scholarly journals Analysis of PLA Geometric Properties Processed by FFF Additive Manufacturing: Effects of Process Parameters and Plate-Extruder Precision Motion

Polymers ◽  
2019 ◽  
Vol 11 (10) ◽  
pp. 1581 ◽  
Author(s):  
Eustaquio García Plaza ◽  
Pedro Núñez López ◽  
Miguel Caminero Torija ◽  
Jesús Chacón Muñoz
Keyword(s):  
Layer Thickness ◽  
Surface Texture ◽  
Feed Rate ◽  
Low Cost ◽  
Dimensional Accuracy ◽  
3D Printer ◽  
Geometric Properties ◽  
Geometric Precision ◽  
Functional Components ◽  
Flatness Error

The evolution of fused filament fabrication (FFF) technology, initially restricted to the manufacturing of prototypes, has led to its application in the manufacture of finished functional products with excellent mechanical properties. However, FFF technology entails drawbacks in aspects, such as dimensional and geometric precision, and surface finish. These aspects are crucial for the assembly and service life of functional parts, with geometric qualities lagging far behind the optimum levels obtained by conventional manufacturing processes. A further shortcoming is the proliferation of low cost FFF 3D printers with low quality mechanical components, and malfunctions that have a critical impact on the quality of finished products. FFF product quality is directly influenced by printer settings, material properties in terms of cured layers, and the functional mechanical efficiency of the 3D printer. This paper analyzes the effect of the build orientation (Bo), layer thickness (Lt), feed rate (Fr) parameters, and plate-extruder movements on the dimensional accuracy, flatness error, and surface texture of polylactic acid (PLA) using a low cost open-source FFF 3D printer. The mathematical modelling of geometric properties was performed using artificial neural networks (ANN). The results showed that thinner layer thickness generated lower dimensional deviations, and feed rate had a minor influence on dimensional accuracy. The flatness error and surface texture showed a quasi-linear behavior correlated to layer thickness and feed rate, with alterations produced by 3D printer malfunctions. The mathematical models provide a comprehensive analysis of the geometric behavior of PLA processing by FFF, in order to identify optimum print settings for the processing of functional components.

scholarly journals Design and implementation of a three dimensions (3D) printer for modeling and pre-manufacturing applications

2019 ◽  
Vol 9 (6) ◽  
pp. 4749
Author(s):  
Ghazi Qaryouti ◽  
Abdel Rahman Salbad ◽  
Sohaib A. Tamimi ◽  
Anwar Almofleh ◽  
Wael A. Salah ◽  
...  
Keyword(s):  
3D Printing ◽  
Manufacturing Sector ◽  
Low Cost ◽  
Three Dimensional ◽  
Three Dimensions ◽  
3D Printer ◽  
Overall Design ◽  
Design And Implementation ◽  
Manufacturing Applications ◽  
Functional Components

The three-dimensional (3D) printing technologies represent a revolution in the manufacturing sector due to their unique characteristics. These printers arecapable to increase the productivitywithlower complexity in addition tothe reduction inmaterial waste as well the overall design cost prior large scalemanufacturing.However, the applications of 3D printing technologies for the manufacture of functional components or devices remain an almost unexplored field due to their high complexity. In this paper the development of 3D printing technologies for the manufacture of functional parts and devices for different applications is presented. The use of 3D printing technologies in these applicationsis widelyused in modelingdevices usually involves expensive materials such as ceramics or compounds. The recent advances in the implementation of 3D printing with the use of environmental friendly materialsin addition to the advantages ofhighperformance and flexibility. The design and implementation of relatively low-cost and efficient 3D printer is presented. The developed prototype was successfully operated with satisfactory operated as shown from the printed samples shown.

Comparison on Dimensional Accuracy Using a Newly Developed Nozzle for Open-Source 3D Printer

2016 ◽  
Vol 859 ◽  
pp. 15-19 ◽  
Author(s):  
Nor Aiman Sukindar ◽  
Mohd Khairol Anuar Mohd Ariffin ◽  
B.T. Hang Tuah bin Baharudin ◽  
Che Nor Aiza Jaafar ◽  
Mohd Idris Shah Ismail
Keyword(s):  
Open Source ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Dimensional Accuracy ◽  
3D Printer ◽  
Constant Heat ◽  
New Era ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Increasing Demand

Fused Deposition Modeling (FDM) or also known as RepRap (Replicating Rapid Prototyper) is a technology that is synonym with 3D printing. This technology has entered a new era with an increasing demand among the community. It has grown commercially in the market of open-source system and it is relatively low cost. Many efforts have been put towards the development of the system in both hardware and software to increase the quality and the performance. The research highlights the development of a new nozzle to evaluate the performance on dimensional accuracy in comparison to the original nozzle. The nozzle emphasizes the die angle for the polylactic acid (PLA) material, the liquefier design which provide constant heat in the liquefier chamber, as well as insulator for the liquefier using highly insulated material. The dimensional accuracies of both nozzles were compared where the result showed that the new nozzle provided better accuracy and stability on the extruding PLA material.

