Lightweight design of two-level supports for extrusion-based additive manufacturing based on metaheuristic algorithms DOI
Ruiliang Feng, Jingchao Jiang, Atul Thakur

et al.

Rapid Prototyping Journal, Journal Year: 2022, Volume and Issue: 29(4), P. 850 - 866

Published: Nov. 9, 2022

Purpose Two-level support with Level 1 consisting of a set beams and 2 tree-like structure is an efficient for extrusion-based additive manufacturing (EBAM). However, the literature finding slim two-level rare. The purpose this paper to design lightweight EBAM. Design/methodology/approach To efficiently solve problem, problem split into two subproblems: support. these subproblems, develops three metaheuristic algorithms, i.e. genetic algorithm (GA), programming (GP) particle swarm optimization (PSO). They are problem-independent powerful in global search. For first subproblem, considering path direction critical factor influencing layout support, solves it by splitting overhang region subregions, determining (vertical or horizontal) each subregion using GA. second hybrid algorithms proposed: GP manipulates topologies tree while PSO optimizes position nodes diameter branches. In particular, chromosome encoded as single virtual make easy manipulate Crossover Mutation. Furthermore, local strategy geometric search designed help reach better result. Findings Simulation results show that proposed method preferred over existing method: saves materials up 26.34%, 6.62% 37.93%. can further improve algorithm, saving 17.88% materials. Research limitations/implications approach sliming requires overhanging be rectilinear polygon vertical horizontal. This limitation limits material savings future research, extended handle arbitrary region, several choices directions. Practical implications details how integrate open-source program CuraEngine 4.13.0 presented. helpful designers manufacturers practice on their own 3D printers. Originality/value planning distribution supporting points will thus influence shape structure. Different from approaches use directions, volume paths overhangs.

Language: Английский

The effect of six key process control parameters on the surface roughness, dimensional accuracy, and porosity in material extrusion 3D printing of polylactic acid: Prediction models and optimization supported by robust design analysis DOI Creative Commons
Nectarios Vidakis, Constantine David, Markos Petousis

et al.

Advances in Industrial and Manufacturing Engineering, Journal Year: 2022, Volume and Issue: 5, P. 100104 - 100104

Published: Nov. 1, 2022

In the material extrusion (MEX) Additive Manufacturing (AM) technology, layer-by-layer nature of fabricated parts, induces specific features which affect their quality and may restrict operating performance. Critical indicators with distinct technological industrial impact are surface roughness, dimensional accuracy, porosity, among others. Their achieving scores can be optimized by adjusting 3D printing process parameters. The effect six (6) control parameters, i.e., raster deposition angle, infill density, nozzle temperature, bed speed, layer thickness, on aforementioned is investigated herein. Optical Microscopy, Profilometry, Micro Χ-Ray Computed Tomography were employed to investigate document these characteristics. Experimental data processed Robust Design Theory. An L25 Taguchi orthogonal array (twenty-five runs) was compiled, for parameters five levels each one them. predictive quadratic regression models then validated two additional confirmation runs, replicas each. For first time, features, as well geometrical structural characteristics in such depth (>500 GB raw experimental produced processed). A deep insight into MEX printed parts provided allowing parameters' ranking optimization. Prediction equations functions introduced herein, merit market-driven practice.

Language: Английский

Citations

65
Optimization of key quality indicators in material extrusion 3D printing of acrylonitrile butadiene styrene: The impact of critical process control parameters on the surface roughness, dimensional accuracy, and porosity DOI
Nectarios Vidakis, Constantine David, Markos Petousis

et al.

Materials Today Communications, Journal Year: 2022, Volume and Issue: 34, P. 105171 - 105171

Published: Dec. 17, 2022

Language: Английский

Citations

60
In silico quantification of 3D thermal gradients and voids during fused filament fabrication deposition to enhance mechanical and dimensional stability DOI
Tom Van Waeleghem, Flávio H. Marchesini, Ludwig Cardon

et al.

Additive manufacturing, Journal Year: 2023, Volume and Issue: 72, P. 103624 - 103624

Published: May 25, 2023

Language: Английский

Citations

17
Advancing the additive manufacturing of PLA-ZnO nanocomposites by fused filament fabrication DOI Creative Commons
Wei Juene Chong, Dejana Pejak Simunec, Adrian Trinchi

et al.

Virtual and Physical Prototyping, Journal Year: 2023, Volume and Issue: 19(1)

Published: Dec. 6, 2023

Poly(lactic acid)-zinc oxide (PLA-ZnO) nanocomposites for fused filament fabrication have potential applications in the biomedical field as they combine bio-compatibility of PLA with antibacterial properties ZnO. This work investigates effects masterbatch mixing strategy, ZnO concentration and surface treatment (silanisation) on printability mechanical performance a pre-requirement to wider uptake these materials. The results showed that decreased filler loading increased. However, powder enhanced matrix-filler interfacial interactions reduced thermal degradation PLA. ameliorated tensile filled up 5 wt.% Moreover, despite additional treatment, melt-mixing prevented degradative effect induced by solvent used mixing. Future will focus assessing nanocomposite FFF parts.

