Browsing by Subject "3D Printing"

Now showing 1 - 10 of 12
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    Cellulose Nano Fibers Infused Polylactic Acid Using the Process of Twin Screw Melt Extrusion for 3d Printing Applications
    (2023-05) Bhaganagar, Siddharth; Dalir, Hamid; Agarwal, Mangilal; Zhang, Jing
    In this thesis, cellulose nanofiber (CNF) reinforced polylactic acid (PLA) filaments were produced for 3D printing applications using melt extrusion. The use of CNF reinforcement has the potential to improve the mechanical properties of PLA, making it a more suitable material for various 3D printing applications. To produce the nanocomposites, a master batch with a high concentration of CNFs was premixed with PLA, and then diluted to final concentrations of 1, 3, and 5 wt% during the extrusion process. The dilution was carried out to assess the effects of varying CNF concentrations on the morphology and mechanical properties of the composites. The results showed that the addition of 3 wt.% CNF significantly enhanced the mechanical properties of the PLA composites. Specifically, the tensile strength increased by 77.7%, the compressive strength increased by 62.7%, and the flexural strength increased by 60.2%. These findings demonstrate that the melt extrusion of CNF reinforced PLA filaments is a viable approach for producing nanocomposites with improved mechanical properties for 3D printing applications. In conclusion, the study highlights the potential of CNF reinforcement in improving the mechanical properties of PLA for 3D printing applications. The results can provide valuable information for researchers and industries in the field of 3D printing and materials science, as well as support the development of more advanced and sustainable 3D printing materials.
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    Characterization and Simulated Analysis of Carbon Fiber with Nanomaterials and Additive Manufacturing
    (2023-12) Omole, Oluwaseun; Dalir, Hamid; Agarwal, Magilal; Tovar, Andres
    Due to the vast increase and versatility of Additive Manufacturing and 3D-printing, in this study, the mechanical behavior of implementing both continuous and short carbon fiber within Nylon and investigated for its effectiveness within additively manufactured prints. Here, 0.1wt% of pure nylon was combined with carbon nanotubes through both dry and heat mixing to determine the best method and used to create printable filaments. Compression, tensile and short beam shear (SBS) samples were created and tested to determine maximum deformation and were simulated using ANSYS and its ACP Pre tool. SEM imaging was used to analyze CNT integration within the nylon filament, as well as the fractography of tested samples. Experimental testing shows that compressive strength increased by 28%, and the average SBS samples increased by 8% with minimal impacts on the tensile strength. The simulated results for Nylon/CF tensile samples were compared to experimental results and showed that lower amounts of carbon fiber samples tend to have lower errors.
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    Design of Self-supported 3D Printed Parts for Fused Deposition Modeling
    (2016) Lischke, Fabian; Tovar, Andres; Anwar, Sohel; Jones, Alan S.
    One of the primary challenges faced in Additive Manufacturing (AM) is reducing the overall cost and printing time. A critical factor in cost and time reduction is post-processing of 3D printed (3DP) parts, which includes removing support structures. Support is needed to prevent the collapse of the part or certain areas under its own weight during the 3D printing process. Currently, the design of self-supported 3DP parts follows experimental trials. A trial and error process is needed to produce high quality parts by Fused Depositing Modeling (FDM). An example for a chamfer angle, is the common use of 45 degree angle in the AM process. Surfaces that are more flat show defects than inclined surfaces, and therefore a numerical model is needed. The model can predict the problematic areas at a print, reducing the experimental prints and providing a higher number of usable parts. Physical-based models have not been established due to the generally unknown properties of the material during the AM process. With simulations it is possible to simulate the part at different temperatures with a variety of other parameters that have influence on the behavior of the model. In this research, analytic calculations and physical tests are carried out to determine the material properties of the thermoplastic polymer Acrylonitrile - Butadiene - Styrene (ABS) for FDM at the time of extrusion. This means that the ABS is going to be extruded at 200C to 245C and is a viscus material during part construction. Using the results from the physical and analytical models, i.e., Timoshenko’s modified beam theory for micro structures, a numerical material model is established to simulate the filament deformation once it is deposited onto the part. Experiments were also used to find the threshold for different geometric specifications, which could then be applied to the numerical model to improve the accuracy of the simulation. The result of the nonlinear finite element analysis is compared to experiments to show the correlation between the prediction of deflection in simulation and the actual deflection measured in physical experiments. A case study was conducted using an application that optimizes topology of complex geometries. After modeling and simulating the optimized part, areas of defect and errors were determined in the simulation, then verified and and measured with actual 3D prints.
