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Abdelmagid AAA, Idriss AIB, Yang CM. Effects of Particle Size on Mechanical Properties and Forming Accuracy of Prosopis chilensis Powder/Polyethersulfone Composites Produced via Selective Laser Sintering. Polymers (Basel) 2024; 16:1786. [PMID: 39000642 PMCID: PMC11244447 DOI: 10.3390/polym16131786] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/28/2024] [Revised: 06/20/2024] [Accepted: 06/20/2024] [Indexed: 07/17/2024] Open
Abstract
Wood-plastic composites are becoming increasingly recognized for their sustainability and their potential for use in various production processes. Nevertheless, enhancing their mechanical strength continues to be a difficult challenge. The objective of this research was to improve the mechanical strength of wood-plastic composite components manufactured through selective laser sintering (SLS). This was achieved by integrating a sustainable composite material, Prosopis chilensis (PCP), with polyethersulfone (PES) to form a composite referred to as PCPC. This study showcased the effect of various PCP particle sizes on mechanical strengths, dimensional accuracies (DAs), and surface roughness of PCPC parts manufactured using AFS-360 SLS. Single-layer sintering was employed to assess PCPC powder's formability with varying PCP particle sizes, and various tests were conducted to understand the materials' thermal properties and analyze particle dispersion and microstructure. The results demonstrated that PCP particle sizes ≤ 0.125 mm significantly enhanced the mechanical strength, forming quality, and DA compared to other particle sizes and pure PES. Key findings for PCPC parts with PCP ≤ 0.125 mm included a bending strength of 10.78 MPa, a tensile strength of 4.94 MPa, an impact strength of 0.91 kJ/m2, and a density of 1.003 g/cm3. Post-processing further improved these parameters, confirming that optimizing PCP particle size is crucial for enhancing the mechanical properties and overall quality of PCPC parts produced via SLS.
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Affiliation(s)
- Alaaeldin A A Abdelmagid
- School of Civil Engineering, Quanzhou University of Information Engineering, Quanzhou 362008, China
| | - Aboubaker I B Idriss
- College of Mechanical and Electrical Engineering, Northeast Forestry University, Harbin 150040, China
- Department of Mechanical Engineering, Faculty of Engineering Science, University of Nyala, P.O. Box 155, Nyala 63312, Sudan
| | - Chun-Mei Yang
- College of Mechanical and Electrical Engineering, Northeast Forestry University, Harbin 150040, China
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Idriss AIB, Yang CM, Li J, Guo Y, Liu J, Abdelmagid AAA, Ahmed GA, Zhang H. Influence of Particle Size on the Mechanical Performance and Sintering Quality of Peanut Husk Powder/PES Composites Fabricated through Selective Laser Sintering. Polymers (Basel) 2023; 15:3913. [PMID: 37835962 PMCID: PMC10575073 DOI: 10.3390/polym15193913] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/21/2023] [Revised: 09/14/2023] [Accepted: 09/25/2023] [Indexed: 10/15/2023] Open
Abstract
This study intends to enhance the mechanical strength of wood-plastic composite selective laser sintering (SLS) parts by using a sustainable composite, peanut husk powder (PHP)/poly ether sulfone (PES) (PHPC). The study aims to address agricultural waste pollution by encouraging the eco-friendly utilization of such waste in SLS technology. To ensure the sintering quality and mechanical properties and prevent deformation and warping during sintering, the thermo-physical properties of PHP and PES powders were analyzed to determine a suitable preheating temperature for PHPC. Single-layer sintering tests were conducted to assess the formability of PHPC specimens with varying PHP particle sizes. The study showed the effects of different PHP particle sizes on the mechanical performance of PHPC parts. The evaluation covered various aspects of PHPC SLS parts, including mechanical strength, density, residual ash content, dimensional accuracy (DA), and surface roughness, with different PHP particle sizes. The mechanical analysis showed that PHPC parts made from PHP particles of ≤0.125 mm were the strongest. Specifically, the density bending strength, residual ash content, tensile, and impact strength were measured as 1.1825 g/cm3, 14.1 MPa, 1.2%, 6.076 MPa, and 2.12 kJ/cm2, respectively. Notably, these parameters showed significant improvement after the wax infiltration treatment. SEM was used to examine the PHP and PES powder particles, PHPC specimen microstructure, and PHPC SLS parts before and after the mechanical tests and waxing. Consequently, SEM analysis wholly confirmed the mechanical test results.
