Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

An Antibacterial-Loaded PLA 3D-Printed Model for Temporary Prosthesis in Arthroplasty Infections: Evaluation of the Impact of Layer Thickness on the Mechanical Strength of a Construct and Drug Release

Infections are one of the main complications in arthroplasties. These infections are difficult to treat because the bacteria responsible for them settle in the prosthesis and form a biofilm that does not allow antimicrobials to reach the infected area. This study is part of a research project aimed at developing 3D-printed spacers (temporary prostheses) capable of incorporating antibacterials for the personalized treatment of arthroplasty infections. The main objective of this research was to analyze the impact of the layer thickness of 3D-printed constructs based on polylactic acid (PLA) for improved treatment of infections in arthroplasty. The focus is on the following parameters: resistance, morphology, drug release, and the effect of antibacterials incorporated in the printed temporary prostheses. The resistance studies revealed that the design and layer thickness of a printed spacer have an influence on its resistance properties. The thickness of the layer used in printing affects the amount of methylene blue (used as a model drug) that is released. Increasing layer thickness leads to a greater release of the drug from the spacer, probably as a result of higher porosity. To evaluate antibacterial release, cloxacillin and vancomycin were incorporated into the constructs. When incorporated into the 3D construct, both antibacterials were released, as evidenced by the growth inhibition of Staphylococcus aureus. In conclusion, preliminary results indicate that the layer thickness during the three-dimensional (3D) printing process of the spacer plays a significant role in drug release.

How to Improve Sustainability in Fused Filament Fabrication (3D Printing) Research?

This review aims to provide an overview of sustainable approaches that can be incorporated into well-known procedures for the development of materials, pre- and post-treatments, modifications, and applications of 3D-printed objects, especially for fused filament fabrication (FFF). Different examples of conductive and non-conductive bespoke filaments using renewable biopolymers, bioplasticizers, and recycled materials are presented and discussed. The main final characteristics of the polymeric materials achieved according to the feedstock, preparation, extrusion, and treatments are also covered. In addition to recycling and remanufacturing, this review also explores other alternative approaches that can be adopted to enhance the sustainability of methods, aiming to produce efficient and environmentally friendly 3D printed products. Adjusting printing parameters and miniaturizing systems are also highlighted in this regard. All these recommended strategies are employed to minimize environmental damage, while also enabling the production of high-quality, economical materials and 3D printed systems. These efforts align with the principles of Green Chemistry, Sustainable Development Goals (SDGs), 3Rs (Reduce, Reuse, Recycle), and Circular Economy concepts.

Numerical Modeling of Mechanical Behavior of Functionally Graded Polylactic Acid-Acrylonitrile Benzidine Styrene Produced via Fused Deposition Modeling: Experimental Observations

Functionally graded materials (FGM) have attracted considerable attention in the field of composite materials and rekindled interest in research on composite materials due to their unique mechanical response achieved through material design and optimization. Compared to conventional composites, FGMs offer several advantages and exceptional properties, including improved deformation resistance, improved toughness, lightness properties, and excellent recoverability. This study focused on the production of functionally graded (FG) polymer materials by the additive manufacturing (AM) method. FG structures were produced by the fused deposition modeling (FDM) method using acrylonitrile benzidine styrene (ABS) and polylactic acid (PLA) materials, and tensile tests were performed according to ASTM D638. The effects of different layer thicknesses, volume ratios, and total thicknesses on mechanical behavior were investigated. The tensile standard of materials produced by additive manufacturing introduces geometric differences. Another motivation in this study is to reveal the differences between the results according to the ASTM standard. In addition, tensile tests were carried out by producing single-layer samples at certain volume ratios to create a numerical model with the finite element method to verify the experimental data. As a result of this study, it is presented that the FG structure produced with FDM improves mechanical behavior.

Electrical Resistivity of 3D-Printed Polymer Elements

During this study, the resistivity of electrically conductive structures 3D-printed via fused filament fabrication (FFF) was investigated. Electrical resistivity characterisation was performed on various structural levels of the whole 3D-printed body, starting from the single traxel (3D-printed single track element), continuing with monolayer and multilayer formation, finalising with hybrid structures of a basic nonconductive polymer and an electrically conductive one. Two commercial conductive materials were studied: Proto-Pasta and Koltron G1. It was determined that the geometry and resistivity of a single traxel influenced the resistivity of all subsequent structural elements of the printed body and affected its electrical anisotropy. In addition, the results showed that thermal postprocessing (annealing) affected the resistivity of a standalone extruded fibre (extruded filament through a printer nozzle in freefall) and traxel. The effect of Joule heating and piezoresistive properties of hybrid structures with imprinted conductive elements made from Koltron G1 were investigated. Results revealed good thermal stability within 70 °C and considerable piezoresistive response with a gauge factor of 15-25 at both low 0.1% and medium 1.5% elongations, indicating the potential of such structures for use as a heat element and strain gauge sensor in applications involving stiff materials and low elongations.

