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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.

The quality of components under fused filament fabrication (FFF) is related to the correct filament spacing and bonding of successively deposited layers and is evaluated mainly by scanning electron microscopy (SEM). However, it is a destructive technique and real-time evaluation is not possible. Optical coherence tomography (OCT), on the other hand, is an optical method that acquires cross-sectional images non-invasively and in real-time. Therefore, this paper aims to propose and validate the use of OCT as a non-destructive quality evaluation tool for FFF using Polylactic Acid (PLA) filaments.

PLA three-dimensional (3D) printed samples were made in a variety of nozzle temperatures and mesh spacing. These samples were fractured in liquid nitrogen and inspected using SEM (as a gold standard) to evaluate dimensions and morphology, then the samples were evaluated by OCT in the same area, allowing the results confrontation.

Our results indicate a good correlation between OCT and SEM for the dimensional assessment of layers. When the filament was extruded in lower temperatures, the OCT images presented sharply defined interfaces between layers, in contrary to higher nozzle temperatures, denoting better fusion between them. However, higher extruding temperatures are incurred in greater deviations from nominal dimensions of the mesh. Finally, we demonstrate the advantage of a full 3D tomographic reconstruction to inspect within a FFF sample, which enabled the inspection of “hidden” information, not visible on a single cross-sectional cut.

This paper proposes OCT as a novel and nondestructive evaluation tool for FFF.

The purpose of this paper is the design and investigation of novel acrylated epoxidized soybean oil-based photocurable systems as candidate materials for optical 3D printing.

Aromatic dithiols, benzene-1,3-dithiol or benzene-1,4-dithiol, were used as cross-linking agents of acrylated epoxidized soybean oil in these systems. Kinetics of photocross-linking was investigated by real-time photorheometry using two different photoinitiators, 2, 2-dimethoxy-2-phenylacetophenone or 2-hydroxy-2-methylpropiophenone, in different quantities. The effect of the initial composition on the rate of photocross-linking, mechanical, thermal properties and swelling of obtained polymers was investigated.

The rate of photocross-linking was higher, more cross-links and shorter polymer chains between cross-linking points of the network were formed when benzene-1,4-dithiol and 2, 2-dimethoxy-2-phenylacetophenone were used in compositions. The higher yield of insoluble fraction, glass transition temperatures and values of compressive modulus were obtained when benzene-1,3-dithiol and 2, 2-dimethoxy-2-phenylacetophenone were used in compositions.

This is the first study of acrylated epoxidized soybean oil-based thiol-ene system by real-time photorheometry. The designed novel photocurable systems based on acrylated epoxidized soybean oil and benzenedithiols are promising renewable photoresins for rapid optical 3D printing on demand.

This study aims to present a design and investigation of novel vanillin-based thiol-ene photocurable systems as candidate materials for optical three-dimensional printing.

Two vanillin acrylates, vanillin dimethacrylate and vanillin diacrylate, were tested in thiol-ene photocurable systems with 1,3-benzenedithiol. The kinetics of photocross-linking was investigated by real-time photorheometry using two photoinitiators, diphenyl (2,4,6-trimethylbenzoyl)phosphine oxide or ethyl (2,4,6-trimethylbenzoyl)phenylphosphinate in different quantities. The dependencies of rheological properties of resins on the used vanillin derivative, photoinitiator, and the presence of a solvent, as well as structure, thermal and mechanical properties of the selected polymers were investigated.

The most rigid polymers were obtained from vanillin diacrylate-based resins without any solvent. The vanillin diacrylate-based polymer possessed higher values of cross-linking density, the yield of insoluble fraction, thermal stability and better mechanical properties in comparison to the vanillin dimethacrylate-based polymer.

The kinetics of photocross-linking of vanillin-based thiol-ene systems was investigated by real-time photorheometry for the first time. The designed novel photocurable systems based on vanillin acrylates and 1,3-benzenedithiol are promising renewable photoresins for optical three-dimensional printing on demand.

