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Fabrication of 3D-printed GNP/TiO2/epoxy composites: an investigation on mechanical and photocatalytic properties Rapid Prototyping J. (IF 3.9) Pub Date : 2024-04-25 Saadet Güler, Ahmet Yavaş, Berk Özler, Ahmet Çagri Kilinç
Purpose Three-dimensional (3D) printing is popular for many applications including the production of photocatalysts. This paper aims to focus on developing of 3D-printed photocatalyst-nano composite lattice structure. Digital light processing (DLP) 3D printing of photocatalyst composites was performed using photosensitive resin mixed with 0.5% Wt. of TiO2 powder and varying amounts (0.025% Wt. to 0
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Benchmarking the quality improvement strategies of wire arc additive manufacturing process using fuzzy QFD approach Rapid Prototyping J. (IF 3.9) Pub Date : 2024-04-23 Naveen Srinivas Madugula, Yogesh Kumar, Vimal K.E.K, Sujeet Kumar
Purpose The purpose of this paper is to improve the productivity and quality of the wire arc additive manufacturing process by benchmarking the strategies from the selected six strategies, namely, heat treatment process, inter pass cooling process, inter pass cold rolling process, peening process, friction stir processing and oscillation process. Design/methodology/approach To overcome the lack of
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Design and analysis of solid ankle foot orthosis by employing mechanical characterization and a low-cost scanning approach for additive manufacturing Rapid Prototyping J. (IF 3.9) Pub Date : 2024-04-22 Muhammad Abas, Tufail Habib, Sahar Noor
Purpose This study aims to investigate the fabrication of solid ankle foot orthoses (SAFOs) using fused deposition modeling (FDM) printing technology. It emphasizes cost-effective 3D scanning with the Kinect sensor and conducts a comparative analysis of SAFO durability with varying thicknesses and materials, including polylactic acid (PLA) and carbon fiber-reinforced (PLA-C), to address research gaps
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Research and implementation of large-area sintering technology based on image-shaped laser Rapid Prototyping J. (IF 3.9) Pub Date : 2024-04-19 Yifan Guo, Yanling Guo, Jian Li, Yangwei Wang, Deyu Meng, Haoyu Zhang, Jiaming Dai
Purpose Selective laser sintering (SLS) is an essential technology in the field of additive manufacturing. However, SLS technology is limited by the traditional point-laser sintering method and has reached the bottleneck of efficiency improvement. This study aims to develop an image-shaped laser sintering (ISLS) system based on a digital micromirror device (DMD) to address this problem. The ISLS system
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Using extrusion-based 3D printing technology to investigate the impact of changing print conditions on tensile characteristics Rapid Prototyping J. (IF 3.9) Pub Date : 2024-04-17 Vidyut Raghu Viswanath, Shivashankar Hiremath, Dundesh S. Chiniwar
Purpose The purpose of this study, most recent advancements in threedimensional (3D) printing have focused on the fabrication of components. It is typical to use different print settings, such as raster angle, infill and orientation to improve the 3D component qualities while fabricating the sample using a 3D printer. However, the influence of these factors on the characteristics of the 3D parts has
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Multiscale characterization of additively manufactured PMMA: the influence of sterilization Rapid Prototyping J. (IF 3.9) Pub Date : 2024-04-12 Celia Rufo-Martín, Ramiro Mantecón, Geroge Youssef, Henar Miguelez, Jose Díaz-Álvarez
Purpose Polymethyl methacrylate (PMMA) is a remarkable biocompatible material for bone cement and regeneration. It is also considered 3D printable but requires in-depth process–structure–properties studies. This study aims to elucidate the mechanistic effects of processing parameters and sterilization on PMMA-based implants. Design/methodology/approach The approach comprised manufacturing samples with
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Induced alterations driven compromised structural properties in additively manufactured products Rapid Prototyping J. (IF 3.9) Pub Date : 2024-04-05 Lida Haghnegahdar, Sameehan S. Joshi, Rohith Yanambaka Venkata, Daniel A. Riley, Narendra B. Dahotre
Purpose Additive manufacturing also known as 3D printing is an evolving advanced manufacturing technology critical for the new era of complex machinery and operating systems. Manufacturing systems are increasingly faced with risk of attacks not only by traditional malicious actors such as hackers and cyber-criminals but also by some competitors and organizations engaged in corporate espionage. This
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Manufacturing-induced stochastic constitutive behaviors of additive manufactured specimens: testing, data-driven modeling, and optimization Rapid Prototyping J. (IF 3.9) Pub Date : 2024-04-09 Baixi Chen, Weining Mao, Yangsheng Lin, Wenqian Ma, Nan Hu
