Search results

This study highlights the demand for low-cost and high accuracy products through the design and development of new 3D printing technologies. Besides, significant progress has been made in this field. A comparative study helps to understand the latest development in materials and future prospect of this technology.

Nevertheless, a large amount of progress still remains to be made. While some of the works have focused on the performances of the materials, the rest have focused on the development of new methods and techniques in additive manufacturing.

This paper critically evaluates the current 3D printing technologies, including the development and optimizations made to the printing methods, as well as the printed objects. Meanwhile, previous developments in this area and contributions to the modern trend in manufacturing technology are summarized briefly.

The paper can be summarized in three sections. Firstly, the existing printing methods along with the frequently used printing materials, as well as the processing parameters, and the factors which influence the quality and mechanical performances of the printed objects are discussed. Secondly, the optimization techniques, such as topology, shape, structure and mechanical property, are described. Thirdly, the latest development and applications of additive manufacturing are depicted, and the scope of future research in the relevant area is put forward.

This study aims to investigate the effect of the material thickness and build orientation on the mass transfer of low molecular weight substances through polyamide 12 (PA12) structures produced by laser sintering (LS).

Disc-shaped PA12 sheets having a nominal thickness ranging from 700 to 2,000 µm were built in horizontal, vertical and diagonal orientations and their permeation properties to oxygen and water vapor were measured. The structural properties of the sheets were examined by X-ray micro-computed tomography, differential scanning calorimetry and polarized light microscopy.

All the LS sheets that were investigated had water vapor and oxygen permeation coefficients that are in the range of those of PA12 produced by traditional manufacturing technologies. Despite significant differences in the porosity characteristics, the permeation properties of sheets built in different orientations were similar. The pores seem to have no measurable effect on the mass transfer rates in the sheets, and the transport processes seem to predominantly follow the rules of a regular solution-diffusion mechanism. The results showed a non-significant trend toward thickness-dependent permeation coefficients, which agrees with the observed differences in the crystal structures of the sheets.

The results are an important basis for the qualification of LS technology for direct manufacturing in applications requiring special barrier performance.

This study provides new information on mechanisms of mass transport through LS PA12 and the effect of the material thickness and build orientation. Furthermore, the results enhance understanding of the structural properties of thin polymeric sheets produced by LS.

This paper aims to present a survey concerning the accuracy of thermoplastic polymeric parts fabricated by additive manufacturing (AM). Based on the scientific literature, the aim is to provide an updated map of trends and gaps in this relevant research field. Several technologies and investigation methods are examined, thus giving an overview and analysis of the growing body of research.

Permutations of keywords, which concern materials, technologies and the accuracy of thermoplastic polymeric parts fabricated by AM, are used for a systematic search in peer-review databases. The selected articles are screened and ranked to identify those that are more relevant. A bibliometric analysis is performed based on investigated materials and applied technologies of published papers. Finally, each paper is categorised and discussed by considering the implemented research methods.

The interest in the accuracy of additively manufactured thermoplastics is increasing. The principal sources of inaccuracies are those shrinkages occurring during part solidification. The analysis of the research methods shows a predominance of empirical approaches. Due to the experimental context, those achievements have consequently limited applicability. Analytical and numerical models, which generally require huge computational costs when applied to complex products, are also numerous and are investigated in detail. Several articles deal with artificial intelligence tools and are gaining more and more attention.

The cross-technology survey on the accuracy issue highlights the common critical aspects of thermoplastics transformed by AM. An updated map of the recent research literature is achieved. The analysis shows the advantages and limitations of different research methods in this field, providing an overview of research trends and gaps.

The purpose of this paper is to reinforce the selective laser sintering (SLS) parts of nylon‐12 using organically modified montmorillonite (OMMT).

A dissolution‐precipitation process is developed to prepare an OMMT/nylon‐12 composite powder (3 wt% OMMT). X‐ray diffraction (XRD) was used to characterize nanostructure features. The dispersion of OMMT in the nylon‐12 matrix was observed by scanning electron microscope (SEM). The effect of OMMT on the thermal properties of nylon‐12 was studied by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The mechanical properties of the SLS parts made from the composite powder and neat nylon‐12 powder were measured and compared.

