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Because of the anisotropy of the process and the variability in the quality of printed parts, finite element analysis is not directly applicable to recycled materials manufactured using fused filament fabrication. The purpose of this study is to investigate the numerical-experimental mechanical behavior modeling of the recycled polymer, that is, recyclable polyethylene terephthalate (rPET), manufactured by a deposition FFF process under compressive stresses for new sustainable designs.

In all, 42 test specimens were manufactured and analyzed according to the ASTM D695-15 standards. Eight numerical analyzes were performed on a real design manufactured with rPET using Young's compression modulus from the experimental tests. Finally, eight additional experimental tests under uniaxial compression loads were performed on the real sustainable design for validating its mechanical behavior versus computational numerical tests.

As a result of the experimental tests, rPET behaves linearly until it reaches the elastic limit, along each manufacturing axis. The results of this study confirmed the design's structural safety by the load scenario and operating boundary conditions. Experimental and numerical results show a difference of 0.001–0.024 mm, allowing for the rPET to be configured as isotropic in numerical simulation software without having to modify its material modeling equations.

The results obtained are of great help to industry, designers and researchers because they validate the use of recycled rPET for the ecological production of real-sustainable products using MEX technology under compressive stress and its configuration for numerical simulations. Major design companies are now using recycled plastic materials in their high-end designs.

Validation results have been presented on test specimens and real items, comparing experimental material configuration values with numerical results. Specifically, to the best of the authors’ knowledge, no industrial or scientific work has been conducted with rPET subjected to uniaxial compression loads for characterizing experimentally and numerically the material using these results for validating a real case of a sustainable industrial product.

Confronting the unveiled sophisticated structural and physical characteristics of permanent magnets, notably the samarium–cobalt (Sm-Co) alloy, This work aims to introduce a simulation scheme that can link physics-based micromagnetics on the nanostructures and magnetostatic homogenization on the mesoscale polycrystalline structures.

The simulation scheme is arranged in a multiscale fashion. The magnetization behaviors on the nanostructures examined with various orientations are surrogated as the micromagnetic-informed hysterons. The hysteresis behavior of the mesoscale polycrystalline structures with micromagnetic-informed hysterons is then evaluated by computational magnetostatic homogenization.

The micromagnetic-informed hysterons can emulate the magnetization reversal of the parameterized Sm-Co nanostructures as the local hysteresis behavior on the mesostructures. The simulation results of the mesoscale polycrystal demonstrate that the demagnetization process starts from the grain with the largest orientation angle (a) and then propagates to the surrounding grains.

The presented scheme depicts the demand for integrating data-driven methods, as the parameters of the surrogate hysteron intrinsically depend on the nanostructure and its orientation. Further hysteron parameters that help the surrogate hysteron emulate the micromagnetic-simulated magnetization reversal should be examined.

This work provides a novel multiscale scheme for simulating the polycrystalline permanent magnets’ hysteresis while recapitulating the nanoscale mechanisms, such as the nucleation of domains, and domain wall migration and pinning. This scheme can be further extended to simulate the part-level hysteresis considering the mesoscale features.

An Autodesk Ember three-dimensional (3D) printer was used to print optical components from Clear PR48 photocurable resin. The cured PR48 was characterized by the per cent of light transmitted and the index of refraction, which was measured with a prism spectrometer. Lenses and diffraction gratings were also printed and characterized. The focal length of the printed lenses agreed with predictions based on the thin lens equation. The periodicity and effective slit width of the printed gratings were determined from both optical micrographs and fits to the Fraunhofer diffraction equation. This study aims to demonstrate the advantages offered by a layer-by-layer DLP printing process for the manufacture of optical components for use in the visible region of the electromagnetic spectrum.

A 3D printer was used to print both lenses and diffraction gratings from Standard Clear PR48 photocurable resin. The manufacturing process of the lenses and the diffraction gratings differ mainly in the printing angle with respect to the printer x-y-axes. The transmission diffraction gratings studied here were manufactured with nominal periodicities of 10, 25 and 50 µm. The aim of this study was to optically determine the effective values for the distance between slits, d, and the effective width of the slits, w, and to compare these values with the printed layer thickness.

The normalized diffraction patterns measured in this experiment for the printed gratings with layer thickness of 10, 25 and 50 µm are shown by the solid dots in Figures 8(a)-(c). Also shown as a red solid line are the fits to the experimental diffraction data. The effective values of d and w obtained from fitting the data are compared to the nominal layer thickness of the printed gratings. The effective distance between slits required to fit the diffraction patterns are well approximated by the printed layer thickness to within 14, 4 and 16 per cent for gratings with a nominal 10, 25 and 50 µm layer thickness, respectively.