Purpose Fused deposition modeling (FDM) is an extensively used additive manufacturing method with the capacity to build complex functional components. Due to the machinery and environmental factors during manufacturing, the FDM parts inevitably demonstrated uncertainty in properties and performance. This study aims to identify the stochastic constitutive behaviors of FDM-fabricated polylactic acid
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SCOBY: an alternate solution to develop cheap and nutritious food by food layered manufacturing (FLM) Rapid Prototyping J. (IF 3.9) Pub Date : 2024-04-05 Rahul Soni, Madhvi Sharma, Ponappa K., Puneet Tandon
Purpose In pursuit of affordable and nutrient-rich food alternatives, the symbiotic culture of bacteria and yeast (SCOBY) emerged as a selected food ink for 3D printing. The purpose of this paper is to harness SCOBY’s potential to create cost-effective and nourishing food options using the innovative technique of 3D printing. Design/methodology/approach This work presents a comparative analysis of
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Deep learning assisted fabrication of metallic components using the robotic wire arc additive manufacturing Rapid Prototyping J. (IF 3.9) Pub Date : 2024-03-29 Pingyang Zheng, Shaohua Han, Dingqi Xue, Ling Fu, Bifeng Jiang
Purpose Because of the advantages of high deposition efficiency and low manufacturing cost compared with other additive technologies, robotic wire arc additive manufacturing (WAAM) technology has been widely applied for fabricating medium- to large-scale metallic components. The additive manufacturing (AM) method is a relatively complex process, which involves the workpiece modeling, conversion of
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Compressive properties of AlSi10Mg lattice structures with novel BCCZZ and FCCZZ configurations fabricated by selective laser melting Rapid Prototyping J. (IF 3.9) Pub Date : 2024-03-29 Hubannur Seremet, Nazim Babacan
Purpose This paper aims to examine the static compression characteristics of cell topologies in body-centered cubic with vertical struts (BCCZ) and face-centered cubic with vertical struts (FCCZ) along with novel BCCZZ and FCCZZ lattice structures. Design/methodology/approach The newly developed structures were obtained by adding extra interior vertical struts into the BCCZ and FCCZ configurations
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Design and characterization of 3D-printed TPU-based lattice structures. Application to methodology for the design of personalized therapeutic products Rapid Prototyping J. (IF 3.9) Pub Date : 2024-03-26 Sergio de la Rosa, Pedro F. Mayuet, Cátia S. Silva, Álvaro M. Sampaio, Lucía Rodríguez-Parada
Purpose This papers aims to study lattice structures in terms of geometric variables, manufacturing variables and material-based variants and their correlation with compressive behaviour for their application in a methodology for the design and development of personalized elastic therapeutic products. Design/methodology/approach Lattice samples were designed and manufactured using extrusion-based additive
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Enhanced fracture toughness and tensile strength of 3D printed recycled ABS composites reinforced with continuous metallic fiber for load-bearing application Rapid Prototyping J. (IF 3.9) Pub Date : 2024-03-26 Vishal Mishra, Ch Kapil Ror, Sushant Negi, Simanchal Kar
Purpose This study aims to present an experimental approach to develop a high-strength 3D-printed recycled polymer composite reinforced with continuous metal fiber. Design/methodology/approach The continuous metal fiber composite was 3D printed using recycled and virgin acrylonitrile butadiene styrene-blended filament (RABS-B) in the ratio of 60:40 and postused continuous brass wire (CBW). The 3D printing
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3D printing of personalised stents using new advanced photopolymerizable resins and Ti-6Al-4V alloy Rapid Prototyping J. (IF 3.9) Pub Date : 2024-03-19 Diana Irinel Baila, Filippo Sanfilippo, Tom Savu, Filip Górski, Ionut Cristian Radu, Catalin Zaharia, Constantina Anca Parau, Martin Zelenay, Pacurar Razvan
Purpose The development of new advanced materials, such as photopolymerizable resins for use in stereolithography (SLA) and Ti6Al4V manufacture via selective laser melting (SLM) processes, have gained significant attention in recent years. Their accuracy, multi-material capability and application in novel fields, such as implantology, biomedical, aviation and energy industries, underscore the growing
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Fabrication of crack-free aluminum alloy 6061 parts using laser foil printing process Rapid Prototyping J. (IF 3.9) Pub Date : 2024-03-18 Yu-Xiang Wang, Chia-Hung Hung, Hans Pommerenke, Sung-Heng Wu, Tsai-Yun Liu
