Anisotropic Mechanical Properties of ABS Parts Fabricated by Fused Deposition Modelling

In recent years, layered manufacturing (LM) processes have begun to progress from rapid prototyping techniques towards rapid manufacturing methods, where the objective is now to produce finished components for potential end use in a product (Caulfield et al., 2007). LM is especially promising for the fabrication of specific need, low volume products such as replacement parts for larger systems. This trend accentuates the need for a thorough understanding of the associated mechanical properties and the resulting behavior of parts produced by layered methods. Not only must the base material be durable, but the mechanical properties of the layered components must be sufficient to meet in-service loading and operational requirements, and be reasonably comparable to parts produced by more traditional manufacturing techniques. This chapter presents the details of a study completed to quantitatively analyze the potential of fused deposition modelling to fully evolve into a rapid manufacturing tool. The project objective is to develop an understanding of the dependence of the mechanical properties of FDM parts on raster orientation and to assess whether these parts are capable of maintaining their integrity while under service loading. The study examines the effect of fiber orientation, i.e. the direction of the polymer beads relative to the loading direction of the part, on a variety of important mechanical properties of ABS components fabricated by fused deposition modeling. Tensile, compressive, flexural, impact, and fatigue strength properties of FDM specimens are examined, evaluated, and placed in context in comparison with the properties of injection molded ABS parts.

Additive manufacturing: studio delle non conformità geometriche e dimensionali in componenti realizzati mediante tecnica fused deposition modelling

La fabbricazione additiva è una classe di metodi di fabbricazione in cui il componente viene costruito aggiungendo strati di materiale l’uno sull’altro, sino alla completa realizzazione dello stesso. Si tratta di un principio di fabbricazione sostanzialmente differente da quelli tradizionali attualmente utilizzati, che si avvalgono di utensili per sottrarre materiale da un semilavorato, sino a conferire all’oggetto la forma desiderata, mentre i processi additivi non richiedono l’utilizzo di utensili. Il termine più comunemente utilizzato per la fabbricazione additiva è prototipazione rapida. Il termine “prototipazione”’ viene utilizzato in quanto i processi additivi sono stati utilizzati inizialmente solo per la produzione di prototipi, tuttavia con l’evoluzione delle tecnologie additive questi processi sono sempre più in grado di realizzare componenti di elevata complessità risultando competitivi anche per volumi di produzione medio-alti. Il termine “rapida” viene invece utilizzato in quanto i processi additivi vengono eseguiti molto più velocemente rispetto ai processi di produzione convenzionali. La fabbricazione additiva offre diversi vantaggi dal punto di vista di: • velocità: questi processi “rapidi” hanno brevi tempi di fabbricazione. • realizzazione di parti complesse: con i processi additivi, la complessità del componente ha uno scarso effetto sui tempi di costruzione, contrariamente a quanto avviene nei processi tradizionali dove la realizzazione di parti complesse può richiedere anche settimane. • materiali: la fabbricazione additiva è caratterizzata dalla vasta gamma di materiali che può utilizzare per la costruzione di pezzi. Inoltre, in alcuni processi si possono costruire pezzi le cui parti sono di materiali diversi. • produzioni a basso volume: molti processi tradizionali non sono convenienti per le produzioni a basso volume a causa degli alti costi iniziali dovuti alla lavorazione con utensili e tempi di setup lunghi.

Analisi della correlazione tra i parametri di processo e le prestazioni dei materiali polimerici ottenuti tramite fused deposition modeling

Questa tesi si propone di realizzare una caratterizzazione del polimero ABS ottenuto con tecnica Fused Deposition Modeling in modo da ottenere dati utili alla realizzazione di parti strutturali tramite rapid prototyping.

Influencia de las condiciones de procesado mediante FDM sobre las propiedades físicas y mecánicas del plástico ABS

