Engineering Commons^™

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 …

Exploring Convergence Of Snake Skin-Inspired Texture Designs And Additive Manufacturing For Mechanical Traction, Catherine Sue Tiner

Graduate Theses and Dissertations

This research focuses on the understanding, development, and additive manufacture of a 3D printed snake skin-inspired texture pattern. The design functionalities of snake skin were determined through the study of the snake species Python Regius otherwise known as the ball python. Each scale of a snake has hierarchical texture with hexagonal macro-patterns aligned on the ventral surface of the skin with overriding anisotropic micro textured patterns such as denticulations and fibrils. Using a laser-powder bed fusion (L-PBF) process, 420 stainless steel samples were 3D printed which closely resemble the above described directional texture of natural snake skin. This printed surface …

A Novel Methodology Of Powder-Based Cementitious Materials In 3d Inkjet Printing For Construction Applications, Pshtiwan Shakor, Shami Nejadi, Gavin Paul, Jay Sanjayan

International Conference on Durability of Concrete Structures

Recently, additive manufacturing techniques such as 3D printing are becoming increasingly popular and widely used in a variety of applications. Inkjet 3D printing (i.e. powder-based printing) is one of the most reliable frequently-implemented techniques in 3D printers. This paper discusses a novel methodology to replace the currently used typical powders in 3D printing to make it possible to use the printed specimens in construction applications. The printed cubic (20Í20Í20mm) and prism (60Í5Í5mm) specimens with different saturation levels are printed to investigate the relative strength of the 3D printed specimens. Curing in different …

Open Source Waste Plastic Granulator, Arvind Ravindran, Sean Scsavnicki, Walker Nelson, Peter Gorecki, Jacob Franz, Shane Oberloier, Theresa K. Meyer, Andrew Barnard, Joshua M. Pearce

Michigan Tech Publications

In order to accelerate deployment of distributed recycling by providing low-cost feed stocks of granulated post-consumer waste plastic, this study analyzes an open source waste plastic granulator system. It is designed, built, and tested for its ability to convert post-consumer waste, 3D printed products and waste into polymer feedstock for recyclebots of fused particle/granule printers. The technical specifications of the device are quantified in terms of power consumption (380 to 404 W for PET and PLA, respectively) and particle size distribution. The open source device can be fabricated for less than $2000 USD in materials. The experimentally measured power use …

Vibration Alert Bracelet For Notification Of The Visually And Hearing Impaired, Kelsey Conley, Alex Foyer, Patrick Hara, Tom Janik, Jason Reichard, Jon D'Souza, Chandana Tamma, Cristinel Ababei

Electrical and Computer Engineering Faculty Research and Publications

This paper presents the prototype of an electronic vibration bracelet designed to help the visually and hearing impaired to receive and send emergency alerts. The bracelet has two basic functions. The first function is to receive a wireless signal and respond with a vibration to alert the user. The second function is implemented by pushing one button of the bracelet to send an emergency signal. We report testing on a prototype system formed by a mobile application and two bracelets. The bracelets and the application form a complete system intended to be used in retirement apartment communities. However, the system …

Application Of Halloysite Nanotubes In Bone Disease Remediation And Bone Regeneration, Yangyang Luo

Doctoral Dissertations

Customized patient therapy has been a major research focus in recent years. There are two research fields that have made a significant contribution to realizing individualized-based treatment: targeted drug delivery and three-dimensional (3D) printing technology. With benefit from the advances in nanotechnology and biomaterial science, various drug delivery systems have been established to provide precise control of therapeutic agents release in time and space. The emergence of three-dimensional (3D) printing technology enables the fabrication of complicated structures that effectively mimic native tissues and makes it possible to print patient-specific implants. My dissertation research used a clay nanoparticle, halloysite, to develop …

Application Of Micro-Scale 3d Printing In Pharmaceutics, Andrew Kjar, Yu Huang

Biological Engineering Faculty Publications

3D printing, as one of the most rapidly-evolving fabrication technologies, has released a cascade of innovation in the last two decades. In the pharmaceutical field, the integration of 3D printing technology has offered unique advantages, especially at the micro-scale. When printed at a micro-scale, materials and devices can provide nuanced solutions to controlled release, minimally invasive delivery, high-precision targeting, biomimetic models for drug discovery and development, and future opportunities for personalized medicine. This review aims to cover the recent advances in this area. First, the 3D printing techniques are introduced with respect to the technical parameters and features that are …

Improving 3d Printed Prosthetics With Sensors And Motors, Rachel Zarin

Honors Projects

A 3D printed hand and arm prosthetic was created from the idea of adding bionic elements while keeping the cost low. It was designed based on existing models, desired functions, and materials available. A tilt sensor keeps the hand level, two motors move the wrist in two different directions, a limit switch signals the fingers to open and close, and another motor helps open and close the fingers. All sensors and motors were built on a circuit board, programmed using an Arduino, and powered by a battery. Other supporting materials include metal brackets, screws, guitar strings, elastic bands, small clamps, …