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    Development of a Mechatronics Instrument Assisted Soft Tissue Mobilization (IASTM) Device to Quantify Force and Orientation Angles
    (2016-05) Alotaibi, Ahmed Mohammed; Anwar, Sohel; Loghmani, Mary T.; Chien, Stanley Yung-Ping
    Instrument assisted soft tissue mobilization (IASTM) is a form of massage using rigid manufactured or cast devices. The delivered force, which is a critical parameter in massage during IASTM, has not been measured or standardized for most clinical practices. In addition to the force, the angle of treatment and frequency play an important role during IASTM. As a result, there is a strong need to characterize the delivered force to a patient, angle of treatment, and stroke frequency. This thesis proposes two novel mechatronic designs for a specific instrument from Graston Technique(Model GT3), which is a frequently used tool to clinically deliver localize pressure to the soft tissue. The first design is based on compression load cells, where 4-load cells are used to measure the force components in three-dimensional space. The second design uses a 3D load cell, which can measure all three force components force simultaneously. Both designs are implemented with IMUduino microcontroller chips which can also measure tool orientation angles and provide computed stroke frequency. Both designs, which were created using Creo CAD platform, were also analyzed thorough strength and integrity using the finite element analysis package ANSYS. Once the static analysis was completed, a dynamic model was created for the first design to simulate IASTM practice using the GT-3 tool. The deformation and stress on skin were measured after applying force with the GT-3 tool. Additionally, the relationship between skin stress and the load cell measurements has been investigated. The second design of the mechatronic IASTM tool was validated for force measurements using an electronic plate scale that provided the baseline force values to compare with the applied force values measured by the tool. The load cell measurements and the scale readings were found to be in agreement within the expected degree of accuracy. The stroke frequency was computed using the force data and determining the peaks during force application. The orientation angles were obtained from the built-in sensors in the microchip.
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    Experimental and Modeling Study of Gas Adsorption in Metal-Organic Framework Coated on 3D Printed Plastics
    (2020-05) Dube, Tejesh C.; Zhang, Jing; Tovar, Andres; Wei, Xiaoliang
    Metal-organic frameworks (MOFs) are a class of compounds consisting of metal ions or clusters coordinated to organic ligands in porous structure forms. MOFs have been proposed in use for gas adsorption, purification, and separation applications. This work combines MOFs with 3D printing technologies, in which 3D printed plastics serve as a mechanical structural support for MOFs powder, in order to realize a component design for gas adsorption. The objective of the thesis is to understand the gas adsorption behavior of MIL-101 (Cr) MOF coated on 3D printed PETG, a glycol modified version of polyethylene terephthalate, through a combined experimental and modeling study. The specific goals are: (1) synthesis of MIL-101 (Cr) MOFs; (2) nitrogen gas adsorption measurements and microstructure and phase characterization of the MOFs; (3) design and 3D printing of porous PETG substrate structures; (4) deposition of MOFs coating on the PETG substrates; and (5) Monte Carlo (MC) modeling of sorption isotherms of nitrogen and carbon dioxide in the MOFs. The results show that pure MIL-101 (Cr) MOFs were successfully synthesized, as confirmed by the scanning electron microscopy (SEM) images and X-ray diffraction (XRD), which are consistent with literature data. The Brunauer-Emmett-Teller (BET) surface area measurement shows that the MOFs samples have a high cover- age of nitrogen. The specific surface area of a typical MIL-101 (Cr) MOFs sample is 2716.83 m2/g. MIL-101 (Cr) also shows good uptake at low pressures in experimental tests for nitrogen adsorption. For the PETG substrate, disk-shape plastic samples with a controlled pore morphology were designed and fabricated using the fused deposition modeling (FDM) process. MOFs were coated on the PETG substrates using a layer-by-layer (LbL) assembly approach, up to 30 layers. The MOFs coating layer thicknesses increase with the number of deposition layers. The computational model illustrates that the MOFs show increased outputs in adsorption of nitrogen as pressure increases, similar to the trend observed in the adsorption experiment. The model also shows promising results for carbon dioxide uptake at low pressures, and hence the developed MOFs based components would serve as a viable candidate in gas adsorption applications.