El propósito del presente proyecto fue seleccionar la configuración de fabricación de probetas obtenidas mediante el proceso de Modelado por Deposición Fundida (FDM) con el termoplástico acrilonitrilo butadieno estireno (ABS), que optimice las propiedades mecánicas de las probetas y el ahorro de material de apoyo. Se aplicaron técnicas de caracterización física y mecánica y de microscopia electrónica de barrido (SEM). Los resultados indicaron que las probetas verticales presentaron aproximadamente el 6 % de pérdida de material frente cerca de un 40% de las probetas horizontales. La rotura de los cordones se produjo longitudinalmente en el borde de las probetas horizontales mientras que en el borde de las probetas verticales fueron por despegue de los cordones de ABS. La rotura de los cordones en el interior de ambas probetas fue en la dirección de los cordones. ABSTRACT The purpose of this project was to select the manufacture design in test specimens obtained using Fused Deposition Modeling (FDM) with Acrylonitrile Butadiene Styrene (ABS), thus optimizing the mechanical properties of the test specimens and saving the support material. The study was carried out by mean of mechanical and physical characterization techniques as well as Scanning Electron Microscopy (SEM). The results indicated that the horizontal test specimen showed approximately 40% of material loss compared to the vertical test specimen showed a loss 8%. The ABS filament breakage occurred longitudinally on the edge of the horizontal test specimen while the ABS filament breakage was transversely by the separation of the ABS filament on the edge of the vertical tests. The breakage of the filament inside both test specimens was in the direction of the filaments.

Resorbable composite scaffolds for craniofacial bone tissue engineering

Aim: Bone loss associated with trauma, osteo-degenerative diseases and tumors has tremendous socioeconomic impact related to personal and occupation disability and health care costs. In the present climate of increasing life expectancy with an ensuing increase in bone-related injuries, orthopaedic surgery is undergoing a paradigm shift from bone-grafting to bone engineering, where a scaffold is implanted to provide adequate load bearing and enhance tissue regeneration. We aim to develop composite scaffolds for bone tissue engineering applications to replace the current gold standard of autografting. ---------- Methods: Medical grade polycaprolactone-tricalcium phosphate (mPCL/TCP) scaffolds (80/20 wt%) were custom made using fused deposition modelling to produce 1x1.5x2 cm sized implants for critical-sized pig cranial implantations, empty defects were used as a control. Autologous bone marrow stromal cells (BMSCs) were extracted and precultured for 2 weeks, dispersed within fibrin glue and injected during scaffold implantation. After 2 years, microcomputed tomography and histology were used to assess bone regenerative capabilities of cell versus cell-free scaffolds. ---------- Results: Extensive bone regeneration was evident throughout the entire scaffold. Clear osteocytes embedded within mineralised matrix and active osteoblasts present around scaffold struts were observed. Cell groups performed better than cell-free scaffolds. ---------- Conclusions: Bone regeneration within defects which cannot heal unassisted can be achieved using mPCL/TCP scaffolds. This is improved by the inclusion of autogenous BMSCs. Further work will include the inclusion of growth factors including BMP-2, VEGF and PDGF to provide multifunctional scaffolds, where the three-dimensional (3D) template itself acts as a biomimetic, programmable and multi-drug delivery device.

Evolutionary design of bone scaffolds with reference to material selection

The favourable scaffold for bone tissue engineering should have desired characteristic features, such as adequate mechanical strength and three-dimensional open porosity, which guarantee a suitable environment for tissue regeneration. In fact, the design of such complex structures like bone scaffolds is a challenge for investigators. One of the aims is to achieve the best possible mechanical strength-degradation rate ratio. In this paper we attempt to use numerical modelling to evaluate material properties for designing bone tissue engineering scaffold fabricated via the fused deposition modelling technique. For our studies the standard genetic algorithm was used, which is an efficient method of discrete optimization. For the fused deposition modelling scaffold, each individual strut is scrutinized for its role in the architecture and structural support it provides for the scaffold, and its contribution to the overall scaffold was studied. The goal of the study was to create a numerical tool that could help to acquire the desired behaviour of tissue engineered scaffolds and our results showed that this could be achieved efficiently by using different materials for individual struts. To represent a great number of ways in which scaffold mechanical function loss could proceed, the exemplary set of different desirable scaffold stiffness loss function was chosen. © 2012 John Wiley & Sons, Ltd.

Application of a human bone engineering platform to an in vitro and in vivo breast cancer metastasis model

