Search Results (8)

Additive manufacturing (AM), or 3D printing, has revolutionized the fabrication of complex parts, but assessing their quality remains a challenge. Quality assessment, especially for the interior part geometry, relies on post-print inspection techniques unsuitable for real-time in situ analysis. Vision-based approaches could be employed to capture images of any layer during fabrication, and then segmentation methods could be used to identify in-layer features in order to establish dimensional conformity and detect defects for in situ evaluation of the overall part quality. This research evaluated five image segmentation methods (simple thresholding, adaptive thresholding, Sobel edge detector, Canny edge detector, and watershed transform) on the same platform for their effectiveness in isolating and identifying features in 3D-printed layers under different contrast conditions for in situ quality assessment. The performance metrics used are accuracy, precision, recall, and the Jaccard index. The experimental set-up is based on an open-frame fused filament fabrication printer augmented with a vision system. The control system software for printing and imaging (acquisition and processing) was custom developed in Python running on a Raspberry Pi. Most of the segmentation methods reliably segmented the external geometry and high-contrast internal features. The simple thresholding, Canny edge detector, and watershed transform methods did not perform well with low-contrast parts and could not reliably segment internal features when the previous layer was visible. The adaptive thresholding and Sobel edge detector methods segmented high- and low-contrast features. However, the segmentation outputs were heavily affected by textural and image noise. The research identified factors affecting the performance and limitations of these segmentation methods and contributing to the broader effort of improving in situ quality assessment in AM, such as automatic dimensional analysis of internal and external features and the overall geometry. Full article

The persistent challenge of adhesion in Fused Filament Fabrication (FFF) technology is deeply rooted in the mechanical and chemical properties of utilized materials, necessitating the exploration of potential resolutions. This involves adjustments targeting the interplay of printing parameters, the mechanical fortification of print beds, and the integration of more adhesive materials, resonating across user levels, from enthusiasts to complex industrial configurations. An in-depth investigation is outlined in this paper, detailing the plan for a systematically designed device. Engineered for FFF device installation, the device facilitates the detachment of printed models, while precisely recording the detachment process, capturing the maximum force, and its progression over time. The primary objective is fabricating a comprehensive measurement apparatus, created for adhesion assessment. The device is adaptable across diverse FFF machines and print bed typologies, conforming to pre-defined conditions, with key features including compactness, facile manipulability, and capacity for recurrent measurements. This pursuit involves evaluating adhesion levels in prints made from diverse materials on varying print bed compositions, aiming to establish a comprehensive database. This repository facilitates judicious material and bed type selection, emphasizing maximal compatibility. Emphasis is placed on operating within a thermally stable context, a pivotal prerequisite for consistent and reproducible results. Full article

Additive manufacturing technologies have developed rapidly in recent decades, pushing the limits of known manufacturing processes. The need to study the properties of the different materials used for these processes comprehensively and in detail has become a primary goal in order to get the best out of the manufacturing itself. The widely used thermoplastic polymer material acrylonitrile butadiene styrene (ABS) was selected in the form of both filaments and ABS-like resins to investigate and compare the mechanical properties through a series of different tests. ABS-like resin material is commercially available, but it is not a sufficiently mechanically studied form of the material, which leads to the rather limited literature. Considering that ABS resin is a declared material that behaves like the ABS filament but in a different form, the objective of this study was to compare these two commercially available materials printed with three different 3D printers, namely Fused Deposition Modelling (FDM), Stereolithography (SLA) and Digital Light Processing (DLP). A total of 45 test specimens with geometries and test protocols conforming to the relevant standards were subjected to a series of tensile, three-point bending and compression tests to determine their mechanical properties. Characterization also included evaluation of morphology with 2D and 3D microscopy, dimensional accuracy of 3D scans, and Shore A hardness of each material and 3D printing process. Tensile testing results have shown that FDM toughness is 40% of the value for DLP. FDM elongation at break is 37% of DLP, while ultimate tensile stress for SLA is 27% higher than FDM value. Elastic modulus for FDM and SLA coincide. Flexure testing results indicate that value of DLP flexural modulus is 54% of the FDM value. SLA strain value is 59% of FDM, and DLP ultimate flexure stress is 77% of the value for FDM. Compression test results imply that FDM specimens absorb at least twice as much energy as vat polymerized specimens. Strain at break for SLA is 72% and strain at ultimate stress is 60% of FDM values. FDM yield stress is 32% higher than DLP value. SLA ultimate compressive stress is half of FDM, while value for DLP compressive modulus is 69% of the FDM value. The results obtained are beneficial and give a more comprehensive picture of the behavior of the ABS polymers used in different forms and different AM processes. Full article

Industrial engineering applications often require manufacturing large components in composite materials to obtain light structures; however, moulds are expensive, especially when manufacturing a limited batch of parts. On the one hand, when traditional approaches are carried out, moulds are milled from large slabs or laminated with composite materials on a model of the part to produce. In this case, the realisation of a mould leads to adding time-consuming operations to the manufacturing process. On the other hand, if a fully additively manufactured approach is chosen, the manufacturing time increases exponentially and does not match the market’s requirements. This research proposes a methodology to improve the production efficiency of large moulds using a hybrid technology by combining additive manufacturing and milling tools. A block of soft material such as foam is milled, and then the printing head of an additive manufacturing machine deposits several layers of plastic material or modelling clay using conformal three-dimensional paths. Finally, the mill can polish the surface, thus obtaining a mould of large dimensions quickly, with reduced cost and without needing trained personnel and handcraft polishing. A software tool has been developed to modify the G-code read by an additive manufacturing machine to obtain material deposition over the soft mould. The authors forced conventional machining instructions to match those of an AM machine. Thus, additive deposition of new material uses 3D conformal trajectories typical of CNC machines. Consequently, communication between two very different instruments using the same language is possible. At first, the code was tested on a modified Fused Filament Fabrication machine whose firmware has been adapted to manage a milling tool and a printing head. Then, the software was tested on a large machine suitable for producing moulds for the large parts typical of marine and aerospace engineering. The research demonstrates that AM technologies can integrate conventional machinery to support the composite materials industry when large parts are required. Full article

