Effects of Different Polypropylene (PP)-Backbones in Aluminium Feedstock for Fused Filament Fabrication (FFF).

The current study presents the effect of the backbone as an important binder component on the mechanical, rheological, and thermal properties of Aluminium (Al) alloy feedstocks. A thermoplastic elastomer (TPE) main binder component was blended with either polypropylene (PP), grafted-maleic anhydride-PP (PPMA), or grafted-maleic anhydride-PPwax (PPMAwax) plus PP, as the backbone. Differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) tests were performed to investigate the thermal properties of binder systems and feedstocks. Fourier-transform infrared (FTIR) spectroscopy was used to study the chemical interaction between the binder and the Al alloy. After making feedstock filaments, tensile tests, scanning electron microscopy (SEM), and fused filament fabrication (FFF) printing were done. The results showed that although the PP printability was acceptable, the best mechanical properties and printed quality can be achieved by PPMA. TGA test showed that all binder systems in the feedstocks could be removed completely around 500 °C. From FTIR, the possibility of chemical reactions between Al alloy particles and maleic anhydride groups on the grafted PP backbone could explain the better dispersion of the mixture and higher mechanical properties. Tensile strength in PP samples was 3.4 MPa which was improved 1.8 times using PPMA as the backbone.

Influence of Binder Composition and Material Extrusion (MEX) Parameters on the 3D Printing of Highly Filled Copper Feedstocks.

This work aims to better understand the type of thermoplastic binders required to produce highly loaded copper filaments that can be successfully printed via low-cost filament-based material extrusion (MEX). Compounding feedstock material with 55 vol.% of copper and three multi-component binder systems has been performed. The MEX behavior of these feedstocks was evaluated by depositing material at different speeds and appropriately selecting the extrusion temperature depending on the binder composition. The rest of the MEX parameters remained constant to evaluate the printing quality for the different feedstocks. Printable filaments were produced with low ovality and good surface quality. The filaments showed good dispersion of the powder and polymeric binder system in SEM analysis. The feedstock mechanical properties, i.e., the tensile strength of the filament, were sufficient to ensure proper feeding in the MEX machine. The viscosity of the feedstock systems at the adjusted printing temperatures lies in the range of 102-103 Pa·s at the shear rate of 100-1000 s-1, which appears to be sufficient to guarantee the correct flowability and continuous extrusion. The tensile properties vary greatly (e.g., ultimate tensile strength 3-9.8 MPa, elongation at break 1.5-40.5%), and the most fragile filament could not be reliably printed at higher speeds. Micrographs of the cross-section of printed parts revealed that as the printing speed increased, the porosity was minimized because the volumetric flow of the feedstock material increased, which can help to fill pores. This study offers new insights into the feedstock requirements needed to produce low-cost intricate copper components of high quality in a reliable and efficient manner. Such components can find many applications in the electronics, biomedical, and many other industries.

Effect of Increased Powder-Binder Adhesion by Backbone Grafting on the Properties of Feedstocks for Ceramic Injection Molding.

The good interaction between the ceramic powder and the binder system is vital for ceramic injection molding and prevents the phase separation during processing. Due to the non-polar structure of polyolefins such as high-density polyethylene (HDPE) and the polar surface of ceramics such as zirconia, there is not appropriate adhesion between them. In this study, the effect of adding high-density polyethylene grafted with acrylic acid (AAHDPE), with high polarity and strong adhesion to the powder, on the rheological, thermal and chemical properties of polymer composites highly filled with zirconia and feedstocks was evaluated. To gain a deeper understanding of the effect of each component, formulations containing different amounts of HDPE and or AAHDPE, zirconia and paraffin wax (PW) were prepared. Attenuated total reflection spectroscopy (ATR), scanning electron microscopy (SEM), differential scanning calorimetry (DSC) and rotational and capillary rheology were used for the characterization of the different formulations. The ATR analysis revealed the formation of hydrogen bonds between the hydroxyl groups on the zirconia surface and AAHDPE. The improved powder-binder adhesion in the formulations with more AAHDPE resulted in a better powder dispersion and homogeneous mixtures, as observed by SEM. DSC results revealed that the addition of AAHDPE, PW and zirconia effect the melting and crystallization temperature and crystallinity of the binder, the polymer-filled system and feedstocks. The better powder--binder adhesion and powder dispersion effectively decreased the viscosity of the highly filled polymer composites and feedstocks with AAHDPE; this showed the potential of grafted polymers as binders for ceramic injection molding.

Metal fused filament fabrication of the nickel-base superalloy IN 718.

