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Most rapid prototyping (RP) relies on energy fields to handle materials, among which electricity has been much more utilized, resulting in distinctive responsiveness of non-linear, overshoot, variable inertia, etc. The purpose of this paper is to eliminate the drawbacks of array nozzle clogging, stringing, melt sagging, particularly in multi-material RP, by focusing on the electrothermal response so as to adaptively distribute thermal more accurate, rapid and balanced.

This paper presents an electrothermal response optimization method of nozzle structure for multi-material RP based on fuzzy adaptive control (FAC). The structural, physical and control model are successively logically built. The fractional order electrothermal model is identified by Riemann Liouville fractional differential equation, using the bisection method to approximate the physical model via least square method to minimize residual sum of squares. The FAC is thereafter implemented by defining fuzzy proportion integration differentiation control rules and fuzzy membership functions for fuzzy inference and defuzzification.

The transient thermodynamic and structural statics, as well as flow field analysis, are conducted. The response time, mean temperature difference and thermal deformation can be found using thermal-solid coupling finite element analysis. In physical experimental research, temperature change, together with material extrusion loading, were measured. Both numerical and physical studies have revealed findings that the electrothermal responsiveness varies with the three-dimensional structure, materials and energy sources, which can be optimized by FAC.

The proposed FAC provides an optimization method for extrusion-based multi-material RP between the balance of thermal response and energy efficiency through fulfilling potential of the hardware configuration. The originality may be widely adopted alongside increasing requirements on high quality and high efficiency RP.

Tool path generation is the key procedure to fabricate multi‐material (MM) assemblies in rapid prototyping (RP) machines. In slicing MM assembly, there will be 2D regions of different materials. The regions need to be filled into 2.5D slabs. In order to complete all regions in a certain slice faster, tool holders should fill the regions simultaneously. In other words, the tool holders will move around in the RP work envelope concurrently. In such case, interference between tool holders may occur. Therefore, collision‐free path plan should be generated. In this paper, a dexel based spatio‐temporal modelling approach is proposed for detecting collision in rapid manufacturing MM assemblies. The approach is based on 2D regions in dexel representation, which needs only simple computation. As a result, tool holders can fill MM regions simultaneously and efficiently.

The purpose of this paper is to present a new method for representing heterogeneous materials using nested STL shells, based, in particular, on the density distributions of human bones.

Nested STL shells, called Matryoshka models, are described, based on their namesake Russian nesting dolls. In this approach, polygonal models, such as STL shells, are “stacked” inside one another to represent different material regions. The Matryoshka model addresses the challenge of representing different densities and different types of bone when reverse engineering from medical images. The Matryoshka model is generated via an iterative process of thresholding the Hounsfield Unit (HU) data using computed tomography (CT), thereby delineating regions of progressively increasing bone density. These nested shells can represent regions starting with the medullary (bone marrow) canal, up through and including the outer surface of the bone.

The Matryoshka approach introduced can be used to generate accurate models of heterogeneous materials in an automated fashion, avoiding the challenge of hand-creating an assembly model for input to multi-material additive or subtractive manufacturing.

This paper presents a new method for describing heterogeneous materials: in this case, the density distribution in a human bone. The authors show how the Matryoshka model can be used to plan harvesting locations for creating custom rapid allograft bone implants from donor bone. An implementation of a proposed harvesting method is demonstrated, followed by a case study using subtractive rapid prototyping to harvest a bone implant from a human tibia surrogate.

Apart from the geometries to be dealt with, rapid prototyping (RP) of heterogeneous objects requires additional material information to be processed. This generally involves a large amount of information to be processed simultaneously. The robustness and efficiency problems, which seem less critical in homogeneous solid fabrications, become an issue. The direct impetus of this paper is to present robust and efficient algorithms for RP of heterogeneous objects.

The robustness is benefited from using the proposed non‐manifold heterogeneous cellular model, which guarantees gap‐free material depositions around material interfaces. The efficiency enhancement is achieved by eliminating repetitive boundary intersections and using a heuristic material interrogation approach.

By using the proposed algorithms, the robustness and efficiency of RP of heterogeneous objects can be improved. It is found that an average 30 percent efficiency improvement is obtained using the proposed heuristic material interrogation approach.