Purpose This paper aims to present the fabrication of 6061 aluminum alloy (AA6061) using a promising laser additive manufacturing process, called the laser-foil-printing (LFP) process. The process window of AA6061 in LFP was established to optimize process parameters for the fabrication of high strength, dense and crack-free parts even though AA6061 is challenging for laser additive manufacturing processes
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Understanding the consolidation mechanism of selective laser sintering/powder bed selective laser process of ceramics: Hydroxyapatite case Rapid Prototyping J. (IF 3.9) Pub Date : 2024-03-01 Asif Ur Rehman, Pedro Navarrete-Segado, Metin U. Salamci, Christine Frances, Mallorie Tourbin, David Grossin
Purpose The consolidation process and morphology evolution in ceramics-based additive manufacturing (AM) are still not well-understood. As a way to better understand the ceramic selective laser sintering (SLS), a dynamic three-dimensional computational model was developed to forecast thermal behavior of hydroxyapatite (HA) bioceramic. Design/methodology/approach AM has revolutionized automotive, biomedical
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Mechanical properties and failure modes of additively-manufactured chiral metamaterials based on Euclidean tessellations: an experimental and finite element study Rapid Prototyping J. (IF 3.9) Pub Date : 2024-02-28 Luke Mizzi, Arrigo Simonetti, Andrea Spaggiari
Purpose The “chiralisation” of Euclidean polygonal tessellations is a novel, recent method which has been used to design new auxetic metamaterials with complex topologies and improved geometric versatility over traditional chiral honeycombs. This paper aims to design and manufacture chiral honeycombs representative of four distinct classes of 2D Euclidean tessellations with hexagonal rotational symmetry
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Improving the mechanical properties of laser powder bed fused AlSi10Mg alloys by eliminating the inevitable micro-voids via hot forging Rapid Prototyping J. (IF 3.9) Pub Date : 2024-02-29 Jie Wan, Biao Chen, Jianghua Shen, Katsuyoshi Kondoh, Shuiqing Liu, Jinshan Li
Purpose The metallic alloys and their components fabricated via laser powder bed fusion (LPBF) suffer from the microvoids formed inevitably due to the extreme solidification rate during fabrication, which are impossible to be removed by heat treatment. This paper aims to remove those microvoids in as-built AlSi10Mg alloys by hot forging and enhance their mechanical properties. Design/methodology/approach
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Direct slicing of microcellular structures for digital light processing (DLP) additive manufacturing Rapid Prototyping J. (IF 3.9) Pub Date : 2024-02-21 Seo-Hyeon Oh, Keun Park
Purpose Additive Manufacturing (AM) conventionally necessitates an intermediary slicing procedure using the standard tessellation language (STL) data, which can be computationally burdensome, especially for intricate microcellular architectures. This study aims to propose a direct slicing method tailored for digital light processing-type AM processes for the efficient generation of slicing data for
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Quasi-static compression and energy absorption behaviour of polymeric selective laser sintered open cell lattices under varying relative densities Rapid Prototyping J. (IF 3.9) Pub Date : 2024-02-21 Mohan Kumar K, Arumaikkannu G
Purpose The purpose of this paper is to compare the influence of relative density (RD) and strain rates on failure mechanism and specific energy absorption (SEA) of polyamide lattices ranging from bending to stretch-dominated structures using selective laser sintering (SLS). Design/methodology/approach Three bending and two stretch-dominated unit cells were selected based on the Maxwell stability criterion
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Sound absorption advancements: exploring 3D printing in the development of tetrakaidecahedron cell-based acoustic metamaterials Rapid Prototyping J. (IF 3.9) Pub Date : 2024-02-15 Saliq Shamim Shah, Daljeet Singh, Jaswinder Singh Saini, Naveen Garg
Purpose This paper aims to study the design and characterization of a 3D printed tetrakaidecahedron cell-based acoustic metamaterial. At present, the mitigation of low-frequency noise involves the utilization of spatially demanding materials for the absorption of sound. These materials lack the ability for targeted frequency control adjustments. Hence, there is a requirement for an approach that can
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On the possibilities of merging additive manufacturing and powder injection molding in the production of metal parts Rapid Prototyping J. (IF 3.9) Pub Date : 2024-02-09 Martin Novák, Berenika Hausnerova, Vladimir Pata, Daniel Sanetrnik
Purpose This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder
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Non-transferring arc and wire additive manufacturing: microstructure, mechanical properties and bulk texture evolution of deposits Rapid Prototyping J. (IF 3.9) Pub Date : 2024-02-01 Suvranshu Pattanayak, Susanta Kumar Sahoo, Ananda Kumar Sahoo, Raviteja Vinjamuri, Pushpendra Kumar Dwivedi
