Advanced FFF of PEEK: Infill Strategies and Material Characteristics for Rapid Tooling.

Traditional vulcanization mold manufacturing is complex, costly, and under pressure due to shorter product lifecycles and diverse variations. Additive manufacturing using Fused Filament Fabrication and high-performance polymers like PEEK offer a promising future in this industry. This study assesses the compressive strength of various infill structures (honeycomb, grid, triangle, cubic, and gyroid) when considering two distinct build directions (Z, XY) to enhance PEEK's economic and resource efficiency in rapid tooling. A comparison with PETG samples shows the behavior of the infill strategies. Additionally, a proof of concept illustrates the application of a PEEK mold in vulcanization. A peak compressive strength of 135.6 MPa was attained in specimens that were 100% solid and subjected to thermal post-treatment. This corresponds to a 20% strength improvement in the Z direction. In terms of time and mechanical properties, the anisotropic grid and isotropic cubic infill have emerged for use in rapid tooling. Furthermore, the study highlights that reducing the layer thickness from 0.15 mm to 0.1 mm can result in a 15% strength increase. The study unveils the successful utilization of a room-temperature FFF-printed PEEK mold in vulcanization injection molding. The parameters and infill strategies identified in this research enable the resource-efficient FFF printing of PEEK without compromising its strength properties. Using PEEK in rapid tooling allows a cost reduction of up to 70% in tool production.

Process Parameter Optimization for Hybrid Manufacturing of PLA Components with Improved Surface Quality.

This paper presents a new method of process parameter optimization, adequate for 3D printing of PLA (Polylactic Acid) components. The authors developed a new piece of Hybrid Manufacturing Equipment (HME), suitable for producing complex parts made from a biodegradable thermoplastic polymer, to promote environmental sustainability. Our new HME equipment produces PLA parts by both additive and subtractive techniques, with the aim of obtaining accurate PLA components with good surface quality. A design of experiments has been applied for optimization purposes. The following manufacturing parameters were analyzed: rotation of the spindle, cutting depth, feed rate, layer thickness, nozzle speed, and surface roughness. Linear regression models and neural network models were developed to improve and predict the surface roughness of the manufactured parts. A new test part was designed and manufactured from PLA to validate the new mathematical models, which can now be applied for producing complex parts made from polymer materials. The neural network modeling (NNM) allowed us to obtain much better precision in predicting the final surface roughness (Ra), as compared to the conventional linear regression models (LNM). Based on these modelling methods, the authors developed a practical methodology to optimize the process parameters in order to improve the surface quality of the 3D-printed components and to predict the actual roughness values. The main advantages of the results proposed for hybrid manufacturing using polymer materials like PLA are the optimized process parameters for both 3D printing and milling. A case study has been undertaken by the authors, who designed a specific test part for their new hybrid manufacturing equipment (HME), in order to test the new methodology of optimizing the process parameters, to validate the capability of the new HME. At the same time, this new methodology could be replicated by other researchers and is useful as a guideline on how to optimize the process parameters for newly developed equipment. The innovative approach holds potential for widespread equipment functionality enhancement among other users.

Finite Element Analysis of Different Osseocartilaginous Reconstruction Techniques in Animal Model Knees.

Lesions of the articular cartilage are frequent in all age populations and lead to functional impairment. Multiple surgical techniques have failed to provide an effective method for cartilage repair. The aim of our research was to evaluate the effect of two different compression forces on three types of cartilage repair using finite element analysis (FEA). Initially, an in vivo study was performed on sheep. The in vivo study was prepared as following: Case 0-control group, without cartilage lesion; Case 1-cartilage lesion treated with macro-porous collagen implants; Case 2-cartilage lesion treated with collagen implants impregnated with bone marrow concentrate (BMC); Case 3-cartilage lesion treated with collagen implants impregnated with adipose-derived stem cells (ASC). Using the computed tomography (CT) data, virtual femur-cartilage-tibia joints were created for each Case. The study showed better results in bone changes when using porous collagen implants impregnated with BMC or ASC stem cells for the treatment of osseocartilaginous defects compared with untreated macro-porous implant. After 7 months postoperative, the presence of un-resorbed collagen influences the von Mises stress distribution, total deformation, and displacement on the Z axis. The BMC treatment was superior to ASC cells in bone tissue morphology, resembling the biomechanics of the control group in all FEA simulations.