Non‐manifold heterogeneous cell representation (HC‐Rep) is used in RP fields for the first time. Based on the HC‐Rep, the robustness and efficiency of RP of heterogeneous object is addressed in this paper.

This paper aims to present a method of reproducing multi-object structures from materials of diverse physical properties with the use of models fabricated by means of rapid prototyping (RP) techniques.

A process of modelling complex anatomical structures of soft tissues and bones using mandible models as examples was described. The study is based on data acquired through standard computed tomography. Physical models of examined objects were fabricated with RP technology from a 3D-CAD virtual model.

In the analysis of complex medical issues, beside numerical methods, one can simultaneously make use of experimental tests to verify obtained results. In the case of experimental tests, it is necessary to fabricate physical models with appropriate material properties. RP techniques used in the method ensure accurate reproduction of the external shape of the fabricated model, whereas consecutive stages allow us to construct moulds and create internal structures within a finished model by wax cast models.

The application of a physical RP model makes the identification of medical problem more efficient and the reconstruction of pathological alterations for experimental tests clearer. It prevents the simplification of assumptions to experimental analysis. The approach may reduce costs of fabricating models for experimental studies and offers the possibility of using materials of desired properties.

The approach developed by the authors and presented in this paper was submitted for patent protection as “A Method of Reconstructing Medical Models with Internal Structure and the Use of Materials of Diverse properties” – patent application no. P.398644.

The application of rapid prototyping in fabricating a non‐assembly, multi‐articulated robotic hand with inserts is presented in this paper. The development of robotic systems that have all necessary components inserted, with no assembly required, and ready to function when the manufacturing process is complete is quite attractive. Layered manufacturing, in particular stereolithography, can provide a means to do this. Stereolithography produces a solid plastic prototype via a manufacturing procedure where three‐dimensional solid models are constructed layer upon layer by the fusion of material under computer control. An important aspect of the rapid prototype method used in this research is that multi‐jointed systems can be fabricated in one step, without requiring assembly, while maintaining the desired joint mobility. This document presents the design and techniques for part insertion into a non‐assembly, multi‐articulated, dexterous finger prototype built with stereolithography.

The traditional tissue engineering approach employs rapid prototyping systems to realise microstructures (i.e. scaffolds) which recapitulate the function and organization of native tissues. The purpose of this paper is to describe a new rapid prototyping system (PAM‐modular micro‐fabrication system, PAM²) able to fabricate microstructures using materials with different properties in a controlled environment.

Computer‐aided technologies were used to design multi‐scale biological models. Scaffolds with specific features were then designed using custom software and manufactured using suitable modules. In particular, several manufacturing modules were realised to enlarge the PAM² processing material window, controlling physical parameters such as pressure, force, temperature and light. These modules were integrated in PAM², allowing a precise control of fabrication parameters through a modular approach and hardware configuration.

Synthetic and natural polymeric solutions, thermo‐sensitive and photo‐sensitive materials can be used to fabricate 3D scaffolds. Both simple and complex architectures with high fidelity and spatial resolution ranging from ±15 μm to ±200μm (according to ink properties and extrusion module used) were realised.

The PAM² system is a new rapid prototyping technique which operates in controlled conditions (for example temperature, pressure or light intensity) and integrates several manufacturing modules for the fabrication of complex or multimaterial microstructures. In this paper it is shown how the system can be configured and then used to fabricate scaffolds mimicking the extra‐cellular matrix, both in its properties (i.e. physic‐chemical and mechanical properties) and architecture.

Virtual voxels (3D pixels) have traditionally been used as a graphical data structure for representing 3D geometry. The purpose of this paper is to study the use of pre‐existing physical voxels as a material building‐block for layered manufacturing and present the theoretical underpinnings for a fundamentally new massively parallel additive fabrication process in which 3D matter is digital. The paper also seeks to explore the unique possibilities enabled by this paradigm.

Digital RP is a process whereby a physical 3D object is made of many digital units (voxels) arranged selectively in a 3D lattice, as opposed to analog (continuous) material commonly used in conventional rapid prototyping. The paper draws from fundamentals of 3D space‐filling shapes, large‐scale numerical simulation, and a survey of modern technology to reach conclusions on the feasibility of a fabricator for digital matter.