Purpose This study aims to demonstrate a modified wire arc additive manufacturing (AM) named non-transferring arc and wire AM (NTA-WAM). Here, the build plate has no electrical arc attachment, and the system’s arc is ignited between tungsten electrode and filler wire. Design/methodology/approach The effect of various deposition conditions (welding voltage, travel speed and wire feed speed [WFS]) on
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Exploring mixed-mode fracture behavior and mechanical properties of selective laser sintered polyamide 12 components Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-30 Burçak Zehir, Mirsadegh Seyedzavvar, Cem Boğa
Purpose This study aims to comprehensively investigate the mixed-mode fracture behavior and mechanical properties of selective laser sintering (SLS) polyamide 12 (PA12) components, considering different build orientations and layer thicknesses. The primary objectives include the following. Conducting mixed-mode fracture and mechanical analyses on SLS PA12 parts. Investigating the influence of build
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Sustainable 3D printing with recycled tire rubber-based filaments: an investigation of process parameters and mechanical behaviour Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-26 Silvia Badini, Serena Graziosi, Michele Carboni, Stefano Regondi, Raffaele Pugliese
Purpose This study evaluates the potential of using the material extrusion (MEX) process for recycling waste tire rubber (WTR). By investigating the process parameters, mechanical behaviour and morphological characterisation of a thermoplastic polyurethane-waste tire rubber composite filament (TPU-WTR), this study aims to establish a framework for end-of-life tire (ELT) recycling using the MEX technology
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Investigating the large strain compression properties of PLA parts manufactured by FDM using experiments and constitutive modeling Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-25 Shrushti Maheshwari, Zafar Alam, Sarthak S. Singh
Purpose The purpose of this study is to experimentally investigate the large deformation compression characteristics of fused deposition modelling (FDM)-printed poly lactic acid (PLA), considering the combined effect of infill density and strain rate, and to develop a constitutive viscoplastic model that can incorporate the infill density to predict the experimental result. Design/methodology/approach
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Effects of post-processing curing parameters and gamma irradiation on the mechanical properties of medical graded vat photopolymerization parts Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-19 Natthawut Daoset, Samroeng Inglam, Sujin Wanchat, Nattapon Chantarapanich
Purpose This paper aims to investigate the influence of post-curing temperature, post-curing time and gamma ray irradiation dose upon the tensile and compressive mechanical properties of the medical graded vat photopolymerization parts. Design/methodology/approach Medical graded vat photopolymerization specimens, made from photopolymer resin, were fabricated using bottom-up vat photopolymerization
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Mechanical behavior investigation of fused deposition modeling joints by using different bonding geometry with variable adhesive thickness Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-18 Uğur Kemiklioğlu, Sermet Demir, Caner Yüksel
Purpose Adhesively bonded joints are used in many fields, especially in the automotive, marine, aviation, defense and outdoor industries. Adhesive bonding offers advantages over traditional mechanical methods, including the ability to join diverse materials, even load distribution and efficient thermal-electrical insulation. This study aims to investigate the mechanical properties of adhesively bonded
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Correlation between the part quality, strength and surface roughness of material extrusion process Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-11 Abdul Samad Rafique, Adnan Munir, Numan Ghazali, Muhammad Naveed Ahsan, Aqeel Ahsan Khurram
Purpose The purpose of this study was to develop a correlation between the properties of acrylonitrile butadiene styrene parts 3D printed by material extrusion (MEX) process. Design/methodology/approach The two MEX parameters and their values have been selected by design of experiment method. Three properties of MEX parts, i.e. strength (tensile and three-point bending), surface roughness and the dimensional
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An investigation into the mechanisms that influence laser sintered polyamide-12 top surfaces Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-09 James Tarver, Kieran Nar, Candice Majewski