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Affiliation(s)
- Aboubaker I. B. Idriss
- College of Mechanical and Electrical Engineering, Northeast Forestry University, Harbin 150040, China; (A.I.B.I.); (Y.G.); (J.L.)
- Department of Mechanical Engineering, Faculty of Engineering Science, University of Nyala, Nyala P.O. Box 155, Sudan
| | - Chun-Mei Yang
- College of Mechanical and Electrical Engineering, Northeast Forestry University, Harbin 150040, China; (A.I.B.I.); (Y.G.); (J.L.)
| | - Jian Li
- College of Mechanical and Electrical Engineering, Northeast Forestry University, Harbin 150040, China; (A.I.B.I.); (Y.G.); (J.L.)
| | - Yanling Guo
- College of Mechanical and Electrical Engineering, Northeast Forestry University, Harbin 150040, China; (A.I.B.I.); (Y.G.); (J.L.)
| | - Jiuqing Liu
- College of Mechanical and Electrical Engineering, Northeast Forestry University, Harbin 150040, China; (A.I.B.I.); (Y.G.); (J.L.)
| | | | - Gafer A. Ahmed
- Department of Mechanical Engineering, College of Engineering, Sudan University of Science and Technology, Khartoum 11113, Sudan;
| | - Hao Zhang
- College of Mechanical and Electrical Engineering, Northeast Forestry University, Harbin 150040, China; (A.I.B.I.); (Y.G.); (J.L.)
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Moraru E, Stoica AM, Donțu O, Cănănău S, Stoica NA, Constantin V, Cioboată DD, Bădiță-Voicu LL. Mechanical and Surface Characteristics of Selective Laser Melting-Manufactured Dental Prostheses in Different Processing Stages. MATERIALS (BASEL, SWITZERLAND) 2023; 16:6141. [PMID: 37763418 PMCID: PMC10533055 DOI: 10.3390/ma16186141] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/11/2023] [Revised: 09/05/2023] [Accepted: 09/07/2023] [Indexed: 09/29/2023]
Abstract
Due to the expansion of the use of powder bed fusion metal additive technologies in the medical field, especially for the realization of dental prostheses, in this paper, the authors propose a comparative experimental study of the mechanical characteristics and the state of their microscale surfaces. The comparison was made from material considerations starting from two dental alloys commonly used to realize dental prostheses: Ni-Cr and Co-Cr, but also technologies for obtaining selective laser melting (SLM) and conventional casting. In addition, to compare the performances with the classical casting technology, for the dental prostheses obtained through SLM, the post-processing stage in which they are in a preliminary finishing and polished state was considered. Therefore, for the determination of important mechanical characteristics and the comparative study of dental prostheses, the indentation test was used, after which the hardness, penetration depths (maximum, permanent, and contact depth), contact stiffness, and contact surface were established, and for the determination of the microtopography of the surfaces, atomic force microscopy (AFM) was used, obtaining the local areal roughness parameters at the miniaturized scale-surface average roughness, root-mean-square roughness (RMS), and peak-to-peak values. Following the research carried out, several interesting conclusions were drawn, and the superiority of the SLM technology over the classic casting method for the production of dental prostheses in terms of some mechanical properties was highlighted. At the same time, the degree of finishing of dental prostheses made by SLM has a significant impact on the mechanical characteristics and especially the local roughness parameters on a miniaturized scale, and if we consider the same degree of finishing, no major differences are observed in the roughness parameters of the surfaces of the prostheses produced by different technologies.
