Shape complexity and process energy consumption in electron beam melting: a case of something for nothing in additive manufacturing?

Additive manufacturing (AM) technology is capable of building up component geometry in a layer-by-layer process, entirely without tools, molds, or dies. One advantage of the approach is that it is capable of efficiently creating complex product geometry. Using experimental data collected during the manufacture of a titanium test part on a variant of AM technology, electron beam melting (EBM), this research studies the effect of a variation in product shape complexity on process energy consumption. This is done by applying a computationally quantifiable convexity-based characteristic associated with shape complexity to the test part and correlating this quantity with per-layer process energy consumption on the EBM system. Only a weak correlation is found between the complexity metric and energy consumption (ρ = .35), suggesting that process energy consumption is indeed not driven by shape complexity. This result is discussed in the context of the energy consumption of computer-controlled machining technology, which forms an important substitute to EBM. This article further discusses the impact of available additional shape complexity at the manufacturing process level on the incentives toward minimization of energy inputs, additional benefits arising later within the product’s life cycle, and its implications for value creation possibilities

Design framework for multifunctional additive manufacturing: placement and routing of three-dimensional printed circuit volumes

A framework for the design of additively manufactured (AM) multimaterial parts with embedded functional systems is presented (e.g., structure with electronic/electrical components and associated conductive paths). Two of the key strands of this proposed framework are placement and routing strategies, which consist of techniques to exploit the true-3D design freedoms of multifunctional AM (MFAM) to create 3D printed circuit volumes (PCVs). Example test cases are presented, which demonstrate the appropriateness and effectiveness of the proposed techniques. The aim of the proposed design framework is to enable exploitation of the rapidly developing capabilities of multimaterial AM

Inkjet printing of polyimide insulators for the 3D printing of dielectric materials for microelectronic applications

In this article, we report the first continuous fabrication of inkjet-printed polyimide films, which were used as insulating layers for the production of capacitors. The polyimide ink was prepared from its precursor poly(amic) acid, and directly printed on to a hot substrate (at around 160 °C) to initialize a rapid thermal imidization. By carefully adjusting the substrate temperature, droplet spacing, droplet velocity, and other printing parameters, polyimide films with good surface morphologies were printed between two conducting layers to fabricate capacitors. In this work, the highest capacitance value, 2.82 ± 0.64 nF, was achieved by capacitors (10 mm × 10 mm) with polyimide insulating layers thinner than 1 μm, suggesting that the polyimide inkjet printing approach is an efficient way for producing dielectric components of microelectronic devices. © 2016 The Authors Journal of Applied Polymer Science Published by Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016, 133, 43361

Navier-Stokes transport coefficients of dd-dimensional granular binary mixtures at low density

The Navier-Stokes transport coefficients for binary mixtures of smooth inelastic hard disks or spheres under gravity are determined from the Boltzmann kinetic theory by application of the Chapman-Enskog method for states near the local homogeneous cooling state. It is shown that the Navier-Stokes transport coefficients are not affected by the presence of gravity. As in the elastic case, the transport coefficients of the mixture verify a set of coupled linear integral equations that are approximately solved by using the leading terms in a Sonine polynomial expansion. The results reported here extend previous calculations [V. Garz\'o and J. W. Dufty, Phys. Fluids {\bf 14}, 1476 (2002)] to an arbitrary number of dimensions. To check the accuracy of the Chapman-Enskog results, the inelastic Boltzmann equation is also numerically solved by means of the direct simulation Monte Carlo method to evaluate the diffusion and shear viscosity coefficients for hard disks. The comparison shows a good agreement over a wide range of values of the coefficients of restitution and the parameters of the mixture (masses and sizes).Comment: 6 figures, to be published in J. Stat. Phy

Patterns of regional lung physiology in cystic fibrosis using ventilation magnetic resonance imaging and multiple-breath washout

