Search results

This papers aims to study lattice structures in terms of geometric variables, manufacturing variables and material-based variants and their correlation with compressive behaviour for their application in a methodology for the design and development of personalized elastic therapeutic products.

Lattice samples were designed and manufactured using extrusion-based additive manufacturing technologies. Mechanical tests were carried out on lattice samples for elasticity characterization purposes. The relationships between sample stiffness and key geometric and manufacturing variables were subsequently used in the case study on the design of a pressure cushion model for validation purposes. Differentiated areas were established according to patient’s pressure map to subsequently make a correlation between the patient’s pressure needs and lattice samples stiffness.

A substantial and wide variation in lattice compressive behaviour was found depending on the key study variables. The proposed methodology made it possible to efficiently identify and adjust the pressure of the different areas of the product to adapt them to the elastic needs of the patient. In this sense, the characterization lattice samples turned out to provide an effective and flexible response to the pressure requirements.

This study provides a generalized foundation of lattice structural design and adjustable stiffness in application of pressure cushions, which can be equally applied to other designs with similar purposes. The relevance and contribution of this work lie in the proposed methodology for the design of personalized therapeutic products based on the use of individual lattice structures that function as independent customizable cells.

This study aimed to analyze the free vibration of a radially graded Ni-Al2O3-based functionally graded (FG) disk with uniform thickness.

Using the energy method, natural frequencies of rotating and non-rotating disks were determined at the limit elastic angular speed. Material properties were estimated using a modified rule of mixture. Both even and uneven porosity variation effects were considered in the material modeling. Finite element analysis validated the analytical approach.

The study explored limit angular speeds and natural frequencies across various grading indices, investigating the impact of porosity types and grading indices on these parameters.

Insights from this research are valuable for researchers and design engineers involved in modeling and fabricating porous FG disks, aiding in more effective design and manufacturing processes.

This study contributes to the field by providing a comprehensive analysis of free vibration behavior in radially graded Ni-Al2O3-based FG disks. The incorporation of material modeling considering both even and uneven porosity variation adds originality to the research. Additionally, the validation through finite element analysis enhances the credibility of the findings.

Metal laser-powder-bed-fusion using laser-beam parts are particularly susceptible to contamination due to particles attached to the surface. This may compromise so-called technical cleanliness (e.g. in NASA RPTSTD-8070, ASTM G93, ISO 14952 or ISO 16232), which is important for many 3D-printed components, such as implants or liquid rocket engines. The purpose of the presented comparative study is to show how cleanliness is improved by design and different surface treatment methods.

Convex and concave test parts were designed, built and surface-treated by combinations of media blasting, electroless nickel plating and electrochemical polishing. After cleaning and analysing the technical cleanliness according to ASTM and ISO standards, effects on particle contamination, appearance, mass and dimensional accuracy are presented.

Contamination reduction factors are introduced for different particle sizes and surface treatment methods. Surface treatments were more effective for concave design features, however, the initial and resulting absolute particle contamination was higher. Results further indicate that there are trade-offs between cleanliness and other objectives in design. Design guidelines are introduced to solve conflicts in design when requirements for cleanliness exist.

This paper recommends designing parts and corresponding process chains for manufacturing simultaneously. Incorporating post-processing characteristics into the design phase is both feasible and essential. In the experimental study, electroless nickel plating in combination with prior glass bead blasting resulted in the lowest total remaining particle contamination. This process applied for cleanliness is a novelty, as well as a comparison between the different surface treatment methods.

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.

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.

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.

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.

The rapid growth of 3D printing has transformed the cost-effective production of prototypes and functional items, primarily using extrusion technology with thermoplastics. This study aims to focus on optimizing mechanical properties, precisely highlighting the crucial role of mechanical compressive strength in ensuring the functionality and durability of 3D-printed components, especially in industrial and engineering applications.

Using the Box−Behnken experimental design, the research investigated the influence of layer thickness, wall perimeter and infill level on mechanical resistance through compression. Parameters such as maximum force, printing time and mass utilization are considered for assessing and enhancing mechanical properties.

The layer thickness was identified as the most influential parameter over the compression time, followed by the degree of infill. The number of surface layers significantly influences both maximum strength and total mass. Optimization strategies suggest reducing infill percentage while maintaining moderate to high values for surface layers and layer thickness, enabling the production of lightweight components with adequate mechanical strength and reduced printing time. Experimental validation confirms the effectiveness of these strategies, with generated regression equations serving as a valuable predictive tool for similar parameters.

This research offers valuable insights for industries using 3D printing in creating prototypes and functional parts. By identifying optimal parameters such as layer thickness, surface layers and infill levels, the study helps manufacturers achieve stronger, lighter and more cost-efficient components. For industrial and engineering applications, adopting the outlined optimization strategies can result in components with enhanced mechanical strength and durability, while also reducing material costs and printing times. Practitioners can use the developed regression equations as predictive tools to fine-tune their production processes and achieve desired mechanical properties more effectively.

This research contributes to the ongoing evolution of additive manufacturing, providing insights into optimizing structural rigidity through polylactic acid (PLA) selection, Box−Behnken design and overall process optimization. These findings advance the understanding of fused deposition modeling (FDM) technology and offer practical implications for more efficient and economical 3D printing processes in industrial and engineering applications.