Purpose The purpose of this paper is to elucidate the extent to which the mechanisms of polymer melt viscous flow and finish layer powder particle adhesion influence the top surface topographies of laser sintered polyamide (PA12) components. Design/methodology/approach Laser sintered specimens were manufactured at varying laser parameters in accordance with a full factorial design of experiments. Focus
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Experimental and numerical study of in-plane uniaxial compression response of PU foam filled aluminum arrowhead auxetic honeycomb Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-09 Chunfu Wu, Guorui Ye, Yonghong Zhao, Baowen Ye, Tao Wang, Liangmo Wang, Zeming Zhang
Purpose Auxetics metamaterials show high performance in their specific characteristics, while the absolute stiffness and strength are much weaker due to substantial porosity. This paper aims to propose a novel auxetic honeycomb structure manufactured using selective laser melting and study the enhanced mechanical performance when subjected to in-plane compression loading. Design/methodology/approach
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A layerwise geometric error compensation procedure for additive manufacturing Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-02 Fernando Peña, José Carlos Rico, Pablo Zapico, Gonzalo Valiño, Sabino Mateos
Purpose The purpose of this paper is to provide a new procedure for in-plane compensation of geometric errors that often appear in the layers deposited by an additive manufacturing (AM) process when building a part, regardless of the complexity of the layer geometry. Design/methodology/approach The procedure is based on comparing the real layer contours to the nominal ones extracted from the STL model
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Manufacture of thermoplastic molds by fused filament fabrication 3D printing for rapid prototyping of polyurethane foam molded products Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-02 Guillermo Guerrero-Vacas, Jaime Gómez-Castillo, Oscar Rodríguez-Alabanda
Purpose Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using fused filament fabrication (FFF) with polylactic acid (PLA) and glycol-modified polyethylene terephthalate (PETG) is proposed as an economical, simpler and faster solution compared to traditional metallic molds or three-dimensional
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Machine learning for forecasting the biomechanical behavior of orthopedic bone plates fabricated by fused deposition modeling Rapid Prototyping J. (IF 3.9) Pub Date : 2024-01-01 Shrutika Sharma, Vishal Gupta, Deepa Mudgal, Vishal Srivastava
Purpose Three-dimensional (3D) printing is highly dependent on printing process parameters for achieving high mechanical strength. It is a time-consuming and expensive operation to experiment with different printing settings. The current study aims to propose a regression-based machine learning model to predict the mechanical behavior of ulna bone plates. Design/methodology/approach The bone plates
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Fiber reinforced additive manufacturing: structurally motivated print orientation and sequential topology optimization of anisotropic material Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-29 Noah Ray, Il Yong Kim
Purpose Fiber reinforced additive manufacturing (FRAM) is an emerging technology that combines additive manufacturing and composite materials. As a result, design freedom offered by the manufacturing process can be leveraged in design optimization. The purpose of the study is to propose a novel method that improves structural performance by optimizing 3D print orientation of FRAM components. Desig
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Effect of scan speed on corrosion and tribocorrosion properties of cobalt-chromium alloy in situ produced by selective laser melting Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-26 Raghad Ahmed Alaloosi, Onur Çomakli, Mustafa Yazici, Ziad A. Taha
Purpose This paper aims to investigate the influence of scan speed on the corrosion and tribocorrosion features of the CoCrMoW samples fabricated via the selective laser melting (SLM) process. Design/methodology/approach CoCrMoW samples were produced by SLM at different scan speeds. Produced samples were made via structural surveys (X-ray diffraction examinations and scanning electron microscopic analyses)
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Enhanced-pixel strategy for wire arc additive manufacturing trajectory planning: operational efficiency and effectiveness analyses Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-21 Rafael Pereira Ferreira, Louriel Oliveira Vilarinho, Americo Scotti
Purpose This study aims to propose and evaluate the progress in the basic-pixel (a strategy to generate continuous trajectories that fill out the entire surface) algorithm towards performance gain. The objective is also to investigate the operational efficiency and effectiveness of an enhanced version compared with conventional strategies. Design/methodology/approach For the first objective, the proposed