Breast cancer in its advanced stage has a high predilection to the skeleton. Currently, treatment options of breast cancer-related bone metastasis are restricted to only palliative therapeutic modalities. This is due to the fact that mechanisms regarding the breast cancer celI-bone colonisation as well as the interactions of breast cancer cells with the bone microenvironment are not fully understood, yet. This might be explained through a lack of appropriate in vitro and in vivo models that are currently addressing the above mentioned issue. Hence the hypothesis that the translation of a bone tissue engineering platform could lead to improved and more physiological in vitro and in vivo model systems in order to investigate breast cancer related bone colonisation was embraced in this PhD thesis. Therefore the first objective was to develop an in vitro model system that mimics human mineralised bone matrix to the highest possible extent to examine the specific biological question, how the human bone matrix influences breast cancer cell behaviour. Thus, primary human osteoblasts were isolated from human bone and cultured under osteogenic conditions. Upon ammonium hydroxide treatment, a cell-free intact mineralised human bone matrix was left behind. Analyses revealed a similar protein and mineral composition of the decellularised osteoblast matrix to human bone. Seeding of a panel of breast cancer cells onto the bone mimicking matrix as well as reference substrates like standard tissue culture plastic and collagen coated tissue culture plastic revealed substrate specific differences of cellular behaviour. Analyses of attachment, alignment, migration, proliferation, invasion, as well as downstream signalling pathways showed that these cellular properties were influenced through the osteoblast matrix. The second objective of this PhD project was the development of a human ectopic bone model in NOD/SCID mice using medical grade polycaprolactone tricalcium phosphate (mPCL-TCP) scaffold. Human osteoblasts and mesenchymal stem cells were seeded onto an mPCL-TCP scaffold, fabricated using a fused deposition modelling technique. After subcutaneous implantation in conjunction with the bone morphogenetic protein 7, limited bone formation was observed due to the mechanical properties of the applied scaffold and restricted integration into the soft tissue of flank of NOD/SCID mice. Thus, a different scaffold fabrication technique was chosen using the same polymer. Electrospun tubular scaffolds were seeded with human osteoblasts, as they showed previously the highest amount of bone formation and implanted into the flanks of NOD/SCID mice. Ectopic bone formation with sufficient vascularisation could be observed. After implantation of breast cancer cells using a polyethylene glycol hydrogel in close proximity to the newly formed bone, macroscopic communication between the newly formed bone and the tumour could be observed. Taken together, this PhD project showed that bone tissue engineering platforms could be used to develop an in vitro and in vivo model system to study cancer cell colonisation in the bone microenvironment.

Energy harvesting from piezoelectric devices embedded in a 3D printed wing

This thesis work has been carried out at Clarkson University in Potsdam NY, USA and involved the design of a low elongation wing, consisting of parts made by polylactide (PLA) using the fused deposition model (FDM) technology of Rapid Prototyping, then assembled together in a thin aluminum spar. The aim of the research is to evaluate the feasibility of collecting electrical energy by converting mechanical energy from the vibration of the wing flutter. With this aim piezoelectric stripes were glued in the inner part of the wing, as well as on the aluminum spar, as monomorphic configuration. During the phases of the project, particular attention was given to the geometry and the materials used, in order to trigger the flutter for low flow velocity. The CAD software SolidWorks® was used for the design of the wing and then the drawings were sent to the Clarkson machine shop in order to to produce the parts required by the wing assembly. FEM simulations were performed, using software MSC NASTRAN/PATRAN®, to evaluate the stiffness of the whole wing as well as the natural vibration modes of the structure. These data, in a first approximation, were used to predict the flutter speed. Finally, experimental tests in the Clarkson wind tunnel facility were carried out in order to validate the results obtained from FEM analysis. The power collected by the piezoelectrics under flutter condition was addressed by tuning the resistors downstream the electronic circuit of the piezoelectrics.

Grundlagen des Rapid Prototyping

Generative Verfahren sind seit etwa 1987 in den USA und seit etwa 1990 in Europa und Deutschland in Form von Rapid Prototyping Verfahren bekannt und haben sich in dieser Zeit von eher als exotisch anzusehenden Modellbauverfahren zu effizienten Werkzeugen für die Beschleunigung der Produktentstehung gewandelt. Mit der Weiterentwicklung der Verfahren und insbesondere der Materialien wird mehr und mehr das Feld der direkten Anwendung der Rapid Technologie zur Fertigung erschlossen. Rapid Technologien werden daher zum Schlüssel für neue Konstruktionssystematiken und Fertigungsstrategien. Die Anwendertagung Rapid.Tech befasst sich mit den neuen Verfahren zur direkten Produktion und den daraus erwachsenden Chancen für Entwickler und Produzenten. Die Kenntnis der Rapid Prototyping Verfahren wird bei den meisten Fachvorträgen auf der Rapid.Tech vorausgesetzt. Für diejenigen, die sich bisher mit generativen Verfahren noch nicht beschäftigt haben, oder die ihre Grundkenntnisse schnell auffrischen wollen, haben wir die folgenden Zusammenfassung der Grundlagen der generativen Fertigungstechnik, der heutigen Rapid Prototyping Verfahren, zusammengestellt.