This study demonstrates metal fused filament fabrication (MF3) as an alternative additive and highly flexible manufacturing method for free-form fabrication of high-performance alloys. This novel processing, which is similar to Metal injection molding (MIM), enables a significant reduction in manufacturing costs for complex geometries, since expensive machining can be avoided. Utilizing existing equipment and reducing material expense, MF3 can pave the way for new and low-cost applications of IN 718, which were previously limited by high manufacturing costs. Iterative process optimization is used to find the most suitable MF3 process parameters. High relative density above 97% after pressureless sintering can be achieved if temperature profiles and atmospheres are well adjusted for thermal debinding and sintering. In this study, the influence of processing parameters on the resulting microstructure of MF3 IN 718 is investigated. Samples sintered in vacuum show coarse-grained microstructure with an area fraction of 0.36% NbC at grain boundaries. Morphology and composition of formed precipitates are analyzed using transmission electron microscopy and atom probe tomography. The γ/γ″/γ' phases' characteristics for IN 718 were identified. Conventional heat treatment is applied for further tailoring of mechanical properties like hardness, toughness and creep behavior. Fabricated samples achieve mechanical properties similar to MIM IN 718 presented in literature.

Research Progress on Low-Pressure Powder Injection Molding.

Powder injection molding (PIM) is a well-known technique to manufacture net-shaped, complicated, macro or micro parts employing a wide range of materials and alloys. Depending on the pressure applied to inject the feedstock, this process can be separated into low-pressure (LPIM) and high-pressure (HPIM) injection molding. Although the LPIM and HPIM processes are theoretically similar, all steps have substantial differences, particularly feedstock preparation, injection, and debinding. After decades of focusing on HPIM, low-viscosity feedstocks with improved flowability have recently been produced utilizing low-molecular-weight polymers for LPIM. It has been proven that LPIM can be used for making parts in low quantities or mass production. Compared to HPIM, which could only be used for the mass production of metallic and ceramic components, LPIM can give an outstanding opportunity to cover applications in low or large batch production rates. Due to the use of low-cost equipment, LPIM also provides several economic benefits. However, establishing an optimal binder system for all powders that should be injected at extremely low pressures (below 1 MPa) is challenging. Therefore, various defects may occur throughout the mixing, injection, debinding, and sintering stages. Since all steps in the process are interrelated, it is important to have a general picture of the whole process which needs a scientific overview. This paper reviews the potential of LPIM and the characteristics of all steps. A complete academic and research background survey on the applications, challenges, and prospects has been indicated. It can be concluded that although many challenges of LPIM have been solved, it could be a proper solution to use this process and materials in developing new applications for technologies such as additive manufacturing and processing of sensitive alloys.

Influence of the Infill Orientation on the Properties of Zirconia Parts Produced by Fused Filament Fabrication.

The fused filament fabrication (FFF) of ceramics enables the additive manufacturing of components with complex geometries for many applications like tooling or prototyping. Nevertheless, due to the many factors involved in the process, it is difficult to separate the effect of the different parameters on the final properties of the FFF parts, which hinders the expansion of the technology. In this paper, the effect of the fill pattern used during FFF on the defects and the mechanical properties of zirconia components is evaluated. The zirconia-filled filaments were produced from scratch, characterized by different methods and used in the FFF of bending bars with infill orientations of 0°, ±45° and 90° with respect to the longest dimension of the specimens. Three-point bending tests were conducted on the specimens with the side in contact with the build platform under tensile loads. Next, the defects were identified with cuts in different sections. During the shaping by FFF, pores appeared inside the extruded roads due to binder degradation and or moisture evaporation. The changes in the fill pattern resulted in different types of porosity and defects in the first layer, with the latter leading to earlier fracture of the components. Due to these variations, the specimens with the 0° infill orientation had the lowest porosity and the highest bending strength, followed by the specimens with ±45° infill orientation and finally by those with 90° infill orientation.

Fused Filament Fabrication (FFF) of Metal-Ceramic Components.

Technical ceramics are widely used for industrial and research applications, as well as for consumer goods. Today, the demand for complex geometries with diverse customization options and favorable production methods is increasing continuously. With fused filament fabrication (FFF), it is possible to produce large and complex components quickly with high material efficiency. In FFF, a continuous thermoplastic filament is melted in a heated nozzle and deposited below. The computer-controlled print head is moved in order to build up the desired shape layer by layer. Investigations regarding printing of metals or ceramics are increasing more and more in research and industry. This study focuses on additive manufacturing (AM) with a multi-material approach to combine a metal (stainless steel) with a technical ceramic (zirconia: ZrO2). Combining these materials offers a broad variety of applications due to their different electrical and mechanical properties. The paper shows the main issues in preparation of the material and feedstock, device development, and printing of these composites.