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Modeling the effect of processing parameters on temperature history in Directed Energy Deposition: an analytical and finite element approach Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-21 Mehran Ghasempour-Mouziraji, Daniel Afonso, Saman Hosseinzadeh, Constantinos Goulas, Mojtaba Najafizadeh, Morteza Hosseinzadeh, D.D. Ganji, Ricardo Alves de Sousa
Purpose The purpose of this paper is to assess the feasibility of analytical models, specifically the radial basis function method, Akbari–Ganji method and Gaussian method, in conjunction with the finite element method. The aim is to examine the impact of processing parameters on temperature history. Design/methodology/approach Through analytical investigation and finite element simulation, this research
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A review on exploration of the mechanical characteristics of 3D-printed biocomposites fabricated by fused deposition modelling (FDM) Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-20 Prashant Anerao, Atul Kulkarni, Yashwant Munde
Purpose This paper aims to investigate the current state of biocomposites used in fused deposition modelling (FDM) with a focus on their mechanical characteristics. Design/methodology/approach The study presents a variety of biocomposite materials that have been used in filaments for 3D printing by different researchers. The process of making filaments is then described, followed by a discussion of
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In situ TiC reinforced Ti6Al4V matrix composites manufactured via selective laser melting Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-20 İdris Tuğrul Gülenç, Mingwen Bai, Ria L. Mitchell, Iain Todd, Beverley J. Inkson
Purpose Current methods for the preparation of composite powder feedstock for selective laser melting (SLM) rely on costly nanoparticles or yield inconsistent powder morphology. This study aims to develop a cost-effective Ti6Al4V-carbon feedstock, which preserves the parent Ti6Al4V particle’s flowability, and produces in situ TiC-reinforced Ti6Al4V composites with superior traits. Design/methodology/approach
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Effect of forming angle on the microstructure and properties of GH3536 nickel-based superalloy formed by SLM Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-20 Jibing Chen, Shisen Huang, Nan Chen, Chengze Yu, Shanji Yu, Bowen Liu, Maohui Hu, Ruidi Li
Purpose This paper aims to identify the optimal forming angle for the selective laser melting (SLM) process and evaluate the mechanical properties of the SLM-formed GH3536 alloy in the aero-engine field. Design/methodology/approach Forming the samples with optimized parameters and analyzing the microstructure and properties of the block samples in different forming angles with scanning electron microscope
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Optimization of the printability envelope of low-viscosity powder-binder feedstocks used in material extrusion 3D printing Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-15 Mohamed Ahmed Omrane, Raphaël Côté, Vincent Demers
Purpose The purpose of this study is to determine the material extrusion (MEX) printability envelope of a new kind of low-viscosity powder-binder feedstocks using rheological properties. Design/methodology/approach Formulation of 13 feedstocks (variation of solid loading 60–67 Vol.% and thickening agent proportion 3–15 Vol.%) that were characterized and printed at different temperatures. Findings Three
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Printed layers height calibration curve and porosity in laser melting deposition of Ti6Al4V combining experiments, mathematical modelling and deep neural network Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-15 Muhammad Arif Mahmood, Chioibasu Diana, Uzair Sajjad, Sabin Mihai, Ion Tiseanu, Andrei C. Popescu
Purpose Porosity is a commonly analyzed defect in the laser-based additive manufacturing processes owing to the enormous thermal gradient caused by repeated melting and solidification. Currently, the porosity estimation is limited to powder bed fusion. The porosity estimation needs to be explored in the laser melting deposition (LMD) process, particularly analytical models that provide cost- and time-effective
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Steady melting in material extrusion additive manufacturing Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-12 Austin R. Colon, David Owen Kazmer, Amy M. Peterson, Jonathan E. Seppala
Purpose A main cause of defects within material extrusion (MatEx) additive manufacturing is the nonisothermal condition in the hot end, which causes inconsistent extrusion and polymer welding. This paper aims to validate a custom hot end design intended to heat the thermoplastic to form a melt prior to the nozzle and to reduce variability in melt temperature. A full 3D temperature verification methodology
