. We also characterize the mechanical properties of the 3D-printed structures under quasistatic and cyclic loading, degradation behavior and biocompatibility. The 3D-printed materials show a Young's modulus of 6.9 ± 0.85 MPa and a failure strain of 457 ± 37.7% while exhibiting good cell viability. Finally, compliant and free-standing structures including a patient-specific heart model and a bifurcating arterial structure are printed to demonstrate the versatility of the 3D-printed material. We anticipate that the 3D printing framework presented in this work will open up new possibilities not only for PCU-Sil, but also for other soft, biocompatible and thermoplastic polymers in various biomedical applications requiring high flexibility and strength combined with biocompatibility, such as vascular implants, heart valves, and catheters.
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Affiliation(s)
- Emilio O Bachtiar
- Department of Mechanical Engineering, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA; Hopkins Extreme Materials Institute, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA
| | - Ozan Erol
- Department of Mechanical Engineering, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA; Hopkins Extreme Materials Institute, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA
| | - Michal Millrod
- Department of Anesthesiology and Critical Care Medicine, Johns Hopkins University, 600 North Wolfe St, Baltimore, MD 21205, USA
| | - Runhan Tao
- Hopkins Extreme Materials Institute, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA; Department of Biomedical Engineering, Johns Hopkins University, 720 Rutland Avenue, Baltimore, MD 21205, USA
| | - David H Gracias
- Department of Chemical and Biomolecular Engineering, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA; Department of Materials Science and Engineering, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA
| | - Lewis H Romer
- Department of Anesthesiology and Critical Care Medicine, Johns Hopkins University, 600 North Wolfe St, Baltimore, MD 21205, USA; Department of Biomedical Engineering, Johns Hopkins University, 720 Rutland Avenue, Baltimore, MD 21205, USA; Departments of Cell Biology, Pediatrics, and the Center for Cell Dynamics, Johns Hopkins University, 725 North Wolfe St, Baltimore, MD 21205, USA
| | - Sung Hoon Kang
- Department of Mechanical Engineering, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA; Hopkins Extreme Materials Institute, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA; Institute for NanoBioTechnology, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD, 21218, USA.
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18
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Nogales A, Gutiérrez-Fernández E, García-Gutiérrez MC, Ezquerra TA, Rebollar E, Šics I, Malfois M, Gaidukovs S, Ge̅cis E, Celms K, Bakradze G. Structure Development in Polymers during Fused Filament Fabrication (FFF): An in Situ Small- and Wide-Angle X-ray Scattering Study Using Synchrotron Radiation. Macromolecules 2019. [DOI: 10.1021/acs.macromol.9b01620] [Citation(s) in RCA: 31] [Impact Index Per Article: 6.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/20/2022]
Affiliation(s)
- Aurora Nogales
- Instituto de Estructura de la Materia (IEM-CSIC), Serrano 121, 28006 Madrid, Spain
| | | | | | - Tiberio A. Ezquerra
- Instituto de Estructura de la Materia (IEM-CSIC), Serrano 121, 28006 Madrid, Spain
| | - Esther Rebollar
- Instituto de Química Física Rocasolano (IQFR-CSIC), Serrano 119, 28006 Madrid, Spain
| | - Igors Šics
- ALBA Synchrotron, Carrer de la Llum 2-26, Cerdanyola del Vallès, 08290 Barcelona, Spain
| | - Marc Malfois
- ALBA Synchrotron, Carrer de la Llum 2-26, Cerdanyola del Vallès, 08290 Barcelona, Spain
| | - Sergejs Gaidukovs
- Faculty of Materials Science and Applied Chemistry, Institute of Polymer Materials, Riga Technical University, Riga LV-1048, Latvia
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19
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D'Amico TP, Barrett C, Presing J, Patnayakuni R, Pourali M, Peterson AM. Harnessing irreversible thermal strain for shape memory in polymer additive manufacturing. J Appl Polym Sci 2019. [DOI: 10.1002/app.48239] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
Affiliation(s)
- Tone P. D'Amico
- Chemical Engineering Department Worcester Polytechnic Institute, 100 Institute Road Worcester Massachusetts 01609
| | - Connor Barrett
- Chemical Engineering Department Worcester Polytechnic Institute, 100 Institute Road Worcester Massachusetts 01609
| | - Joseph Presing
- Mechanical Engineering Department Worcester Polytechnic Institute, 100 Institute Road Worcester Massachusetts 01609
| | | | - Masoumeh Pourali
- Plastics Engineering Department University of Massachusetts Lowell, 1 University Ave Lowell Massachusetts 01854
| | - Amy M. Peterson
- Chemical Engineering Department Worcester Polytechnic Institute, 100 Institute Road Worcester Massachusetts 01609
- Plastics Engineering Department University of Massachusetts Lowell, 1 University Ave Lowell Massachusetts 01854
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20
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Microstructure and Mechanical Performance of Additively Manufactured Aluminum 2024-T3/Acrylonitrile Butadiene Styrene Hybrid Joints Using an AddJoining Technique. MATERIALS 2019; 12:ma12060864. [PMID: 30875863 PMCID: PMC6471680 DOI: 10.3390/ma12060864] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/20/2019] [Revised: 03/08/2019] [Accepted: 03/11/2019] [Indexed: 11/17/2022]
Abstract
AddJoining is an emerging technique that combines the principles of the joining method and additive manufacturing. This technology is an alternative method to produce metal–polymer (composite) structures. Its viability was demonstrated for the material combination composed of aluminum 2024-T3 and acrylonitrile butadiene styrene to form hybrid joints. The influence of the isolated process parameters was performed using the one-factor-at-a-time approach, and analyses of variance were used for statistical analysis. The mechanical performance of single-lap joints varied from 910 ± 59 N to 1686 ± 39 N. The mechanical performance thus obtained with the optimized joining parameters was 1686 ± 39 N, which failed by the net-tension failure mode with a failure pattern along the 45° bonding line. The microstructure of the joints and the fracture morphology of the specimens were studied using optical microscopy and scanning electron microscopy. From the microstructure point of view, proper mechanical interlocking was achieved between the coated metal substrate and 3D-printed polymer. This investigation can be used as a base for further improvements on the mechanical performance of AddJoining hybrid-layered applications.
