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SummaryWe review the process rates and energy intensities of various additive processing technologies and focus on recent progress in improving these metrics for laser powder bed fusion processing of metals, and filament and pellet extrusion processing of polymers and composites. Over the last decade, observed progress in raw build rates has been quite substantial, with laser metal processes improving by about 1 order of magnitude, and polymer extrusion processes by more than 2 orders of magnitude. We develop simple heat transfer models that explain these improvements, point to other possible strategies for improvement, and highlight rate limits. We observe a pattern in laser metal technologies that mimics the development of machine tools; an efficiency plateau, where faster rates require more power with no change in energy nor rate efficiency.

PurposeThe purpose of this paper is to present results of an investigation, where the elastic tensor based on the engineering constants of sinterized Nylon 12 is characterized and is modeled considering a transversely isotropic behavior as a function of apparent density (relative mass density).Design/methodology/approachThe ultrasound propagation velocity measurement through the material in specific directions by means of the pulse transmission method was used, relating the elastic tensor elements to the phase velocity magnitude through Christoffel's equation. In addition conventional uniaxial tensile tests were carried out to validate the used technique. Laser sintering of Nylon 12 powder (Duraform PA) has been performed at different laser energy densities, fabricating cube‐shaped coupons as well as dogbone flat coupons, using an SLS 125 former DTM machine.FindingsCorrelations for each one of the Young moduli, Shear constants and Poisson's ratios, presenting an exponential behavior as a function of the sintering degree, were generated. In addition, as the apparent density reaches a maximum value of 977 kg/m3 at an energy density of 0.032 J/mm2, the material behaves in an almost isotropic form, presenting average values for the Young modulus, Shear modulus and Poisson's ratio corresponding to 2,310 MPa, 803 MPa and 0.408, respectively.Research limitations/implicationsThe research is limited only to one type of material within the elastic range. Validation of the Young modulus measured along one direction only is performed using a tensile test machine, due to the difficulties in evaluating Poisson's ratios and Shear moduli using conventional tests.Practical implicationsThe results presented can be applied to virtual design and evaluating processes such as finite element analysis.Originality/valueThe paper incorporates detailed information regarding the complete elastic characteristics of Nylon 12, including additional measurements of the Shear moduli and Poisson's ratios not studied previously.

Purpose -In medical applications, it is crucial to evaluate the geometric accuracy of rapid prototyping (RP) models. Current research on evaluating geometric accuracy has focused on identifying two or more specific anatomical landmarks on the original structure and the RP model, and comparing their corresponding linear distances. Such kind of accuracy metrics is ambiguous and may induce misrepresentations of the actual errors. The purpose of this paper is to propose an alternative method and metrics to measure the accuracy of RP models. Design/methodology/approach -The authors propose an accuracy metric composed of two different approaches: a global accuracy evaluation using volumetric intersection indexes calculated over segmented Computed Tomography scans of the original object and the RP model. Second, a local error metric that is computed from the surfaces of the original object and the RP model. This local error is rendered in a 3D surface using a color code, that allow differentiating regions where the model is overestimated, underestimated, or correctly estimated. Global and local error measurements are performed after rigid body registration, segmentation and triangulation. Findings -The results show that the method can be applied to different objects without any modification, and provide simple, meaningful and precise quantitative indexes to measure the geometric accuracy of RP models. Originality/value -The paper presents a new approach to characterize the geometric errors in RP models using global indexes and a local surface distribution of the errors. It requires minimum human intervention and it can be applied without any modification to any kind of object.

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Polymer scaffolds are used as an alternative to support tissue regeneration when it does not occur on its own. Cell response on polymer scaffolds is determined by factors such as polymer composition, topology, and the presence of other molecules. We evaluated the cellular response of murine skeletal muscle myoblasts on aligned or unaligned fibers obtained by electrospinning poly(ε-caprolactone) (PCL), and blends with poly(lactic-co-glycolic acid) (PLGA) or decorin, a proteoglycan known to regulate myogenesis. The results showed that aligned PCL fibers with higher content of PLGA promote cell growth and improve the quality of differentiation with PLGA scaffolds having the highest confluence at over 68% of coverage per field of view for myoblasts and more than 7% of coverage for myotubes. At the same time, the addition of decorin greatly improves the quantity and quality of differentiated cells in terms of cell fusion, myotube length and thickness, being 71, 10, and 51% greater than without the protein, respectively. Interestingly, our results suggest that at certain concentrations, the effect of decorin on myoblast differentiation exceeds the topological effect of fiber alignment. © 2017 Wiley Periodicals, Inc. J Biomed Mater Res Part A: 105A: 2241-2251, 2017.

This work reports a theoretical and numerical study of the parameters related to the process of laser powder deposition through a lateral nozzle. For this purpose, a 3D quasi-stationary finite element model was developed analytically and implemented numerically. The proposed model estimates the shape of the melt pool depending on the process parameters including scanning speed, powder mass flow, laser power, and physical properties. Also, phase transformations and physical properties (density, thermal conductivity, and specific heat) vary as function of temperature. In addition, thermo-capillary forces and their effect on fluid flow inside the melt pool are considered. The obtained set of equations coupled through the temperature variable was solved using COMSOL Multiphysics. The results are presented and compared with previously obtained experimental data, in which chromium powder was deposited, allowing validation of the model. Finally, variations at the melt pool geometry in terms of the operational parameters are analyzed. This model aims at estimation of melt pool geometry during laser powder deposition in time reasonably short to allow for predictable process control.