The X‐ray diffraction and SEM results indicate that the OMMT is intercalated by nylon‐12 molecular chains and uniformly dispersed in the nylon‐12 matrix during the dissolution‐precipitation process, and thus the OMMT/nylon‐12 intercalated nanocomposites are formed. The DSC and TGA results show that the OMMT can increase the melting enthalpy, relative crystalline content, crystallization temperature and thermal stability of nylon‐12. The tensile strength, tensile modulus, flexural strength, flexural modulus and impact strength of the SLS specimens made from the composite powder are 23.2, 31.7, 18.7, 32.4 and 8.4 percent higher than those of neat nylon‐12 SLS specimens, respectively, while the elongation at break decreases by 17.5 percent.

The conclusion of forming intercalated nanocomposites was drawn from the XRD results in the present work. Further work should be done to observe the nanostructures of the materials by transmission electron microscope.

A dissolution‐precipitation process was used to prepare OMMT/nylon‐12 composite powders for SLS process. During the preparation process the OMMT could be intercalated by nylon‐12 molecular chains and uniformly dispersed in the nylon‐12 matrix, thus forming the OMMT/nylon‐12 intercalated nanocomposites. Therefore, the mechanical and thermal properties of nylon‐12 SLS parts were enhanced.

There are over 40 million amputees globally with more than 185,000 Americans losing their limbs every year. For most of the world, prosthetic devices remain too expensive and uncomfortable. This paper aims to outline advancements made by a multidisciplinary research group, interested in advancing the restoration of human motion through accessible lower limb prostheses.

Customization, comfort and functionality are the most important metrics reported by prosthetists and patients. The work of this paper presents the design and manufacturing of a custom made, cost-effective and functional three-dimensional (3D) printed transtibial prosthesis monocoque design. The design of the prosthesis integrates 3D imaging, modelling and optimization techniques coupled with additive manufacturing.

The successful fabrication of a functional monocoque prosthesis through 3D printing indicates the workflow may be a solution to the worldwide accessibility crisis. The digital workflow developed in this work offers great potential for providing prosthetic devices to rural communities, which lack access to skilled prosthetic physicians. The authors found that using the workflow together with 3D printing, this study can create custom monocoque prostheses (Figure 16). These prostheses are comfortable, functional and properly aligned. In comparison with traditional prosthetic devices, the authors slowered the average cost, weight and time of production by 95%, 55% and 95%, respectively.

This novel digital design and manufacturing workflow has the potential to democratize and globally proliferate access to prosthetic devices, which restore the patient’s mobility, quality of life and health. LIMBER’s toolbox can reach places where proper prosthetic and orthotic care is not available. The digital workflow reduces the cost of making custom devices by an order of magnitude, enabling broader reach, faster access and improved comfort. This is particularly important for children who grow quickly and need new devices every few months or years, timely access is both physically and psychologically important.

In this manuscript, the authors show the application of digital design techniques for fabricating prosthetic devices. The proposed workflow implements several advantageous changes and, most importantly, digitally blends the three components of a transtibial prosthesis into a single, 3D printable monocoque device. The development of a novel unibody transtibial device that is properly aligned and adjusted digitally, greatly reduces the number of visits an amputee must make to a clinic to have a certified prosthetist adjust and modify their prosthesis. The authors believe this novel workflow has the potential to ease the worldwide accessibility crisis for prostheses.

Protection of medical personnel against pathogenic viruses is a challenging task for the world scientific community. The purpose of this paper is to collect, analyze, critique, rearrange and present the scattered information scientifically to form a base for product development for viral protection.

A huge range of recently available information has been collected, studied and arranged judiciously.

After an exhaustive study of this topic, it is possible to present all information in a manner that will be helpful to start product development activity on both sides of the Atlantic. Initially, various coated textiles with zero breathability were used to cover doctors, nurses and staff but thereafter microporous coatings replaced the poreless surface coatings. However, the pore size distribution in microporous films and coatings could not be controlled precisely and manufacturers could not claim the surface offered foolproof protection against viruses. Monolithic films are able to claim guaranteed protection against virus penetration, with sufficient breathability. Monolithic film technology has prime importance in protective clothing that has to be discussed judiciously. Permeability of block copolymers based monolithic films is an important feature for barrier materials, high performance impermeable breathable clothing and membrane separation processes.

This is a first paper in the field of viral barrier fabrics which will remain helpful to the scientific community to start further research work and product development.