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Effect of recycled powder and gear profile into the functionality of additive manufacturing polymer gears Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-08 Flaviana Calignano, Alessandro Bove, Vincenza Mercurio, Giovanni Marchiandi
Purpose Polymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such
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The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-07 Murat Isik, Isa Emami Tabrizi, Raja Muhammad Awais Khan, Mehmet Yildiz, Eda Aydogan, Bahattin Koc
Purpose In recent years, additive manufacturing (AM) has started to be used for manufacturing real functional parts and assemblies for critical applications in aerospace, automotive, and machinery industries. Most complex or assembled parts require internal features (IF) such as holes, channels, slots, or guides for locational and mating requirements. Therefore, it is critical to understand and compare
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Powder bed defect classification methods: deep learning vs traditional machine learning Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-01 Francois Du Rand, André Francois van der Merwe, Malan van Tonder
Purpose This paper aims to discuss the development of a defect classification system that can be used to detect and classify powder bed surface defects from captured layer images without the need for specialised computational hardware. The idea is to develop this system by making use of more traditional machine learning (ML) models instead of using computationally intensive deep learning (DL) models
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Predictive modeling for online in-plane shape deviation inspection and compensation of additive manufacturing Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-01 Hao Wang, Hamzeh Al Shraida, Yu Jin
Purpose Limited geometric accuracy is one of the major challenges that hinder the wider application of additive manufacturing (AM). This paper aims to predict in-plane shape deviation for online inspection and compensation to prevent error accumulation and improve shape fidelity in AM. Design/methodology/approach A sequence-to-sequence model with an attention mechanism (Seq2Seq+Attention) is proposed
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Study on the mechanism and performance of 3D-printed PLA/epoxy composite for stab resistance Rapid Prototyping J. (IF 3.9) Pub Date : 2023-12-01 Zhe Du, Changjie Chen, Xinhou Wang
Purpose Stab-resistant body armor (SRBA) is used to protect the body from sharp knives. However, most SRBA materials currently have the disadvantages of large weight and thickness. This paper aims to prepare lightweight and high-performance SRBA by 3D printing truss structure and resin-filling method. Design/methodology/approach The stab resistance truss structure was prepared by the fused deposition
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On 3D printed intelligent diaphragmatic hernia sensor Rapid Prototyping J. (IF 3.9) Pub Date : 2023-11-29 Rupinder Singh, Gurwinder Singh, Arun Anand
Purpose The purpose of this paper is to design and manufacture an intelligent 3D printed sensor to monitor the re-occurrence of diaphragmatic hernia (DH; after surgery) in bovines as an Internet of Things (IOT)-based solution. Design/methodology/approach The approach used in this study is based on a bibliographic analysis for the re-occurrence of DH in the bovine after surgery. Using SolidWorks and
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Fabrication of continuous woven E-glass fiber composite using vat photopolymerization additive manufacturing process Rapid Prototyping J. (IF 3.9) Pub Date : 2023-11-20 Annada Prasad Moharana, Ratnesh Raj, Amit Rai Dixit
Purpose The industrial application of continuous glass fabric-reinforced polymer composites (GFRPCs) is growing; however, the manufacturing boundedness of complex structures and the high cost of molds restrict their use. This research proposes a three-dimensional (3 D) printing process for GFRPCs that allows low-cost and rapid fabrication of complex composite parts. Design/methodology/approach The
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Direct-print thermally responsive 4D textiles by depositing PLA on prestretched fabrics Rapid Prototyping J. (IF 3.9) Pub Date : 2023-11-17 Jinyu Zhang, Danni Shen, Yuxiang Yu, Defu Bao, Chao Li, Jiapei Qin
Purpose This study aims to develop a four-dimensional (4D) textile composite that self-forms upon thermal stimulation while eliminating thermomechanical programming steps by using fused deposition modeling (FDM) 3D printing technology, and tries to refine the product development path for this composite. Design/methodology/approach Polylactic acid (PLA) printing filaments were deposited on prestretched
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Additively manufactured rectangular waveguides for the electromagnetic characterization of materials using the transmission/reflection line method Rapid Prototyping J. (IF 3.9) Pub Date : 2023-11-10 Connor Shane Smith, Alanna Julius, Christian Arbeeny, John Davenport Stevens
