Technologies

Research

20 pages, 4150 KiB

Open AccessArticle

Characterization of Commercial and Custom-Made Printing Filament Materials for Computed Tomography Imaging of Radiological Phantoms

by Filippos Okkalidis, Chrysoula Chatzigeorgiou, Nikiforos Okkalidis, Nikolay Dukov, Minko Milev, Zhivko Bliznakov, Giovanni Mettivier, Paolo Russo and Kristina Bliznakova

Technologies 2024, 12(8), 139; https://doi.org/10.3390/technologies12080139 - 20 Aug 2024

Cited by 1 | Viewed by 1076

Abstract

In recent years, material extrusion-based additive manufacturing, particularly fused filament fabrication (FFF), has gained significant attention due to its versatility and cost-effectiveness in producing complex geometries. This paper presents the characterization of seven novel materials for FFF and twenty-two commercially available filaments in [...] Read more.

In recent years, material extrusion-based additive manufacturing, particularly fused filament fabrication (FFF), has gained significant attention due to its versatility and cost-effectiveness in producing complex geometries. This paper presents the characterization of seven novel materials for FFF and twenty-two commercially available filaments in terms of X-ray computed tomography (CT) numbers, as tissue mimicking materials for the realization of 3D printed radiological phantoms. Two technical approaches, by 3D printing of cube samples and by producing cylinders of melted materials, are used for achieving this goal. Results showed that the CT numbers, given in Hounsfield unit (HU), of all the samples depended on the beam kilovoltage (kV). The CT numbers ranged from +411 HU to +3071 HU (at 80 kV), from −422 HU to +3071 HU (at 100 kV), and from −442 HU to +3070 HU (at 120 kV). Several commercial and custom-made filaments demonstrated suitability for substituting soft and hard human tissues, for realization of 3D printed phantoms with FFF in CT imaging. For breast imaging, an anthropomorphic phantom with two filaments could be fabricated using ABS-C (conductive acrylonitrile butadiene styrene) as a substitute for breast adipose tissue, and ASA-A (acrylic styrene acrylonitrile) for glandular breast tissue. Full article

(This article belongs to the Special Issue 3D Printing Technologies II)

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20 pages, 2226 KiB

Open AccessArticle

Development and Evaluation of an mHealth App That Promotes Access to 3D Printable Assistive Devices

by Jeffrey Bush, Sara Benham and Monica Kaniamattam

Technologies 2024, 12(7), 114; https://doi.org/10.3390/technologies12070114 - 13 Jul 2024

Viewed by 2218

Abstract

Three-dimensional printing is an emerging service delivery method for on-demand access to customized assistive technology devices. However, barriers exist in locating and designing appropriate models and having the devices printed. The purpose of this work is to outline the development of an app, [...] Read more.

Three-dimensional printing is an emerging service delivery method for on-demand access to customized assistive technology devices. However, barriers exist in locating and designing appropriate models and having the devices printed. The purpose of this work is to outline the development of an app, 3DAdapt, which allows users to overcome these issues by searching within a curated list of 3D printable assistive devices, customizing models that support it, and ordering the device to be printed by manufacturers linked within the app or shared with local 3D printing operators. The app integrates searching and filters based on the International Classification of Functioning, Disability, and Health, with the available devices including those developed from fieldwork collaborations with multiple professionals and students within clinical, community, and educational settings. It provides users the ability to customize select models to meet their needs. The model can then be shared, downloaded, or ordered from a third-party 3D printing service. This development and expert testing phase to assess feasibility and modify the app based on identified themes then prepared the team for the next phases of beta testing to reach the overall aim of 3DAdapt to connect individuals to affordable and customizable devices to increase independence and quality of life. Full article

(This article belongs to the Special Issue 3D Printing Technologies II)

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17 pages, 6623 KiB

Open AccessArticle

Cost-Effective 3D Printing of Silicone Structures Using an Advanced Intra-Layer Curing Approach

by Cormac D. Fay and Liang Wu

Technologies 2023, 11(6), 179; https://doi.org/10.3390/technologies11060179 - 12 Dec 2023

Cited by 4 | Viewed by 3077

Abstract

We present an advanced, low-cost 3D printing system capable of fabricating intricate silicone structures using commercially available off-the-shelf materials. Our system used a custom-designed, motorised syringe pump with a driving lead screw and excellent control of material extrusion to accommodate the high viscosity [...] Read more.

