The Influence of the Gradient Infill of PLA Samples Produced with the FDM Technique on Their Mechanical Properties

Trimming flow, plasticity, and mechanical properties by cubic silsesquioxane chemistry

In this work, the possibility of managing the rheological and mechanical parameters of composites based on PLA with the use of cubic structures of organofunctional spherosilicates was verified. To accurately observe the effect of various organosilicon modifier substitutions on changes in composites' properties, we synthesized and used monofunctional octasubstituted derivatives as reference systems. The OSS/PLA systems were tested with concentrations of 0.1-2.5% (w/w) using extrusion to obtain a filament with a diameter of 1.75 mm. The printed samples underwent comprehensive tests including microscopic (SEM-EDS, optical microscope), rheological, thermal (TG, DSC, HDT), mechanical (impact and strength) as well as water contact angle tests. The work is interdisciplinary in nature and combines elements of organosilicon synthesis, materials engineering, and materials processing and characterization technology.

Extra-Articular Distal Humerus Plate 3D Model Creation by Using the Method of Anatomical Features

Proper fixation techniques are crucial in orthopedic surgery for the treatment of various medical conditions. Fractures of the distal humerus can occur due to either high-energy trauma with skin rupture or low-energy trauma in osteoporotic bone. The recommended surgical approach for treating these extra-articular distal humerus fractures involves performing an open reduction and internal fixation procedure using plate implants. This surgical intervention plays a crucial role in enhancing patient recovery and minimizing soft tissue complications. Dynamic Compression Plates (DCPs) and Locking Compression Plates (LCPs) are commonly used for bone fixation, with LCP extra-articular distal humerus plates being the preferred choice for extra-articular fractures. These fixation systems have anatomically shaped designs that provide angular stability to the bone. However, depending on the shape and position of the bone fracture, additional plate bending may be required during surgery. This can pose challenges such as increased surgery time and the risk of incorrect plate shaping. To enhance the accuracy of plate placement, the study introduces the Method of Anatomical Features (MAF) in conjunction with the Characteristic Product Features methodology (CPF). The utilization of the MAF enables the development of a parametric model for the contact surface between the plate and the humerus. This model is created using specialized Referential Geometrical Entities (RGEs), Constitutive Geometrical Entities (CGEs), and Regions of Interest (ROI) that are specific to the human humerus bone. By utilizing this anatomically tailored contact surface model, the standard plate model can be customized (bent) to precisely conform to the distinct shape of the patient's humerus bone during the pre-operative planning phase. Alternatively, the newly designed model can be fabricated using a specific manufacturing technology. This approach aims to improve geometrical accuracy of plate fixation, thus optimizing surgical outcomes and patient recovery.

On the Possibility of Using 3D Printed Polymer Models for Modal Tests on Shaking Tables: Linking Material Properties Investigations, Field Experiments, Shaking Table Tests, and FEM Modeling

In this article, the possibility and the pertinence of using 3D printed polymeric materials for models in modal tests on shaking tables were recognized. Four stages of the research have been linked: The material properties investigation, the field experiment on the modal properties of the reinforced concrete chimney (a prototype), the shaking table tests on the modal properties of the 3D printed polymer model of the chimney, scaled according to the similarity criteria, and the numerical calculations of the FE model of the 3D printed mockup. First, the investigation of the properties of 3D printed polymer materials revealed that the direction of lamination had no significant effect on the modulus of elasticity of the material. This is a great benefit, especially when printing models of tall structures, such as chimneys, which for technical reasons could only be printed in a spiral manner with the horizontal direction of lamination. The investigation also proved that the yield strength depended on the direction of the lamination of the specimens. Next, the natural frequencies of the chimney, assessed through the field experiment and the shaking table tests were compared and showed good compatibility. This is a substantial argument demonstrating the pertinence of using 3D printed polymer materials to create models for shaking table tests. Finally, the finite element model of the 3D printed polymer mockup was completed. Modal properties obtained numerically and obtained from the shaking table test also indicated good agreement. The presented study may be supportive in answering the question of whether traditional models (made of the same material as prototypes) used in shaking table tests are still the best solution, or whether innovative 3D printed polymer models can be a better choice, in regard to the assessment of the modal properties and the dynamic performance of structures.

Effects of Infill Density, Wall Perimeter and Layer Height in Fabricating 3D Printing Products

Three-dimensional printing is widely used in many fields, including engineering, architecture and even medical purposes. The focus of the study is to obtain the ideal weight-to-performance ratio for making a 3D-printed part. The end products of the 3D-printed part are hugely affected by not only the material but also the printing parameters. The printing parameters to be highlighted for this study are the infill density, wall perimeter and layer height, which are the commonly adjusted parameters in 3D printing. The study will be divided into two parts, the simulation analysis and the experimental analysis, to confirm both results toward the trend of Young's modulus for the material. It will then be analyzed and discussed toward any differences between the two results. The results showed that increasing the value of all three parameters will increase the tensile elasticity of the part.