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives.

Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented.

Comparison of tissue plasminogen activator administration management between Telestroke Network hospitals and academic stroke centers: the Telemedical Pilot Project for Integrative Stroke Care in Bavaria/Germany.

BACKGROUND AND PURPOSE: Systemic thrombolysis is the only therapy proven to be effective for ischemic stroke. Telemedicine may help to extend its use. However, concerns remain whether management and safety of tissue plasminogen activator (tPA) administration after telemedical consultation are equivalent in less experienced hospitals compared with tPA administration in academic stroke centers. METHODS: During the second year of the ongoing Telemedical Pilot Project for Integrative Stroke Care, all systemic thrombolyses in stroke patients of the 12 regional clinics and the 2 stroke centers were recorded prospectively. Patients' demographics, stroke severity (National Institutes of Health Stroke Scale), frequency of administration, time management, protocol violations, and safety were included in the analysis. RESULTS: In 2004, 115 of 4727 stroke or transient ischemic attack patients (2.4%) in the community hospitals and 110 of 1889 patients in the stroke centers (5.8%) received systemic thrombolysis. Prehospital latencies were shorter in the regional hospitals despite longer distances. Door to needle times were shorter in the stroke centers. Although blood pressure was controlled more strictly in community hospitals, symptomatic intracerebral hemorrhage rate (7.8%) was higher (P=0.14) than in stroke centers (2.7%) but still within the range of the National Institute of Neurological Disorders and Stroke trial. In-hospital mortality rate was low in community hospitals (3.5%) and in stroke centers (4.5%). CONCLUSIONS: Although with a lower rate of systemic thrombolysis, there was no evidence of lower treatment quality in the remote hospitals. With increasing numbers of tPA administration and growing training effects, the telestroke concept promises better coverage of systemic thrombolysis in nonurban areas.

Telemedicine for safe and extended use of thrombolysis in stroke: the Telemedic Pilot Project for Integrative Stroke Care (TEMPiS) in Bavaria.

BACKGROUND AND PURPOSE: Systemic thrombolysis represents the only proven therapy for acute ischemic stroke, but safe treatment is reported only in established stroke units. One major goal of the ongoing Telemedic Pilot Project for Integrative Stroke Care (TEMPiS) in Bavaria is to extend the use of tissue plasminogen activator (tPA) treatment in nonurban areas through telemedic support. METHODS: The stroke centers in Munich-Harlaching and in Regensburg established a telestroke network to provide consultations for 12 local hospitals in eastern Bavaria. The telemedic system consists of a digital network that includes a 2-way video conference system and CT/MRI image transfer with a high-speed data transmission up to 2 Mb/s. Each network hospital established specialized stroke wards in which qualified teams treat acute stroke patients. Physicians in these hospitals are able to contact the stroke centers 24 hours per day. RESULTS: A total of 106 systemic thrombolyses were indicated via teleconsultations between February 1, 2003, and April 7, 2004. During the first 12 months, the rate of thrombolyses was 2.1% of all stroke patients. Mean age was 68 years, and median National Institutes of Health Stroke Scale score was 13. Mean delay between onset and hospital admission was 65 minutes, and door-to-needle time was on average 76 minutes, which included 15 minutes for the teleconsultation. Symptomatic hemorrhage occurred in 8.5% of patients, and in-hospital mortality was 10.4%. CONCLUSIONS: The present data suggest that systemic thrombolysis indicated via stroke experts in the setting of teleconsultation exhibits similar complication rates to those reported in the National Institute of Neurological Disorders and Stroke trial. Therefore, tPA treatment is also safe in this context and can be extended to nonurban areas.

Elevated C-reactive protein is associated with an increased intima to media thickness of the common carotid artery.

In this study, we analyzed the relationship between serum C-reactive protein (CRP) and the intima to media thickness (IMT) of the common carotid artery in 411 consecutive neurological inpatients (215 males, mean age 64.1 years). The CRP concentration was determined within 12 h and patients were subdivided according to the CRP level. Patients with an elevated CRP (n = 149) showed a significantly larger IMT [1.05 mm (95% confidence interval (CI) 1.02-1.09) vs. 0.92 mm (95% CI 0.89-0.94)]. Multivariate linear regression analysis revealed that an elevated CRP level, age, pack-years of smoking, body mass index, incidence of diabetes mellitus and ischemic stroke were independently associated with an increased IMT (p < 0.05).