We present an advanced, low-cost 3D printing system capable of fabricating intricate silicone structures using commercially available off-the-shelf materials. Our system used a custom-designed, motorised syringe pump with a driving lead screw and excellent control of material extrusion to accommodate the high viscosity of silicone printing ink, which is composed of polydimethylsiloxane (PDMS), diluent, and a photo-initiator (LAP). We modified an open-source desktop 3D printer to mount the syringe pump and programmed it to deposit controlled intricate patterns in a layer-by-layer fashion. To ensure the structural integrity of the printed objects, we introduced an intra-layer curing approach that fused the deposited layers using a custom-built UV curing system. Our experiments demonstrated the successful fabrication of silicone structures at different infill percentages, with excellent resolution and mechanical properties. Our low-cost solution (costing less than USD 1000 and requiring no specialised facilities or equipment) shows great promise for practical applications in areas such as micro-fluidics, prosthesis, and biomedical engineering based on our initial findings of 300 μ

m

width channels (with excellent scope for smaller channels where desirable) and tunable structural properties. Our work represents a significant advance in low-cost desktop 3D printing capabilities, and we anticipate that it could have a broad impact on the field by providing these capabilities to scholars without the means to purchase expensive fabrication systems. Full article

(This article belongs to the Special Issue 3D Printing Technologies II)

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14 pages, 3108 KiB

Open AccessArticle

Combined Treatment of Parts Produced by Additive Manufacturing Methods for Improving the Surface Quality

by Sergey Grigoriev, Alexander Metel, Marina Volosova, Yury Melnik and Enver Mustafaev

Technologies 2022, 10(6), 130; https://doi.org/10.3390/technologies10060130 - 11 Dec 2022

Viewed by 2135

Abstract

To improve the quality of a part manufactured by the additive method, it is necessary to eliminate the porosity and high roughness of its surface, as well as to deposit a coating on it. For this purpose, in the present work, we studied [...] Read more.

To improve the quality of a part manufactured by the additive method, it is necessary to eliminate the porosity and high roughness of its surface, as well as to deposit a coating on it. For this purpose, in the present work, we studied the combined processing in a gas discharge plasma of complex shape parts obtained by the additive manufacturing method, which includes explosive ablation of surface protrusions when voltage pulses are applied to the part immersed in the plasma; polishing with a concentrated beam of fast neutral argon atoms at a large angle of incidence on the surface of the part, and magnetron deposition of a coating on it with assistance by fast argon atoms. Combined processing made it possible to completely get rid of porosity and reduce the surface roughness from Ra ~ 5 µm to Ra ~ 0.05 µm. Full article

(This article belongs to the Special Issue 3D Printing Technologies II)

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24 pages, 11090 KiB

Open AccessEditor’s ChoiceArticle

Influence of Postprocessing on Wear Resistance of Aerospace Steel Parts Produced by Laser Powder Bed Fusion

by Alexander S. Metel, Sergey N. Grigoriev, Tatiana V. Tarasova, Anastasia A. Filatova, Sergey K. Sundukov, Marina A. Volosova, Anna A. Okunkova, Yury A. Melnik and Pavel A. Podrabinnik

Technologies 2020, 8(4), 73; https://doi.org/10.3390/technologies8040073 - 2 Dec 2020

Cited by 13 | Viewed by 3200

Abstract

The paper is devoted to the research of the effect of ultrasonic postprocessing—specifically, the effects of ultrasonic cavitation-abrasive finishing, ultrasonic plastic deformation, and vibration tumbling on surface quality, wear resistance, and the ability of real aircraft parts with complex geometries and with sizes [...] Read more.

The paper is devoted to the research of the effect of ultrasonic postprocessing—specifically, the effects of ultrasonic cavitation-abrasive finishing, ultrasonic plastic deformation, and vibration tumbling on surface quality, wear resistance, and the ability of real aircraft parts with complex geometries and with sizes less than and more than 100 mm to work in exploitation conditions. The parts were produced by laser powder bed fusion from two types of anticorrosion steels of austenitic and martensitic grades—20Kh13 (DIN 1.4021, X20Cr13, AISI 420) and 12Kh18N9T (DIN 1.4541, X10CrNiTi18-10, AISI 321). The finishing technologies based on mechanical action—plastic deformation, abrasive wear, and complex mechanolysis showed an effect on reducing the submicron surface roughness, removing the trapped powder granules from the manufactured functional surfaces and their wear resistance. The tests were completed by proving resistance of the produced parts to exploitation conditions—vibration fatigue and corrosion in salt fog. The roughness arithmetic mean deviation R_a was improved by 50–52% after cavitation-abrasive finishing, by 28–30% after ultrasonic plastic deformation, and by 65–70% after vibratory tumbling. The effect on wear resistance is correlated with the improved roughness. The effect of used techniques on resistance to abrasive wear was explained and grounded. Full article

(This article belongs to the Special Issue 3D Printing Technologies II)

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Review

Jump to: Research, Other

29 pages, 7426 KiB

Open AccessReview

Nano-Level Additive Manufacturing: Condensed Review of Processes, Materials, and Industrial Applications

by Ismail Fidan, Mohammad Alshaikh Ali, Vivekanand Naikwadi, Shamil Gudavasov, Mushfig Mahmudov, Mahdi Mohammadizadeh, Zhicheng Zhang and Ankit Sharma

Technologies 2024, 12(7), 117; https://doi.org/10.3390/technologies12070117 - 18 Jul 2024

Viewed by 1712

Abstract

Additive manufacturing, commonly known as 3D printing, represents the forefront of modern manufacturing technology. Its growing popularity spans across research and development, material science, design, processes, and everyday applications. This review paper presents a crucial review of nano-level 3D printing, examining it from [...] Read more.

