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Open Access
Article
Publication date: 22 July 2024

Alessandro Bove, Fulvio Lieske, Flaviana Calignano and Luca Iuliano

Material extrusion (MEX) is one of the most known techniques in the additive manufacturing (AM) sector to produce components with a wide range of polymeric and composite…

Abstract

Purpose

Material extrusion (MEX) is one of the most known techniques in the additive manufacturing (AM) sector to produce components with a wide range of polymeric and composite materials. Moisture causes alterations in material properties and for filaments strongly hygroscopic like nylon-based composites this means greater ease of deterioration. Drying the filament to reduce the moisture content may not be sufficient if the humidity is not controlled during printing. The purpose of this study is to achieve the recovery of a commercial nylon-based composite filament by applying process optimization using an open source MEX machine.

Design/methodology/approach

A statistical approach based on Taguchi’s method allowed to achieve an ultimate tensile strength (UTS). A verification of the geometrical capabilities of the process has been performed according to the standard ISO/ASTM 52902-2019. Chemical tests were also carried out to test the resistance to corrosion in acid and basic solutions.

Findings

An UTS of 71.37 MPa was obtained, significantly higher than the value declared by the filament’s manufacturer (Stratasys Inc., USA). The best configuration of process parameters leads to good geometrical deviations for flat surfaces, in a range of 0.01 and 0.38 for flatness, while cylindrical faces showed more important deviations from the nominal values. The good applicability of the material in corrosive environments has been confirmed.

Originality/value

This study examined the performance restoration potential of a nylon composite filament that was significantly affected by storage conditions. For the filament manufacturer, if the material remains in ambient air for an hour or idle in the machine for more than 24 h, the material may no longer be suitable for printing. The study highlighted that the drying of the filament must not be temporary but constant to guarantee printability, and, by acting on the process parameters, it is possible to obtain better mechanical properties than declared by the manufacturer.

Details

Rapid Prototyping Journal, vol. 30 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Open Access
Article
Publication date: 2 July 2024

Fredrick Mwania, Maina Maringa, Joseph Nsengimana and Jacobus Gert van der Walt

The current analysis was conducted to investigate the quality of surfaces and geometry of tracks printed using PolyMideTM CoPA, PolymaxTM PC and PolyMideTM PA6-CF materials…

Abstract

Purpose

The current analysis was conducted to investigate the quality of surfaces and geometry of tracks printed using PolyMideTM CoPA, PolymaxTM PC and PolyMideTM PA6-CF materials through fused deposition modelling (FDM). This study also examined the degree of fusion of adjacent filaments (tracks) to approximate the optimal process parameters of the three materials.

Design/methodology/approach

Images of fused adjacent filaments were acquired using scanning electron microscopy (SEM), after which, they were analysed using Image J Software and Minitab Software to determine the optimal process parameters.

Findings

The optimal process parameters for PolyMideTM CoPA are 0.25 mm, 40 mm/s, −0.10 mm, 255°C and 0.50 mm for layer thickness, printing speed, hatch spacing, extrusion temperature and extrusion width, respectively. It was also concluded that the optimal process parameters for PolymaxTM PC are 0.30 mm, 40 mm/s, 0.00 mm, 260°C and 0.6 mm for layer thickness, printing speed, hatch spacing, extrusion temperature and extrusion width, respectively.

Research limitations/implications

It was difficult to separate tracks printed using PolyMideTM PA6-CF from the support structure, making it impossible to examine and determine their degree of fusion using SEM.

Social implications

The study provides more knowledge on FDM, which is one of the leading additive manufacturing technology for polymers. The information provided in this study helps in continued uptake of the technique, which can help create job opportunities, especially among the youth and young engineers.

Originality/value

This study proposes a new and a more accurate method for optimising process parameters of FDM at meso-scale level.

Details

Rapid Prototyping Journal, vol. 30 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 20 September 2024

Liberato Venant Haule

A review of sustainability challenges of flame retardants (FRs) for textiles has been conducted. Specifically, the purpose of this paper is to identify and recommend solutions to…

Abstract

Purpose

A review of sustainability challenges of flame retardants (FRs) for textiles has been conducted. Specifically, the purpose of this paper is to identify and recommend solutions to sustainability challenges emanating from the raw material, processing technology and performance of the FRs used for textiles.

