The work aims to propose a comprehensive design framework for additive manufacturing and apply it to a case study of the height adjuster handle of a car. The aim is to provide designers and engineers ...with a practical example of how the framework can be used to design a complex part for additive manufacturing. The article also aims to demonstrate the potential benefits of additive manufacturing in the automotive industry, such as improved performance, reduced times, and cost savings. Additionally, the article aims to compare the developed framework with existing design for additive manufacturing (DFAM) methodologies and highlight its unique features and advantages in designing the height adjuster handle.The study used qualitative and quantitative data collection and analysis methods. The first phase of the study involved a systematic review of existing DfAM methodologies and a critical analysis of their strengths and weaknesses. Based on this analysis, a new DfAM framework is developed, which aims to address the limitations of existing frameworks and provide a comprehensive design approach for additive manufacturing. The second phase of the study involved applying the developed framework to a case study of a complex automotive part - a height adjuster handle. The design requirements of the height adjuster handle were identified based on the principles of DfAM, and the part was designed using computer-aided design (CAD) software and optimised topologically using ANSYS software. In the third phase, the performance of the height adjuster handle designed using the developed framework was compared with a part manufactured with injection moulding technology. The comparison was based on various performance criteria, including mechanical properties, dimensional accuracy, and production time and cost.The findings of the study demonstrate the effectiveness of the developed design framework for additive manufacturing (DfAM) in producing a complex automotive part with improved performance characteristics and reduced lead time.Although the results of the study provide important insights into the effectiveness of the developed DfAM framework for producing a complex automotive part, there are some limitations to the research that should be considered, such as the case study involved the design of a single part, and the results may not be generalisable to other parts or applications. Further research is needed to validate the effectiveness of the DfAM framework for a broader range of automotive parts.The findings of the study have important practical implications for the automotive industry. The developed DfAM framework can be used in the FDM technology. It can be used as a decision aid in the manufacturing of FDM parts in order to improve the efficiency and cost-effectiveness of the production process for complex automotive parts.The value of the study is the development of a novel DfAM framework and the demonstration of its effectiveness in a case study. The proposed framework can be used as a reference for future research. It can also provide practical guidance for industry professionals seeking to improve the efficiency and cost-effectiveness of their additive manufacturing processes.
Nowadays additive manufacturing is a very unique process of making objects layer by layer. The additive manufacturing process has been improved, but the additive production process is not going much ...further than the subtraction manufacturing process. In this study, the integrated structure of multicriteria decision making analysis process for position selection analysis in additive manufacturing has been investigated. Primarily, measurable data was evaluated using a multi-standard decision-making process without the decision-maker's choice. In contrast, a decision maker's preferences are qualitatively analyzed using the analytic hierarchy process and multi-objective optimization on the basis of the ratio analysis technique. In this study, a special combination production process such as fused deposit modeling is used and this case study has shown a good agreement with experiment. Further, printing time of analytic hierarchy process and multi-objective optimization on the basis of the ratio analysis method has been compared in this study. Among various orientation, PLA_Position-2 has been identified as most efficient alternative.
Full text
Available for:
GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
Fused deposition modeling (FDM) is a three-dimensional (3D) printing technology that is usually performed with polymers that are molten in a printer nozzle and placed line by line on the printing bed ...or the previous layer, respectively. Nowadays, hybrid materials combining polymers with functional materials are also commercially available. Especially combinations of polymers with metal particles result in printed objects with interesting optical and mechanical properties. The mechanical properties of objects printed with two of these metal-polymer blends were compared to common poly (lactide acid) (PLA) printed objects. Tensile tests and bending tests show that hybrid materials mostly containing bronze have significantly reduced mechanical properties. Tensile strengths of the 3D-printed objects were unexpectedly nearly identical with those of the original filaments, indicating sufficient quality of the printing process. Our investigations show that while FDM printing allows for producing objects with mechanical properties similar to the original materials, metal-polymer blends cannot be used for the rapid manufacturing of objects necessitating mechanical strength.
Full text
Available for:
IZUM, KILJ, NUK, PILJ, PNG, SAZU, UL, UM, UPUK
Abstract
This article is devoted to one of the new directions of creating and obtaining porous materials. The cellular material part is a new element that provides high specific strength of the ...structure in combination with low density. An urgent task is to develop and obtain a cellular structure with optimal geometric parameters to ensure maximum manufacturability of the structure. The obtained data can be used in the development of technological processes of hybrid casting technologies, as well as for the manufacture of new lightweight parts with increased specific strength characteristics.
A new SERS device is reported for direct detection of low-concentration molecules in water, which consists of 3D-printed polylactic acid (PLA) lines coated with Ag. Strong optical confinement and ...local field enhancement by the MIM scheme within the plasmonic nanogaps between the adjacent PLA lines supply the main mechanisms. An enhancement factor of 2.26×106 was achieved with respect to that by a pure glass substrate.