On the Behavior of Honeycomb, Grid and Triangular PLA Structures under Symmetric and Asymmetric Bending

Additive manufacturing technologies enable the production of components with lightweight cores, by means of infills with various patterns and densities. Together with reduced mass and material consumption, infill geometries must ensure that strength and stiffness conditions are fulfilled. For the proper correlation of the infill type with the loading case of the part, the mechanical behavior of the infill along all three principal axes of inertia has to be known. In this paper, the behavior in symmetric and asymmetric bending of three infill geometries, commonly used in 3D printing processes (honeycomb, grid and triangles) is analyzed. The variations of deflections as a function of force orientation are presented, showing that honeycomb and triangular structures exhibit similar behaviors along the Y and Z principal axes of inertia. Furthermore, the displacements obtained for the three types of structures are compared, in relation to the consumed volume of material. The larger displacements of the grid structure compared to the honeycomb and triangular structures are highlighted.

Effect of an Adaptive-Density Filling Structure on the Mechanical Properties of FDM Parts with a Variable Cross-Section

Fused deposition modeling (FDM) technique is one of the most popular additive manufacturing techniques. Infill density is a critical factor influencing the mechanical properties of 3D-printed components using the FDM technique. For irregular components with variable cross-sections, to increase their overall mechanical properties while maintaining a lightweight, it is necessary to enhance the local infill density of the thin part while decreasing the infill density of the thick part. However, most current slicing software can only generate a uniform infill throughout one model to be printed and cannot adaptively create a filling structure with a varying infill density according to the dimensional variation of the cross-section. In the present study, to improve the mechanical properties of irregular components with variable cross-sections, an adaptive-density filling structure was proposed, in which Hilbert curve with the same order was used to fill each slice, i.e., the level of the Hilbert curves in each slice is the same, but the side length of the Hilbert curve decreases with the decreasing size of each slice; hence, the infill density of the smaller cross-section is greater than that of the larger cross-section. The ultimate bearing capacity of printed specimens with the adaptive-density filling structure was evaluated by quasi-static compression, three-point bending, and dynamic compression tests, and the printed specimens with uniform filling structure and the same overall infill density were tested for comparison. The results show that the maximum flexural load, the ultimate compression load, and the maximum impact resistance of the printed specimens with the adaptive-density filling structure were increased by 140%, 47%, and 82%, respectively, compared with their counterparts using the uniform filling structure.

Evaluation of Relative Permittivity and Loss Factor of 3D Printing Materials for Use in RF Electronic Applications

3D printing is more and more often used for the development and manufacturing of electronic devices and components. These applications require knowledge about the dielectric properties of the used materials—in particular minimal and stable values of relative permittivity and dielectric losses. The paper deals with the testing of the relative permittivity and loss factor of materials as follows: PLA (in three dye modifications), PET-G, and ABS and ASA in the frequency range 1–100 MHz. It was found that relative permittivity varied between 2.88–3.48 and the loss factor was in the range 0.03–4.31%. In terms of relative permittivity, all tested materials manifested a slight decline with increasing frequency. Concerning loss factor PLA (colorless) and ABS were proven to be more suitable for electrotechnical application due to the lower values and frequency dependences of the loss factor. Different results were observed in PLA-Silver and PLA-Metallic green. These materials showed a higher frequency dependency of loss factor with increasing frequency. The reasonable influence of added dyes was found. A study of the internal structure of the tested materials has not proven any significant defects (air gaps) that could affect the material’s dielectric properties.

Infill Density Influence on Mechanical and Thermal Properties of Short Carbon Fiber-Reinforced Polyamide Composites Manufactured by FFF Process

In three-dimensional (3D) printing, one of the main parameters influencing the properties of 3D-printed materials is the infill density (ID). This paper presents the influence of ID on the microstructure, mechanical, and thermal properties of carbon fiber-reinforced composites, commercially available, manufactured by the Fused Filament Fabrication (FFF) process. The samples were manufactured using FFF by varying the infill density (25%, 50%, 75%, and 100%) and were subjected to tensile tests, three-point bending, and thermal analyses by Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). It was shown that the samples with 100% ID had the highest values of both tensile, 90.8 MPa, and flexural strengths, 114 MPa, while those with 25% ID had the lowest values of 56.4 MPa and 62.2 MPa, respectively. For samples with infill densities of 25% and 50%, the differences between the maximum tensile and flexural strengths were small; therefore, if the operating conditions of the components allow, a 25% infill density could be used instead of 50%. After DSC analysis, it was found that the variation in the ID percentage determined the change in the glass transition temperature from 49.6 °C, for the samples with 25% ID, to 32.9 °C, for those with 100% ID. TGA results showed that the samples with IDs of 75% and 100% recorded lower temperatures of onset degradation (approximately 344.75 °C) than those with infill densities of 25% and 50% (348.5 °C, and 349.6 °C, respectively).