Closed-Loop Filament Feed Control in Fused Filament Fabrication

Fused filament fabrication (FFF) is an additive manufacturing process where a thermoplastic polymeric material, provided in the form of a filament, is extruded to create layers. Achieving a consistent flow of the extruded material is key to ensure quality of the final part. Extrudate flow depends on many factors; among these, the rate at which the filament is fed into the extruder. In a conventional FFF machine, filament transport is achieved through the use of a drive gear. However, slippage between the gear and the filament may occur, leading to reduced transport and the consequent local decrease of extrudate flow rate, which in turn leads to a series of imperfections in the fabricated part due to underextrusion, including reduced density. In this work, we propose a closed-loop control system to ensure the correct filament transport to the extruder. The system works through the comparison between the nominal transport of the filament and the actual filament transport measured using an encoder. The measured value is used to correct the filament feed rate in real time, ensuring a material flow close to the nominal one, regardless of the other process parameters. In this work, an instrumented FFF machine prototype was used to investigate the performance of the approach. For validation, parts were realized using different process parameters, while enabling and disabling the closed-loop control system. Results showed that the relative filament transport error decreased from up to 9% to below 0.25% and a density increase up to ∼10% regardless of the process parameters, as well as the reduction of interlayer and intralayer voids, as highlighted through cross-sectional imaging of realized samples. A reduction of defects on realized parts was observed, especially at higher fabrication feed rates.

Bulk-Material Bond Strength Exists in Extrusion Additive Manufacturing for a Wide Range of Temperatures, Speeds, and Layer Times

Do extrusion temperature, printing speed, and layer time affect mechanical performance of interlayer bonds in material extrusion additive manufacturing (MEAM)? The question is one of the main challenges in 3D printing of polymers. This article aims to analyze the independent effect of printing parameters on interlayer bonding in MEAM. In previous research, printing parameters were unavoidably interrelated, such as printing speed and layer cooling time. Here, original specimen designs allow the effects to be studied independently for the first time to provide new understanding of the effects of a wide range of thermal factors on mechanical properties of 3D-printed polylactide. The experimental approach used direct GCode design to manufacture specially designed single-filament-thick specimens for tensile testing to measure mechanical and thermal properties normal to the interface between layers. In total, five different extrusion temperatures (a range of 60°C), five different printing speeds (a 16-fold change in the magnitude) and four different layer times (an 8-fold change) were independently studied. The results demonstrate interlayer bond strength to be equivalent to that of the bulk material within experimental scatter. This study provides strong evidence about the crucial role of microscale geometry for apparent interlayer bond strength relative to the role of thermal factors. By designing specimens specifically for the MEAM process, this study clearly demonstrates that bulk-material strength can be achieved for interlayer bonds in MEAM even when printing parameters change severalfold. Widespread industrial and academic efforts to improve interlayer bonding should be refocused to study extrusion geometry-the primary cause of anisotropy in MEAM.

Additive Manufacturing of Biodegradable Hemp-Reinforced Polybutylene Succinate (PBS) and Its Mechanical Characterization

The additive manufacturing of natural fibre-reinforced polymers is a pivotal method in developing sustainable engineering solutions. Using the fused filament fabrication method, the current study investigates the additive manufacturing of hemp-reinforced polybutylene succinate (PBS) alongside its mechanical characterization. Two types of hemp reinforcement are considered: short fibres (max. length smaller than 2 mm) and long fibres (max. length smaller than 10 mm), which are compared against non-reinforced (pure) PBS. A detailed analysis is performed regarding the determination of suitable 3D printing parameters (overlap, temperature, nozzle diameter). In a comprehensive experimental study, additionally to general analyses regarding the influence of hemp reinforcement on the mechanical behaviour, the effect of printing parameters is determined and discussed. Introducing an overlap in the additive manufacturing of the specimens results in improved mechanical performance. The study highlights that the Young's modulus of PBS can be improved by 63% by introducing hemp fibres in conjunction with overlap. In contrast, hemp fibre reinforcement reduces the tensile strength of PBS, while this effect is less pronounced considering overlap in the additive manufacturing process.

Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing

Fused Filament Fabrication (FFF) 3D printing is an additive technology used to manufacture parts. Used in the engineering industry for prototyping polymetric parts, this disruptive technology has been adopted commercially and there are affordable printers on the market that allow for at-home printing. This paper examines six methods of reducing the energy and material consumption of 3D printing. Using different commercial printers, each approach was investigated experimentally, and the potential savings were quantified. The modification most effective at reducing energy consumption was the hot-end insulation, with savings of 33.8-30.63%, followed by the sealed enclosure, yielding an average power reduction of 18%. For material, the most influential change was noted using 'lightning infill', reducing material consumption by 51%. The methodology includes a combined energy- and material-saving approach in the production of a referenceable 'Utah Teapot' sample object. Using combined techniques on the Utah Teapot print, the material consumption was reduced by values between 55.8% and 56.4%, and power consumption was reduced by 29% to 38%. The implementation of a data-logging system allowed us to identify significant thermal management and material usage opportunities to minimise power consumption, providing solutions for a more positive impact on the sustainable manufacturing of 3D printed parts.

Optimizing fused filament fabrication process parameters for quality enhancement of PA12 parts using numerical modeling and taguchi method

Fused Filament Fabrication (FFF) is an Additive Manufacturing (AM) technique implemented in widespread applications and several components. Despite its benefits, the physics behind the FFF process is quite complicated and requires fast heating and cooling rate of the extruded material. Consequently, the component experiences extremely non-uniform internal stresses that might lead to warpage deformation. It is necessary to optimize the printing parameters as they are associated with the warpage deformation of printed components. One method for achieving this target is conducting physical tests that offer precise findings, but it is an expensive strategy. Another approach is to simulate the printing parameters with special software. In this work, Digimat-AM was employed to develop a thermomechanical Finite Element Model of the FFF to simulate parts made of Polyamide12 (PA12). An L27 orthogonal array, a tool of the Taguchi orthogonal array, and an analysis of variance (ANOVA) were used to estimate the impact of five printing parameters and their ultimate levels to improve the dimension's quality by minimizing the warpage deformation. Results showed a significant impact of the bed temperature on the warpage deformation values. The infill density contributed 2.84% in reducing the warpage deformation, and the rest of the parameters' contribution was less than 1% for each.

Effect of Process Parameters on the Performance of Drop-On-Demand 3D Inkjet Printing: Geometrical-Based Modeling and Experimental Validation

As additive manufacturing has evolved, 3D inkjet printing (IJP) has become a promising alternative manufacturing method able to manufacture functional multi-material parts in a single process. However, issues with part quality in terms of dimensional errors and lack of precision still restrict its industrial and commercial applications. This study aims at improving the dimensional accuracy of 3D IJP parts by developing an optimization-oriented simulation tool of droplet behavior during the drop-on-demand 3D IJP process. The simulation approach takes into consideration the effect of droplet volume, droplet center-to-center distance, coverage percentage of jetted droplets, the contact angle of the ink on the solid substrate and coalescence performance of overlapping droplets, in addition to the number of printed layers. Following the development of the simulation tool using MATLAB, its feasibility was experimentally validated and the results showed a good agreement with a maximum deviation of 2.25% for horizontal features. In addition, the simulated horizontal features are compared with the results of “Inkraster” software, which also illustrates droplet behavior, however, only in 2D. For vertical features, a dial gauge indicator is used to measure the sample height, and the validation results show that the simulation tool can predicate the height of the sample with an average error of 10.89% for a large droplet diameter and 8.09% for a small diameter. The simulation results were found to be in a good agreement with the dimensions of the printed parts. The developed tool was then used to elucidate the effect of resolution of processed TIFF image and droplet diameter on the dimensional accuracy of 3D IJP parts.

Fused Filament Fabrication 3D Printing: Quantification of Exposure to Airborne Particles

Fused Filament Fabrication (FFF) has been established as a widely practiced Additive Manufacturing technique, using various thermoplastic filaments. Carbon fibre (CF) additives enhance mechanical properties of the materials. The main operational hazard of the FFF technique explored in the literature is the emission of Ultrafine Particles and Volatile Organic Compounds. Exposure data regarding novel materials and larger scale operations is, however, still lacking. In this work, a thorough exposure assessment measurement campaign is presented for a workplace applying FFF 3D printing in various setups (four different commercial devices, including a modified commercial printer) and applying various materials (polylactic acid, thermoplastic polyurethane, copolyamide, polyethylene terephthalate glycol) and CF-reinforced thermoplastics (thermoplastic polyurethane, polylactic acid, polyamide). Portable exposure assessment instruments are employed, based on an established methodology, to study the airborne particle exposure potential of each process setup. The results revealed a distinct exposure profile for each process, necessitating a different safety approach per setup. Crucially, high potential for exposure is detected in processes with two printers working simultaneously. An updated engineering control scheme is applied to control exposures for the modified commercial printer. The establishment of a flexible safety system is vital for workplaces that apply FFF 3D printing.

