Elastic Asymmetry of PLA Material in FDM-Printed Parts: Considerations Concerning Experimental Characterisation for Use in Numerical Simulations

Development of bone surrogates by material extrusion-based additive manufacturing to mimic flexural mechanical behaviour and fracture prediction via phase-field approach

BACKGROUND AND OBJECTIVE

The limited availability of human bone samples for investigation leads to the demand for alternatives. Bone surrogates are crucial in promoting research on the intricate mechanics of osseous tissue. However, solutions are restricted to commercial brands, which frequently fail to faithfully replicate the mechanical response of bone, or oversimplified customised simulants designed for a specific application. The manufacturing and assessment of reliable bone surrogates made of polylactic acid via material extrusion-based additive manufacturing are presented in this work.

METHODS

An experimental and numerical study with 3D-printed dog-bone and prismatic specimens was carried out to characterise the polymeric feedstock and analyse the influence of process parameters under three-point bending and quasi-static conditions. Besides, three porcine rib samples were considered as a reference for the development of the artificial bones. Bone surrogates were manufactured from the 3D-scanned real bone geometries. In order to reproduce the trabecular and cortical bone, a lattice structure for the infill and a compact shell surrounding the core were employed. Infill density and shell thickness were evaluated through different printing configurations. Additionally, a computational analysis based on the phase-field approach was conducted to simulate the experimental tests and predict fracture. The modelling considered homogenisation of the infill material.

RESULTS

Outcomes demonstrated the potential of the presented methodology. Maximum force and flexural stiffness were compared to real bone properties to find the optimal printing configuration, replicating the flexural mechanical behaviour of bone tissue. Certain configurations accurately reproduce the studied properties. Regarding the numerical model, strength and stiffness prediction was validated with experimental results.

CONCLUSIONS

The presented methodology enables the manufacturing of artificial bones with accurate geometries and tailored mechanical properties. Furthermore, the described modelling strategy offers a powerful tool for designing bone surrogates.

Effects of Nozzle Temperature on Mechanical Properties of Polylactic Acid Specimens Fabricated by Fused Deposition Modeling

This paper investigates the effect of nozzle temperature, from 180 to 260 °C, on properties of polylactic acid (PLA) samples manufactured by fused deposition modeling (FDM) technology. The main objective of this research is to determinate an optimum nozzle temperature relative to tensile, flexural and compressive properties of printed specimens. After manufacturing, the samples exhibit an amorphous structure, without crystallization effects, independently of the fabrication temperature. In order to determine the influence of printing temperature on mechanical properties, uniaxial tensile, three-point flexural and compression strength tests were carried out. The obtained results suggest that a relative low printing temperature could reduce the material flow and decrease the density of the final prototype, with a negative effect on both the quality and the mechanical properties of the pieces. If temperature increases up to 260 °C, an excess of material can be deposited, but with no significant negative effect on mechanical parameters. There is an optimum nozzle temperature interval, depending on the considered piece and test, for which mechanical values can be optimized. Taking into account all tests, a recommended extruder temperature interval may be identified as 220-240 °C. This range encompasses all mechanical parameters, avoiding the highest temperature where an excess of material was observed. For this printing temperature interval, no significant mechanical variations were appreciated, which corresponds to a stable behavior of the manufactured specimens.

Understanding compressive viscoelastic properties of additively manufactured PLA for bone-mimetic scaffold design

Bone tissue engineering has been recognized as a promising strategy to repair or replace damaged bone tissues. The mechanical properties of bone scaffolds play a critical role in successful bone regeneration, as it is essential to match the mechanical properties of the scaffold with the surrounding bone tissue. In this study, we investigated the effects of fused deposition modeling (FDM) process parameters, including printing speed, printing temperature, and layer thickness, on the compressive viscoelastic properties of polylactic acid (PLA) scaffolds. The compressive viscoelastic properties of bulk PLA specimens were characterized using a Zhu-Wang-Tang (ZWT) constitutive model under different compressive strain rates. A comprehensive statistical analysis comprising multivariate and univariate analysis of variance (MANOVA and ANOVA) and Tukey's post hoc analysis was utilized to quantify the effect of each FDM parameter on the viscoelastic mechanical properties of the PLA specimens. Subsequently, we fabricated modified face-centered cubic (MFCC) scaffolds using FDM and varied the FDM process parameters to achieve a compressive viscoelastic response that matched the natural trabecular bone tissue. The viscoelastic performance of the MFCC scaffolds was compared with traditional orthogonal cylindrical struts (OCS) scaffolds. Our methodology contributes to the design of bone-mimetic scaffolds with optimized mechanical properties by controlling FDM process parameters.