Results of studying the dimensional accuracy of the bases of complete removable prostheses made using 3D printing and traditional technologies

2020 ◽  
pp. 34-39
Author(s):  
Vokulova Yu.A. Vokulova ◽  
E.N. Zhulev
Keyword(s):  
3D Printing ◽  
Traditional Method ◽  
Laser Scanning ◽  
Laser Scanner ◽  
Digital Technologies ◽  
Dimensional Accuracy ◽  
3D Printer ◽  
Significance Level ◽  
Average Value ◽  
The Difference

This article presents the results of studying the dimensional accuracy of the bases of complete removable prostheses made using a 3D printer and the traditional method. Bases of complete removable prostheses were made using an intraoral laser scanner iTero Cadent (USA) and a 3D printer Asiga Max UV (Australia). To study the dimensional accuracy of the bases of complete removable prostheses, we used the DentalCAD 2.2 Valletta software. The Nonparametric Wilcoxon W-test was used for statistical analysis of the obtained data. We found that the average value of the difference with the standard for bases made using digital technologies is 0.08744±0.0484 mm. The average value of the difference with the standard for bases made by the traditional method is 0.5654±0.1611 mm. Based on these data, we concluded that the bases of complete removable prostheses made using modern digital technologies (intraoral laser scanning and 3D printer) have a higher dimensional accuracy compared to the bases of complete removable prostheses made using the traditional method with a significance level of p<0.05 (Wilcoxon's W-test=0, p=0.031). Keywords: digital technologies in dentistry, digital impressions, intraoral scanner, 3D printing, ExoCAD, complete removable dentures.

scholarly journals Accuracy Verification of an Anatomical Model Manufactured Using Low-Cost Additive Production

2021 ◽  
Vol 11 (2) ◽  
pp. 594
Author(s):  
Teodor Tóth ◽  
Patrik Varga ◽  
Branko Štefanovič ◽  
Lucia Bednarčíková ◽  
Marek Schnitzer ◽  
...  
Keyword(s):  
Surface Coverage ◽  
Reference Model ◽  
Low Cost ◽  
Cervical Vertebra ◽  
3D Printer ◽  
3D Scanner ◽  
Entire Surface ◽  
Additive Production ◽  
The Third ◽  
And Training

The paper deals with the separation of the third cervical vertebra using the software VGStudio MAX, Mimics, and inVesalius. During the separation, various parameters of the threshold were used to determine the effect. The comparison of models from Mimics and inVesalius to VGStudio MAX showed that the cumulative variance distribution for 95% surface coverage is less than 0.935 mm. When comparing medically oriented software, Mimics and inVesalius, the deviation was less than 0.356 mm. The model was made of polylactic acid (PLA) material on a low-cost 3D printer, Prusa i3 MK2.5 MMU1. The printed model was scanned by four scanners: Artec Eva, 3Shape D700, Steinbichler Comet L3D, and Creaform EXAscan. The outputs from the scanners were compared to the reference model (standard tessellation language (STL) model for 3D printing) as well as to the scanner with the best accuracy (3Shape). Compared to the publications below, the analysis of deviations was evaluated on the entire surface of the model and not on selected dimensions. The cumulative variance distribution for comparing the output from the 3D scanner with the reference model, as well as comparing the scanners, shows that the deviation for 95% of the surface coverage is at the level of 0.300 mm. Since the model of the vertebra is planned for education and training, the used software and technologies are suitable for use in the design and the production process.

scholarly journals Low-Cost Customized Cranioplasty with Polymethyl Methacrylate Using 3D Printer Generated Mold: An Institutional Experience and Review of Literature

2021 ◽  
Author(s):  
Ankit Chaudhary ◽  
Virendra Deo Sinha ◽  
Sanjeev Chopra ◽  
Jitendra Shekhawat ◽  
Gaurav Jain
Keyword(s):  
Polymethyl Methacrylate ◽  
Bone Fractures ◽  
Low Cost ◽  
Operating Time ◽  
Three Dimensional ◽  
Wound Dehiscence ◽  
3D Printer ◽  
Skull Defects ◽  
Aesthetic Appearance ◽  
The Mean