Simulating energy consumption based on material addition rates for material extrusion of CFR-PEEK: a trade-off between energy costs and cycle time

While many studies for material extrusion-based additive manufacturing (AM) of polymers focus on experimental approaches to evaluate relevant performance measures from process parameters, there is a lack of discussion to connect experimental results with useful applications. Also, one of the major deficiencies in the application literature is a trade-off analysis between energy costs and cycle time (time to produce an item from the beginning to the end) since improving these two measures simultaneously is challenging. Thus, this paper proposes an energy simulation method for performing a trade-off analysis between energy costs and cycle time using combinations of major AM process parameters for material extrusion. We conduct experiments using carbon fiber-reinforced poly-ether-ether-ketone (CFR-PEEK), which is increasingly used in material extrusion. From experimental results, we build a power model in which power (kW) is derived as a linear function of material addition rates (MAR). This MAR regression model is then used in a proposed simulation model that integrates discrete event simulation and numerical simulation. In our simulation case study of 50 machines and 40 scenarios, we investigate trade-offs between energy costs and cycle time with three control policies (P₁, P₂₅, and P₅₀) that allow 1, 25, or 50 machines to start heating, respectively. The trade-off analysis results show that P₂₅ can be preferred when a balance between cycle time and energy costs is pursued, while P₁ or P₅₀ can be chosen if either energy cost (with P₁) or cycle time (with P₅₀) is more important than the other measure. Moreover, we find that the machine utilization, variability, and product volume have significant effects on energy costs and cycle time.

Influence of Extruder's Nozzle Diameter on the Improvement of Functional Properties of 3D-Printed PLA Products

The dynamic growth of the use of polymer construction parts manufactured individually and in a small series makes it necessary to improve additive methods in the areas of materials, equipment and processes. By observing selected phenomena occurring during the processing of polymer materials in other production technologies (e.g., extrusion and injection molding), it is possible to obtain solutions that positively affect the final performance properties of the products obtained in additive manufacturing technologies using thermoplastic filament. The aim of this research was to determine the effect of the diameter of the print head nozzle on the spatial structure (path width) and selected mechanical properties of samples produced by the FFF method with PLA material. The obtained results were compared to the samples with a solid structure produced using injection molding technology. In the experiment, the RepRap device for additive manufacturing was used, with the use of nozzles with diameters of 0.2 mm, 0.4 mm, 0.8 mm and 1.2 mm. The test objects were produced with a layer height of 0.2 mm, full filling (100%) and with constant remaining printing parameters. The conducted research allowed us to conclude that the use of layer heights lower than the standard ones gives favorable results for selected mechanical properties. The use of an extruder nozzle diameter of 0.8 mm allows one to obtain a macrostructure with a high degree of interconnection of layers and paths and favorable mechanical properties. The test results can be used in the construction of functional elements that are produced by fused deposition modeling (FDM) and fused filament fabrication (FFF) methods in prototype, unit and small-lot production.

A Review on Additive Manufacturing of Micromixing Devices

In recent years, additive manufacturing has gained importance in a wide range of research applications such as medicine, biotechnology, engineering, etc. It has become one of the most innovative and high-performance manufacturing technologies of the moment. This review aims to show and discuss the characteristics of different existing additive manufacturing technologies for the construction of micromixers, which are devices used to mix two or more fluids at microscale. The present manuscript discusses all the choices to be made throughout the printing life cycle of a micromixer in order to achieve a high-quality microdevice. Resolution, precision, materials, and price, amongst other relevant characteristics, are discussed and reviewed in detail for each printing technology. Key information, suggestions, and future prospects are provided for manufacturing of micromixing machines based on the results from this review.

Progress of 3D Bioprinting in Organ Manufacturing

Three-dimensional (3D) bioprinting is a family of rapid prototyping technologies, which assemble biomaterials, including cells and bioactive agents, under the control of a computer-aided design model in a layer-by-layer fashion. It has great potential in organ manufacturing areas with the combination of biology, polymers, chemistry, engineering, medicine, and mechanics. At present, 3D bioprinting technologies can be used to successfully print living tissues and organs, including blood vessels, skin, bones, cartilage, kidney, heart, and liver. The unique advantages of 3D bioprinting technologies for organ manufacturing have improved the traditional medical level significantly. In this article, we summarize the latest research progress of polymers in bioartificial organ 3D printing areas. The important characteristics of the printable polymers and the typical 3D bioprinting technologies for several complex bioartificial organs, such as the heart, liver, nerve, and skin, are introduced.