The purpose of this paper is to extend existing knowledge of 4D printing, in line with Khoo et al. (2015) who defined the production of 4D printing using a single material, and 4D printing of multiple materials. It is proposed that 4D printing can be achieved through the use of functionally graded materials (FGMs) that involve gradational mixing of materials and are produced using an additive manufacturing (AM) technique to achieve a single component.

The latest state-of-the-art literature was extensively reviewed, covering aspects of materials, processes, computer-aided design (CAD), applications and made recommendations for future work.

This paper clarifies that functionally graded additive manufacturing (FGAM) is defined as a single AM process that includes the gradational mixing of materials to fabricate freeform geometries with variable properties within one component. The paper also covers aspects of materials, processes, CAD, applications and makes recommendations for future work.

This paper examines the relationship between FGAM and 4D printing and defines FGAM as a single AM process involving gradational mixing of materials to fabricate freeform geometries with variable properties within one component. FGAM requires better computational tools for modelling, simulation and fabrication because current CAD systems are incapable of supporting the FGAM workflow.

It is also identified that other factors, such as strength, type of materials, etc., must be taken into account when selecting an appropriate process for FGAM. More research needs to be conducted on improving the performance of FGAM processes through extensive characterisation of FGMs to generate a comprehensive database and to develop a predictive model for proper process control. It is expected that future work will focus on both material characterisation as well as seamless FGAM control processes.

This paper examines the relationship between FGAM and 4D printing and defines FGAM as a single AM process that includes gradational mixing of materials to fabricate freeform geometries with variable properties within one component.

This case study aims to investigate how locally additively manufactured functional parts can make African metrology institutes more sustainable and independent. These institutes provide calibration services, which links the measurement units to industrial and everyday measurements. This traceability is critical to overcome technical barriers to trade and industrialisation. Most African countries have such a designated institute that requires advanced scientific instrumentation. These instruments are custom-built for a specific application, hard to procure or sometimes obsolete. Servicing these instruments or obtaining spare parts are also difficult. The purpose aims to evaluate if three-dimensional (3D) printing can significantly improve this situation, by providing six institutes with a 3D printer and training.

Therefore, a 3D printer pilot project was launched, involving six African metrology institutes, with the aim of developing the basic manufacturing capabilities of these institutes so that they can produce functional parts. The project included training on both digital part modelling and 3D printer usage. This case study reviews the technology selection method, project risks, needs, challenges and results, with the aid of research questions.

The results of the project illustrate how additive manufacturing (AM) has started to enable metrology in Africa and how it can be expanded to the general scientific endeavour on the continent.

The success of this project can be used to motivate the further adoption of AM in African National Metrology Institutes, as well as other scientific institutes.

The project is the first AM project of its kind for African National Metrology Institutes.

To characterise the optical performance of organic multi‐mode optical waveguides integrated with printed circuit board (PCB) and to demonstrate the feasibility of 2.5 and 10 Gbps optical interconnection in board‐level, respectively.

This paper provides both qualitative and quantitative approaches for the characterization the wave guide performance, i.e. using loss measurement, optical beam profiling, ethernet verification, and eye‐diagram testing. In addition to wave guide loss measurement, the most significance part of the work reported in this paper is to evaluate optical wave guides with coupled VCSELs, by which a 3 dB coupling design budget can thus be identified. Furthermore, by artificially manipulating coupling conditions, practical concerns of EOPCB integration, including waveguide geometry, VCSEL driving power, alignment tolerance, coupling spacing, etc. are studied.

Thermal stability studies related to PCB lamination processes show the feasibility of organic waveguides integrated to traditional PCB manufacturing. For a direct VCSEL/PD coupling scheme, a 3 dB power budget is experimentally identified. For short reach optical interconnection, 10 Gbps up to 17 cm propagation on PCB can be achieved by using 50×50 μm multi‐mode organic waveguides, where a±25 μm tolerance of optical alignment is compatible to the design rules of PCB.

