A Comparative Study between Polymer and Metal Additive Manufacturing Approaches in Investigating Stiffened Hexagonal Cells

Laban, Othman; Mahdi, E.; Samim, Samahat; Cabibihan, John-John

doi:10.3390/ma14040883

Cited by 8 publications

(8 citation statements)

References 20 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Of course, different materials have their own specific mechanical behavior, especially in the case of additive manufacturing. However, in an elastic region, this difference is minimal [ 19 , 20 ], especially if the same material specimens are used. That is why, because of economic expediency, the specimens were made from photopolymer resin.…”

Section: Methodsmentioning

confidence: 99%

Numerical and Experimental Study of a Lattice Structure for Orthopedic Applications

2023

View full text Add to dashboard Cite

Prosthetic reconstructions provide anatomical reconstruction to replace bones and joints. However, these operations have a high number of short- and long-term complications. One of the main problems in surgery is that the implant remains in the body after the operation. The solution to this problem is to use biomaterial for the implant, but biomaterial does not have the required strength characteristics. The implant must also have a mesh-like structure so that the bone can grow into the implant. The additive manufacturing process is ideal for the production of such a structure. The study deals with the correlation between different prosthetic structures, namely, the relationship between geometry, mechanical properties and biological additivity. The main challenge is to design an endoprosthesis that will mimic the geometric structure of bone and also meet the conditions of strength, hardness and stiffness. In order to match the above factors, it is necessary to develop appropriate algorithms. The main objective of this study is to augment the algorithm to ensure minimum structural weight without changing the strength characteristics of the lattice endoprosthesis of long bones. The iterative augmentation process of the algorithm was implemented by removing low-loaded ribs. A low-loaded rib is a rib with a maximum stress that is less than the threshold stress. Values within the range (10, 13, 15, 16, 17, 18, 19 and 20 MPa) were taken as the threshold stress. The supplement to the algorithm was applied to the initial structure and the designed structure at threshold stresses σf = 10, 13, 15, 16, 17, 18, 19 and 20 MPa. A Pareto diagram for maximum stress and the number of ribs is plotted for all cases of the design: original, engineered and lightened structures. The most optimal was the designed “lightweight” structure under the condition σf = 17 MPa. The maximum stress was 147.48 MPa, and the number of ribs was 741. Specimens were manufactured using additive manufacturing and then tested for four-point bending.

show abstract

Section: Methodsmentioning

confidence: 99%

Numerical and Experimental Study of a Lattice Structure for Orthopedic Applications

2023

View full text Add to dashboard Cite

show abstract

“…Concerning 3D-printed structures, energy absorption characteristics have been studied by many researchers (Habib et al, 2017;Antony et al, 2020;Laban et al, 2021). Many of these studies have considered 3D-printed structures with different geometries and shapes inspired by nature, numerical topology optimization, or parametric design.…”

Section: Introductionmentioning

confidence: 99%

“…The authors in Laban et al (2021) have recently investigated the load-carrying and energy absorption capacities of four different 3Dprinted hexagonal honeycomb geometries. Two additive manufacturing methods have been used, Fused Deposition Modelling (FDM) and Direct Metal Laser Sintering (DMLS).…”

Section: Introductionmentioning

confidence: 99%

“…Overall, many geometrical optimization studies were devoted to investigating the energy absorption characteristics of different structures (Wang et al, 2011;Mahdi and Hamouda, 2012;Habib et al, 2017;Yang et al, 2018;Antony et al, 2020;Ha and Lu, 2020;Laban et al, 2021;Santos et al, 2021). The previously discussed experimental studies were performed through compression tests conducted on cellular structures such as honeycomb structures (Habib et al, 2017;Yang et al, 2018;Antony et al, 2020;Laban et al, 2021).…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Mechanical and energy absorption properties of 3D-printed honeycomb structures with Voronoi tessellations

Ragab

Mahdi

Oosterhuis³

et al. 2023

Front. Mech. Eng.

Self Cite

View full text Add to dashboard Cite

3D printing technology is the new frontier in building construction. It is especially useful for making small structures within a short period. Full construction, including interior partitions and exterior façades, can be achieved with this technology. This paper proposes a parametric Voronoi tessellations model for quickly generating and fabricating 3D-printed hexagonal honeycomb partitions for interior design. Comprehensive experimental testing was conducted to characterize the mechanical properties and investigate the energy absorption characteristics of the proposed 3D-printed hexagonal honeycomb while comparing it to alternative hexagonal honeycomb structures. The tests included tensile testing (ASTM-D638) of the printed Polylactic Acid (PLA) material, especially with the almost total absence of conducted research that reported mechanical properties for 3D printed material with low infill percentages such as 10%. In addition, an in-plane quasi-static axial compression testing of the lightweight honeycomb structures was also conducted on the printed structure with the same low infill percentage. Compared to non-Voronoi honeycomb structures, the Voronoi honeycomb resulted in superior mechanical and energy absorption properties with energy absorption values ranging from 350 to 435 J and crash force efficiency being 1.42 to 1.65.

show abstract

“…In addition, the quality and reliability of solid-based FDM processed parts mainly depend on the careful selection of process variables, and is also limited by several drawbacks, including a lack of high mechanical strength and, in some cases, reduced dimensional accuracy (mainly due to high printing speeds) [2,5]. Thus, identifying the FDM process parameters that significantly affect the quality of FDM processed parts is essential, and researchers have explored several ways to improve mechanical properties and part quality using various experimental design techniques and concepts in recent years [6][7][8].…”

Section: Introductionmentioning

confidence: 99%

Structural Integrity of Polymeric Components Produced by Additive Manufacturing (AM)—Polymer Applications

et al. 2021

View full text Add to dashboard Cite

In the work presented herein, the structural integrity of polymeric functional components made of Nylon-645 and Polylactic acid (PLA) produced by additive manufacturing (Fused Deposition Modelling, FDM) is studied. The PLA component under study was selected from the production line of a brewing company, and it was redesigned and analyzed using the Finite Element Method, 3D printed, and installed under real service. The results obtained indicated that, even though the durability of the 3D printed part was lower than the original, savings of about EUR 7000 a year could be achieved for the component studied. Moreover, it was shown that widespread use of AM with other specific PLA components could result in even more significant savings. Additionally, a metallic hanger (2700 kg/m3) from the cockpit of an airplane ATR 70 series 500 was successfully redesigned and additively manufactured in Nylon 645, resulting in a mass reduction of approximately 60% while maintaining its fit-for-purpose. Therefore, the components produced by FDM were used as fully functional components rather than prototype models, which is frequently stated as a major constraint of the FDM process.

show abstract

A Comparative Study between Polymer and Metal Additive Manufacturing Approaches in Investigating Stiffened Hexagonal Cells

Cited by 8 publications

References 20 publications

Numerical and Experimental Study of a Lattice Structure for Orthopedic Applications

Numerical and Experimental Study of a Lattice Structure for Orthopedic Applications

Mechanical and energy absorption properties of 3D-printed honeycomb structures with Voronoi tessellations

Structural Integrity of Polymeric Components Produced by Additive Manufacturing (AM)—Polymer Applications

Contact Info

Product

Resources

About