Enhancement of High-Resolution 3D Inkjet-Printing of Optical Freeform Surfaces Using Digital Twins

3D-inkjet-printing is just beginning to take off in the optical field. Advantages of this technique include its fast and cost-efficient fabrication without tooling costs. However, there are still obstacles preventing 3D inkjet-printing from a broad usage in optics, e.g., insufficient form fidelity. In this article, we present the formulation of a digital twin by the enhancement of an optical model by integrating geometrical measurement data. This approach strengthens the high-precision 3D printing process to fulfil optical precision requirements. A process flow between the design of freeform components, fabrication by inkjet printing, the geometrical measurement of the fabricated optical surface, and the feedback of the measurement data into the simulation model was developed, and its interfaces were defined. The evaluation of the measurements allowed for the adaptation of the printing process to compensate for process errors and tolerances. Furthermore, the performance of the manufactured component was simulated and compared with the nominal performance, and the enhanced model could be used for sensitivity analysis. The method was applied to a highly complex helical surface that allowed for the adjustment of the optical power by rotation. We show that sensitivity analysis could be used to define acceptable tolerance budgets of the process.

3D Printing of Oil Paintings Based on Material Jetting and Its Reduction of Staircase Effect

Material jetting is a high-precision and fast 3D printing technique for color 3D objects reproduction, but it also suffers from color accuracy and jagged issues. The UV inks jetting processes based on the polymer jetting principle have been studied from printing materials regarding the parameters in the default layer order, which is prone to staircase effects. In this work, utilizing the Mimaki UV inks jetting system with a variable layer thickness, a new framework to print a photogrammetry-based oil painting 3D model has been proposed with the tunable coloring layer sequence to improve the jagged challenge between adjacent layers. Based on contour tracking, a height-rendering image of the oil painting model is generated, which is further segmented and pasted to the corresponding slicing layers to control the overall printing sequence of coloring layers and white layers. The final results show that photogrammetric models of oil paintings can be printed vividly by UV-curable color polymers, and that the proposed reverse-sequence printing method can significantly improve the staircase effect based on visual assessment and color difference. Finally, the case of polymer-based oil painting 3D printing provides new insights for optimizing color 3D printing processes based on other substrates and print accuracy to improve the corresponding staircase effect.

Study of the Influence of Technological Parameters on Generating Flat Part with Cylindrical Features in 3D Printing with Resin Cured by Optical Processing

The objective of this paper is to determine how the supporting structure in the DLP 3D printing process has influences on the characteristics of the flat and cylindrical surfaces. The part is printed by using the Light Control Digital (LCD) 3D printer technology. A Coordinate Measuring Machine (CMM) with contact probes is used for measuring the physical characteristics of the printed part. Two types of experiment were chosen by the authors to be made. The first part takes into consideration the influence of the density of the generated supports, at the bottom of the printed body on the characteristics of the flat surface. In parallel, it is studying the impact of support density on the dimension and quality of the surface. In the second part of the experiment, the influence of the printed supports dimension on the flatness, straightness and roundness of the printed elements were examined. It can be observed that both the numerical and dimensional optimum zones of the support structure for a prismatic element could be determined, according to two experiments carried out and the processing of the resulting data. Based on standardized data of flatness, straightness and roundness, it is possible to put in accord the values determined by measurement within the limits of standardized values.

Synthetic Polymers for Organ 3D Printing

Three-dimensional (3D) printing, known as the most promising approach for bioartificial organ manufacturing, has provided unprecedented versatility in delivering multi-functional cells along with other biomaterials with precise control of their locations in space. The constantly emerging 3D printing technologies are the integration results of biomaterials with other related techniques in biology, chemistry, physics, mechanics and medicine. Synthetic polymers have played a key role in supporting cellular and biomolecular (or bioactive agent) activities before, during and after the 3D printing processes. In particular, biodegradable synthetic polymers are preferable candidates for bioartificial organ manufacturing with excellent mechanical properties, tunable chemical structures, non-toxic degradation products and controllable degradation rates. In this review, we aim to cover the recent progress of synthetic polymers in organ 3D printing fields. It is structured as introducing the main approaches of 3D printing technologies, the important properties of 3D printable synthetic polymers, the successful models of bioartificial organ printing and the perspectives of synthetic polymers in vascularized and innervated organ 3D printing areas.