Design and manufacturing engineers are not fully aware of the different possibilities that PolyJet ä technology offers. The goal of this article is to provide the design and manufacturing engineers with greater knowledge about the final properties of parts printed with PolyJet rapid prototyping technology. This knowledge includes the effect of printing orientation and post-processing on the mechanical and surface properties of printed parts. Eighteen different samples considered all the possible printing orientations and the surface finishing treatments recommended by the manufacturer. These finishing properties include part printing using the matte/glossy option and removal of the support material using water pressure and/or a caustic soda bath. Tensile tests and surface roughness measurements were analysed for the printed samples using the statistical design of experiments in order to determinate the influence of the printing orientation and finishing properties on the results. These tests showed that the part orientation has a significant effect on elastic modulus and fracture stress while there is no statistical significance on ultimate tensile strength. With regard to the finish, none of the tensile test outputs showed significant differences. In terms of roughness, the analysis of variance indicated that position and finish presented statistically significant differences between the means of the three roughness directions. From all these experiences, it is possible to conclude that the glossy finish and the xy printing direction worked very well regarding roughness, whereas the critical load direction of the part should be placed along the x-axis when printing.
Rheumatoid arthritis is a chronic disease affecting the joints. Treatment can include immobilisation of the affected joint with a custom-fitting splint, which is typically fabricated by hand from low temperature thermoplastic, but the approach poses several limitations. This study focused on the evaluation, by finite element analysis, of additive manufacturing techniques for wrist splints in order to improve upon the typical splinting approach. An additive manufactured/3D printed splint, specifically designed to be built using Objet Connex multi-material technology and a virtual model of a typical splint, digitised from a real patient-specific splint using three-dimensional scanning, were modelled in computer-aided design software. Forty finite element analysis simulations were performed in flexion-extension and radial-ulnar wrist movements to compare the displacements and the stresses. Simulations have shown that for low severity loads, the additive manufacturing splint has 25%, 76% and 27% less displacement in the main loading direction than the typical splint in flexion, extension and radial, respectively, while ulnar values were 75% lower in the traditional splint. For higher severity loads, the flexion and extension movements resulted in deflections that were 24% and 60%, respectively, lower in the additive manufacturing splint. However, for higher severity loading, the radial defection values were very similar in both splints and ulnar movement deflection was higher in the additive manufacturing splint. A physical prototype of the additive manufacturing splint was also manufactured and was tested under normal conditions to validate the finite element analysis data. Results from static tests showed maximum displacements of 3.46, 0.97, 3.53 and 2.51 mm flexion, extension, radial and ulnar directions, respectively. According to these results, the present research argues that from a technical point of view, the additive manufacturing splint design stands at the same or even better level of performance in displacements and stress values in comparison to the typical low temperature thermoplastic approach and is therefore a feasible approach to splint design and manufacture.
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