Design/methodology/approach

The approach used in preparing this paper was based on the review of various scholarly databases about the subject matter. The review approach is designed to inform the readers about the sustainability challenges of FRs for textiles. The science of burning and FRs for synthetic and cellulosic fibres were reviewed. Both synthetic and natural biodegradable FRs for textiles has been identified. The obtained literature was then synthesised to get information about sustainable challenges of non-halogenated FRs both synthetic and natural biodegradable. Finally, possible approaches for mitigating the identified challenges have been recommended.

Findings

The sustainability challenges of the FRs in terms of raw material, processing, affordability and performance have been identified. Synthetic FRs suffer from sustainability challenges in terms of raw materials, processing and non-renewability. Despite the environmental friendliness and sustainability in terms of being renewability, processability and biodegradability, natural biodegradable FRs have poor performance compared to synthetic ones. Moreover, natural biodegradable FRs depend on geographical condition and lack economic variability data. Potentially, the challenges of FRs can be mitigated through eco-friendly synthesis, chemical modification and sustainable methods of applications. Because of its renewability and environmental friendliness, biodegradable FRs have a potential to becoming sustainable if researched more.

Originality/value

In this review, a collection of literature about sustainability challenges of FRs and the approaches to overcome the challenges has been provided. The collected information was analysed and synthesised to bring understanding of the science of burning, types and application of FRs for textiles and biodegradable FRs. Sustainability challenges have been identified, and mitigation approaches are provided.

Details

Research Journal of Textile and Apparel, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1560-6074

Keywords

Open Access
Article
Publication date: 8 December 2023

Flaviana Calignano, Alessandro Bove, Vincenza Mercurio and Giovanni Marchiandi

Polymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing…

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Abstract

Purpose

Polymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such as material extrusion to produce gears. This study aims to demonstrate that it is possible to overcome the problems due to the physics of the process to produce accurate mechanism.

Design/methodology/approach

Technological aspects such as orientation, wheel-shaft thicknesses and degree of powder recycling were examined. Furthermore, the evolving tooth profile was considered as a design parameter to provide a manufacturability map of gear-based mechanisms.

Findings

Results show that there are some differences in the functioning of the gear depending on the type of powder used, 100% virgin or 50% virgin and 50% recycled for five cycles. The application of a groove on a gear produced with 100% virgin powder allows the mechanism to be easily unlocked regardless of the orientation and wheel-shaft thicknesses. The application of a specific evolutionary profile independent of the diameter of the reference circle on vertically oriented gears guarantees rotation continuity while preserving the functionality of the assembled mechanism.

Originality/value

In the literature, there are various studies on material aging and reuse in the PBF-LB/P process, mainly focused on the powder deterioration mechanism, powder fluidity, microstructure and mechanical properties of the parts and process parameters. This study, instead, was focused on the functioning of gears, which represent one of the applications in which this technology can have great success, by analyzing the two main effects that can compromise it: recycled powder and vertical orientation during construction.

Details

Rapid Prototyping Journal, vol. 30 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 21 June 2023

Ravikantha Prabhu, Sharun Mendonca, Pavana Kumara Bellairu, Rudolf Charles D’Souza and Thirumaleshwara Bhat

This paper aims to report the effect of titanium oxide (TiO2) particles on the specific wear rate (SWR) of alkaline treated bamboo and flax fiber-reinforced composites (FRCs…

Abstract

Purpose

This paper aims to report the effect of titanium oxide (TiO2) particles on the specific wear rate (SWR) of alkaline treated bamboo and flax fiber-reinforced composites (FRCs) under dry sliding condition by using a robust statistical method.

Design/methodology/approach

In this research, the epoxy/bamboo and epoxy/flax composites filled with 0–8 Wt.% TiO2 particles have been fabricated using simple hand layup techniques, and wear testing of the composite was done in accordance with the ASTM G99-05 standard. The Taguchi design of experiments (DOE) was used to conduct a statistical analysis of experimental wear results. An analysis of variance (ANOVA) was conducted to identify significant control factors affecting SWR under dry sliding conditions. Taguchi prediction model is also developed to verify the correlation between the test parameters and performance output.

Findings

The research study reveals that TiO2 filler particles in the epoxy/bamboo and epoxy/flax composite will improve the tribological properties of the developed composites. Statistical analysis of SWR concludes that normal load is the most influencing factor, followed by sliding distance, Wt.% TiO2 filler and sliding velocity. ANOVA concludes that normal load has the maximum effect of 31.92% and 35.77% and Wt.% of TiO2 filler has the effect of 17.33% and 16.98%, respectively, on the SWR of bamboo and flax FRCs. A fairly good agreement between the Taguchi predictive model and experimental results is obtained.

