Fused deposition of ceramics: a comprehensive experimental, analytical and computational study of material behavior, fabrication process and equipment design

2021 ◽  
Author(s):  
Anna Bellini
Keyword(s):  
Computational Study ◽  
Equipment Design ◽  
Fabrication Process ◽  
Material Behavior ◽  
Fused Deposition ◽  
Fused Deposition Of Ceramics

scholarly journals Additive Manufacturing of β-Tricalcium Phosphate Components via Fused Deposition of Ceramics (FDC)

Materials ◽  
2020 ◽  
Vol 14 (1) ◽  
pp. 156
Author(s):  
Steffen Esslinger ◽  
Axel Grebhardt ◽  
Jonas Jaeger ◽  
Frank Kern ◽  
Andreas Killinger ◽  
...  
Keyword(s):  
Tricalcium Phosphate ◽  
Critical Size ◽  
Bone Defects ◽  
Healthcare Systems ◽  
The Body ◽  
Patient Specific ◽  
Poly Lactic Acid ◽  
Fused Deposition ◽  
Poly Ethylene ◽  
Fused Deposition Of Ceramics

Bone defects introduced by accidents or diseases are very painful for the patient and their treatment leads to high expenses for the healthcare systems. When a bone defect reaches a critical size, the body is not able to restore this defect by itself. In this case a bone graft is required, either an autologous one taken from the patient or an artificial one made of a bioceramic material such as calcium phosphate. In this study β-tricalcium phosphate (β-TCP) was dispersed in a polymer matrix containing poly(lactic acid) (PLA) and poly(ethylene glycole) (PEG). These compounds were extruded to filaments, which were used for 3D printing of cylindrical scaffolds via Fused Deposition of Ceramics (FDC) technique. After shaping, the printed parts were debindered and sintered. The components combined macro- and micropores with a pore size of 1 mm and 0.01 mm, respectively, which are considered beneficial for bone healing. The compressive strength of sintered cylindrical scaffolds exceeded 72 MPa at an open porosity of 35%. The FDC approach seems promising for manufacturing patient specific bioceramic bone grafts.

scholarly journals Fully resolved numerical simulations of fused deposition modeling. Part II – solidification, residual stresses and modeling of the nozzle

2018 ◽  
Vol 24 (6) ◽  
pp. 973-987 ◽  
Author(s):  
Huanxiong Xia ◽  
Jiacai Lu ◽  
Gretar Tryggvason
Keyword(s):  
Residual Stresses ◽  
Numerical Simulations ◽  
Fused Deposition Modeling ◽  
Fixed Bed ◽  
Ground Truth ◽  
Deposition Process ◽  
Material Behavior ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling

Purpose The purpose of this paper is to continue to describe the development of a comprehensive methodology for fully resolved numerical simulations of fused deposition modeling. Design/methodology/approach A front-tracking/finite volume method introduced in Part I to simulate the heat transfer and fluid dynamics of the deposition of a polymer filament on a fixed bed is extended by adding an improved model for the injection nozzle, including the shrinkage of the polymer as it cools down, and accounting for stresses in the solid. Findings The accuracy and convergence properties of the new method are tested by grid refinement, and the method is shown to produce convergent solutions for the shape of the filament, the temperature distribution, the shrinkage and the solid stresses. Research limitations/implications The method presented in the paper focuses on modeling the fluid flow, the cooling and solidification and volume changes and residual stresses, using a relatively simple viscoelastic constitutive model. More complex material models, depending, for example, on the evolution of the conformation tensor, are not included. Practical implications The ability to carry out fully resolved numerical simulations of the fused deposition process is expected to be critical for the validation of mathematical models for the material behavior, to help explore new deposition strategies and to provide the “ground truth” for the development of reduced-order models. Originality/value The paper completes describing the development of the first numerical method for fully resolved simulation of fused filament modeling.

scholarly journals Basic Research for Additive Manufacturing of Rubber

Polymers ◽  
2020 ◽  
Vol 12 (10) ◽  
pp. 2266 ◽  
Author(s):  
Welf-Guntram Drossel ◽  
Jörn Ihlemann ◽  
Ralf Landgraf ◽  
Erik Oelsch ◽  
Marek Schmidt
Keyword(s):  
Fused Deposition Modeling ◽  
Basic Research ◽  
Traverse Speed ◽  
Material Behavior ◽  
Technical Solution ◽  
Fused Deposition ◽  
Optimum Parameters ◽  
Printing Quality ◽  
Deposition Modeling ◽  
Printing Parameters

The dissemination and use of additive processes are growing rapidly. Nevertheless, for the material class of elastomers made of vulcanizable rubber, there is still no technical solution for producing them using 3D printing. Therefore, this paper deals with the basic investigations to develop an approach for rubber printing. For this purpose, a fused deposition modeling (FDM) 3D printer is modified with a screw extruder. Tests are carried out to identify the optimal printing parameters. Afterwards, test prints are performed for the deposition of rubber strands on top of each other and for the fabrication of simple two-dimensional geometries. The material behavior during printing, the printing quality as well as occurrences of deviations in the geometries are evaluated. The results show that the realization of 3D rubber printing is possible. However, there is still a need for research to stabilize the layers during the printing process. Additionally, further studies are necessary to determine the optimum parameters for traverse speed and material discharge, especially on contours.