Modelling Influence on Bending Behaviour Simulation of the Poly(Lactic Acid) Structures, 3D Printed

The paper presents the influence of the loading modelling on the simulation process results of the bending behaviour for 3D printed structures. The study is done on structures having different geometries of the cross section, and the type of structure is bar or tube. The materials used for 3D printing are poly(lactic) acid and poly(lactic acid) mixed with glass fibres. The simulation was carried out both based on a simple modelling (schematization) of the bending loading and a complex one. The complex modelling reproduces the bending of 3D printed structures more accurately but is also more time-consuming for the computer-aided design stage. Analysis of the study results shows that in terms of the Von Mises stresses determined by simulation, they are in line with those of the tests but with a slight advantage for the complex modelling compared to the simple one. In terms of deformations, the simulation introduces errors compared to the test results, but the source of the errors is the high elasticity of some 3D printed structures. The study also shows that the high elasticity is due to both the shape of the structure cross section and its arrangement during the bending test.

Effect of Process Parameters and Postprocessing on Mechanical Properties of Additive Manufacturing Polylactic Acid Obtained by Fused Deposition Modeling

The aim of this article is to study the influence of some printing parameters and postprocessing on mechanical properties of polylactic acid samples manufactured by fused deposition modeling with a 3D printer. The effects of different building orientations, concentric infill, and postprocessing by annealing were analyzed. In this sense, uniaxial tensile and three-point bending tests were performed to determine the ultimate strength, modulus of elasticity, and elongation at break. Among all printing parameters of interest, the print orientation can be considered one of the most important, being fundamental in the mechanical behavior. Once samples were fabricated, annealing processes were also considered, close to the T g, in order to study the effects on mechanical properties. In the modified print orientation, the average values for the E and the σ TS are 3337.15-3337.92 and 36.42-37.62 MPa, compared with default printing with the E and the σ TS that are 2541.63-2692.34 and 28.81-28.89 MPa, respectively. In the annealed samples, the values for the Ef and the σf are 2337.73 and 63.96 MPa, compared with the reference samples with the Ef and the σf values of 2164.40 and 59.66 MPa, respectively. Hence, the print orientation and postprocessing must be taken into account as important factors for the final properties of the desired product.

The Influence of the Process Parameters on the Mechanical Properties of PLA Specimens Produced by Fused Filament Fabrication-A Review

Polylactic acid (PLA) is produced from renewable materials, has a low melting temperature and has a low carbon footprint. These advantages have led to the extensive use of polylactic acid in additive manufacturing, particularly by fused filament fabrication (FFF). PLA parts that are 3D printed for industrial applications require stable mechanical properties and predictability regarding their dependence on the process parameters. Therefore, the development of the FFF process has been continuously accompanied by the development of software packages that generate CNC codes for the printers. A large number of user-controllable process parameters have been introduced in these software packages. In this respect, a lot of articles in the specialized literature address the issue of the influence of the process parameters on the mechanical properties of 3D-printed specimens. A systematic review of the research targeting the influence of process parameters on the mechanical properties of PLA specimens additively manufactured by fused filament fabrication was carried out by the authors of this paper. Six process parameters (layer thickness, printing speed, printing temperature, build plate temperature, build orientation and raster angle) were followed. The mechanical behavior was evaluated by tensile, compressive and bending properties.