Recycled PET Composites Reinforced with Stainless Steel Lattice Structures Made by AM.

Polyethylene terephthalate (PET) recycling is one of the most important environmental issues, assuring a cleaner environment and reducing the carbon footprint of technological products, taking into account the quantities used year by year. The recycling possibilities depend on the quality of the collected material and on the targeted product. Current research aims to increase recycling quantities by putting together recycled PET in an innovative way as a filler for the additive manufactured metallic lattice structure. Starting from the structures mentioned above, a new range of composite materials was created: IPC (interpenetrating phase composites), materials with a complex architecture in which a solid phase, the reinforcement, is uniquely combined with the other phase, heated to the temperature of melting. The lattice structure was modeled by the intersection of two rings using Solid Works, which generates the lattice structure, which was further produced by an additive manufacturing technique from 316L stainless steel. The compressive strength shows low values for recycled PET, of about 26 MPa, while the stainless-steel lattice structure has about 47 MPa. Recycled PET molding into the lattice structure increases its compressive strength at 53 MPa. The Young's moduli are influenced by the recycled PET reinforcement by an increase from about 1400 MPa for the bare lattice structure to about 1750 MPa for the reinforced structure. This sustains the idea that recycled PET improves the composite elastic behavior due to its superior Young's modulus of about 1570 MPa, acting synergically with the stainless-steel lattice structure. The morphology was investigated with SEM microscopy, revealing the binding ability of recycled PET to the 316L surface, assuring a coherent composite. The failure was also investigated using SEM microscopy, revealing that the microstructural unevenness may act as a local tensor, which promotes the interfacial failure within local de-laminations that weakens the composite, which finally breaks.

Impact of laser parameters on additively manufactured cobalt-chromium restorations.

STATEMENT OF PROBLEM: The selective laser melting (SLM) process has become popular for the fabrication of frameworks for metal-ceramic restorations, although their surface roughness is greater than with cast or milled frameworks. Limited information is available regarding the surface mechanical characteristics of cobalt-chromium (Co-Cr) SLM-manufactured restorations. PURPOSE: The purpose of this in vitro study was to adapt the laser parameters for a remelting strategy, scanning the outer boundary of Co-Cr specimens, to reduce surface roughness and solidification defects, to determine microhardness, to investigate surface morphology and microstructure, and to establish surface mechanical characteristics. MATERIAL AND METHODS: Co-Cr specimens were SLM manufactured by using a typical melting (TM) strategy and an adaptive remelting (AR) strategy. The AR strategy involves rescanning 50% of the contour, varying the laser parameters. The roughness parameters considered were Ra and Rz. Vickers hardness was measured by microindentation with a 9.81-N force (ASTM E384-17). The surface morphology was investigated by scanning electron microscopy, the chemical composition by energy-dispersive X-ray spectroscopy, and the phase identification by using X-ray diffraction. The mechanical surface properties measured were the nanohardness, elastic modulus, and dissipation energy. One-way ANOVA with the Tukey procedure was used to compare the groups (α=.05). RESULTS: The innovative AR strategy reduced the surface roughness by 45% compared with TM, comparable with their cast counterpart. The smoothest AR surface was obtained by using 75 W and 350 mm/s for the first scanning of the contour, followed by a second remelting with 80 W and 700 mm/s. The microstructure of AR specimens had limited solidification defects, a chemical composition similar to that of raw powder, and a surface microhardness over 600 HV1. A fine grain structure in a single matrix phase was detected both on TM and AR specimens. The mechanical characteristics of the smoothest Co-Cr surface were 218 GPa elastic modulus, 746 HVIT Vickers nanohardness, 21 243 pJ plastic energy, and 26% nanoindentation work ratio. Significant differences were observed between the melting strategies (P<.05) both for surface roughness and microhardness. CONCLUSIONS: The laser scanning strategy affects both the surface roughness and the hardness of SLM-manufactured specimens. The results show that using the AR strategy and proper laser parameters can reduce the roughness and increase the surface hardness of Co-Cr specimens made of conventional powder feedstock.