Abstract Background Cranioplasty is performed to repair skull defects and to restore normal skull anatomy. Optimal reconstruction remains a topic of debate. Autologous bone flap is the standard option but it may not be available due to traumatic bone fractures, bone infection, and resorption. The authors present their experience with prefabrication of precise and low-cost polymethyl methacrylate (PMMA) mold using three-dimensional (3D) digital printing. Methods A total of 30 patients underwent cranioplasty between March 2017 and September 2019 at Sawai Man Singh Medical College Jaipur, India. Preoperative data included diagnosis for which decompressive craniectomy was done and Glasgow coma scale score. Intraoperative data included operating time. Postoperative data included cosmetic outcome in the form of cranial contour and margins, complications such as infection, seroma, implant failure, wound dehiscence, and hematoma. Results Patient age at cranioplasty ranged from 12 to 63 years with a mean age of 36.7 years. The mean operating time was 151.6 minutes (range 130–190 minutes). The mean follow-up period was 8 months (range 6–13 months). Postoperative wound dehiscence developed in one case (3.3%). Cranial contour and approximation of the margins were excellent and aesthetic appearance improved in all patients. Conclusion Low-cost PMMA implant made by digital 3D printer mold is associated with reconstruction of the deformed skull contour giving satisfactory results to the patient and his family members, at a low cost compared with other commercially available implants. This technique could be a breakthrough in cranioplasty.

Performance of Low-Cost 3D Printer in Medical Application

2021 ◽  
Author(s):  
Nor Aiman Sukindar ◽  
Azib Azhari Awang Dahan ◽  
Sharifah Imihezri Syed Shaharuddin ◽  
Nor Farah Huda Abd Halim
Keyword(s):  
Low Cost ◽  
Medical Application ◽  
Fused Deposition Modelling ◽  
3D Printer ◽  
Layer By Layer ◽  
Total Deformation ◽  
Element Analysis ◽  
Porosity Level ◽  
Fused Deposition ◽  
Printing Parameters

Abstract Fused Deposition Modelling (FDM) is an additive manufacturing (AM) process that produces a physical object directly from a CAD design using layer-by-layer deposition of the filament material that is extruded via a nozzle. In industry, FDM has become one of the most used AM processes for the production of low batch quantity and functional prototypes, due to its safety, efficiency, reliability, low cost, and ability to process manufacturing-grade engineering thermoplastic. Recently, the market is flooded with the availability of low-cost printers produced by numerous companies. This research aims to investigate the effect of different porosity levels on a scaffold structure produced using a low-cost 3D printer. Comparisons of these porous structures were made in terms of Von-Mises strain, total deformation, as well as compressive stress. Various porosity levels were created by varying printing parameters, including layer height, infill density, and shell thickness by slicing the initial solid CAD file using Repetier Host 3D printing software. Finite Element Analysis (FEA) simulation was then performed on the created scaffold structures by using Ansys Workbench 19.2. The simulation result indicates that the greater porosity level will result in higher total deformation of the structure. Meanwhile, the compression test shows that the minimum strength value obtained was favourable at 22 MPa and had exceeded that of the trabecular femur (15 MPa). However, its porosity level (maximum at 52%) was still below that of the minimum threshold of porosity level of 70 percent. However, the printing parameters currently used can be adjusted in the future. Therefore, it was deduced that the low-cost 3D printer offers promising potential to fabricate different porosity structures with multiple outcomes.

scholarly journals Simulation of incremental forming processes of a pyramidal ring made of two materials

2018 ◽  
Vol 19 (3) ◽  
pp. 313
Author(s):  
Masood Ghassabi ◽  
Milad Salimi ◽  
Mohammad Haghpanahi
Keyword(s):  
Feed Rate ◽  
Rotational Speed ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Cnc Machine ◽  
Forming Force ◽  
Forming Process ◽  
Dimensional Precision

Incremental forming is one of the most well-known forming processes for complex and asymmetric parts. This method uses a CNC machine, simple forming tool, and a die. This study focused on effects of some parameters such as the material, feed rate, pitch, rotational speed and movement strategy of tool on the dimensional precision, forming force, thickness distribution and fracture in the welding area. The results showed that single point incremental forming (SPIF) led to a better thickness distribution with lower tool force, whereas two-point incremental forming led to better dimensional accuracy. Rotational speed does not have any significant impact on the forming process while decreasing the feed rate partially reduced the forming force. According to the results, although dimensional precision in double point incremental forming is better than SPIF, when it comes to the thickness distribution, forming force, and economic issues, SPIF is in favor. The results also showed that by connecting two materials, different parameters for the two materials could be investigated simultaneously in one simulation process.