The purpose of this paper is to acquire thermal conductivities of both fresh and preheated polyamide 12 powder under various conditions to provide a basis for effective and accurate control during the laser sintering (LS) process.

A Hot Disk® TPS 500 thermal measurement system using a transient plane source (TPS) technology was employed for thermal conductivity measurements. Polyamide 12 powder was packed at different densities, and different carrier gases were used. Tests were also performed on fully dense laser sintered polyamide 12 to establish a baseline.

Polyamide 12 powder thermal conductivity varies with packing density and temperature, which is approximately one-third bulk form thermal conductivity. Inter-particle bonding is the primary factor influencing polyamide 12 thermal conductivity.

Limited ranges of density were tested, and the carrier gas needed carefully control to prevent powder oxidation. Thermal properties obtained were not tested in the LS process.

This experimental result could be used to enhance thermal control during the LS process.

The use of laser sintering (LS) in the medical sector has increased dramatically in recent years. With the move towards direct use of these parts in clinical applications, there is a greater need to understand the effects of standard processes on the part properties. The purpose of this study is to determine the effect that steam sterilisation has on the mechanical properties of LS polyamide 12 parts.

The research presented here focusses on the effect of a single steam sterilisation cycle on the mechanical properties of polyamide 12 parts manufactured using LS. The influence of water content on the properties was investigated, with additional drying steps trialled to establish the potential to reverse any changes observed and to determine their root cause.

The results show that steam sterilisation has a significant effect on the mechanical properties of LS polyamide 12 parts, with a 39% reduction in elastic modulus, a 13% decrease in ultimate tensile strength and a 64% increase in the elongation at break. These properties were also all found to correlate with the water content, suggesting that this was the cause of the difference. The original properties of the parts were able to be recovered after oven drying.

These results show that with an additional drying step, LS polyamide 12 parts can be steam sterilised with no effect on the mechanical properties.

This is believed to be the first investigation into the effects of steam sterilisation in isolation on LS polyamide 12 parts, the first instance of drying parts to recover mechanical properties and the first instance of multiple water content measurements being directly linked to the mechanical properties.

The purpose of this paper is to report selected optical properties of laser sintered polyamide 12 blank plates under different monochromatic and white light conditions and to apply these properties in production of laser sintered lithophanes.

A UNICO 1201E spectrophotometer was used to measure the transmittance of laser sintered polyamide 12 plates as a function of plate thickness. Monochromatic light-emitting diodes were used to assess the wavelength dependence on the transmission and contrast as captured by a SONY DSC-W55 camera.

The transmittance decreased with increasing plate thickness which varied significantly depending on the monochromatic wavelength. Highest transmission was observed using green light (525 nm) and poorest transmission was measured for yellow light (589 nm).

There is a limit to the amount of contrast obtained in polyamide lithophanes because the thickness of the plates is limited to less than about 5 mm. Greater thickness results in discernible topology on the lithophane which impairs the quality of the image.

Light transmittance of polyamide 12 plates under different lighting conditions is reported and applied to optically defined laser sintered lithophanes.

Laser sintering kinetics and part reliability are critically dependent on the melt viscosity of materials, including polyamide 12 (PA‐12). The purpose of this paper is to characterise the viscosity of PA‐12 powders using alternative scientific methods: constrained boundary flows (capillary rheometry) and rotational rheometry.

Various PA‐12 powders were selected and characterised by both techniques. Measurement of molecular weight was also carried out to interpret the viscosity data.

Results demonstrate conventional pseudoplastic flow in all PA‐12 materials. Zero‐shear viscosity has been quantified by rotational rheometry; a notable observation is the striking difference between virgin/used PA‐12. This is interpreted in terms of molecular weight and chain structure modifications, arising from polycondensation of PA‐12 held at the bed temperature during laser sintering.

Accurate zero‐shear viscosity data provide scope for use in predictive computational models for laser sintering processes. Careful sample preparation and equipment operation are critical prerequisites for accurate rheological characterisation of PA‐12 powders.

Differences in flow behaviour and molecular structure allow prediction and deeper understanding of process‐property relationships in laser sintering, giving potential for further optimisation of material specification and in‐process machine parameter control.

This is believed to be the first time that techniques other than melt flow rate (MFR) have been reported to measure the viscosity of PA‐12 in a laser sintering context, noting the effects of pre‐drying and molecular weight, then predicting differences between virgin/used powders in practical sintering behaviour.