Mechanical Properties And Applications Of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing, Matthew J. Reich, Aubrey Woern, Nagendra Gautam Tanikella, Joshua M. Pearce

Michigan Tech Publications

Past work has shown that particle material extrusion (fused particle fabrication (FPF)/fused granular fabrication (FGF)) has the potential for increasing the use of recycled polymers in 3D printing. This study extends this potential to high-performance (high-mechanical-strength and heat-resistant) polymers using polycarbonate (PC). Recycled PC regrind of approximately 25 mm² was 3D printed with an open-source Gigabot X and analyzed. A temperature and nozzle velocity matrix was used to find useful printing parameters, and a print test was used to maximize the output for a two-temperature stage extruder for PC. ASTM type 4 tensile test geometries as well as ASTM-approved …

Fabrication And Characterization Of Collagen-Polypyrrole Constructs Using Direct-Ink Write Additive Manufacturing, Rooshan Arshad

Electronic Thesis and Dissertation Repository

Current efforts in the tissue engineering field are being directed towards the creation of platforms which will facilitate in instructing cells towards biologically relevant outcomes such as stem cell differentiation and disease pathophysiology. Traditional fabrication methods serve as a limiting factor for the production of such platforms as they lack feature and geometric complexity. Additive Manufacturing (AM) offers advantage over said methods by affording designers creative freedom and great control over printed constructs. Such constructs can then be used to create appropriate models for study- ing a plethora of tissues and structures. An AM methodology for Direct-Ink Write (DIW) printing …

Experimental Study Of Condensation In Different 3d Printed Regenerators In A Thermoacoustic Cooler, Aibek Bekkulov

Theses and Dissertations

Thermoacoustics (TA) deals with the conversion of heat into sound and vice versa. Device that converts heat into acoustic work is called TA heat engine, while the device that transfers energy from a low temperature reservoir to a high temperature one by utilizing acoustic work is called TA cooler. A simple construction of TA cooler includes an acoustic speaker, a resonator tube and a regenerator stack in which the temperature gradient is being imposed. Such a TA cooler has several advantages over traditional compression/expansion cooling machine such as its simplicity of the construction, high reliability and lack of toxic refrigerants. …

3d Printed Smart Mobile, Bingfang Chen

Publications and Research

The goal of this research project is to design and build a prototype of a smart mobile robot to participate and compete in IEEE Micro-mouse and similar competitions. The robot has to find its way out of a maze as quickly as possible, by exploring and learning the paths in the maze. 3D printing technology will be used to build a lightweight robot frame so that it can move at a fast speed.

3d Printing A Microfluidic Chip Capable Of Droplet Emulsion Using Ninjaflex Filament, Robert Andrews

Mechanical Engineering Undergraduate Honors Theses

This paper details an investigation into methods and designs of 3D printing a microfluidic system capable of droplet emulsion using NinjaFlex filament. The specific field in which this paper’s experiment is rooted is dubbed “BioMEMS,” short for bio microelectromechanical systems. One prominent research area in BioMEMS is developing a “lab on a chip.” Essentially, the goal is to miniaturize common lab processes to the micro scale, rendering it possible to include these processes in a small chip. Reducing necessary sample sizes, shortening the reaction times of lab processes, and increasing mobility of lab processes can all be realized through microfluidic …

Modeling And Numerical Simulation Of Tissue Engineering Scaffold 3d Printing Process, Congping Chen, Jieguang Huang, Hu Qiong, Yanhua Ran, Li Bo

Journal of System Simulation

Abstract: In the process of tissue engineering scaffold fabrication using injecting 3D printing, the viscous fluid material is extruded out with a style of microfilament, which is deposited on a substrate layer by layer. The materials spread, pile up, remelt and solidify as a consequence of the couple effects of gravity, surface tension, viscous force and solidification drag force. Aiming at the above issues, the forming process of scaffold with homogeneously-sized space pores is studied with a CFD approach to research the pore forming mechanism. The results show that the viscous fluid is cooled mainly by the substrate, and heat …

Design And Process Of 3d-Printed Parts Using Composite Theory, Jordan Garcia

Theses and Dissertations--Mechanical Engineering

3D printing is a revolutionary manufacturing method that allows the productions of engineering parts almost directly from modeling software on a computer. With 3D printing technology, future manufacturing could become vastly efficient. However, it is observed that the procedures used in 3D printing differ substantially among the printers and from those used in conventional manufacturing. In this thesis, the mechanical properties of engineering products fabricated by 3D printing were comprehensively evaluated and then compared with those made by conventional manufacturing. Three open-source 3D printers, i.e., the Flash Forge Dreamer, the Tevo Tornado, and the Prusa, were used to fabricate the …

