Rapid Prototyping Journal: Volume 30 Issue 11

Enhanced-pixel strategy for wire arc additive manufacturing trajectory planning: operational efficiency and effectiveness analyses

Rafael Pereira Ferreira, Louriel Oliveira Vilarinho, Americo Scotti

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…

Effect of recycled powder and gear profile into the functionality of additive manufacturing polymer gears

Flaviana Calignano, Alessandro Bove, Vincenza Mercurio, Giovanni Marchiandi

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…

Manufacture of thermoplastic molds by fused filament fabrication 3D printing for rapid prototyping of polyurethane foam molded products

Guillermo Guerrero-Vacas, Jaime Gómez-Castillo, Oscar Rodríguez-Alabanda

Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using…

On the possibilities of merging additive manufacturing and powder injection molding in the production of metal parts

Martin Novák, Berenika Hausnerova, Vladimir Pata, Daniel Sanetrnik

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…

Mechanical properties and failure modes of additively-manufactured chiral metamaterials based on Euclidean tessellations: an experimental and finite element study

Luke Mizzi, Arrigo Simonetti, Andrea Spaggiari

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…

Design and characterization of 3D-printed TPU-based lattice structures. Application to methodology for the design of personalized therapeutic products

Sergio de la Rosa, Pedro F. Mayuet, Cátia S. Silva, Álvaro M. Sampaio, Lucía Rodríguez-Parada

This papers aims to study lattice structures in terms of geometric variables, manufacturing variables and material-based variants and their correlation with compressive behaviour…

Artificial reefs through additive manufacturing: a review of their design, purposes and fabrication process for marine restoration and management

Ilse Valenzuela Matus, Jorge Lino Alves, Joaquim Góis, Paulo Vaz-Pires, Augusto Barata da Rocha

The purpose of this paper is to review cases of artificial reefs built through additive manufacturing (AM) technologies and analyse their ecological goals, fabrication process…

Prototyping and characterisation of 316L stainless steel parts and lattice structures printed via metal fused filament fabrication

Ludovico Martignoni, Andrea Vegro, Sara Candidori, Mohammad Qasim Shaikh, Sundar V. Atre, Serena Graziosi, Riccardo Casati

This study aims to deepen the knowledge concerning the metal fused filament fabrication technology through an analysis of the printing parameters of a commercial 316L stainless…

Effects of anisotropy and infill pattern on compression properties of 3D printed CFRP: mechanical analysis and elasto-plastic finite element modelling

Francesco Bandinelli, Martina Scapin, Lorenzo Peroni

Finite element (FE) analysis can be used for both design and verification of components. In the case of 3D-printed materials, a proper characterization of properties, accounting…

Investigating surfaces, geometry and degree of fusion of tracks printed using fused deposition modelling to optimise process parameters for polymeric materials at meso-scale

Fredrick Mwania, Maina Maringa, Joseph Nsengimana, Jacobus Gert van der Walt

The current analysis was conducted to investigate the quality of surfaces and geometry of tracks printed using PolyMideTM CoPA, PolymaxTM PC and PolyMideTM PA6-CF materials…

Technical cleanliness of additively manufactured Inconel 718: a comparative study of surface treatment methods

Felix Endress, Julius Tiesler, Markus Zimmermann

Metal laser-powder-bed-fusion using laser-beam parts are particularly susceptible to contamination due to particles attached to the surface. This may compromise so-called…

Application of fused filament fabrication 3D printing and molding to produce flexible, scaled neuron morphology models

Osama Habbal, Ahmad Farhat, Reem Khalil, Christopher Pannier

The purpose of this study is to assess a novel method for creating tangible three-dimensional (3D) morphologies (scaled models) of neuronal reconstructions and to evaluate its…

Restoration of a wet corrosion-resistant composite filament for material extrusion process

Alessandro Bove, Fulvio Lieske, Flaviana Calignano, Luca Iuliano

Material extrusion (MEX) is one of the most known techniques in the additive manufacturing (AM) sector to produce components with a wide range of polymeric and composite…