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    Extrusion Based Ceramic 3D Printing - Printer Development, Part Characterization, and Model-Based Systems Engineering Analysis
    (2020-12) Pai Raikar, Piyush Shrihari; Zhang, Jing; Agarwal, Mangilal; Anasori, Babak
    Ceramics have been extensively used in aerospace, automotive, medical, and energy industries due to their unique combination of mechanical, thermal, and chemical properties. The objective of this thesis is to develop an extrusion based ceramic 3D printing process to digitally produce a casting mold. To achieve the objective, an in-house designed ceramic 3D printer was developed by converting a filament based plastic 3D printer. For mold making applications, zircon was selected because it is an ultra-high temperature ceramic with high toughness and good refractory properties. Additionally, alumina, bioglass, and zirconia slurries were formulated and used as the feedstock material for the ceramic 3D printer. The developed 3D printing system was used to demonstrate successful printing of special feature parts such as thin-walled high aspect ratio structures and biomimetically inspired complex structures. Also, proof of concept with regard to the application of 3D printing for producing zircon molds and casting of metal parts was also successfully demonstrated. To characterize the printed parts, microhardness test, scanning electron microscopy (SEM), and X-ray diffraction (XRD) analyses were conducted. The zircon samples showed an increase in hardness value with an initial increase in heat treatment temperature followed by a drop due to the development of porosity in the microstructure, caused by the decomposition of the binder. The peak hardness value for zircon was observed to be 101±10 HV0.2. Similarly, the microhardness values of the other 3D printed ceramic specimens were observed to increase from 37±3 to 112±5 HV0.2 for alumina, 23±5 to 35±1 HV0.2 for bioglass, and 22±5 to 31±3 HV0.2 for zirconia, before and after the heat-treatment process, respectively. Finally, a system model for the ceramic 3D printing system was developed through the application of the model-based systems engineering (MBSE) approach using the MagicGrid framework. Through the system engineering effort, a logical level solution architecture was modeled, which captured the different system requirements, the system behaviors, and the system functionalities. Also, a traceability matrix for the system from a very abstract logical level to the definition of physical requirements for the subsystems was demonstrated.
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    Fabrication and Characterization of Lithium-ion Battery Electrode Filaments Used for Fused Deposition Modeling 3D Printing
    (2022-08) Kindomba, Eli; Zhang, Jing; Zhu, Likun; Schubert, Peter
    Lithium-Ion Batteries (Li-ion batteries or LIBs) have been extensively used in a wide variety of industrial applications and consumer electronics. Additive Manufacturing (AM) or 3D printing (3DP) techniques have evolved to allow the fabrication of complex structures of various compositions in a wide range of applications. The objective of the thesis is to investigate the application of 3DP to fabricate a LIB, using a modified process from the literature [1]. The ultimate goal is to improve the electrochemical performances of LIBs while maintaining design flexibility with a 3D printed 3D architecture. In this research, both the cathode and anode in the form of specifically formulated slurry were extruded into filaments using a high-temperature pellet-based extruder. Specifically, filament composites made of graphite and Polylactic Acid (PLA) were fabricated and tested to produce anodes. Investigations on two other types of PLA-based filament composites respectively made of Lithium Manganese Oxide (LMO) and Lithium Nickel Manganese Cobalt Oxide (NMC) were also conducted to produce cathodes. Several filaments with various materials ratios were formulated in order to optimize printability and battery capacities. Finally, flat battery electrode disks similar to conventional electrodes were fabricated using the fused deposition modeling (FDM) process and assembled in half-cells and full cells. Finally, the electrochemical properties of half cells and full cells were characterized. Additionally, in parallel to the experiment, a 1-D finite element (FE) model was developed to understand the electrochemical performance of the anode half-cells made of graphite. Moreover, a simplified machine learning (ML) model through the Gaussian Process Regression was used to predict the voltage of a certain half-cell based on input parameters such as charge and discharge capacity. The results of this research showed that 3D printing technology is capable to fabricate LIBs. For the 3D printed LIB, cells have improved electrochemical properties by increasing the material content of active materials (i.e., graphite, LMO, and NMC) within the PLA matrix, along with incorporating a plasticizer material. The FE model of graphite anode showed a similar trend of discharge curve as the experiment. Finally, the ML model demonstrated a reasonably good prediction of charge and discharge voltages.