Comparison between Tests and Simulations Regarding Bending Resistance of 3D Printed PLA Structures

Additive manufacturing is one of the technologies that is beginning to be used in new fields of parts production, but it is also a technology that is constantly evolving, due to the advances made by researchers and printing equipment. The paper presents how, by using the simulation process, the geometry of the 3D printed structures from PLA and PLA-Glass was optimized at the bending stress. The optimization aimed to reduce the consumption of filament (material) simultaneously with an increase in the bending resistance. In addition, this paper demonstrates that the simulation process can only be applied with good results to 3D printed structures when their mechanical properties are known. The inconsistency of printing process parameters makes the 3D printed structures not homogeneous and, consequently, the occurrence of errors between the test results and those of simulations become natural and acceptable. The mechanical properties depend on the values of the printing process parameters and the printing equipment because, in the case of 3D printing, it is necessary for each combination of parameters to determine their mechanical properties through specific tests.

Influence of Infill Pattern on the Elastic Mechanical Properties of Fused Filament Fabrication (FFF) Parts through Experimental Tests and Numerical Analyses

Fused Filament Fabrication (FFF) is one of the most extensive additive manufacturing technologies for printing prototypes or final parts in various fields. Some printed parts need to meet structural requirements to be functional parts. Therefore, it is necessary to know the mechanical behavior of the printed samples as a function of the printing parameters in order to optimize the material used during the manufacturing process. It is known that FFF parts can present orthotropic characteristics as a consequence of the manufacturing process, in which the material is deposited layer by layer. Therefore, these characteristics must be considered for a correct evaluation of the printed parts from a structural point of view. In this paper, the influence of the type of filling pattern on the main mechanical properties of the printed parts is analyzed. For this purpose, the first parts are 3D printed using three different infill patterns, namely grid, linear with a raster orientation of 0 and 90°, and linear with a raster orientation of 45°. Then, experimental tensile tests, on the one hand, and numerical analyses using finite elements, on the other hand, are carried out. The elastic constants of the material are obtained from the experimental tests. From the finite element analysis, using a simple approach to create a Representative Volume Model (RVE), the constitutive characteristics of the material are estimated: Young's Moduli and Poisson's ratios of the printed FFF parts. These values are successfully compared with those of the experimental tests. The results clearly show differences in the mechanical properties of the FFF printed parts, depending on the internal arrangement of the infill pattern, even if similar 3D printing parameters are used.

Comparison between the Test and Simulation Results for PLA Structures 3D Printed, Bending Stressed

The additive manufacturing process is one of the technical domains that has had a sustained development in recent decades. The designers' attention to equipment and materials for 3D printing has been focused on this type of process. The paper presents a comparison between the results of the bending tests and those of the simulation of the same type of stress applied on 3D-printed PLA and PLA-glass structures. The comparison of the results shows that they are close, and the simulation process can be applied with confidence for the streamline of filament consumption, with direct consequences on the volume and weight of additive manufactured structures. The paper determines whether the theories and concepts valid in the strength of materials can be applied to the additive manufacturing pieces. Thus, the study shows that the geometry of the cross-section, by its shape (circular or elliptical) and type (solid or ring shaped), influences the strength properties of 3D-printed structures. The use of simulation will allow a significant shortening of the design time of the new structures. Moreover, the simulation process was applied with good results on 3D-printed structures in which two types of filaments were used for a single piece (structure).

Effect of Printing Parameters on the Thermal and Mechanical Properties of 3D-Printed PLA and PETG, Using Fused Deposition Modeling

Fused Deposition Modeling (FDM) can be used to manufacture any complex geometry and internal structures, and it has been widely applied in many industries, such as the biomedical, manufacturing, aerospace, automobile, industrial, and building industries. The purpose of this research is to characterize the polylactic acid (PLA) and polyethylene terephthalate glycol (PETG) materials of FDM under four loading conditions (tension, compression, bending, and thermal deformation), in order to obtain data regarding different printing temperatures and speeds. The results indicated that PLA and PETG materials exhibit an obvious tensile and compression asymmetry. It was observed that the mechanical properties (tension, compression, and bending) of PLA and PETG are increased at higher printing temperatures, and that the effect of speed on PLA and PETG shows different results. In addition, the mechanical properties of PLA are greater than those of PETG, but the thermal deformation is the opposite. The above results will be a great help for researchers who are working with polymers and FDM technology to achieve sustainability.