Vimentin, a type III intermediate filament protein, is found in most cells along with microfilaments and microtubules. It has been shown that the head domain folds back to associate with the rod domain and this association is essential for filament assembly. The N-terminally tagged vimentin has been widely used to label the cytoskeleton in live cell imaging. Although there is previous evidence that EGFP tagged vimentin fails to form filaments but is able to integrate into a pre-existing network, no study has systematically investigated or established a molecular basis for this observation. To determine whether a tag would affect de novo filament assembly, we used vimentin fused at the N-terminus with two different sized tags, AcGFP (239 residues, 27 kDa) and 3 × FLAG (22 residues; 2.4 kDa) to assemble into filaments in two vimentin-deficient epithelial cells, MCF-7 and A431. We showed that regardless of tag size, N-terminally tagged vimentin aggregated into globules with a significant proportion co-aligning with β-catenin at cell–cell junctions. However, the tagged vimentin aggregates could form filaments upon adding untagged vimentin at a ratio of 1:1 or when introduced into cells containing pre-existing filaments. The resultant filament network containing a mixture of tagged and untagged vimentin was less stable compared to that formed by only untagged vimentin. The data suggest that placing a tag at the N-terminus may create steric hinderance in case of a large tag (AcGFP) or electrostatic repulsion in case of highly charged tag (3 × FLAG) perhaps inducing a conformational change, which deleteriously affects the association between head and rod domains. Taken together our results shows that a free N-terminus is essential for filament assembly as N-terminally tagged vimentin is not only incapable of forming filaments, but it also destabilises when integrated into a pre-existing network. Full article

Quadcopters represent rotary wing configuration of the Unmanned Aerial Vehicles (UAVs) with immense application potential in industrial and strategic contexts. Tradeoff between flight endurance and payload capacity renders design optimization of UAVs a critical activity with substantial impact on the application possibilities. Among the structural parts of a typical Quadcopter, the central body frame constitutes major portion of the total weight. The present study aims at reduction of the frame weight while conforming with structural integrity requirements, through an integrated approach involving topology optimization, part consolidation and design for additive manufacturing (DFAM). Commercial UAV designs consist of multiple parts and fastening elements that necessitate considerable time and effort for assembly. This study reengineers the frame as a monocoque structure with desirable outcomes of weight reduction and less assembly time. The reengineered Quadcopter structure is manufactured through Fused Filament Fabrication (FFF) and characterized with reference to structural, vibrational and fatigue characteristics. Concomitant application of modal analysis, computational fluid dynamics and wind tunnel testing reveals close match between theoretical estimates and experimental results. Assembly and field trials of the monocoque Quadcopter structure affirm betterment of operational superiority and endurance vis-a-vis commercial UAV designs. Full article

In contrast to the traditional 3D printing process, where material is deposited layer-by-layer on horizontal flat surfaces, conformal 3D printing enables users to create structures on non-planar surfaces for different and innovative applications. Translating a 2D pattern to any arbitrary non-planar surface, such as a tessellated one, is challenging because the available software for printing is limited to planar slicing. The present research outlines an easy-to-use mathematical algorithm to project a printing trajectory as a sequence of points through a vector-defined direction on any triangle-tessellated non-planar surface. The algorithm processes the ordered points of the 2D version of the printing trajectory, the tessellated STL files of the target surface, and the projection direction. It then generates the new trajectory lying on the target surface with the G-code instructions for the printer. As a proof of concept, several examples are presented, including a Hilbert curve and lattices printed on curved surfaces, using a conventional fused filament fabrication machine. The algorithm’s effectiveness is further demonstrated by translating a printing trajectory to an analytical surface. The surface is tessellated and fed to the algorithm as an input to compare the results, demonstrating that the error depends on the resolution of the tessellated surface rather than on the algorithm itself. Full article

As the usage of wireless technology grows, it demands more complex architectures and conformal geometries, making the manufacturing of radio frequency (RF) systems challenging and expensive. The incorporation of emerging alternative manufacturing technologies, like additive manufacturing (AM), could consequently be a unique and cost-effective solution for flexible RF and microwave circuits and devices. This work presents manufacturing methodologies of 3D-printed conformal microstrip antennas made of a commercially available conductive filament, Electrifi, as the conductive trace on a commercially available nonconductive filament, NinjaFlex, as the substrate using the fused filament fabrication (FFF) method of AM technology. Additionally, a complete high frequency characterization of the prototyped antenna was studied and presented here through a comparative analysis between full-wave simulation and measurements in a fully calibrated anechoic chamber. The prototyped antenna measures 65.55 × 55.55 × 1.2 mm³ in size and the measured results show that the 3D-printed Electrifi based patch antenna achieved very good impedance matching at a resonant frequency of 2.4 GHz and a maximum antenna gain of −2.78 dBi. Finally, conformality performances of the developed antenna were demonstrated by placing the antenna prototype on five different cylindrical curved surfaces for possible implementation in flexible electronics, smart communications, and radar applications. Full article