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    Incisal Endodontics Access vs Traditional Palatal Access to Negotiate Simulated Obliterated Canals Using Guided Endodontic Techniques
    (2022-06) Gohil, Arjun A.; Spolnik, Kenneth J.; Dutra, Vinicius; Ehrlich, Ygal; Warner, Ned
    Introduction: Endodontic treatment in teeth with pulp canal obliteration (PCO) is challenging. Guided Endodontic Access (GEA) combines information from a cone-beam computed tomography (CBCT) scan with an intra-oral scan to create a stent that can be used as a guide to treat teeth with PCO. GEA stents designed with traditional palatal accesses were shown to be successful in accurately negotiating these 3D printed teeth with simulated PCO, however, the difference in accuracy between the traditional palatal access compared to a conservative incisal access is not yet known. Objective: This in vitro study compares GEA stents designed with an incisal access approach to GEA stents designed with a traditional palatal access approach. The effect on the overall degree of deviation of the designed access path from the prepared path is evaluated by measuring the degree of angle of deviation and amount of deviation in millimeters. Materials and Methods: A 3-D printed maxillary model of an anonymous patient was used. PCO was simulated in a 3D printed natural #8 using the coDiagnostiX software tooth at two levels: coronal and mid-root. A GEA stent that extended from tooth #3 to tooth #14 with a guide sleeve over the simulated tooth #8 was accessed with a dedicated 1.0 mm diameter and 20 mm length drill that is designed to fit the access sleeve. 15 GEA stents had guides utilized for the incisal access approach, and 15 GEA stents had guides utilized for the traditional palatal access approach. Results: Angle, mesio-distal (base), and mesio-distal (tip) deviations were significantly lower for the incisal access compared to the traditional access. Inciso-apical (base) deviation was significantly more negative for incisal access compared to the traditional access. Bucco-lingual (base) deviation was significantly more negative for traditional access compared to the incisal access, while incisal and traditional accesses were not significantly different for bucco-lingual (tip) deviation. Coronal 1/3 calcification groups had significantly more mesio-distal (base) deviation than the middle 1/3 and no PCO groups. The no PCO group had significantly more negative inciso--apical (base) deviation than the coronal 1/3 calcification and middle 1/3 calcification groups, and the coronal 1/3 calcification group was significantly more negative than the middle 1/3 calcification group. The coronal 1/3 calcification group had significantly more mesio-distal (tip) deviation than the no PCO group. PCO level did not have a significant effect on angle, bucco-lingual (base), or bucco-lingual (tip) deviations. Conclusion: The utilization GEA via incisal access resulted in less degree and amount of drill deviation compared to the traditional access at all levels of calcification, however, the level of PCO did not influence the degree and amount of drill deviation between the incisal and traditional access approaches. It can be concluded that the use of a GEA stent that utilizes an incisal access approach in teeth with PCO will result in a more predictable outcome.