Hyperpolarised helium-3 (3He) ventilation magnetic resonance imaging (MRI) and multiple-breath washout (MBW) are sensitive methods for detecting lung disease in cystic fibrosis (CF). We aimed to explore their relationship across a broad range of CF disease severity and patient age, as well as assess the effect of inhaled lung volume on ventilation distribution.32 children and adults with CF underwent MBW and 3He-MRI at a lung volume of end-inspiratory tidal volume (EIVT). In addition, 28 patients performed 3He-MRI at total lung capacity. 3He-MRI scans were quantitatively analysed for ventilation defect percentage (VDP), ventilation heterogeneity index (VHI) and the number and size of individual contiguous ventilation defects. From MBW, the lung clearance index, convection-dependent ventilation heterogeneity (Scond) and convection-diffusion-dependent ventilation heterogeneity (Sacin) were calculated.VDP and VHI at EIVT strongly correlated with lung clearance index (r=0.89 and r=0.88, respectively), Sacin (r=0.84 and r=0.82, respectively) and forced expiratory volume in 1 s (FEV1) (r=-0.79 and r=-0.78, respectively). Two distinct 3He-MRI patterns were highlighted: patients with abnormal FEV1 had significantly (p<0.001) larger, but fewer, contiguous defects than those with normal FEV1, who tended to have numerous small volume defects. These two MRI patterns were delineated by a VDP of ∼10%. At total lung capacity, when compared to EIVT, VDP and VHI reduced in all subjects (p<0.001), demonstrating improved ventilation distribution and regions of volume-reversible and nonreversible ventilation abnormalities

Insights into the mechanical properties of several triply periodic minimal surface lattice structures made by polymer additive manufacturing

Three-dimensional lattices have applications across a range of fields including structural lightweighting, impact absorption and biomedicine. In this work, lattices based on triply periodic minimal surfaces were produced by polymer additive manufacturing and examined with a combination of experimental and computational methods. This investigation elucidates their deformation mechanisms and provides numerical parameters crucial in establishing relationships between their geometries and mechanical performance. Three types of lattice were examined, with one, known as the primitive lattice, being found to have a relative elastic modulus over twice as large as those of the other two. The deformation process of the primitive lattice was also considerably different from those of the other two, exhibiting strut stretching and buckling, while the gyroid and diamond lattices deformed in a bending dominated manner. Finite element predictions of the stress distributions in the lattices under compressive loading agreed with experimental observations. These results can be used to create better informed lattice designs for a range of mechanical and biomedical applications

Tracer diffusion in granular shear flows

Tracer diffusion in a granular gas in simple shear flow is analyzed. The analysis is made from a perturbation solution of the Boltzmann kinetic equation through first order in the gradient of the mole fraction of tracer particles. The reference state (zeroth-order approximation) corresponds to a Sonine solution of the Boltzmann equation, which holds for arbitrary values of the restitution coefficients. Due to the anisotropy induced in the system by the shear flow, the mass flux defines a diffusion tensor $D_{ij}$ instead of a scalar diffusion coefficient. The elements of this tensor are given in terms of the restitution coefficients and mass and size ratios. The dependence of the diffusion tensor on the parameters of the problem is illustrated in the three-dimensional case. The results show that the influence of dissipation on the elements $D_{ij}$ is in general quite important, even for moderate values of the restitution coefficients. In the case of self-diffusion (mechanically equivalent particles), the trends observed in recent molecular dynamics simulations are similar to those obtained here from the Boltzmann kinetic theory.Comment: 5 figure