The value of the paper lies in its systematic approaches to identify the waveguide performance through both qualitative and quantitative indices. The correlation between geometry design, processes, coupling conditions, and optical performance of organic waveguides explored in detail. Not only is a standard eye‐diagram test used to verify the waveguide at 2.5 and 10 Gbps bandwidth, but also a prototype of optical data‐communication on giga‐ethernet is demonstrated for long term stability. Following these analytical methods, readers can understand more about the optical performance of waveguides when designing optical interconnection for high speed electro‐optical integrated PCBs.

The purpose of this paper is to establish new computer-aided-design (CAD) framework to design custom product that is fabricated additive manufacturing (AM), which can produce complex three-dimensional (3D) object without additional tool or fixture. Additive manufacturing (AM) enables the fabrication of three-dimensional (3D) objects with complex shapes without additional tools and refixturing. However, it is difficult for user to use traditional computer-aided design tools to design custom products.

In this paper, the authors presented a design system to help user design custom 3D printable products based on some reference freeform shapes. The user can define and edit styling curves on the reference model using the interactive geometric operations for styling curve. Incorporating with the reference models, these curves can be converted into 3D printable models through the fabrication interface.

The authors tested their system with four design applications including a hollow patterned bicycle helmet, a T-rex with skin frame structure, a face mask with Voronoi patterns and an AM-specific night dress with hollow patterns.

The executable prototype of the presented design framework used in the customization process is publicly available.

Traditional nanocomposite production methods such as in situ polymerization, melt blending and solvent technique, have some deficits. Some of these are non-homogeneous particle distribution, setup difficulties, time-consuming and costly. On the other hand, three-dimensional printing technology is a quite popular method. Especially, Stereolithography (SLA) printing offers some benefits such as fast printing, easy setup and smooth surface specialties. Furthermore, surface modification of Graphene Oxide (GO) and its effects on polymer nanocomposites are quite important. The purpose of this study is to examine the effect of surface modification of GO nanoparticles on the mechanical properties and morphology of epoxy acrylate (BisGMA/1,6 hexane diol diacrylate) matrix nanocomposites.

In this study, Ultraviolet (UV) curable end groups of synthesized resin were linked to functional groups of graphene oxide, which are synthesized by the Tour method, which is a kind of modified Hummer method. In addition, synthesized GO nanoparticle’s surfaces were modified by 3-(methacryloyloxy) propyl trimethoxysilane. Significant weight percentages of GO were added into the epoxy acrylate resin. Different Wt.% of modified graphene oxide/acrylate resins was used to print test specimens with SLA type three-dimensional printer.

Surface modification has a significant effect on tensile strength for graphene oxide nanoparticles contained composites. In addition, a specific trend was not observed for tensile test results of non-modified graphene oxide. The tendency of impact and hardness test finding were similar for both surfaces modified and non-modified nanoparticles. Finally, the distribution of particles was homogeneous.

This paper is unique because of the inclusion of both surface modifications of graphene oxide nanoparticles and SLA production of nanocomposites with its own production of three-dimensional printer and photocurable polymer resin.

Orange peel formation remains to be understood clearly because it is difficult to directly observe a laser-sintered process in a partcake. Therefore, this study aims to provide insight into the orange peel formation mechanism through the nondestructive observation of laser-sintered specimens and their surrounding powders.

This study observed polyamide 12 powder in the vicinity of a laser-sintered specimen via X-ray computed tomography (CT) scanning. The specimen for nondestructive observation was 3D modeled in a hollow box using 3D CAD software. The boxes built using a laser-sintering system contained unsintered surrounding powder and sintered specimens. The box contents were preserved even after the boxes were removed from the partcake. After X-ray CT scanning, the authors broke the boxes and evaluated the unevenness formed on the specimen surface (i.e. the orange peel evaluation).

Voids (not those in sintered parts) generated in the powder in the vicinity of the specimen triggered the orange peel formation. Voids were less likely to form in the build with a 178.5° powder bed than in the build with a 173.5° powder bed. Similarly, the increment in laser energy density effectively suppressed void formation, although there was a tradeoff with overmelting. Thin-walled parts avoided void growth and made the orange peel less noticeable.

To the best of the authors’ knowledge, this study is the first to observe and understand the relationship between voids generated in the powder in the vicinity of sintered parts and orange peel formation.