Chromatic aberration is present in all polymer lenses, and the authors have not attempted to characterize it in this study. These materials could be used for achromatic lenses if paired with a crown-type material in an achromatic doublet configuration, because this would correct the chromatic aberration issues. It is worthwhile to compare the per cent transmission in cured PR48 resin (approximately 80 per cent) to the percent transmission found in common optical materials like BK7 (approximately 92 per cent) over the visible region. The authors attribute the lower transmission in PR48 to a combination of surface scattering and increased absorption. At the present time, the authors do not know what fraction of the lower transmission is related to the surface quality resulting from sample polishing.

There are inherent limitations to the 3D manufacturing process that affect the performance of lenses. Approximations to a curved surface in the design software, the printing resolution of the Autodesk Ember printer and the anisotropy due to printing in layers are believed to be the main issues. The performance of the lenses is also affected by internal imperfections in the printed material, in particular the presence of bubbles and the inclusion of debris like dust or fibers suspended in air. In addition, the absorption of wavelengths in the blue/ultraviolet produces an undesirable yellowing in any printed part.

One of the most interesting results from this study was the manufacture of diffraction gratings using 3D printing. An analysis of the diffraction pattern produced by these printed gratings yielded estimates for the slit periodicity and effective slit width. These gratings are unique because the effective slit width fills the entire volume of the printed part. This aspect makes it possible to integrate two or more optical devices in a single printed part. For example, a lens combined with a diffraction grating now becomes possible.

Many additively manufactured parts suffer from reduced interlayer strength. This anisotropy is necessarily tied to the orientation during manufacture. When individual features on a part have conflicting optimal orientations, the part is unavoidably compromised. This paper aims to demonstrate a strategy in which conflicting features can be functionally separated into “co-parts” which are individually aligned in an optimal orientation, selectively reinforced with continuous fiber, printed simultaneously and, finally, assembled into a composite part with substantially improved performance.

Several candidate parts were selected for co-part decomposition. They were printed as standard fused filament fabrication plastic parts, parts reinforced with continuous fiber in one plane and co-part assemblies both with and without continuous fiber reinforcement (CFR). All parts were loaded until failure. Additionally, parts representative of common suboptimally oriented features (“unit tests”) were similarly printed and tested.

CFR delivered substantial improvement over unreinforced plastic-only parts in both standard parts and co-part assemblies, as expected. Reinforced parts held up to 2.5x the ultimate load of equivalent plastic-only parts. The co-part strategy delivered even greater improvement, particularly when also reinforced with continuous fiber. Plastic-only co-part assemblies held up to 3.2x the ultimate load of equivalent plastic only parts. Continuous fiber reinforced co-part assemblies held up to 6.4x the ultimate load of equivalent plastic-only parts. Additionally, the thought process behind general co-part design is explored and a vision of simulation-driven automated co-part implementation is discussed.

This technique is a novel way to overcome one of the most common challenges preventing the functional use of additively manufactured parts. It delivers compelling performance with continuous carbon fiber reinforcement in 3D printed parts. Further study could extend the technique to any anisotropic manufacturing method, additive or otherwise.

Because of the significant differences in the features and requirements of specific products and the capabilities of various additive manufacturing (AM) solutions, selecting the most appropriate AM technology can be challenging. This study aims to propose a method to solve the complex process selection in 3D printing applications, especially by creating a new multicriteria decision-making tool that takes the direct certainty of each comparison to reflect the decision-maker’s desire effectively.

The methodology proposed includes five steps: defining the AM technology selection decision criteria and constraints, extracting available AM parameters from the database, evaluating the selected AM technology parameters based on the proposed decision-making methodology, improving the accuracy of the decision by adopting newly proposed weighting scheme and selecting optimal AM technologies by integrating information gathered from the whole decision-making process.

To demonstrate the feasibility and reliability of the proposed methodology, this case study describes a detailed industrial application in rapid investment casting that applies the weightings to a tailored AM technologies and materials database to determine the most suitable AM process. The results showed that the proposed methodology could solve complicated AM process selection problems at both the design and manufacturing stages.

This research proposes a unique multicriteria decision-making solution, which employs an exclusive weightings calculation algorithm that converts the decision-maker's subjective priority of the involved criteria into comparable values. The proposed framework can reduce decision-maker's comparison duty and potentially reduce errors in the pairwise comparisons used in other decision-making methodologies.

This paper aims to investigate the feasibility of adding macro-textures to triangle meshes for additive manufacturing (AM) focusing on possible time and quality issues in both software processing and part fabrication.

A demonstrative software tool was developed to apply user-selected textures to existing meshes. The computational procedure is a three-dimensional extension of the solid texturing method used in computer graphics. The tool was tested for speed and quality of results, considering also the pre- and post-processing operations required. Some textured meshes were printed by different processes to test build speed and quality.

The tool can handle models with realistic complexity in acceptable computation times. Parts are built without difficulties or extra-costs achieving a good aesthetic yield of the texture.