This study aims to develop a production-oriented approach for optimal mass-customisation of floor panel layouts in cross-laminated timber (CLT) buildings. The study enables meeting building clients’ unique floor plan requirements at an optimal cost and simultaneously enhances manufacturers’ profit by minimising material and manufacturing process waste.

The present research uses a hybrid approach consisting of field data collection, mathematical modelling, development of a Genetic Algorithm (GA) and scenario analysis. Field data includes engineered timber production information, design data and building code requirements. The study adopts the Flexible Demand Assignment (FDA) technique to formulate a mathematical model for optimising the design of mass timber buildings and employs GA to identify optimal production solutions. Scenario analysis is performed to validate model outputs.

The proposed model successfully determines the load-bearing wall placement and building spans and specifications of floor panels that result in optimal production efficiency and the desired architectural layout. The results indicate that buildings made of a single category of thickness of panels but customised in various lengths to suit building layout are the most profitable scenario for CLT manufacturers and are a cost-effective option for clients.

The originality of the present study lies in its mathematical and model-driven approach towards implementing mass customisation in multi-storey buildings. The proposed model has been developed and validated based on a comprehensive set of real-world data and constraints.

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.

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.

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.

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.

Although ceramic additive manufacturing (AM) could be used to fabricate complex, high-resolution parts for diverse, functional applications, one ongoing challenge is optimizing the post-process, particularly sintering, conditions to consistently produce geometrically accurate and mechanically robust parts. This study aims to investigate how sintering temperature affects feature resolution and flexural properties of silica-based parts formed by vat photopolymerization (VPP) AM.

Test artifacts were designed to evaluate features of different sizes, shapes and orientations, and three-point bend specimens printed in multiple orientations were used to evaluate mechanical properties. Sintering temperatures were varied between 1000°C and 1300°C.

Deviations from designed dimensions often increased with higher sintering temperatures and/or larger features. Higher sintering temperatures yielded parts with higher strength and lower strain at break. Many features exhibited defects, often dependent on geometry and sintering temperature, highlighting the need for further analysis of debinding and sintering parameters.

To the best of the authors’ knowledge, this is the first time test artifacts have been designed for ceramic VPP. This work also offers insights into the effect of sintering temperature and print orientation on flexural properties. These results provide design guidelines for a particular material, while the methodology outlined for assessing feature resolution and flexural strength is broadly applicable to other ceramics, enabling more predictable part performance when considering the future design and manufacture of complex ceramic parts.

This paper aims to analyze deeply the effect of surface roughness conditions of the common interface of the two-layered riveted cantilever beams on their frictional damping during free lateral vibration at first mode. Here, the product, (µ × α), and damping ratio, ξ, are the parameters whose variations are analyzed in this investigation. For this, the influencing parameters considered are the natural frequency of vibration, f; the amplitude of initial excitation, y; and surface roughness value, Ra.

For experimentally evaluating logarithmic damping decrement, d, the frequency response function analyzer for the case of free lateral vibrations was used. Later, for evaluating the product, µ × α (where µ is the kinematic coefficient of friction and α is the dynamic slip ratio), and then, the damping ratio, ξ, the empirical relation suggested for logarithmic damping decrement, d, of riveted cantilever beams was used. After this, the full and reduced quadratic models of the product, µ × α, ξ, response surface methodology (RSM) with the help of Design Expert 11 software was used. Corresponding main effects plots, surface plots and prediction comparison plots were obtained to observe the variations of the product, µ × α, ξ for the variations of influencing parameters: f, y and Ra. Finally, a machine learning technique such as artificial neural networks (ANNs) using “nntool” present in MATLAB R13a software was used to predict the ξ for the different combinations of f, y and Ra.

The full and reduced quadratic regression models for the product, (µ × α) and the damping ratio, ξ of riveted cantilever beams for free lateral vibrations of the first mode in terms of the parameters: f, y and Ra were obtained. In addition, the main effects plots, surface plots and prediction comparison plots for the product, µ × α, ξ, with the corresponding experimental values of the product, µ × α, ξ, were obtained. Also, the execution of ANNs using MATLAB R13a software is proved to be the more accurate tool for the prediction of damping ratios in comparison to quadratic regression equations obtained from Design Expert 11 software. In the end, the assumption that the effect of surface roughness value on the product, (µ × α), and the damping ratio, ξ, is negligible is proved to be true using the main effects plots for the product, (µ × α) and ξ obtained from the Design Expert 11 software.

Obtaining the full and reduced quadratic regression equations for the product, (µ × α), and ξ of the two-layered riveted cantilever beams in terms of parameters: f, y and Ra was done. In addition, the conditions for the corresponding minimum and maximum values of the product, (µ × α), and ξ were obtained. Later, the main effects plots, surface plots and comparison plots of the predicted product, (µ × α), and ξ versus experimental product, (µ × α), and ξ were also obtained. Finally, the predicted values of the product, (µ × α), and ξ using the ANNs tool are observed to be the more accurate values in comparison to that obtained from RSM using the Design Expert 11 software.

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.

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.

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.

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.