Socioeconomic inequalities in vaccine uptake: A global umbrella review

This global umbrella review aimed to synthesise evidence of socioeconomic inequalities in the uptake of routine vaccinations and identify the mechanisms that may contribute to the association. To our knowledge, no attempt has been made to synthesise the global body of systematic reviews across a variety of vaccines, geographical locations, and measures of SES. The inclusion criteria were as follows: studies assessing vaccination uptake according to education, income, occupation/employment, and/or area-level deprivation; any country or universally recommended routine vaccination (according to the WHO); qualitative or quantitative reviews, published 2011-present. The searches were performed in eight databases. The screening process followed PRISMA-E guidelines, each stage was performed by one reviewer, and a 10% sample checked by a second for consistency. Included reviews underwent data extraction, quality appraisal (AMSTAR-2), and narrative synthesis according to country-context. After deduplication, 9,163 reports underwent title and abstract screening, leaving 119 full texts to be assessed for eligibility. Overall, 26 studies were included in the umbrella review. Evidence for lower uptake amongst disadvantaged SES individuals was found in all 26 reviews. However, 17 reviews showed mixed results, as inverse associations were also identified (lower uptake for advantaged SES, and/or higher uptake for disadvantaged SES). Those that explored high-income countries had a greater prevalence of mixed findings than those focusing on low/middle-income countries. The two most frequently cited mechanisms were vaccination knowledge, and confidence in vaccination or vaccination providers. These mechanisms were often understood by review authors as varying by level of education. We find socioeconomic differences in routine vaccination uptake, but the association did not always follow a gradient. Whilst education may be associated with uptake globally, our study indicates that its role varies by country-context. A limitation is the overlap of some primary studies across the included systematic reviews

3D printing of tablets using inkjet with UV photoinitiation

Additive manufacturing (AM) offers significant potential benefits in the field of drug delivery and pharmaceutical/medical device manufacture. Of AM processes, 3D inkjet printing enables precise deposition of a formulation, whilst offering the potential for significant scale up or scale out as a manufacturing platform. This work hypothesizes that suitable solvent based ink formulations can be developed that allow the production of solid dosage forms that meet the standards required for pharmaceutical tablets, whilst offering a platform for flexible and personalised manufacture. We demonstrate this using piezo-activated inkjetting to 3D print ropinirole hydrochloride. The tablets produced consist of a cross-linked poly(ethylene glycol diacrylate) (PEGDA) hydrogel matrix containing the drug, photoinitiated in a low oxygen environment using an aqueous solution of Irgacure 2959. At a Ropinirole HCl loading of 0.41 mg, drug release from the tablet is shown to be Fickian. Raman and IR spectroscopy indicate a high degree of cross-linking and formation of an amorphous solid dispersion. This is the first publication of a UV inkjet 3D printed tablet. Consequently, this work opens the possibility for the translation of scalable, high precision and bespoke ink-jet based additive manufacturing to the pharmaceutical sector

Fluctuation-Dissipation relations in Driven Granular Gases

We study the dynamics of a 2d driven inelastic gas, by means of Direct Simulation Monte Carlo (DSMC) techniques, i.e. under the assumption of Molecular Chaos. Under the effect of a uniform stochastic driving in the form of a white noise plus a friction term, the gas is kept in a non-equilibrium Steady State characterized by fractal density correlations and non-Gaussian distributions of velocities; the mean squared velocity, that is the so-called {\em granular temperature}, is lower than the bath temperature. We observe that a modified form of the Kubo relation, which relates the autocorrelation and the linear response for the dynamics of a system {\em at equilibrium}, still holds for the off-equilibrium, though stationary, dynamics of the systems under investigation. Interestingly, the only needed modification to the equilibrium Kubo relation is the replacement of the equilibrium temperature with an effective temperature, which results equal to the global granular temperature. We present two independent numerical experiment, i.e. two different observables are studied: (a) the staggered density current, whose response to an impulsive shear is proportional to its autocorrelation in the unperturbed system and (b) the response of a tracer to a small constant force, switched on at time $t_w$, which is proportional to the mean-square displacement in the unperturbed system. Both measures confirm the validity of Kubo's formula, provided that the granular temperature is used as the proportionality factor between response and autocorrelation, at least for not too large inelasticities.Comment: 11 pages, 7 figures, submitted for publicatio