Originality/value

This research paper attempts to include both TiO2 filler and bamboo/flax fibers to develop a novel hybrid composite material. TiO2 micro and nanoparticles are promising filler materials, it helps to enhance the mechanical and tribological properties of the epoxy composites. Taguchi DOE and ANOVA used for statistical analysis serve as guidelines for academicians and practitioners on how to best optimize the control variable with particular reference to natural FRCs.

Details

World Journal of Engineering, vol. 21 no. 5
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 17 September 2024

Sinan Obaidat, Mohammad Firas Tamimi, Ahmad Mumani and Basem Alkhaleel

This paper aims to present a predictive model approach to estimate the tensile behavior of polylactic acid (PLA) under uncertainty using the fused deposition modeling (FDM) and…

Abstract

Purpose

This paper aims to present a predictive model approach to estimate the tensile behavior of polylactic acid (PLA) under uncertainty using the fused deposition modeling (FDM) and American Society for Testing and Materials (ASTM) D638’s Types I and II test standards.

Design/methodology/approach

The prediction approach combines artificial neural network (ANN) and finite element analysis (FEA), Monte Carlo simulation (MCS) and experimental testing for estimating tensile behavior for FDM considering uncertainties of input parameters. FEA with variance-based sensitivity analysis is used to quantify the impacts of uncertain variables, resulting in determining the significant variables for use in the ANN model. ANN surrogates FEA models of ASTM D638’s Types I and II standards to assess their prediction capabilities using MCS. The developed model is applied for testing the tensile behavior of PLA given probabilistic variables of geometry and material properties.

Findings

The results demonstrate that Type I is more appropriate than Type II for predicting tensile behavior under uncertainty. With a training accuracy of 98% and proven presence of overfitting, the tensile behavior can be successfully modeled using predictive methods that consider the probabilistic nature of input parameters. The proposed approach is generic and can be used for other testing standards, input parameters, materials and response variables.

Originality/value

Using the proposed predictive approach, to the best of the authors’ knowledge, the tensile behavior of PLA is predicted for the first time considering uncertainties of input parameters. Also, incorporating global sensitivity analysis for determining the most contributing parameters influencing the tensile behavior has not yet been studied for FDM. The use of only significant variables for FEA, ANN and MCS minimizes the computational effort, allowing to simulate more runs with reduced number of variables within acceptable time.

Details

Rapid Prototyping Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1355-2546

Keywords

Open Access
Article
Publication date: 21 June 2024

Francesco Bandinelli, Martina Scapin and Lorenzo Peroni

Finite element (FE) analysis can be used for both design and verification of components. In the case of 3D-printed materials, a proper characterization of properties, accounting…

452

Abstract

Purpose

Finite element (FE) analysis can be used for both design and verification of components. In the case of 3D-printed materials, a proper characterization of properties, accounting for anisotropy and raster angles, can help develop efficient material models. This study aims to use compression tests to characterize short carbon-reinforced PA12 made by fused filament fabrication (FFF) and to model its behaviour by the FE method.

Design/methodology/approach

In this work, the authors focus on compression tests, using post-processed specimens to overcome external defects introduced by the FFF process. The material’s elastoplastic mechanical behaviour is modelled by an elastic stiffness matrix, Hill’s anisotropic yield criterion and Voce’s isotropic hardening law, considering the stacking sequence of raster angles. A FE analysis is conducted to reproduce the material’s compressive behaviour through the LS-DYNA software.

Findings

The proposed model can capture stress values at different deformation levels and peculiar aspects of deformed shapes until the onset of damage mechanisms. Deformation and damage mechanisms are strictly correlated to orientation and raster angle.

Originality/value

The paper aims to contribute to the understanding of 3D-printed material’s behaviour through compression tests on bulk 3D-printed material. The methodology proposed, enriched with an anisotropic damage criterion, could be effectively used for design and verification purposes in the field of 3D-printed components through FE analysis.

Details

Rapid Prototyping Journal, vol. 30 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 25 September 2024

Jinzhou Li, Jie Ma, Yujie Hu, Li Zhang, Zhijie Liu and Shiying Sun

This study aims to tackle control challenges in soft robots by proposing a visually-guided reinforcement learning approach. Precise tip trajectory tracking is achieved for a soft…

Abstract

Purpose

This study aims to tackle control challenges in soft robots by proposing a visually-guided reinforcement learning approach. Precise tip trajectory tracking is achieved for a soft arm manipulator.