Additive manufacturing, commonly known as 3D printing, represents the forefront of modern manufacturing technology. Its growing popularity spans across research and development, material science, design, processes, and everyday applications. This review paper presents a crucial review of nano-level 3D printing, examining it from the perspectives of processes, materials, industrial applications, and future trends. The authors have synthesized the latest insights from a wide range of archival articles and source books, highlighting the key findings. The primary contribution of this study is a condensed review report that consolidates the newest research on nano-level 3D printing, offering a broad overview of this innovative technology for researchers, inventors, educators, and technologists. It is anticipated that this review study will significantly advance research in nanotechnology, additive manufacturing, and related technological fields. Full article

(This article belongs to the Special Issue 3D Printing Technologies II)

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71 pages, 13628 KiB

Open AccessReview

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

by Muhammad Mu’az Imran, Azam Che Idris, Liyanage Chandratilak De Silva, Yun-Bae Kim and Pg Emeroylariffion Abas

Technologies 2024, 12(6), 86; https://doi.org/10.3390/technologies12060086 - 7 Jun 2024

Cited by 1 | Viewed by 2416

Abstract

This paper provides a comprehensive analysis of recent advancements in additive manufacturing, a transformative approach to industrial production that allows for the layer-by-layer construction of complex parts directly from digital models. Focusing specifically on Directed Energy Deposition, it begins by clarifying the fundamental [...] Read more.

This paper provides a comprehensive analysis of recent advancements in additive manufacturing, a transformative approach to industrial production that allows for the layer-by-layer construction of complex parts directly from digital models. Focusing specifically on Directed Energy Deposition, it begins by clarifying the fundamental principles of metal additive manufacturing as defined by International Organization of Standardization and American Society for Testing and Materials standards, with an emphasis on laser- and powder-based methods that are pivotal to Directed Energy Deposition. It explores the critical process mechanisms that can lead to defect formation in the manufactured parts, offering in-depth insights into the factors that influence these outcomes. Additionally, the unique mechanisms of defect formation inherent to Directed Energy Deposition are examined in detail. The review also covers the current landscape of process evaluation and non-destructive testing methods essential for quality assurance, including both traditional and contemporary in situ monitoring techniques, with a particular focus given to advanced machine-vision-based methods for geometric analysis. Furthermore, the integration of process monitoring, multiphysics simulation models, and data analytics is discussed, charting a forward-looking roadmap for the development of Digital Twins in Laser–Powder-based Directed Energy Deposition. Finally, this review highlights critical research gaps and proposes directions for future research to enhance the accuracy and efficiency of Directed Energy Deposition systems. Full article

(This article belongs to the Special Issue 3D Printing Technologies II)

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Other

Jump to: Research, Review

23 pages, 22420 KiB

Open AccessTechnical Note

HUB3D: Intelligent Manufacturing HUB System

by Antonio Trejo-Morales, Edgar Adrián Franco-Urquiza, Hansell David Devilet-Castellanos and Dario Bringas-Posadas

Technologies 2024, 12(7), 109; https://doi.org/10.3390/technologies12070109 - 9 Jul 2024

Viewed by 1314

Abstract

HUB3D represents a cutting-edge solution for managing and operating a 3D printer farm through the integration of advanced hardware and software. It features intuitive, responsive interfaces that support seamless interaction across various devices. Leveraging cloud services ensures the system’s stability, security, and scalability, [...] Read more.

HUB3D represents a cutting-edge solution for managing and operating a 3D printer farm through the integration of advanced hardware and software. It features intuitive, responsive interfaces that support seamless interaction across various devices. Leveraging cloud services ensures the system’s stability, security, and scalability, enabling users from diverse locations to effortlessly upload and manage their 3D printing projects. The hardware component includes a purpose-built rack capable of housing up to four 3D printers, each synchronized and managed by a manipulator arm controlled via Raspberry Pi technology. This setup facilitates continuous operation and high automation, optimizing production efficiency and reducing downtime significantly. This integrated approach positions HUB3D at the forefront of additive manufacturing management. By combining robust hardware capabilities with sophisticated software functionalities and cloud integration, the system offers unparalleled advantages. It supports continuous manufacturing processes, enhances workflow efficiency, and enables remote monitoring and management of printing operations. Overall, HUB3D’s innovative design and comprehensive features cater to both individual users and businesses seeking to streamline 3D printing workflows. With scalability, automation, and remote accessibility at its core, HUB3D represents a pivotal advancement in modern manufacturing technology, promising increased productivity and operational flexibility in the realm of additive manufacturing. Full article

(This article belongs to the Special Issue 3D Printing Technologies II)

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