Product Design by Additive Manufacturing for Water Environments: Study of Degradation and Absorption Behavior of PLA and PETG

Additive manufacturing technologies are shifting from rapid prototyping technologies to end use or final parts production. Polymeric material extrusion processes have been broadly addressed with a specific definition of all parameters and variables for all different of technologies approaches and materials. Recycled polymeric materials have been studied due to the growing importance of the environmental awareness of the contemporary society. Beside this, little specific research has been found in product development applications for AM where the printed parts are in highly moisture environments or surrounded by water, but polymers have been for long used in such industries with conventional manufacturing approaches. This work focuses on the analysis and comparison of two different additively manufactured polymers printed by fused filament fabrication (FFF) processes using desktop-size printers to be applied for product design. The polymers used have been a recycled material: polyethylene terephthalate glycol (PETG) and polylactic acid (PLA). Degradation and water absorption behaviors of both materials are presented, analyzed and discussed in this paper, where different samples have been immersed in saturated solutions of water with maritime salt and sugar together with a control sample immersed in distilled water. The samples have been dimensionally and weight-controlled weekly as well as microscopically analyzed to understand degradation and absorption processes that appear in the fully saturated solutions. The results revealed how the absorption process is stabilized after a reduced number of weeks for both materials and how the degradation process is more remarked in the PLA material due to its organic nature.

The Influence of Raster Angle and Moisture Content on the Mechanical Properties of PLA Parts Produced by Fused Deposition Modeling

The additive manufacturing (AM) processes and technologies of 3D-printed materials and components using fused deposition modeling (FDM) are currently very popular and widely used for building parts and prototypes. Many manufacturing parameters can affect the strength and strain of the manufactured parts. The manufacturing parameters may be altered to reach an optimum setting for highly effective parts or components. This research studies the influence of the raster angle and the moisture content percentages on the mechanical properties of 3D printed polylactic acid (PLA) material. The three raster angles tested in this research were 0°, 45°, and 90°. The moisture content of the PLA material was altered to verify its effect on the mechanical properties. Twenty-seven specimens were subjected to tensile tests to examine the effect of different manufacturing parameters. The results show the specimens with a 90° raster angle and 10% moisture content have the optimum strength and strain mechanical properties.

Surface Etching of 3D Printed Poly(lactic acid) with NaOH: A Systematic Approach

The article describes a systematic investigation of the effects of an aqueous NaOH treatment of 3D printed poly(lactic acid) (PLA) scaffolds for surface activation. The PLA surface undergoes several morphology changes and after an initial surface roughening, the surface becomes smoother again before the material dissolves. Erosion rates and surface morphologies can be controlled by the treatment. At the same time, the bulk mechanical properties of the treated materials remain unaltered. This indicates that NaOH treatment of 3D printed PLA scaffolds is a simple, yet viable strategy for surface activation without compromising the mechanical stability of PLA scaffolds.

Development of AM Technologies for Metals in the Sector of Medical Implants

Additive manufacturing (AM) processes have undergone significant progress in recent years, having been implemented in sectors as diverse as automotive, aerospace, electrical component manufacturing, etc. In the medical sector, different devices are printed, such as implants, surgical guides, scaffolds, tissue engineering, etc. Although nowadays some implants are made of plastics or ceramics, metals have been traditionally employed in their manufacture. However, metallic implants obtained by traditional methods such as machining have the drawbacks that they are manufactured in standard sizes, and that it is difficult to obtain porous structures that favor fixation of the prostheses by means of osseointegration. The present paper presents an overview of the use of AM technologies to manufacture metallic implants. First, the different technologies used for metals are presented, focusing on the main advantages and drawbacks of each one of them. Considered technologies are binder jetting (BJ), selective laser melting (SLM), electron beam melting (EBM), direct energy deposition (DED), and material extrusion by fused filament fabrication (FFF) with metal filled polymers. Then, different metals used in the medical sector are listed, and their properties are summarized, with the focus on Ti and CoCr alloys. They are divided into two groups, namely ferrous and non-ferrous alloys. Finally, the state-of-art about the manufacture of metallic implants with AM technologies is summarized. The present paper will help to explain the latest progress in the application of AM processes to the manufacture of implants.