Design/methodology/approach

A closed-loop control strategy uses deep learning-powered perception and model-free reinforcement learning. Visual feedback detects the arm’s tip while efficient policy search is conducted via interactive sample collection.

Findings

Physical experiments demonstrate a soft arm successfully transporting objects by learning coordinated actuation policies guided by visual observations, without analytical models.

Research limitations/implications

Constraints potentially include simulator gaps and dynamical variations. Future work will focus on enhancing adaptation capabilities.

Practical implications

By eliminating assumptions on precise analytical models or instrumentation requirements, the proposed data-driven framework offers a practical solution for real-world control challenges in soft systems.

Originality/value

This research provides an effective methodology integrating robust machine perception and learning for intelligent autonomous control of soft robots with complex morphologies.

Details

Robotic Intelligence and Automation, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2754-6969

Keywords

Article
Publication date: 23 September 2024

Ana Carrasco-Huertas, Ana Reyes Pérez and Domingo Campillo García

This study aims to delve into the effectiveness of applying traditional and more advanced digital means to document elements of cultural heritage, in this case large-format…

Abstract

Purpose

This study aims to delve into the effectiveness of applying traditional and more advanced digital means to document elements of cultural heritage, in this case large-format cartography. Application of multimethod digitalisation to a school map of the American continent dating to the early part of the 20th century has served to address specific issues, notably its multilayers consisting of paper, inks and a protective varnish on a textile medium. Its large format is likewise an obstacle to its digital capture.

Design/methodology/approach

The method applied here resorted to three registration systems: single-shot photography, panoramic photography and photogrammetry. The first two widely serve to capture works of large-format, whereas the third is commonly used to record volumetric assets. A variety of parameters were applied, notably different focal lengths, capture methods and processing software. The images obtained in each case were subjected to qualitative and quantitative comparisons so as to analyse their differences in terms of resolution and accuracy when compared to the map's real measurements, key criteria when duplicating cartographic documents.

Findings

Although the final products gleaned from the digital photographs, panoramic photographs and photogrammetry fulfil the basic functions required to record documents housed in archives, libraries, museums and other cultural institutions, this study highlights new advances and complementary functions stemming from certain of these techniques.

Originality/value

Digitalisation is a tool that serves to register, preserve, disseminate and analyse cultural heritage. However, some of the available techniques have rarely been applied specifically to graphic and documentary artefacts. It is for this reason that this study intends to demonstrate their utility in the detailed study of this heritage typology. Moreover, optimising the school map into a digital form favours its dissemination and remote consultation while simultaneously minimising direct manipulation, hence improving its long-term preservation.

Details

Digital Library Perspectives, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2059-5816

Keywords

Article
Publication date: 2 January 2023

Mustafa S. Al-Khazraji, S.H. Bakhy and M.J. Jweeg

The purpose of this review paper is to provide a review of the most recent advances in the field of manufacturing composite sandwich panels along with their advantages and…

Abstract

Purpose

The purpose of this review paper is to provide a review of the most recent advances in the field of manufacturing composite sandwich panels along with their advantages and limitations. The other purpose of this paper is to familiarize the researchers with the available developments in manufacturing sandwich structures.

Design/methodology/approach

The most recent research articles in the field of manufacturing various composite sandwich structures were reviewed. The review process started by categorizing the available sandwich manufacturing techniques into nine main categories according to the method of production and the equipment used. The review is followed by outlining some automatic production concepts toward composite sandwich automated manufacturing. A brief summary of the sandwich manufacturing techniques is given at the end of this article, with recommendations for future work.

Findings

It has been found that several composite sandwich manufacturing techniques were proposed in the literature. The diversity of the manufacturing techniques arises from the variety of the materials as well as the configurations of the final product. Additive manufacturing techniques represent the most recent trend in composite sandwich manufacturing.

Originality/value

This work is valuable for all researchers in the field of composite sandwich structures to keep up with the most recent advancements in this field. Furthermore, this review paper can be considered as a guideline for researchers who are intended to perform further research on composite sandwich structures.

Details

Journal of Engineering, Design and Technology , vol. 22 no. 5
Type: Research Article
ISSN: 1726-0531

Keywords

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