Comparative fatigue performance of as-built vs etched Ti64 in TPMS-gyroid and stochastic structures fabricated via PBF-LB for biomedical applications

Miguel Araya-Calvo, Antti Järvenpää, Timo Rautio, Johan Enrique Morales-Sanchez, Teodolito Guillen-Girón

This study compares the fatigue performance and biocompatibility of as-built and chemically etched Ti-6Al-4V alloys in TPMS-gyroid and stochastic structures fabricated via Powder…

Productivity improvement opportunities for metal powder bed fusion technologies: a systematic literature review

Sean McConnell, David Tanner, Kyriakos I. Kourousis

Productivity is often cited as a key barrier to the adoption of metal laser-based powder bed fusion (ML-PBF) technology for mass production. Newer generations of this technology…

Polymer-based 3D printing of function-integrated optomechanics – design guidelines and system evaluation

Fabian Kranert, Moritz Hinkelmann, Roland Lachmayer, Jörg Neumann, Dietmar Kracht

This study aims to extend the known design guidelines for the polymer-based fused filament fabrication (FFF) 3D printing process with the focus on function-integrated components…

Effect of sintering temperature on feature resolution and flexural strength of ceramics fabricated through vat photopolymerization additive manufacturing

Lindsey Bezek, Kwan-Soo Lee

Although ceramic additive manufacturing (AM) could be used to fabricate complex, high-resolution parts for diverse, functional applications, one ongoing challenge is optimizing…

3D printing application for orthopedic pediatric surgery – a systematic review

Danilo Calderone, Giuseppe Cesarelli, Carlo Ricciardi, Francesco Amato, Fabrizio Clemente

This paper aims to present a systematic review of the latest scientific literature, in the context of pediatric orthopedics, on the development by additive manufacturing of…

3D printed polymers for transseptal puncture simulation

Francesco Buonamici, Tommaso Stomaci, Monica Carfagni

This study aims to examine the efficacy of 3D printing polymers to realistically mimic the fossa ovalis (FO) – a cardiac structure that is positioned in the interatrial septum �…

An alloy-agnostic machine learning framework for process mapping in laser powder bed fusion

Toby Wilkinson, Massimiliano Casata, Daniel Barba

This study aims to introduce an image-based method to determine the processing window for a given alloy system using laser powder bed fusion equipment based on achieving the…

Multi-material bronze-steel plain bearings produced by laser-directed energy deposition

Matteo Perini, Alessia Teresa Silvestri

This study aims to manufacture bimetallic bearings by achieving a sound deposition of bronze. Indeed, systems with rotating components use parts that reduce friction by allowing…

An investigation into the effect of CoCrMo powder characteristics on the powder bed density in laser-based powder bed fusion units

Cornelius P. Kloppers, Deon J. de Beer

The increased use cases for laser powder bed fusion (LPBF) in the research and commercial domains necessitate a better understanding of the inputs and the processing parameters…

RSM applied to lattice patterns for stiffness optimization

Giampiero Donnici, Marco Freddi, Alfredo Liverani

In this study, response surface methodology (RSM) is applied to a three-point bending stiffness analysis of low-cost material (PLA) specimens printed using FDM technology to…

A 3D printed microfluidic device for centrifugal droplet generation

Wojciech Kubicki, Aung Thiha, Tymon Janisz, Karunan Joseph, Nurul Fauzani Jamaluddin, Marc Madou, Rafał Walczak, Goran M. Stojanovic, Fatimah Ibrahim

This study aims to use an additive process for the first time to develop a microfluidic device that uses centrifugal technique for precise and repeatable generation of…

Sintering model for predicting distortion of additively manufactured complex parts

Elisa Torresani, Alberto Cabo Rios, Thomas Grippi, Andrii L. Maximenko, Marco Zago, Ilaria Cristofolini, Eugene A. Olevsky

This study aims to provide understanding of the influence of external factors, such as gravity, during sintering of three dimensional (3D)-printed parts in which the initial…