Embedding ultra-high-molecular-weight polyethylene fibers in 3D-printed Polylactic Acid (PLA) parts

This study aims to assess whether ultra-high-molecular-weight polyethylene (UHMWPE) fibers can be successfully embedded in a polylactic acid (PLA) matrix in a material extrusion 3D printing (ME3DP) process, despite the apparent thermal incompatibility between the two materials. The work started with assessing the maximum PLA extrusion temperatures at which UHMWPE fibers withstand the 3D printing process without melting or severe degradation. After testing various fiber orientations and extrusion temperatures, it has been found that the maximum extrusion temperature depends on fiber orientation relative to extrusion pathing and varies between 175 C and 185 C at an ambient temperature of 25 C. Multiple specimens with embedded strands of UHMWPE fibers have been 3D printed and following tensile strength tests on the fabricated specimens, it has been found that adding even a small number of fiber strands laid in the same direction as the load increased tensile strength by 12% to 23% depending on the raster angle, even when taking into account the decrease in tensile strength due to reduced performance of the PLA substrate caused by lower extrusion temperatures.EEA Grants/Norway GrantsPeer reviewe

Adaptive robotic end-effector with embedded 3D-printed sensing Circuits

The paper presents the development and testing of an adaptive robotic end-effector used for manipulation of sensitive objects such as fruits and vegetables. The end-effector uses Fin-Ray-structured 3D-printed fingers with embedded conductive 3D-printed sensing circuits, which give the end-effector capacitive touch sensing and bend sensing capabilities. The conductive 3D-printed circuit is connected to a control circuit consisting of a low-current DC power source and a microcontroller. As the end-effector finger is subjected to various forces and other external stimuli, changes in the electric signals that run through the conductive circuit of the end-effector finger are detected by the microcontroller. The electric signal is processed in order to provide real-time information about contact detection, finger position or gripping force. This information was used for process monitoring purposes and as feedback for the end-effector actuator

3D-Printed shoe last for bespoke shoe manufacturing

This paper presents a new approach for the production of bespoke shoe lasts used in shoe industry. It is based on measuring key geometric features of existing shoe lasts and establishing a parametric system which can then be used to create a 3D model of a customized fit shoe last. Thus, instead of 3D-scanning the foot and then doing time consuming and skill intensive point cloud data processing, the proposed solution requires only taking several measurements of the customer’s foot and inputting them into the parametric model to obtain the tailored shoe last 3D geometry. Furthermore, the internal geometry of this shoe last is topologically optimized to reduce material volume and 3D printing time, while still withstanding temperatures and loads specific to the shoe manufacturing process. The 3D model also includes geometrical features allowing the attaching of process-specific mounting hardware. Material Extrusion 3D Printing (ME3DP) was used to fabricate the shoe last from thermoplastic material. 3D-printed shoe lasts were tested in a real manufacturing setting, successfully producing bespoke canvas shoes with rubber soles. During testing, the shoe lasts were subjected to typical process loads and to high temperatures

Paste Extruder—Hardware Add-On for Desktop 3D Printers

This paper presents the design, development and testing of a paste/clay extrusion device intended to be used as a drop-in replacement for the conventional thermoplastic extruder of a desktop filament-based 3D printer. A plastic cylinder loaded with gel, paste or clay material is placed into the device. Feedstock is pressed through an extrusion nozzle by a piston driven by an electrically actuated drive-screw and nut mechanism. The device allows the build material to heat up to 80 °C. Forced air cooling is used to assist the cooling or hardening process of the freshly-printed material during fabrication. The feedstock container, nozzle, and material-loading process are all suitable for use in a sterile environment. The device is designed for seamless integration with existing 3D printing firmware and slicing software. After designing the device, a prototype was produced and installed on a 3D printer. Silicone and acrylic polymers, as well as dental gel, were used to fabricate 3D printed sample objects

Augmented reality application for training in pipe defects ultrasonic investigation

The paper presents the development process of an Augmented Reality (AR) application used for training operators in using ultrasonic equipment for non-destructive testing (NDT) of pipework. The application provides workers useful information regarding the process steps, the main components of ultrasonic equipment and the proper modality of placing, aligning and moving it on pipe and weld. Using tablet or mobile phone device, an operator can see on screen written details and images on standardized working method, thus offering assistance during the training process. Allowing 3D augmented visualization of ultrasonic equipment overlaid on the real-world environment consisting in pipes and welds, the AR application makes the NDT process easier to understand and learn, as the initial evaluation results showed

Mechanical properties of 3D printed composites with ABS/ASA substrate and glass fiber inserts

3D printed specimens (ASTM D638 Type I) were manufactured from ABS and ASA material via additive manufacturing through material extrusion 3D printing (ME3DP). During manufacturing, the printing process has been paused, pre-impregnated biaxial or uniaxial glass fiber mesh has been placed onto the ABS/ASA substrate and then the printing process has been resumed. The obtained composite specimens have been subjected to tensile strength testing and results have been compared to those of specimens printed from homogenous material. The influence of raster angle, glass fiber direction and mesh density on resulting toughness has also been analyzed. It was found that inserting uniaxial glass fiber increases toughness of specimens in the axial direction, with a drop in layer adhesion if biaxial fiber is used. Test specimens manufactured with 30 uniaxial fiber strands embedded in a 0o raster angle 3D printed thermoplastic matrix match mechanical characteristics of injection-molded parts. The maximum mesh density without leading to delamination is one layer of glass fiber every two layers of thermoplastic matrix