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21
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Benwood C, Anstey A, Andrzejewski J, Misra M, Mohanty AK. Improving the Impact Strength and Heat Resistance of 3D Printed Models: Structure, Property, and Processing Correlationships during Fused Deposition Modeling (FDM) of Poly(Lactic Acid). ACS OMEGA 2018; 3:4400-4411. [PMID: 31458666 PMCID: PMC6641607 DOI: 10.1021/acsomega.8b00129] [Citation(s) in RCA: 62] [Impact Index Per Article: 10.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/22/2018] [Accepted: 03/28/2018] [Indexed: 05/21/2023]
Abstract
A fused deposition modeling method was used in this research to investigate the possibility of improving the mechanical properties of poly(lactic acid) by changing the thermal conditions of the printing process. Sample models were prepared while varying a wide range of printing parameters, including bed temperature, melt temperature, and raster angle. Certain samples were also thermally treated by annealing. The prepared materials were subjected to a detailed thermomechanical analysis (differential scanning calorimetry, dynamic mechanical analysis, heat deflection temperature (HDT)), which allowed the formulation of several conclusions. For all prepared samples, the key changes in mechanical properties are related to the content of the poly(lactic acid) crystalline phase, which led to superior properties in annealed samples. The results also indicate the highly beneficial effect of increased bed temperature, where the best results were obtained for the samples printed at 105 °C. Compared to the reference samples printed at a bed temperature of 60 °C, these samples showed the impact strength increased by 80% (from 35 to 63 J/m), HDT increased by 20 °C (from 55 to 75 °C), and also a significant increase in strength and modulus. Scanning electron microscopy observations confirmed the increased level of diffusion between the individual layers of the printed filament.
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Affiliation(s)
- Claire Benwood
- Bioproducts
Discovery and Development Centre, Department of Plant Agriculture, University of Guelph, Crop Science Building, Guelph ON N1G
2W1, Ontario, Canada
| | - Andrew Anstey
- Bioproducts
Discovery and Development Centre, Department of Plant Agriculture, University of Guelph, Crop Science Building, Guelph ON N1G
2W1, Ontario, Canada
| | - Jacek Andrzejewski
- Bioproducts
Discovery and Development Centre, Department of Plant Agriculture, University of Guelph, Crop Science Building, Guelph ON N1G
2W1, Ontario, Canada
- Polymer
Processing Division, Institute of Materials Technology, Faculty of
Mechanical Engineering and Management, Poznan
University of Technology, Piotrowo 3 Street, Poznan 61-138, Poland
| | - Manjusri Misra
- Bioproducts
Discovery and Development Centre, Department of Plant Agriculture, University of Guelph, Crop Science Building, Guelph ON N1G
2W1, Ontario, Canada
- School
of Engineering, University of Guelph, Thornbrough Building, Guelph ON N1G 2W1, Ontario, Canada
- E-mail: (M.M.)
| | - Amar K. Mohanty
- Bioproducts
Discovery and Development Centre, Department of Plant Agriculture, University of Guelph, Crop Science Building, Guelph ON N1G
2W1, Ontario, Canada
- School
of Engineering, University of Guelph, Thornbrough Building, Guelph ON N1G 2W1, Ontario, Canada
- E-mail: (A.K.M.)
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22
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Seppala JE, Hoon Han S, Hillgartner KE, Davis CS, Migler KB. Weld formation during material extrusion additive manufacturing. SOFT MATTER 2017; 13:6761-6769. [PMID: 28819658 PMCID: PMC5684701 DOI: 10.1039/c7sm00950j] [Citation(s) in RCA: 64] [Impact Index Per Article: 9.1] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 05/08/2023]
Abstract
Material extrusion (ME) is a layer-by-layer additive manufacturing process that is now used in personal and commercial production where prototyping and customization are required. However, parts produced from ME frequently exhibit poor mechanical performance relative to those from traditional means; moreover, fundamental knowledge of the factors leading to development of inter-layer strength in this highly non-isothermal process is limited. In this work, we seek to understand the development of inter-layer weld strength from the perspective of polymer interdiffusion under conditions of rapidly changing mobility. Our framework centers around three interrelated components: in situ thermal measurements (via infrared imaging), temperature dependent molecular processes (via rheology), and mechanical testing (via mode III fracture). We develop the concept of an equivalent isothermal weld time and test its relationship to fracture energy. For the printing conditions studied the equivalent isothermal weld time for Tref = 230 °C ranged from 0.1 ms to 100 ms. The results of these analysis provide a basis for optimizing inter-layer strength, the limitations of the ME process, and guide development of new materials.
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Affiliation(s)
- Jonathan E Seppala
- Materials Science and Engineering Division, National Institute of Standards and Technology, Gaithersburg, MD 20899, USA.
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