Fabrication of Piezoelectric CeramicPolymer Composite Transducers Using Fused Deposition of Ceramics

2000 ◽  
Vol 83 (1) ◽  
pp. 124-28 ◽  
Author(s):  
Gwenalle M. Lous ◽  
Ivn A. Cornejo ◽  
Thomas F. McNulty ◽  
Ahmad Safari ◽  
Stephen C. Danforth
Keyword(s):  
Fused Deposition ◽  
Fused Deposition Of Ceramics

Processing and Characterization of Al2O3 and Al2O3 / Cu Alloy Composites

2001 ◽  
Vol 698 ◽  
Author(s):  
R.C. McCuiston ◽  
S.C. Danforth ◽  
D.E. Niesz
Keyword(s):  
Copper Alloys ◽  
Metal Composites ◽  
Binder Removal ◽  
Fused Deposition ◽  
Cu Alloy ◽  
Scanning Electron Microcopy ◽  
Potential Applications ◽  
Fused Deposition Of Ceramics ◽  
Scanning Electron

ABSTRACTFused deposition of ceramics (FDC) has been used to fabricate macroscopically graded ceramic skeletons. These Al2O3 skeletons were subjected to binder removal and sintering treatments. The sintered skeletons were infiltrated with copper alloys. Both the skeletons and composites were characterized for micro and macrostructure using scanning electron microcopy. Potential applications for the macroscopically graded ceramic/metal composites focus primarily on impact.

Mechanical Properties of Feedstock Material for Fused Deposition of Ceramics

1998 ◽  
Vol 542 ◽  
Author(s):  
N. Venkataraman ◽  
T. McNulty ◽  
S. Rangarajan ◽  
M. Vidaic ◽  
M. J. Matthewson ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Lead Zirconate Titanate ◽  
Storage Time ◽  
Failure Strain ◽  
Lead Zirconate ◽  
Failure Stress ◽  
Fused Deposition ◽  
Crosshead Displacement ◽  
Fused Deposition Of Ceramics ◽  
Feedstock Material

AbstractA scientific methodology to characterize the critical mechanical properties of feedstock material for fused deposition of ceramics has been developed. A detailed discussion of the methodology of mechanical characterization and results for lead zirconate titanate (PZT) fused deposition of ceramics (FDC) feedstock is presented. The effect of storage time, temperature and crosshead displacement rates on the mechanical properties of the PZT FDC feedstock was studied. The modulus and the failure stress increase with displacement rate. The modulus and failure stress decrease with temperature indicating the necessity for cooling filaments prior to entrance to liquefier. The modulus also decreases with storage time in 50% RH while failure strain increases with storage time in 50% RH.

scholarly journals Custom TMJ Hemi-joint Fabrication Process

2008 ◽  
Vol 2 (2) ◽  
Author(s):  
Joel L. Kuhlmann ◽  
Sean McEligot
Keyword(s):  
Temporomandibular Joint ◽  
Mayo Clinic ◽  
Fused Deposition Modeling ◽  
High Strength ◽  
Fabrication Process ◽  
Implant Design ◽  
3D Cad ◽  
Fused Deposition ◽  
Joint Disorder ◽  
Unique Shape

Temporomandibular joint disorder afflicts 10 million Americans, many of whom have osteoarthritis of the temporomandibular joint (TMJ). This condition can inflict severe pain and disrupt the lives of sufferers in many ways. Partial or total replacement of the temporomandibular joint is a last resort treatment option. Surgeons at Mayo Clinic believe a new hemijoint implant design coupled with unique surgical technique can improve joint kinematics and reduce pain. They are currently investigating a patent-pending implant design in a series of patient trials. The Division of Engineering at Mayo Clinic has developed a novel process for fabricating TMJ implants for this study. Computed Tomagraphy (CT) images of the surgical site are first converted into a 3D computer model of the mandibular fossa and condyle area. A fused deposition modeling process is used to create a plastic model of the anatomy, and the surgeons use that model to create a wax mold of the implant. The wax mold is laser scanned to create a 3D CAD model that can be machined with a standard four axis milling machine out of implant grade CoCrMo material. Because of the unique shape of the implant, the machining takes place in two phases, with the implant being refixtured between machining phases using a high strength industrial adhesive. Finally, the implant is polished, inspected, passivated and sterilized for surgery. This fabrication process has allowed Mayo Clinic surgeons to quickly and accurately test their unique implant design.

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