Engineering Commons^™

3d-Printed Hydrogels Dressings With Bioactive Borate Glass For Continuous Hydration And Treatment Of Second-Degree Burns, Fateme Fayyazbakhsh, Michael J. Khayat, Candy Sadler, Delbert Day, Yue-Wern Huang, Ming-Chuan Leu

Biological Sciences Faculty Research & Creative Works

Recent advances in additive manufacturing have led to the development of innovative solutions for tissue regeneration. Hydrogel materials have gained significant attention for burn wound treatment in clinical practice among various advanced dressings due to their soothing and moisturizing activity. However, prolonged healing, pain, and traumatic removal due to the lack of long-term wound hydration are some of the challenges in the treatment of second-degree burn wounds. In this study, 3D-printed dressings were fabricated using gelatin, alginate, and bioactive borate glass (BBG) using an extrusion-based bioprinter. After ionic crosslinking, the 3D-printed dressings were characterized for mechanical properties, degradation rate, hydration …

Modeling The Effect Of In Situ Nozzle-Integrated Compression Rolling On The Mechanical And Fracture Behavior Of Fused Filament Fabrication (Fff) 3d Printed Parts, Momen Mohammad Qasaimeh

Mechanical and Aerospace Engineering Dissertations

Fused filament fabrication (FFF) is one of the most common additive manufacturing/3D printing techniques where continuously extruded semi-molten filaments are deposited in a layer-by-layer manner. The quality of the manufactured part depends on some major factors such as filament-filament contact and adhesion as well as the void fraction. Filament to filament adhesion affects the part strength under transverse load. In our earlier work, we studied the effect of in situ ball rolling on the thermal and mechanical properties of the printed parts. It was found that when printing/rolling parameters are correctly tuned and in situ compression rolling is appropriately applied …

Investigation On Microstructure And Mechanical Properties Of Porous Structures Processed By Laser Powder Bed Fusion, Samarth Ramachandra

Mechanical and Aerospace Engineering Theses

Inconel 718 (i.e., IN718) is a prominent nickel-based, precipitation-hardening superalloy which exhibits exceptionally stable mechanical and corrosion resistant properties, even at temperature range of 650ºC to 700ºC, making it suitable for a wide range of applications such as aerospace, nuclear reactors, tooling, turbines, oil and gas applications. The high toughness and work hardening offered by this superalloy, however, greatly limits the choice of machinability. The presence of low levels of aluminum permits good weldability which further allows the use of laser-based additive manufacturing (AM) to efficiently fabricate IN718 parts without the limitations associated with conventional manufacturing methods. Thanks to AM …

Investigation Of The Microstructural And Mechanical Properties Of Selectively Laser Melted In718 Overhangs Fabricated Without Support Structures, Manjunath Hanumantha

Mechanical and Aerospace Engineering Theses

Additive manufacturing is a new manufacturing technology that allows for extreme design freedom as well as the simultaneous production of many parts with high complexities. IN718 is a high-strength, corrosion-resistant super alloy of nickel and chromium. It is ideal for high-end applications such as rocket nozzles and turbines because it can handle exceptionally high pressure and heat. Because of its high stiffness qualities, conventional manufacturing of complex IN718 geometries is challenging. Various fabrication techniques have been developed, and this study focuses on selective laser melting (SLM) because of its potential to produce near-perfect parts at a low cost when working …

Estimation Of The Fatigue Life Of Additively Manufactured Metallic Components Using Modified Strain Life Parameters Based On Surface Roughness, Peter Grohs

Masters Theses

In this study, a method is developed to estimate the effects of surface roughness on the fatigue life of additively manufactured titanium Ti6Al4V, aluminum 7075–T6, and steel 4340 alloys through modified strain life parameters using finite element analysis (FEA). This method is highly beneficial to the fatigue analysis of as-built additively manufactured metal components, which possess rough surfaces that reduce fatigue life significantly but are challenging to analyze directly using finite element simulation because of complex geometries, i.e., modeling an exact surface profile is arduous.

An effective stress concentration factor, incorporating roughness data, is defined to quantify their effects on …

Material Characterization And Fracture Prediction Of Fdm Printed Parts, Sanchita Sheth

Mechanical and Aerospace Engineering Theses

In order to take advantage of the design freedom that Additive Manufacturing offers, most applications require reliable material characterization. This can ensure that a design performs within its environment and life requirements. This work discusses two models. One investigates the raster angle dependency of stiffness properties and the other numerically predicts fracture in Fused Deposition Modeling (FDM) printed polymer parts. Pre-processing of FDM geometry was done in Abaqus CAE (SIMULIA TM). FEA and post-processing was done in BSAM, which is a damage prediction software developed for composites. BSAM uses a regularized extended finite element approach of Discrete Damage Modeling. In …

Static Response Calibration Of 3d Printed Thin Walled Structures Using Fused Deposition Modelling, Akhilesh Ravindra Kulkarni