scholarly journals Full in-Office Guided Surgery with Open Selective Tooth-Supported Templates: A Prospective Clinical Study on 20 Patients

2018 ◽  
Vol 15 (11) ◽  
pp. 2361 ◽  
Author(s):  
Francesco Mangano ◽  
Uli Hauschild ◽  
Oleg Admakin
Keyword(s):  
Clinical Study ◽  
Low Cost ◽  
Prospective Clinical Study ◽  
3D Printer ◽  
Guided Surgery ◽  
Operative Complications ◽  
Edentulous Patients ◽  
One Year ◽  
Single Crowns ◽  
Surgical Templates

Background: Guided implant surgery appears to have several benefits, such as the possibility of inserting flapless implants in a prosthetically driven manner, avoiding dangerous anatomical structures. However, to date, only a few surgeons routinely use guided surgery in partially edentulous patients. Aim: To present the results obtained with tooth-supported surgical templates characterized by an innovative open design with selective support, and manufactured via a full in-office procedure with a low-cost desktop 3D printer. Methods: Over a two-year period (2016–2018), all partially edentulous patients with one to three missing teeth (in maxilla and/or mandible), referred to a private dental practice for restoration with dental implants, were considered for inclusion in this prospective clinical study. An intraoral scanner (CS 3600®, Carestream Dental) and cone beam computed tomography (CS 9300®, Carestream Dental) were used to acquire the 3D information on the patients. Guided surgery software (SMOP®, Swissmeda) was used to plan the surgeries and to design open, selective, tooth-supported templates that were fabricated with a stereolithographic (SLA) desktop 3D printer (XFAB2000®, DWS). Guided implant surgeries were performed and patients were followed for a period of one year. The study outcomes were fit and stability of surgical templates, duration (time) of surgery, intra and post-operative complications, and implant stability and survival. Results: Twenty (20) partially edentulous patients (9 males, 11 females; mean age 54.4 ± 9.4 years) were included in the study; 28 open, selective, tooth-supported templates were designed with the aim of inserting 38 implants. Among the surgical templates, 24 had optimal fit and stability, three had optimal fit and sufficient stability, and only one had inadequate fit and unsatisfactory stability and was therefore not suitable for clinical use. The average time of the intervention was 15.7 ± 5.2 min per template. No intra-operative complications were reported, but one implant was not stable at placement and had to be removed. In total, 36 implants were restored with 10 two-unit fixed partial prostheses and 16 single crowns. All implants were successfully functioning at one year, even if, in two single crowns, minor prosthetic complications (abutment screw loosening) occurred. Conclusions: Full in-office guided surgery with open, selective, tooth-supported templates seem to represent a clinically predictable surgical procedure to restore partially edentulous patients. Further studies are needed to confirm these positive outcomes.

scholarly journals Precise Drilling of Holes in Alumina Ceramic (Al2O3) by Rotary Ultrasonic Drilling and its Parameter Optimization using MOGA-II

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1059 ◽  
Author(s):  
Hisham Alkhalefah
Keyword(s):  
Feed Rate ◽  
Dimensional Accuracy ◽  
Alumina Ceramic ◽  
Process Variables ◽  
Multi Objective Genetic Algorithm ◽  
Ultrasonic Drilling ◽  
Drilling Quality ◽  
Processing Techniques ◽  
Validation Tests ◽  
Rotary Ultrasonic Drilling

Alumina is an advanced ceramic with applications in dental and medical sciences. Since ceramics are hard and brittle, their conventional machining is expensive, arduous, and time-consuming. As rotary ultrasonic machining is among the most adequate and proficient processing techniques for brittle materials like ceramics. Therefore, in this study, rotary ultrasonic drilling (RUD) has been utilized to drill holes on alumina ceramic (Al2O3). This study investigates the effect of key RUD process variables, namely vibration frequency, vibration amplitude, spindle speed, and feed rate on the dimensional accuracy of the drilled holes. A four-variable three-level central composite design (thirty experiments on three sample plates) is utilized to examine the comparative significance of different RUD process variables. The multi-objective genetic algorithm is employed to determine the optimal parametric conditions. The findings revealed that material removal rates depend on feed rate, while the cylindricity of the holes is mostly controlled by the speed and feed rate of the spindles. The optimal parametric combination attained for drilling quality holes is speed = 4000 rpm, feed rate = 1.5 (mm/min), amplitude = 20 (µm), and frequency = 23 (kHz). The validation tests were also conducted to confirm the quality of drilled holes at the optimized process parameters.

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