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Affiliation(s)
- Edgar Moraru
- Faculty of Mechanical Engineering and Mechatronics, National University of Science and Technology Politehnica Bucharest, 313 Splaiul Independentei, 060042 Bucharest, Romania; (E.M.); (O.D.); (S.C.); (N.-A.S.); (V.C.)
| | - Alina-Maria Stoica
- Faculty of Mechanical Engineering and Mechatronics, National University of Science and Technology Politehnica Bucharest, 313 Splaiul Independentei, 060042 Bucharest, Romania; (E.M.); (O.D.); (S.C.); (N.-A.S.); (V.C.)
| | - Octavian Donțu
- Faculty of Mechanical Engineering and Mechatronics, National University of Science and Technology Politehnica Bucharest, 313 Splaiul Independentei, 060042 Bucharest, Romania; (E.M.); (O.D.); (S.C.); (N.-A.S.); (V.C.)
| | - Sorin Cănănău
- Faculty of Mechanical Engineering and Mechatronics, National University of Science and Technology Politehnica Bucharest, 313 Splaiul Independentei, 060042 Bucharest, Romania; (E.M.); (O.D.); (S.C.); (N.-A.S.); (V.C.)
| | - Nicolae-Alexandru Stoica
- Faculty of Mechanical Engineering and Mechatronics, National University of Science and Technology Politehnica Bucharest, 313 Splaiul Independentei, 060042 Bucharest, Romania; (E.M.); (O.D.); (S.C.); (N.-A.S.); (V.C.)
| | - Victor Constantin
- Faculty of Mechanical Engineering and Mechatronics, National University of Science and Technology Politehnica Bucharest, 313 Splaiul Independentei, 060042 Bucharest, Romania; (E.M.); (O.D.); (S.C.); (N.-A.S.); (V.C.)
| | - Daniela-Doina Cioboată
- The National Institute of Research and Development in Mechatronics and Measurement Technique, 6-8 Soseaua Pantelimon, 021631 Bucharest, Romania; (D.-D.C.); (L.-L.B.-V.)
| | - Liliana-Laura Bădiță-Voicu
- The National Institute of Research and Development in Mechatronics and Measurement Technique, 6-8 Soseaua Pantelimon, 021631 Bucharest, Romania; (D.-D.C.); (L.-L.B.-V.)
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Idriss AI, Li J, Guo Y, Shuhui T, Wang Y, Elfaki EA, Ahmed GA. Selective Laser Sintering Parameter Optimization of Prosopis Chilensis/Polyethersulfone Composite Fabricated by AFS-360 SLS. 3D PRINTING AND ADDITIVE MANUFACTURING 2023; 10:697-710. [PMID: 37609577 PMCID: PMC10440679 DOI: 10.1089/3dp.2021.0118] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 08/24/2023]
Abstract
The current available selective laser sintering (SLS) materials are often high in cost and limited in variety; the mechanical properties of wood-composite SLS parts are low quality, which restricts the development of SLS technology. This article aims to optimize the SLS processing parameters to enhance the mechanical properties of the Prosopis chilensis powder (PCP)/polyethersulfone (PES) composite (PCPC) part fabricated via SLS. The PCP and PES powder were proposed as the feedstock of the PCPC powder bed for SLS. First, the thermal decomposition and glass transition temperatures (Tg) of PCP and PES powder were estimated to reduce the produced PCPC parts from warping and deformation during SLS. An orthogonal experimental methodology with five factors and four levels was used to optimize the SLS parameters for the PCPC SLS test. The scanning speed, preheating temperature, and laser power are selected as the main affecting factors on this study. The influence of these factors on dimension accuracies, bending and tensile strengths, and surface roughness quality of the produced PCPC parts was studied. The PCPC particle distribution and microstructure were inspected via scanning electron microscopy. Furthermore, the synthesis weighted scoring methods were utilized to determine the optimal SLS processing parameters of the produced PCPC parts. The combined results of tests showed that the optimal SLS parameters were as follows: the scanning speed is 1.8 m/s, preheating temperature is 80°C, and the laser power is 12 W. Thus, the quality of PCPC SLS parts was significantly enhanced when the optimal parameters were utilized in the SLS process. This article provided the main reference values of SLS parameters of the PCPC. To further enhance the surface roughness quality and mechanical strengths, the postprocessing infiltration with wax was introduced; after wax infiltration, the surface roughness and mechanical strengths were significantly improved.