Mechanical and Aerospace Engineering Theses

3-D printing has enabled flexible, tool-less fabrication that yields numerous benefits. One benefit is unique and complex structural arrangements that increase design freedom to minimize weight. Such arrangements can be guided by advanced topology, shape, and sizing optimization tools using appropriate process constraints to ensure a printable design and can include highly integrated structural details such as stiffeners, flanges, frames, and other connections. 3D printing thin wall aircraft structures presents challenges for material and structural characterization. 3D printing enables integrated structural details, each detail is affected by the print process capability to fabricate the local geometry and deviations from designed …

Characterization Of Thermo-Mechanical Properties Of Copper Nano-Particles Infused Acrylonitrile Butadiene Styrene (Abs)- 3d Printed Specimens, Viswajit Talluru

Mechanical and Aerospace Engineering Theses

Now a days the use of metal nanoparticle infused polymer is becoming widespread, since the development of polymer with enhanced thermal properties are being used for the growth of electronic packaging industry. In this study, copper nanoparticles are mixed with the Acrylonitrile Butadiene Styrene (ABS) thermoplastic in varying mass proportions, to observe the changes in thermal and structural properties of ABS. As expected, the extruded wire with high nano-particle concentration exhibited much higher thermal conductivity than its raw ABS form. For the case of 2% copper nanoparticle infused ABS using one dimensional steady state heat flux method though extrude wire …

An Analytical Design Of Experiments Method For Fatigue Constrained Design Optimization Of A 3d Printed Structure, Ashish Pokharel

Mechanical and Aerospace Engineering Theses

A design of experiments approach has been used to analytically determine a low cycle fatigue (LCF) constraint for use in design optimization of 3D printed structures. In context of metal additive manufacturing, the process of melting, solidification and consolidation of metal powder introduces very high temperature gradient field within the build which in turn results in high compressive stresses at the core and tensile stresses at the outer surface of the part after it has cooled down to room temperature post build. An approach of finite element modeling in ANSYS Additive has been used to develop a residual stress profile …

A Multiphysics Study Of Interfacial Properties Of 3d Printed Filaments, Alireza Rezaee

Mechanical and Aerospace Engineering Dissertations

Fused Deposition Modeling has become the most popular 3-D printing method over the last decade. Due to its potential to save time, cost and, labor, there is a great deal of interest to use this technique for production of functional load carrying parts and assemblies in bio-medical, automotive, aerospace, and oil and gas industries. In general, materials used in FDM process are isotropic; however, parts printed using FDM process show anisotropic mechanical properties with inconsistent properties in the transverse direction to the filaments’ cross-section. This anisotropic behavior is due to the fabrication process, and the inconsistency in the transverse mechanical …

A Study Of Effect Of Bond Length On Bond Strength Using Transient Heat Transfer Analysis, Junaid Mohamed Baig

Mechanical and Aerospace Engineering Theses

It is important to understand the mechanical properties of the bonding between the adjacent layers of 3D printed parts build by fused deposition modeling. The bonding process is highly nonlinear and depends on various geometrical and thermal process parameters. This work aims to quantify the degree of bonding by calculating bond potential between the extruded layers using finite element heat transfer analysis. Successive transient analysis were carried out using this model by constantly updating the boundary conditions and geometric model during the deposition of the extruded bead. Temperatures at critical points were calculated over a period to calculate the bond …

Predicting Mechanical Behavior Of 3d Printed Structures Using Mechanics Of Composites And Fracture, Megha Tangri

Mechanical and Aerospace Engineering Theses

Recently, additive manufacturing, or 3D printing as it is more commonly called, has taken a big leap in the manufacturing industry. This technology is rapidly moving from prototyping to manufacturing using metals, polymers, concrete and even composites. Unlike subtractive methods of manufacturing, additive manufacturing can be used to manufacture parts with highly directional mechanical properties. This research focuses on predicting tensile failure of 3D printed polymer structures in different raster orientations using composites lamination theory. Previously it was found experimentally that tensile strengths of 3D printed specimens decrease when raster orientations changes from 0° to 90°. The proposed model developed …

On The Development And Integration Of Pneumatic Extrusion Module And A Methodology To Identify Process Parameters For Additive Manufacturing Using Machine Learning, Kashish Dhal

Mechanical and Aerospace Engineering Theses

Commonly used additive manufacturing platforms have a single extrusion module based on Fused Filament Fabrication (FFF) and their processing software generates G-Codes for this FFF module using defined process parameters. These platforms and software do not accommodate different processing modules such as viscous extruders or Direct Ink Writing (DIW). This research is focused on the development of a Pneumatic Extrusion Module (PEM) capable of dispensing viscous materials such as gels or slurries controlled through a digital pneumatic valve. A PEM is developed, integrated and its performance is evaluated on a multi-modality additive manufacturing platform in the MARS Lab. The operation …

Case Study: Cooling Channels For Material Testing Applications Using Laser Powder Bed Fusion, Benjamin M. Doane, Ryan P. O'Hara, K. Liu, Carl R. Hartsfield

Faculty Publications

Additive Manufacturing continues to gain a reputation as a key technology that will have a major impact on all aspects of mechanical engineering. The United States Air Force’s (USAF) Air Force Institute of Technology (AFIT), based in Dayton, Ohio, has expanded its AM-focused education and R&D capabilities with the purchase of a Laser Powder Bed Fusion system from Germany’s Concept Laser.