Purpose Radio frequency (RF) technology relies on the electromagnetic properties of the materials used, which includes their complex permittivities and loss tangents. To measure these properties, techniques for material characterization such as the transmission/reflection method are used in conjunction with conversion techniques to calculate these values from scattering parameters. Unfortunately, these
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Numerical and experimental investigation on the heat transfer and mass transport in LPBF in-situ alloying of Al/Cu alloy Rapid Prototyping J. (IF 3.9) Pub Date : 2023-11-08 Yang Zhou, Zhong Li, Yuhe Huang, Xiaohan Chen, Xinggang Li, Xiaogang Hu, Qiang Zhu
Purpose Laser powder bed fusion (LPBF) in-situ alloying is a recently developed technology that provides a facile approach to optimizing the microstructural and compositional characteristics of the components for high performance goals. However, the complex mass and heat transfer behavior of the molten pool results in an inhomogeneous composition distribution within the samples fabricated by LPBF in-situ
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Multimaterial 3D printing of auxetic jounce bumpers for automotive suspensions Rapid Prototyping J. (IF 3.9) Pub Date : 2023-10-31 Alberto Giubilini, Paolo Minetola
Purpose The purpose of this study is to evaluate the 3D printability of a multimaterial, fully self-supporting auxetic structure. This will contribute to expanding the application of additive manufacturing (AM) to new products, such as automotive suspensions. Design/methodology/approach An experimental approach for sample fabrication on a multiextruder 3D printer and characterization by compression
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Investigation and optimization of hot pressed porcelain dental prostheses production by MSLA application Rapid Prototyping J. (IF 3.9) Pub Date : 2023-10-30 Ana Carla Cordeiro, Gustavo George Verdieri Nuernberg, Lilian Cristina Côcco, Marlon Wesley Machado Cunico
Purpose Different technologies may currently be used to produce dental prostheses, such as additive manufacturing and traditional milling. This study aims to evaluate and improve the fabrication process for hot-pressed porcelain dental prostheses and compare the use of masked stereolithography apparatus (MSLA) casting to computer-aided design/computer-aided manufacturing (CAD/CAM) casting. The cost-benefit
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Method for manufacturing ergonomic bespoke external breast prostheses using low-cost computer-aided technology Rapid Prototyping J. (IF 3.9) Pub Date : 2023-10-25 Lucia Regina, José Aguiomar Foggiatto
Purpose Breast cancer is the most diagnosed type of cancer in the world, and mastectomies to remove tumors are still common. An external breast prosthesis (EBP) can be used to minimize the asymmetry, due to the ablation. Some governments do not cover costs of that assistive technology, and women end up using socks and fabric pockets filled with seeds, to simulate the volume lost in the surgery. This
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Development of process-structure linkage for Inconel 718 processed by laser powder bed fusion: a numerical modeling approach Rapid Prototyping J. (IF 3.9) Pub Date : 2023-10-19 Anuj Kumar, Mukul Shukla
Purpose Understanding and tailoring the solidification characteristics and microstructure evolution in as-built parts fabricated by laser powder bed fusion (LPBF) is crucial as they influence the final properties. Experimental approaches to address this issue are time and capital-intensive. This study aims to develop an efficient numerical modeling approach to develop the process–structure (P-S) linkage
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Evaluation of a method for the additive tooling of injection mould inserts Rapid Prototyping J. (IF 3.9) Pub Date : 2023-10-19 Steffen Schrock, Stefan Junk, Albert Albers
Purpose This study aims to investigate a systematic approach to the production and use of additively manufactured injection mould inserts in product development (PD) processes. For this purpose, an evaluation of the additive tooling design method (ATDM) is performed. Design/methodology/approach The evaluation of the ATDM is conducted within student workshops, where students develop products and validate
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Simulation of temperature profile in fused filament fabrication 3D printing method Rapid Prototyping J. (IF 3.9) Pub Date : 2023-10-10 Nastaran Mosleh, Masoud Esfandeh, Soheil Dariushi
Purpose Temperature is a critical factor in the fused filament fabrication (FFF) process, which affects the flow behavior and adhesion of the melted filament and the mechanical properties of the final object. Therefore, modeling and predicting temperature in FFF is crucial for achieving high-quality prints, repeatability, process control and failure prediction. This study aims to investigate the melt