Magnesium Filled Polylactic Acid (PLA) Material for Filament Based 3D Printing

The main objective of this research is to prove the viability of obtaining magnesium (Mg) filled polylactic acid (PLA) biocomposites as filament feedstock for material extrusion-based additive manufacturing (AM). These materials can be used for medical applications, thus benefiting of all the advantages offered by AM technology in terms of design freedom and product customization. Filaments were produced from two PLA + magnesium + vitamin E (α-tocopherol) compositions and then used for manufacturing test samples and ACL (anterior cruciate ligament) screws on a low-cost 3D printer. Filaments and implant screws were characterized using SEM (scanning electron microscopy), FTIR (fourier transform infrared spectrometry), and DSC (differential scanning calorimetry) analysis. Although the filament manufacturing process could not ensure a uniform distribution of Mg particles within the PLA matrix, a good integration was noticed, probably due to the use of vitamin E as a precursor. The results also show that the composite biomaterials can ensure and maintain implant screws structural integrity during the additive manufacturing process

Enhancing Mechanical Properties of Polymer 3D Printed Parts

Parts made from thermoplastic polymers fabricated through 3D printing have reduced mechanical properties compared to those fabricated through injection molding. This paper analyzes a post-processing heat treatment aimed at enhancing mechanical properties of 3D printed parts, in order to reduce the difference mentioned above and thus increase their applicability in functional applications. Polyethylene Terephthalate Glycol (PETG) polymer is used to 3D print test parts with 100% infill. After printing, samples are packed in sodium chloride powder and then heat treated at a temperature of 220 °C for 5 to 15 min. During heat treatment, the powder acts as support, preventing deformation of the parts. Results of destructive testing experiments show a significant increase in tensile and compressive strength following heat treatment. Treated parts 3D printed in vertical orientation, usually the weakest, display 143% higher tensile strength compared to a control group, surpassing the tensile strength of untreated parts printed in horizontal orientation—usually the strongest. Furthermore, compressive strength increases by 50% following heat treatment compared to control group. SEM analysis reveals improved internal structure after heat treatment. These results show that the investigated heat treatment increases mechanical characteristics of 3D printed PETG parts, without the downside of severe part deformation, thus reducing the performance gap between 3D printing and injection molding when using common polymers

Aging of 3D Printed Polymers under Sterilizing UV-C Radiation

In the context of the COVID-19 pandemic, shortwave ultraviolet radiation with wavelengths between 200 nm and 280 nm (UV-C) is seeing increased usage in the sterilization of medical equipment, appliances, and spaces due to its antimicrobial effect. During the first weeks of the pandemic, healthcare facilities experienced a shortage of personal protective equipment. This led to hospital technicians, private companies, and even members of the public to resort to 3D printing in order to produce fast, on-demand resources. This paper analyzes the effect of accelerated aging through prolonged exposure to UV-C on mechanical properties of parts 3D printed by material extrusion (MEX) from common polymers, such as polylactic acid (PLA) and polyethylene terephthalate-glycol (PETG). Samples 3D printed from these materials went through a 24-h UV-C exposure aging cycle and were then tested versus a control group for changes in mechanical properties. Both tensile and compressive strength were determined, as well as changes in material creep properties. Prolonged UV-C exposure reduced the mechanical properties of PLA by 6–8% and of PETG by over 30%. These findings are of practical importance for those interested in producing functional MEX parts intended to be sterilized using UV-C. Scanning electron microscopy (SEM) was performed in order to assess any changes in material structure

Accelerated Aging Effect on Mechanical Properties of Common 3D-Printing Polymers

In outdoor environments, the action of the Sun through its ultraviolet radiation has a degrading effect on most materials, with polymers being among those affected. In the past few years, 3D printing has seen an increased usage in fabricating parts for functional applications, including parts destined for outdoor use. This paper analyzes the effect of accelerated aging through prolonged exposure to UV-B on the mechanical properties of parts 3D printed from the commonly used polymers polylactic acid (PLA) and polyethylene terephthalate–glycol (PETG). Samples 3D printed from these materials went through a dry 24 h UV-B exposure aging treatment and were then tested against a control group for changes in mechanical properties. Both the tensile and compressive strengths were determined, as well as changes in material creep characteristics. After irradiation, PLA and PETG parts saw significant decreases in both tensile strength (PLA: −5.3%; PETG: −36%) and compression strength (PLA: −6.3%; PETG: −38.3%). Part stiffness did not change significantly following the UV-B exposure and creep behavior was closely connected to the decrease in mechanical properties. A scanning electron microscopy (SEM) fractographic analysis was carried out to better understand the failure mechanism and material structural changes in tensile loaded, accelerated aged parts