Language: Английский

Citations

12
Development of a Hybrid Model to Estimate Surface Roughness of 3D Printed Parts DOI

Sowrabh Kugunavar,

Mridul Viralka,

Kuldip Singh Sangwan

et al.

Additive manufacturing, Journal Year: 2024, Volume and Issue: 92, P. 104368 - 104368

Published: July 1, 2024

Language: Английский

Citations

4
Exploring the Impact of Surface Modifications on the Mechanical Characteristics of Acrylonitrile Butadiene Styrene Parts Manufactured Using Fused Deposition Modeling 3D Printing DOI Creative Commons

R. Karthikeyan,

Rajesh Ranganathan,

V. S. Sreebalaji

et al.

Journal of Materials Engineering and Performance, Journal Year: 2025, Volume and Issue: unknown

Published: Jan. 3, 2025

Language: Английский

Citations

0
Acrylonitrile‐butadiene‐styrene‐based composites for the manufacture of anthropomorphic simulators DOI
Eduardo Thomazi, Celso Bañeza Román, Jéssica Silvestre Vanni

et al.

Polymer Composites, Journal Year: 2024, Volume and Issue: 45(7), P. 6720 - 6732

Published: Feb. 14, 2024

Abstract The development of functional compounds for extrusion applied in the additive manufacturing anthropomorphic simulators is interesting, as it guarantees manufacture a 3D model similar to patient. These find applications therapies or laboratory tests involving x‐rays. In order replicate human conditions these tests, essential create materials that closely match properties tissue, including smoothness soft tissues and hardness bone tissue. This study developed ceramic‐polymeric composites, where tomography intensity each mixture was measured experimentally. Combinations acrylonitrile butadiene styrene (ABS) with zirconium oxide basic bismuth carbonate allowed imitation samples containing presented results exceeded minimum limit reached value close 2000 Hounsfield units (HU) 12% content. ABS hydroxyapatite aluminum can imitate tissues. use surfactant facilitated mixing ceramic filler polymer. Finally, printing physical performed using dual extruder printer, allowing simultaneous tissue components. Highlights Material mimicking x‐ray attenuation Relation between porosity unit. Computed on printed phantom. Creating from Tomography scan. Double two simultaneously.

Language: Английский

Citations

3
A filament 3D printing approach for CT-compatible bone tissues replication DOI Creative Commons
Nikiforos Okkalidis, Kristina Bliznakova,

Nikola Kolev

et al.

Physica Medica, Journal Year: 2022, Volume and Issue: 102, P. 96 - 102

Published: Sept. 23, 2022

The aim of this study is the development a methodology for manufacturing 3D printed anthropomorphic structures, which mimic X-ray properties human bone tissue.A mixing approach two different materials proposed fabrication radiologically equivalent hip an abdominal phantom. employed phantom were polylactic acid (PLA) and Stonefil, while custom-made dual motor filament extrusion setup software associating medical images directly with printing process employed.Three phantoms representing utilizing filaments under three scenarios. are based on patient's CT scan images. Histograms scans calculated compared to original histogram, demonstrating that constant composition 30% Stonefil 70% PLA 0.0375 rate per voxel (93.75% flow fulfilling single voxel) cancellous bone, using 100% 0.04 (100% flow) cortical results in realistic anatomy replication bone. Reproduced HU varied between 700 800, close those bone.The demonstrated it possible mix real-time during obtain radiographically tissue attenuation. will be explored CT-compatible

Language: Английский

Citations

14
Technical improvements in preparing 3D printed anatomical models for comminuted fracture preoperative planning DOI Creative Commons
Naomi C. Paxton, Brandon G. Wilkinson, Daniel Fitzpatrick

et al.

3D Printing in Medicine, Journal Year: 2023, Volume and Issue: 9(1)

Published: Sept. 11, 2023

Abstract Preoperative planning of comminuted fracture repair using 3D printed anatomical models is enabling surgeons to visualize and simulate the reduction processes before surgery. However, preparation such can be challenging due complexity certain fractures, particularly in preserving fine detail bone fragments, maintaining positioning displaced accurate multiple bones. This study described several key technical considerations for preparing preoperative planning. An optimized segmentation protocol was developed that preserves resulting a more representation fracture. Additionally, struts were manually added digital model maintain fragments after fabrication, reducing likelihood errors during printing or misrepresentation fragment positioning. Magnets also used enable separation visualization bones, making it easier components otherwise obscured by anatomy. Finally, infill non-target structures adjusted minimize print time material wastage. These optimizations improved accuracy efficiency planning, improving opportunities better plan surgical treatment advance, errors, with goal outcomes.

Language: Английский

Citations

8
Effect of post-processing on the mechanical properties of polymers printed by the fused filament fabrication method used as prosthodontic materials and dental biomaterials: a systematic review DOI
Murilo Rodrigues de Campos, Andréa Cândido dos Reis

Polymer Bulletin, Journal Year: 2023, Volume and Issue: 81(3), P. 2001 - 2021

Published: May 21, 2023

Language: Английский

Citations

3