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Affiliation(s)
- Aboubaker I.B. Idriss
- College of Mechanical and Electrical Engineering, Department of Mechanical Engineering, Northeast Forestry University, Harbin, China
- Department of Mechanical Engineering, Faculty of Engineering Science, University of Nyala, Nyala, Sudan
| | - Jian Li
- College of Mechanical and Electrical Engineering, Department of Mechanical Engineering, Northeast Forestry University, Harbin, China
| | - Yanling Guo
- College of Mechanical and Electrical Engineering, Department of Mechanical Engineering, Northeast Forestry University, Harbin, China
| | - Tong Shuhui
- Department of Mechanical Engineering, Avic Harbin Aircraft Industry Group Co., LTD, Harbin, China
| | - Yangwei Wang
- College of Mechanical and Electrical Engineering, Department of Mechanical Engineering, Northeast Forestry University, Harbin, China
| | - Elkhawad A. Elfaki
- Mechanical Engineering Department, College of Engineering, The University of Bisha, Bisha, Saudi Arabia
- Department of Mechanical Engineering, College of Engineering, Sudan University of Science and Technology, Khartoum, Sudan
| | - Gafer A. Ahmed
- Department of Mechanical Engineering, College of Engineering, Sudan University of Science and Technology, Khartoum, Sudan
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Idriss AI, Li J, Guo Y, Wang Y, Elfaki EA, Ahmed EA. Improved Sintering Quality and Mechanical Properties of Peanut Husk Powder/Polyether Sulfone Composite for Selective Laser Sintering. 3D PRINTING AND ADDITIVE MANUFACTURING 2023; 10:111-123. [PMID: 36998798 PMCID: PMC10049862 DOI: 10.1089/3dp.2021.0036] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/19/2023]
Abstract
Current wood-plastic materials available for selective laser sintering (SLS) are limited and often suffer from low-quality and mechanical strength. In this study, a new composite of peanut husk powder (PHP)/polyether sulfone (PES) was developed for SLS additive manufacturing (AM). To use the biomass waste materials in AM technology, such as furniture and wood flooring, this composite based on agricultural waste is environmentally friendly, energy efficient, and low in production cost. SLS parts made from PHPC had good mechanical strength and excellent dimensional precision (DP). The thermal decomposition temperature of composite powder components and the glass transition temperatures of PES and various PHPC were determined first to prevent the PHPC parts from warping during sintering. Furthermore, the formability of PHPC powders in various mixing ratios was examined through single-layer sintering; and the density, mechanical strength, surface roughness, and DP of the sintered parts were measured. Particle distribution and microstructure of the powders and the SLS parts (both before and after breakage in mechanical tests) were inspected using scanning electron microscopy. According to the combined results, a ratio of PHP/PES = 10/90 (w/w) resulted in the best forming quality and mechanical strength compared with other ratios and pure PES. The measured density, impact strength, tensile strength, and bending strength for this PHPC are 1.1825 g/cm3, 2.12 kJ/cm2, 6.076 MPa, and 14.1 MPa, respectively. After wax infiltration, these parameters were further improved to 2.0625 g/cm3, 2.96 kJ/cm2, 7.476 MPa, and 15.7 MPa, respectively.