Design And Testing Of An Additively Manufactured Cubesat Structural Bus, Karson A. Roberts

Theses and Dissertations

Recent innovations in additive manufacturing and design capabilities have opened the door for more opportunities to integrate multiple functions into a structural de- sign. Specifically, 3D printing through advanced laser powder bed fusion of metal powder allows for the development and integration of advanced structures that were previously unachievable. The demonstration of these techniques on a small satellite results in a structural bus consisting of various external and internal features, increasing its functionality and capabilities beyond simply providing structural support. 3D printing a multi-functional CubeSat bus with these integrated features such as internal lattices and wiring tabs demonstrates a new …

Analysis Of Additively Manufactured Injectors For Rotating Detonation Engines, Michael C. Waters

Theses and Dissertations

This research represents an experimental and computational analysis of additively manufactured injectors for Rotating Detonation Engines (RDEs) for use in rocket propulsion. This research was based on the manufacture and testing of existing injector element designs using additive techniques. The designs were modeled from geometries gathered from Sutton and Biblarz Elements of Rocket Propulsion [23]. The goal of this research was to characterize the viscous losses of each design based on the discharge coefficient. The designs were computationally simulated to gain insight to the flow characteristics using multiple sets of conditions for surface roughness and inlet pressure. The results were …

An Investigation Of Avian Wing Tip Vortex Generation Using A Biomimetic Approach, David Stewart Martin

Master's Theses

An experimental study has been conducted to develop a process allowing the creation of biologically accurate aerodynamic test models mimicking the slotted primary feather geometry of the Brown Pelican (Pelecanus occidentalis). Preserved examples of both a full Brown Pelican wing and a single primary feather were 3D scanned and digitally reconstructed using a combination of MATLAB and CAD software. The final model was then 3D printed as a collection of smaller components using a LulzBot TAZ 6 printer and Taulman3D T-Glase PET filament. After using various surface finishing techniques to improve the finish of all 3D printed parts, …

Manufacturing And Characterization Of A 3d-Printable, Antibacterial, Magnesium Oxide Nanoparticles Reinforced Abs Filament, Saket Thapliyal

Mechanical and Aerospace Engineering Theses

This research work consists of two phases. In phase one it is intended to manufacture an antibacterial 3D printable filament by extruding a solid state mixture of (MgO) nanoparticles (NPs) and Acrylonitrile Butadiene Styrene (ABS) pellets. A single screw extruder was used to extrude ABS pellets containing 0, 0.5, 1, 2 and 4 wt. % MgO NP. This phase deals with manufacturing and testing the filament for mechanical properties, antibacterial properties and 3D printability. On one hand tensile strength, ductility and 3D-printabiliy were observed to decrease with increasing concentrations of MgO NP in ABS matrix, on the other hand the …

Effect Of Manufacturing-Induced Defects And Orientation On The Failure And Fracture Mechanism Of 3d Printed Structures, Amit Khatri

Mechanical and Aerospace Engineering Theses

Additive manufacturing is a rapidly growing cutting edge technology. Number of experimental studies have shown that strength of product manufactured by additive Fused Deposition Method (FDM) is influenced by different processing parameters involved during manufacturing. This thesis work presents experimental and theoretical investigation of mechanical behavior of ABS material fabricated with variation in some of process parameters such as Axis Orientations, Raster Orientation, Infill Percentage, Layer Height and Number of Shells. Different experiments were designed to understand the basics of 3D printing manufacturing and to characterize the mechanical behavior of 3D printed structures. This study helps to understand, how different …

Design Of Elastic Metamaterials, Yu-Chi Su

Open Access Dissertations

This study focused on the design and fabrication of a double negativity and three broadband single negativity elastic metamaterials using a 3D printer. We investigated dispersion curves and dynamic material properties of the metamaterials. Negative phase velocity in the double negativity metamaterial was also demonstrated.

For metamaterials with single negativity, three types of broadband metamaterials were designed from parametric studies. A comparison showed that using frame bending/stretching mode is more effective than applying beam bending mode to broaden bandgap. Furthermore, it is found that adding internal resonant components could enlarge the bandgap. The single negativity metamaterials were validated by numerical …

Does Material Choice Drive Sustainability Of 3d Printing?, Jeremy Faludi, Zhongyin Hu, Shahd Alrashed, Christopher Braunholz, Suneesh Kaul, Leulekal Kassaye

Dartmouth Scholarship

Environmental impacts of six 3D printers using various materials were compared to determine if material choice drove sustainability, or if other factors such as machine type, machine size, or machine utilization dominate. Cradle-to-grave life-cycle assessments were performed, comparing a commercial-scale FDM machine printing in ABS plastic, a desktop FDM machine printing in ABS, a desktop FDM machine printing in PET and PLA plastics, a polyjet machine printing in its proprietary polymer, an SLA machine printing in its polymer, and an inkjet machine hacked to print in salt and dextrose. All scenarios were scored using ReCiPe Endpoint H methodology to combine …