Rapid Prototyping Journal: Volume 23 Issue 1

A method of reproducing complex, multi-object anatomical structures

Tomasz Kudasik, Slawomir Miechowicz

This paper aims to present a method of reproducing multi-object structures from materials of diverse physical properties with the use of models fabricated by means of rapid…

Characterisation of direct 3D sand printing process for the production of sand cast mould tools

Philip Mark Hackney, Richard Wooldridge

Metal casting industry is in recovery phase after the crisis in 2008; customer demand continues to increase, with 98.6 million metric tons cast in 2011. Traditional ferrous and…

Effects of the unit cell topology on the compression properties of porous Co-Cr scaffolds fabricated via selective laser melting

Changjun Han, Chunze Yan, Shifeng Wen, Tian Xu, Shuai Li, Jie Liu, Qingsong Wei, Yusheng Shi

Selective laser melting (SLM) is an additive manufacturing process suitable for fabricating metal porous scaffolds. The unit cell topology is a significant factor that determines…

Effect of laser speeds on the mechanical property and corrosion resistance of CoCrW alloy fabricated by SLM

Yanjin Lu, Yiliang Gan, Junjie Lin, Sai Guo, Songquan Wu, Jinxin Lin

The aim of the study is to obtain dense Ni-free CoCrW parts fabricated by selective laser melting (SLM) technique for dental application.

Smooth geometry generation in additive manufacturing file format: problem study and new formulation

Kai-Ming Yu, Yu Wang, Charlie C.L. Wang

In the newly released ASTM standard specification for additive manufacturing file (AMF) format – version 1.1 – Hermite curve-based interpolation is used to refine input triangles…

Piezoelectric component fabrication using projection-based stereolithography of barium titanate ceramic suspensions

Xuan Song, Zeyu Chen, Liwen Lei, Kirk Shung, Qifa Zhou, Yong Chen

Conventional machining methods for fabricating piezoelectric components such as ultrasound transducer arrays are time-consuming and limited to relatively simple geometries. The…

Models partition for 3D printing objects using skeleton

Xiaotong Jiang, Xiaosheng Cheng, Qingjin Peng, Luming Liang, Ning Dai, Mingqiang Wei, Cheng Cheng

It is a challenge to print a model with the size that is larger than the working volume of a three-dimensional (3D) printer. The purpose of this paper is to present a feasible…

Stereo vision-based repair of metallic components

Renwei Liu, Zhiyuan Wang, Todd Sparks, Frank Liou, Cedo Nedic

This paper aims to investigate a stereo vision-based hybrid (additive and subtractive) manufacturing process using direct laser metal deposition, computer numerical control (CNC…

Investigation of concrete mixtures for additive construction

Todd S. Rushing, Ghassan Al-Chaar, Brian Andrew Eick, Jedadiah Burroughs, Jameson Shannon, Lynette Barna, Michael Case

This paper aims to qualify traditional concrete mixtures for large-scale material extrusion in an automated, additive manufacturing process or additive construction.

Rapid tooling using friction stir welding and machining

Esraa Saleh Abdel-All, Matthew Charles Frank, Iris Violeta Rivero

This paper aims to present a friction stir molding (FSM) method for the rapid manufacturing of metal tooling. The method uses additive and subtractive techniques to sequentially…

Feasibility study on accurate rapid prototyping for human hand bones and affiliated artery

Dafeng Ji, Peng Wang, Xinhua Zhang, Xinrong Chen

This paper aims to explore the feasibility of rapid prototyping for human hand bones and additional artery with topological preservation.

A digital design methodology for surgical planning and fabrication of customized mandible implants

Emad Abouel Nasr, Abdurahman Mushabab Al-Ahmari, Khaja Moiduddin, Mohammed Al Kindi, Ali K. Kamrani

The purpose of this paper is to demonstrate the route to digitize the customized mandible implants consisting of image acquisition, processing, implant design, fitting rehearsal…

Production of Ti-6Al-4V acetabular shell using selective laser melting: possible limitations in fabrication

AmirMahyar Khorasani, Ian Gibson, Moshe Goldberg, Guy Littlefair

The purpose of this paper is to improve the manufacturing of a prosthetic acetabular shell by analyzing the main factors leading to failure during the selective laser melting…

Tensile strength of partially filled FFF printed parts: experimental results

Shahrain Mahmood, A.J. Qureshi, Kheng Lim Goh, Didier Talamona

This paper aims to discuss the effect of changes of a comprehensive list of process parameters on part scalability and tensile strength of fused filament fabrication (FFF) printed…

Development of CNTs-filled photopolymer for projection stereolithography

Hengky Eng, Saeed Maleksaeedi, Suzhu Yu, Yu Ying Clarrisa Choong, Florencia Edith Wiria, Ruihua Eugene Kheng, Jun Wei, Pei-Chen Su, Huijun Phoebe Tham

Polymeric parts produced by 3D stereolithography (SL) process have poorer mechanical properties as compared to their counterparts fabricated via conventional methods, such as…

Activity model for homogenization of data sets in laser-based powder bed fusion

Shaw C. Feng, Paul Witherell, Gaurav Ameta, Duck Bong Kim

Additive manufacturing (AM) processes are the integration of many different science and engineering-related disciplines, such as material metrology, design, process planning…

Slice data representation and format for multi-material objects for additive manufacturing processes

Zhengyan Zhang, Sanjay Joshi

This paper aims to develop a slice-based representation of geometry and material information of a multi-material object to be produced by additive manufacturing. Representation of…

Tissue transformation mold design and stereolithography fabrication

Yihao Zheng, Yancheng Wang, Roland K. Chen, Sagar Deshpande, Noah S. Nelson, Steven R. Buchman, Albert J. Shih

To obtain a vascularized autologous bone graft by in-vivo tissue transformation, a biocompatible tissue transformation mold (TTM) is needed. An ideal TTM is of high geometric…

Geometrical analysis and tensile behaviour of parts manufactured with flame retardant polymers by additive manufacturing

Anderson Vicente Borille, Jefferson de Oliveira Gomes, Daniel Lopes

Flame-retardant plastics are used in critical applications, such as aircraft interior parts, when the occurrence of fire can lead to serious injury to people. However, there is a…

Structure and mechanical behavior of Big Area Additive Manufacturing (BAAM) materials

Chad E. Duty, Vlastimil Kunc, Brett Compton, Brian Post, Donald Erdman, Rachel Smith, Randall Lind, Peter Lloyd, Lonnie Love

This paper aims to investigate the deposited structure and mechanical performance of printed materials obtained during initial development of the Big Area Additive Manufacturing…

Dynamic resolution control in a laser projection-based stereolithography system

Yayue Pan, Chintan Dagli

In a typical additive manufacturing (AM) system, it is critical to make a trade-off between the resolution and the build area for applications in which varied dimensions, feature…

Investigation of additive manufacturing surface smoothing process

Marlon Wesley Machado Cunico, Miriam Machado Cunico, Patrick Medeiros Cavalheiro, Jonas de Carvalho

The additive manufacturing technologies have been facing an extraordinary growth along the past years. This phenomenon might be correlated with rise of low-cost FDM technologies…

3D printing for continuous fiber reinforced thermoplastic composites: mechanism and performance

Chuncheng Yang, Xiaoyong Tian, Tengfei Liu, Yi Cao, Dichen Li

Continuous fiber reinforced thermoplastic composites (CFRTPCs) are becoming more significant in industrial applications but are limited by the high cost of molds, the…