Display omitted
•A 3D printing technique is established for the development of new SERS sensors, where metal(Ag)-isolator(water)-metal(Ag) schemes are produced by depositing Ag on the surface of closely arranged polymeric cylindrical lines.•Surface plasmon polaritons along the silver film and strong optical confinement within the nanogap constitute the most important mechanisms for local-field enhancement with an enhancement factor larger than 2 × 106.•A PLA-based simple, low-cost, and convenient-fabrication SERS sensor is achieved with biodegradable, biocompatible, and environment friendly properties.•Such a SERS device has great potentials for in-situ and real-time trace detection of pollutant molecules in liquid food and environmental water.
Surface enhanced Raman scattering (SERS) spectroscopy is a widely used analytical technique for detecting chemicals or biological molecules with high sensitivity and high specificity. Enhancing the sensitivity and lowering the detection limits are always the working direction of this research field. Furthermore, direct detection of low-concentration molecules in liquids remains a big challenge. In this work, we construct a SERS device consisting of periodically arranged polylactic acid (PLA) lines that are coated with silver, where the PLA line array is produced by 3D printing technique. The plasmonic nanogroove within the gap between the two adjacent PLA lines is found to be the dominant mechanism for SERS detection. A maximum enhancement factor of 2.26 × 106 has been achieved for the plasmonic nanogroove, with respect to a pure planar glass substrate. A detection limit of lower than 0.5 ppm has been research for such a sensor device in the direct detection of melamine in its aqueous solution. Furthermore, the PLA lines have advantages of biodegradability, biocompatibility, low costs, and thermo-plasticity, making the device environmentally friendly in potential applications in food safety inspection and pollutant detection in water.
Full text
Available for:
GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
Regardless of the species, birds are exposed to injuries that lead to amputation of part of the body structure and often euthanasia. Based on the need for new technologies that improve the quality of ...life of birds with locomotor problems, the present case reports aimed to describe the development of custom-made three-dimensional (3D) prostheses for domestic and wild birds that suffered amputation or malformation of the hind limb. Using the measurements of the bird, a digital model was created for 3D printing using fused deposition modeling technology (FDM) by the Brazilian company 3D Medicine. In this study we report the use of 3D prosthesis for the rehabilitation of three birds with locomotor disorders in Brazil, the animals adapted to the custom-made prosthesis with an improvement in quality of life, better distribution of body weight, locomotion, and landing. This study describes the development of 3D prostheses for birds in Brazil, the first report of this technology for these species, and the pioneering development of socket prostheses for small birds. 3D prostheses offer a high-efficiency solution to improve the quality of life of animals with amputations and malformations of the hind limbs. In addition, 3D technology provides valuable tools for veterinary medicine, developing custom-made models for the most different anatomical demands of animal patients.
Full text
Available for:
IZUM, KILJ, NUK, PILJ, PNG, SAZU, UL, UM, UPUK
This work concerns the design, fabrication, and testing of a novel air-flow sensor employing exclusively additive manufacturing that can be fabricated on-site, aboard a ship, or in a similarly remote ...area, without relying on external manufacturing facilities. The developed device’s principle of operation is based on vortex shedding; its novelty focuses on employing solely additive manufacturing technology, for the manufacturing—in a single process step—of all the sensor’s main elements. In more detail, the required flow-shaping housing, the appropriate piezoresistive sensing element, and the electrical interconnection pads are all constructed in a single process step, through standard Fused Deposition Modeling (FDM) 3D technology. Direct communication to the necessary readout circuitry can be easily achieved through standard soldering utilizing the integrated contact pads of the sensor. The prototype was preliminary characterized, validating its proper functionality. Key features of the proposed device are low cost, fast on-site manufacturing of the entire measuring device, robustness, and simplicity, suggesting numerous potential applications in the shipbuilding industry and other industrial sectors.
Full text
Available for:
IZUM, KILJ, NUK, PILJ, PNG, SAZU, UL, UM, UPUK
The aim of the research was to investigate the usability and legibility of 3D printed typeface characters in smaller sizes. In the experimental investigation two software programs for letter ...modelling, three typefaces, three type sizes, two weight options, and two printing materials were tested. The samples were analysed visually and with image analysis. The legibility tests were conducted in laboratory conditions and testing chamber. The participants were asked to read pangrams and answer close-ended questions. The reading speed and understanding of the text were measured and analysed. It was found that the success of printing parts of letters, as well as their recognition and visual evaluation, is most often influenced by two analysed factors, i.e. weight option and type size, in all three typefaces. We established that the type size is statistically significant, and that the typographic tonal density is influenced by the typeface and the material used.
Practitioner summary: The research presents the investigation of usability and legibility of 3D printed typefaces at smaller sizes. Five variables were analysed visually and with image analysis. Typographic tonal density, reading speed, and text comprehension were evaluated. The findings demonstrated that weight option, type size, and material influence the reading speed and text comprehension.
HIGHLIGHTS
Five different parameters were investigated regarding usability of 3D printed typeface.
Legibility of different typefaces, weight options, and type sizes were tested.
Typographic tonal density was evaluated with image analysis.
Print quality of different materials using an FDM technology printer was evaluated.
Full text
Available for:
BFBNIB, GIS, IJS, KISLJ, NUK, PNG, UL, UM, UPUK
PDF