Special Issue of the Manufacturing Engineering Society 2019 (SIMES-2019)

The Special Issue of the Manufacturing Engineering Society 2019 (SIMES-2019) has been launched as a joint issue of the journals "Materials" and "Applied Sciences". The 29 contributions published in this Special Issue of Materials present cutting-edge advances in the field of manufacturing engineering focusing on additive manufacturing and 3D printing, advances and innovations in manufacturing processes, sustainable and green manufacturing, manufacturing of new materials, metrology and quality in manufacturing, industry 4.0, design, modeling, and simulation in manufacturing engineering and manufacturing engineering and society. Among them, these contributions highlight that the topic "additive manufacturing and 3D printing" has collected a large number of contributions in this journal because its huge potential has attracted the attention of numerous researchers over the last years.

Transverse Impact on Rectangular Metal and Reinforced Concrete Beams Taking into Account Bimodularity of the Material

This article is devoted to the stress-strain state (SSS) study of metal and reinforced fiber-reinforced concrete beam under static and shock loading, depending on the bimodularity of the material, the mass of the beam, and the location of the reinforcing bars in zones under tension and compression. It is known that many materials have different tensile and compression properties, but in most cases, this is not taken into account. The calculations were carried out by using load-bearing metal beams made of silumin and steel and reinforced concrete beams under the action of a concentrated force applied in the middle of the span. The impact load is considered as the plastic action of an absolutely rigid body on the elastic system, taking into account the hypothesis of proportionality of the dynamic and static characteristics of the stress-strain state of the body. The dependences of the maximum dynamic normal stresses on the number of locations of reinforcing bars in zones under tension and compression, the bimodularity of the material, and the reduced mass of the beam are obtained. A numerical study of SSS for metal and concrete beams has shown that bimodularity allows the prediction of beam deflections and normal stresses more accurately.

Novel Synthesis of Core-Shell Biomaterials from Polymeric Filaments with a Bioceramic Coating for Biomedical Applications

Bone tissue engineering is constantly in need of new material development with improved biocompatibility or mechanical features closer to those of natural bone. Other important factors are the sustainability, cost, and origin of the natural precursors involved in the technological process. This study focused on two widely used polymers in tissue engineering, namely polylactic acid (PLA) and thermoplastic polyurethane (TPU), as well as bovine-bone-derived hydroxyapatite (HA) for the manufacturing of core-shell structures. In order to embed the ceramic particles on the polymeric filaments surface, the materials were introduced in an electrical oven at various temperatures and exposure times and under various pressing forces. The obtained core-shell structures were characterized in terms of morphology and composition, and a pull-out test was used to demonstrate the particles adhesion on the polymeric filaments structure. Thermal properties (modulated temperature and exposure time) and the pressing force’s influence upon HA particles’ insertion degree were evaluated. More to the point, the form variation factor and the mass variation led to the optimal technological parameters for the synthesis of core-shell materials for prospect additive manufacturing and regenerative medicine applications.

Solidification Crack Evolution in High-Strength Steel Welding Using the Extended Finite Element Method

High-strength steel suffers from an increasing susceptibility to solidification cracking in welding due to increasing carbon equivalents. However, the cracking mechanism is not fully clear for a confidently completely crack-free welding process. To present a full, direct knowledge of fracture behavior in high-strength steel welding, a three-dimensional (3-D) modeling method is developed using the extended finite element method (XFEM). The XFEM model and fracture loads are linked with the full model and the output of the thermo-mechanical finite element method (TM-FEM), respectively. Solidification cracks in welds are predicted to initiate at the upper tip at the current cross-section, propagate upward to and then through the upper weld surface, thereby propagating the lower crack tip down to the bottom until the final failure. This behavior indicates that solidification cracking is preferred on the upper weld surface, which has higher weld stress introduced by thermal contraction and solidification shrinkage. The modeling results show good agreement with the solidification crack fractography and in situ observations. Further XFEM results show that the initial defects that exhibit higher susceptibility to solidification cracking are those that are vertical to the weld plate plane, open to the current cross-section and concentratedly distributed compared to tilted, closed and dispersedly distributed ones, respectively.