The tool cannot reproduce sample patterns but requires the development of a generation algorithm for different type of textures. Mesh processing operations may take a long time when very fine textures are added to large parts.

Direct texturing can help obtain parts with aesthetic or functional textures without the need for surface post-treatments, which can be especially difficult and expensive for plastic parts.

The proposed method improves the uniformity and consistency of textures compared to existing approaches, and can support future systematic studies on the detail resolution of AM processes.

The goal of this work is to create a computational finite element model to perform thermoelastic stress analysis (TSA) with the usage of a non-ideal load frequency, containing the effects of the material thermal properties.

Throughout this document, the methodology of the model is presented first, followed by the procedure and results. The last part is reserved to results, discussion and conclusions.

This work had the main goal to create a model to perform TSA with the usage of non-ideal loading frequencies, considering the materials’ thermal properties. Loading frequencies out of the ideal range were applied and the model showed capable of good results. The created model reproduced acceptably the TSA, with the desired conditions.

This work creates a model to perform TSA with the usage of non-ideal loading frequencies, considering the materials’ thermal properties.

Laser sintering of polyamide lattice-based lightweight fairing components for subsequent racetrack testing requires a high quality and a reliable design. Hence, the purpose of this study was to develop a design methodology for such additively manufactured prototypes, considering efficient generation and structural simulation of boundary conformal non-periodic lattices, optimization of production parameters as well as experimental validation.

Multi-curved, sandwich structure-based demonstrators were designed, simulated and experimentally tested with boundary conformal lattice cells. The demonstrator’s non-periodic lattice cells were simplified by forward homogenization processes. To represent the stiffness of the top and bottom face sheet, constant isotropic and mapped transversely isotropic simulation approaches were compared. The dimensional accuracy of lattice cells and demonstrators were measured with a gauge caliper and a three-dimensional scanning system. The optimized process parameters for lattice structures were transferred onto a large volume laser sintering system. The stiffness of each finite element analysis was verified by an experimental test setup including a digital image correlation system.

The stiffness prediction of the mapped was superior to the constant approach and underestimated the test results with −6.5%. Using a full scale fairing the applicability of the development process was successfully demonstrated.

The design approach elaborated in this research covers aspects from efficient geometry generation over structural simulation to experimental testing of produced parts. This methodology is not only relevant in the context of motor sports but is transferrable for all additively manufactured large scale components featuring a complex lattice sub-structure and is, therefore, relevant across industries.

The overall objective of this study is envisaged to provide decision makers with actionable insights and access to multi-risk maps for the most in-danger stave churches (SCs) among the existing 28 churches at high spatial resolution to better understand, reduce and mitigate single- and multi-risk. In addition, the present contribution aims to provide decision makers with some information to face the exacerbation of the risk caused by the expected climate change.

Material and data collection started with the consultation of the available literature related to: (1) SCs' conservation status, (2) available methodologies suitable in multi-hazard approach and (3) vulnerability leading indicators to consider when dealing with the impact of natural hazards specifically on immovable cultural heritage.

The paper contributes to a better understanding of place-based vulnerability with local mapping dimension also considering future threats posed by climate change. The results highlight the danger at which the SCs of Røldal, in case of floods, and of Ringebu, Torpo and Øye, in case of landslide, may face and stress the urgency of increasing awareness and preparedness on these potential hazards.

The contribution for the first time aims to homogeneously collect and report all together existing spread information on architectural features, conservation status and geographical attributes for the whole group of SCs by accompanying this information with as much as possible complete 2D sections collection from existing drawings and novel 3D drawn sketches created for this contribution. Then the paper contributes to a better understanding of place-based vulnerability with local mapping dimension also considering future threats posed by climate change. Then it highlights the danger of floods and landslides at which the 28 SCs are subjected. Finally it reports how these risks will change under the ongoing impact of climate change.

The purpose of this study is to describe the design and validation of a three-dimensional (3D)-printed phantom of a uterus to support the development of uterine balloon tamponade devices conceived to stop post-partum haemorrhages (PPHs).

The phantom 3D model is generated by analysing the main requirements for validating uterine balloon tamponade devices. A modular approach is implemented to guarantee that the phantom allows testing these devices under multiple working conditions. Once finalised the design, the phantom effectiveness is validated experimentally.

The modular phantom allows performing the required measurements for testing the performance of devices designed to stop PPH.

PPH is the leading obstetric cause of maternal death worldwide, mainly in low- and middle-income countries. The proposed phantom could speed up and optimise the design and validation of devices for PPH treatment, reducing the maternal mortality ratio.

To the best of the authors’ knowledge, the 3D-printed phantom represents the first example of a modular, flexible and transparent uterus model. It can be used to validate and perform usability tests of medical devices.