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Affiliation(s)
- Aboubaker I.B. Idriss
- College of Mechanical and Electrical Engineering, Department of Mechanical Engineering, Northeast Forestry University, Harbin, China
- Department of Mechanical Engineering, Faculty of Engineering Science, University of Nyala, Nyala, Sudan
| | - Jian Li
- College of Mechanical and Electrical Engineering, Department of Mechanical Engineering, Northeast Forestry University, Harbin, China
| | - Yanling Guo
- College of Mechanical and Electrical Engineering, Department of Mechanical Engineering, Northeast Forestry University, Harbin, China
| | - Yangwei Wang
- College of Mechanical and Electrical Engineering, Department of Mechanical Engineering, Northeast Forestry University, Harbin, China
| | - Elkhawad A. Elfaki
- Department of Mechanical Engineering, College of Engineering, The University of Bisha, Bisha, Saudi Arabia
- Department of Mechanical Engineering, College of Engineering, Sudan University of Science and Technology, Khartoum, Sudan
| | - Elhaj A.I. Ahmed
- Department of Mechanical Engineering, Faculty of Engineering Science, University of Nyala, Nyala, Sudan
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Czyżewski W, Jachimczyk J, Hoffman Z, Szymoniuk M, Litak J, Maciejewski M, Kura K, Rola R, Torres K. Low-Cost Cranioplasty—A Systematic Review of 3D Printing in Medicine. MATERIALS 2022; 15:ma15144731. [PMID: 35888198 PMCID: PMC9315853 DOI: 10.3390/ma15144731] [Citation(s) in RCA: 10] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/13/2022] [Revised: 06/20/2022] [Accepted: 07/02/2022] [Indexed: 11/22/2022]
Abstract
The high cost of biofabricated titanium mesh plates can make them out of reach for hospitals in low-income countries. To increase the availability of cranioplasty, the authors of this work investigated the production of polymer-based endoprostheses. Recently, cheap, popular desktop 3D printers have generated sufficient opportunities to provide patients with on-demand and on-site help. This study also examines the technologies of 3D printing, including SLM, SLS, FFF, DLP, and SLA. The authors focused their interest on the materials in fabrication, which include PLA, ABS, PET-G, PEEK, and PMMA. Three-dimensional printed prostheses are modeled using widely available CAD software with the help of patient-specific DICOM files. Even though the topic is insufficiently researched, it can be perceived as a relatively safe procedure with a minimal complication rate. There have also been some initial studies on the costs and legal regulations. Early case studies provide information on dozens of patients living with self-made prostheses and who are experiencing significant improvements in their quality of life. Budget 3D-printed endoprostheses are reliable and are reported to be significantly cheaper than the popular counterparts manufactured from polypropylene polyester.
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Affiliation(s)
- Wojciech Czyżewski
- Department of Didactics and Medical Simulation, Medical University of Lublin, 20-093 Lublin, Poland; (W.C.); (K.T.)
- Department of Neurosurgery and Pediatric Neurosurgery in Lublin, 20-090 Lublin, Poland; (J.L.); (K.K.); (R.R.)
| | - Jakub Jachimczyk
- Student Scientific Society, Medical University of Lublin, 20-059 Lublin, Poland;
| | - Zofia Hoffman
- Student Scientific Society, Medical University of Lublin, 20-059 Lublin, Poland;
- Correspondence:
| | - Michał Szymoniuk
- Student Scientific Association of Neurosurgery, Department of Neurosurgery and Pediatric Neurosurgery, Medical University of Lublin, 20-090 Lublin, Poland;
| | - Jakub Litak
- Department of Neurosurgery and Pediatric Neurosurgery in Lublin, 20-090 Lublin, Poland; (J.L.); (K.K.); (R.R.)
- Department of Clinical Immunology, Medical University of Lublin, 20-093 Lublin, Poland
| | - Marcin Maciejewski
- Department of Electronics and Information Technology, Faculty of Electrical Engineering and Computer Science, Lublin University of Technology, 20-618 Lublin, Poland;
| | - Krzysztof Kura
- Department of Neurosurgery and Pediatric Neurosurgery in Lublin, 20-090 Lublin, Poland; (J.L.); (K.K.); (R.R.)
| | - Radosław Rola
- Department of Neurosurgery and Pediatric Neurosurgery in Lublin, 20-090 Lublin, Poland; (J.L.); (K.K.); (R.R.)
| | - Kamil Torres
- Department of Didactics and Medical Simulation, Medical University of Lublin, 20-093 Lublin, Poland; (W.C.); (K.T.)
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