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    Slurry preparation of zeolite and metal - organic framework for extrusion based 3D – printing
    (2018-05) Hawaldar, Nishant Hemant; Jing, Zhang
    Extrusion-based 3D printing is one of the emerging additive manufacturing technologies used for printing a range of materials from metal to ceramics. In this process, the required material is extruded from the extruder in the form of a slurry. Zeolite and MOFs are mainly used for CO2 adsorption in the form of pellets and beads due to their good adsorptive property. Researchers are developing monoliths of Zeolite and MOFs and fabricate them using traditional extrusion and implement them in the gas adsorption applications as an option for beads and pellets by developing a monolithic structure. Previous research on Zeolite 13X and 5A have shown good structural and physical properties in monolith form. In this study, we developed slurry of two molecular sieve Zeolite 3A and 4A monoliths powders, mixing it with bentonite clay, methyl cellulose, and PVA as a binder. The slurry preparation was carried out at room temperature. Once the 3D printed samples are dried at room temperature, a sintering process was performed to increase mechanical strength. To be used in real-time applications, the 3D printed Zeolite sample need to have sufficient mechanical strength. The BET surface area test showed good results for Zeolite 13X compared to available literature. The surface area calculated for 3D printed Zeolite 13X was 767m2/g and available literature showed 498 m2/g for 3D printed Zeolite 13X. The microhardness values of 3D printed Zeolite samples were measured using a Vicker hardness tester. The hardness value of the 3D - printed Zeolite samples increased from 8.3 ± 2 to 12.5 ± 3 HV0.05 for Zeolite 13X, 3.3 ± 1 to 7.3 ± 1 HV0.05 for Zeolite 3A, 4.3 ± 2 to 7.5 ± 2 HV0.05 for Zeolite 4A, 7.4 ± 1 to 14.0 ± 0.5 HV0.05 for Zeolite 5A respectively. The SEM, EDS and XRD analysis was performed for 3D printed samples before and after sintering to evaluate their structural properties. The SEM analysis reveals that all 3D printed Zeolite samples retained their microstructure after slurry preparation and also after the sintering process. The porous nature of 3D printed Zeolite walls was retained after the sintering process. The EDS analysis showed that the composition of 3D printed Zeolite samples remained somewhat similar with minor variation for before and after sintering. The framework structure of Zeolite Type X for Zeolite 13X and Zeolite Type A for Zeolite 3A, 4A, 5A were in good shape after sintering as standard peak intensity points were retained. Zn-MOF74 was synthesized using solvothermal synthesis which is a well-established synthesis process used for the synthesis of MOFs. We also developed slurry for Zn-MOF-74 using bentonite clay and PVA as binders and printed small parts using hand printing.
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    A study on the material characterization and finite element analysis of digital materials and their applications
    (2017-12) Lopez, Eduardo Salcedo; Ryu, Jong E.; Tovar, Andres; Wagner, Diane
    Material jetting (MJ) additive manufacturing (AM) has experienced an increased adoption in several industry areas and as well as research applications. One of MJ’s distinct benefits is the ability to print tunable composites, digital materials (DM) by carefully adjusting the ratio of droplets of heterogeneous base-polymeric inks. However, the lack of material information usable in computer simulations has hampered its acceptance in some end-use applications. For these materials to be used in Finite Element Analysis (FEA) simulations the mechanical properties of the DMs need to be characterized into usable material models. DMs printable with an MJ printer has a wide variety of materials properties, ranging from flexible silicone rubber to rigid Acrylonitrile Butadiene Styrene (ABS). Therefore, to cohesively express the mechanical behavior of the DMs it is necessary to utilize non-linear material models. The objective this research is to conduct physical testing to characterize the mechanical behavior of DMs printable with an MJ. Subsequently, to validate the effectiveness of the material models for multi-DM prints. Utilizing the newly characterized material models two use cases were investigated, with the goal of improving the performance of printed parts through simulation. In this study, an MJ printer was used to fabricate the test specimens as well as the components used in the use case studies. The study was focused on the family of six DMs printable from the mixture of the base polymers Tango Black+ (TB+) and Vero White+ (VW+). To characterize the mechanical properties of the materials a tensile test was conducted utilizing the KS-M6518 standard as a basis. The mechanical properties of the DMs were then fitted into four non-linear models and the results compared. The fitted models were, the Neo Hookean model, a two-parameter, three-parameter, and a five-parameter Mooney Rivlin model. To confidently use the material models for multi-DM prints FEA simulations need to validate the accuracy to which they can predict the deformation of the samples under load. To compare the results of the computer simulations and the physical test, strain maps for both results were analyzed. Four different test specimens were printed and tested. A baseline single material samples were compared to three multi-material samples with different embedded structures. The results confirmed the validity of the material models even when used for multi-DM prints. The recently characterized models are utilized in two use case studies which showcase the potential of DMs. The first use case was focused on printing multi-DM substrates for the use of stretchable electronics. The second use case investigated the benefits of utilizing multiple materials to create 3D conductive traces utilizing a new method, the “swollen-off” method. Both case studies showed the benefits of utilizing DMs as well as the applicability of the material models in predictive simulations.