Design criteria and appropriate 3D voxel geometries are presented that self‐align and are suitable for rapid parallel assembly and economical manufacturing. Theory and numerical simulation predict dimensional accuracy to scale favorably as the number of voxels increases. Current technology will enable rapid parallel assembly of billions of microscale voxels.

Many novel voxel functions could be realized in the electromechanical and microfluidic domains, enabling inexpensive prototyping of complex 3D integrated systems. The paper demonstrates the feasibility of a 3D digital fabricator, but an instantiation is out of scope and left to future work.

Digital manufacturing offers the possibility of desktop fabrication of perfectly repeatable, precise, multi‐material objects with microscale accuracy.

The paper constitutes a comprehensive review of physical voxel‐based manufacturing and presents the groundwork for an emerging new field of additive manufacturing.

The purpose of this study is to highlight the direct fabrication of rapid tooling (RT) with desired mechanical, tribological and thermal properties using fused deposition modelling (FDM) process. Further, the review paper demonstrated development procedure of alternative feedstock filament of low-cost composite material for FDM to extend the range of RT applications.

The alternative materials for FDM and their processing requirements for fabrication in filament form as reported by various researchers have been summarized. The literature demonstrates the role of various post-processing techniques on surface finish of FDM prints. Further, low-cost materials for feedstock filament have been investigated experimentally to check their adaptability/suitability for commercial FDM setup. The approach was to realize the requirements of FDM (melt flow rate, flexibility, stiffness, glass transition temperature and mechanical strength), necessary for the successful run of an alternative filament. The effect of constituents (additives, plasticizers, surfactants and fillers) in polymeric matrix on mechanical, tribological and thermal properties has been investigated.

It is possible to develop composite material feedstock as filament for commercial FDM setup without changing its hardware and software. Surface finish of the parts can further be improved by applying various post-processing techniques. Most of the composite parts have high mechanical strength, hardness, thermal stability, wear resistant and better bond formation than standard material parts.

Future research may be focused on improving the surface quality of parts fabricated with composite feedstock, solving issues related to the uniform distribution of filled materials during the fabrication of feedstock filament which in turns further increases mechanical strength, high dimensional stability of composite filament and transferring the technology from laboratory scale to various industrial applications.

Potential applications of direct fabrication with RT includes rapid manufacturing (RM) of metal-filled parts and ceramic-filled parts (which have complex shape and cannot be rapidly made by any other manufacturing techniques) in the field of biomedical and dentistry.

This new manufacturing methodology is based on the proper selection and processing of various materials and additives to form high-performance, low-cost composite material feedstock filament (which fulfil the necessary requirements of FDM process). Finally, newly developed feedstock filament material has both quantitative and qualitative advantage in RT and RM applications as compared to standard material filament.

The purpose of this paper is to propose and evaluate a novel tool for the assessment and selection of rapid prototyping (RP)/manufacturing (RM) systems as alternative processes for low‐volume production in the machinery and equipment design sector. By analysing previous RP/RM selectors, this research addresses the necessary factors that a knowledge‐based engineering (KBE) system must include for the analysis, comparison and ranking of candidate technologies.

This research starts with the analysis of previous KBE solutions for RP/RM process selection, then a new KBE tool is proposed through the integration of artificial intelligence tools such as fuzzy logic, artificial neural networks (ANNs) and relational databases. Three case studies, provided by a Spanish machinery design centre, are used in order to measure the suitability of the proposed system for the assessment of real designs of special purpose mechanical parts.

The paper reports several improvements based on case studies which include a more suitable logic for process selection according to the designer's criteria and improvements in the overall parts cost estimation when compared to conventional parametric methods.

The newly proposed KBE system has proven useful especially in cases where non‐experts or students need to select a RP/RM process according to an initial product design specification. The cost estimation module based on ANNs provides a practical tool which may be used by academics but also practitioners who wish to automate product costing calculations.

Unlike previous solutions, the proposed system provides a straightforward means for RP/RM selection by an overall ranking of candidate processes, part cost estimation and materials selection. The main contribution is the modular design and logical planning, that overcomes the dilemma: material‐or‐process first.