Physical-Mechanical Characteristics and Microstructure of Ti6Al7Nb Lattice Structures Manufactured by Selective Laser Melting.

The demand of lattice structures for medical applications is increasing due to their ability to accelerate the osseointegration process, to reduce the implant weight and the stiffness. Selective laser melting (SLM) process offers the possibility to manufacture directly complex lattice applications, but there are a few studies that have focused on biocompatible Ti6Al7Nb alloy. The purpose of this work was to investigate the physical-mechanical properties and the microstructure of three dissimilar lattice structures that were SLM-manufactured by using Ti6Al7Nb powder. In particular, the strut morphology, the fracture characterization, the metallographic structure, and the X-ray phase identification were analyzed. Additionally, the Gibson-Ashby prediction model was adapted for each lattice topology, indicating the theoretical compressive strength and Young modulus. The resulted porosity of these lattice structures was approximately 56%, and the pore size ranged from 0.40 to 0.91 mm. Under quasi-static compression test, three failure modes were recorded. Compared to fully solid specimens, the actual lattice structures reduce the elastic modulus from 104 to 6-28 GPa. The struts surfaces were covered by a large amount of partial melted grains. Some solidification defects were recorded in struts structure. The fractographs revealed a brittle rupture of struts, and their microstructure was mainly α' martensite with columnar grains. The results demonstrate the suitability of manufacturing lattice structures made of Ti6Al7Nb powder having unique physical-mechanical properties which could meet the medical requirements.

Improving the Mechanical Strength of Dental Applications and Lattice Structures SLM Processed.

To manufacture custom medical parts or scaffolds with reduced defects and high mechanical characteristics, new research on optimizing the selective laser melting (SLM) parameters are needed. In this work, a biocompatible powder, 316L stainless steel, is characterized to understand the particle size, distribution, shape and flowability. Examination revealed that the 316L particles are smooth, nearly spherical, their mean diameter is 39.09 µm and just 10% of them hold a diameter less than 21.18 µm. SLM parameters under consideration include laser power up to 200 W, 250-1500 mm/s scanning speed, 80 µm hatch spacing, 35 µm layer thickness and a preheated platform. The effect of these on processability is evaluated. More than 100 samples are SLM-manufactured with different process parameters. The tensile results show that is possible to raise the ultimate tensile strength up to 840 MPa, adapting the SLM parameters for a stable processability, avoiding the technological defects caused by residual stress. Correlating with other recent studies on SLM technology, the tensile strength is 20% improved. To validate the SLM parameters and conditions established, complex bioengineering applications such as dental bridges and macro-porous grafts are SLM-processed, demonstrating the potential to manufacture medical products with increased mechanical resistance made of 316L.

Cranioplasty with custom-made implants: analyzing the cases of 10 patients.

PURPOSE: The aim of this study was to assess quantitatively whether a symmetric reconstruction of the calvaria could be achieved using 3-dimensional (3D) custom-made implants and to examine any complications caused by the cranioplasty. PATIENTS AND METHODS: Custom-made cranial implants were produced using data obtained from computed tomographic scanning of the defect using computer-aided design and rapid prototyping techniques. Polymethylmethacrylate was used as the reconstruction material and the implant was cast from a silicone rubber mold. These implants were used in 10 patients (9 men and 1 woman) who previously received a craniectomy. The symmetry gained after cranioplasty was quantified by volumetric analysis using 3D reconstructed postoperative computed tomographic imaging. Any complications after cranioplasty also were recorded. RESULTS: The average follow-up was 42.5 months (range, 7 to 85 mo). The esthetic appearance of all patients was much improved. When the volume of the reconstructed right calvaria was compared with the left calvaria, the difference was not statistically significant (P > .05). There were 2 cases of complications. One exhibited a transient seroma collection. Another had a wrinkle formation in the forehead. No infectious episodes or signs of plate rejection were encountered. CONCLUSIONS: The custom-made implants for cranioplasty showed a significant improvement in morphology. The implants may be very useful for repairing large and complex-shaped cranial defects. The technique may be useful for the bone reconstruction of other sites.