A Study Of The Effect Of Heat Treatment On 3d Printed Pla Impact Strength, Suresh Thota

Electronic Theses and Dissertations

Environmental conditions have a significant effect on the mechanical properties of various materials. Environmental parameters such as temperature and humidity have a major impact on mechanical properties of materials such as compressive strength, tensile strength, bending strength and impact strength. The purpose of this research is to study how temperature and humidity affect the impact strength of 3D printed PLA plastic. Impact strength is the ability of a material to absorb energy subjected to an impact load by a pendulum. In this research, 3D printing was employed to produce PLA specimens which were later used for different experimental testings. For …

Engineering Of Bio-Mimetic Substratum Topographies For Enhanced Early Colonization Of Filamentous Algae, Ali Khoshkhoo, Andres L. Carrano, David M. Blersch

Systems Science and Industrial Engineering Faculty Scholarship

No abstract provided.

Mechanical Characterizations Of 3d-Printed Plla/Steel Particle Composites, Hozhabr Mozafari, Pengfei Dong, Haitham Hadidi, Michael P. Sealy, Linxia Gu

Department of Mechanical and Materials Engineering: Faculty Publications

The objective of this study is to characterize the micromechanical properties of poly-L-lactic acid (PLLA) composites reinforced by grade 420 stainless steel (SS) particles with a specific focus on the interphase properties. The specimens were manufactured using 3D printing techniques due to its many benefits, including high accuracy, cost effectiveness and customized geometry. The adopted fused filament fabrication resulted in a thin interphase layer with an average thickness of 3 μm. The mechanical properties of each phase, as well as the interphase, were characterized by nanoindentation tests. The effect of matrix degradation, i.e., imperfect bonding, on the elastic modulus of …

3d Printing Of Hybrid Mos2-Graphene Aerogels As Highly Porous Electrode Materials For Sodium Ion Battery Anodes, Emery Brown, Pengli Yan, Halil Tekik, Ayyappan Elangovan, Jian Wang, Dong Lin, Jun Li

Department of Mechanical and Materials Engineering: Faculty Publications

This study reports a 3D freeze-printing method that integrates inkjet printing and freeze casting to control both the microstructure and macroporosity via formation of ice microcrystals during printing. A viscous aqueous ink consisting of a molecular MoS₂ precursor (ammonium thiomolybdate) mixed with graphene oxide (GO) nanosheets is used in the printing process. Post-treatments by freeze-drying and reductive thermal annealing convert the printed intermediate mixture into a hybrid structure consisting of MoS₂ nanoparticles anchored on the surface of 2D rGO nanosheets in a macroporous framework, which is fully characterized with FESEM, TEM, XRD, Raman spectroscopy and TGA. The resulting …

Developing A Commercial Product Using A Consumer Grade 3d Printer, Calvin Smith

All Graduate Theses, Dissertations, and Other Capstone Projects

The development of affordable, quality, consumer grade 3D printers has allowed entrepreneurs to develop new products and start small businesses. As the print quality of consumer grade printers has improved entrepreneurs have been able to develop consumer quality products without the traditional expense of mass manufacturing. This change from mass manufacturing to small scale and custom production has allowed for the growth of small businesses. Websites such as www.etsy.com show hundreds of small businesses based on 3D printing, these businesses showcase thousands of products ranging from useful household items to cosplay. This thesis covers the process of a small business …

Development Of Test Methods For Characterizing Extrudability Of Cement-Based Materials For Use In 3d Printing, Jonathan Thomas Kuchem

Masters Theses

"3D printing is the process of creating three-dimensional objects using an automated additive manufacturing process. The 3D printing process has been used with materials such as metals and polymers, but application with cement based materials for the construction industry has yet to be developed. In this research, two main problems were investigated for printing cement based composite materials: extrudability and tensile reinforcement. Fiber-reinforced concrete (FRC) was studied as an internal reinforcing system to increase tensile/flexural strength. First, FRC was studied to investigate mechanical properties and use of fibers from waste tires as an environmentally friendly option. A reference mixture with …

Developing A Testing Instrument To Evaluate The Performance Of 3d-Printed Body-Powered Prosthetic Hands, Araz Al-Dawoodi

All Graduate Theses, Dissertations, and Other Capstone Projects

A 3D printed prosthetic hand is an open source technology that became a good substitution for many products in the market. For many reasons, Low-cost, easy made / easy build. As an open source product, 3D printed prosthetic designs are available to anyone around the world, a good option for young children because they need to have a new prosthetic more frequent until they reach the adulthood age. Most families cannot pay a thousand dollars technology. From the research, it found that that there are not enough studies cover the open source wrist body-powered prosthetic. Other studies covered products used …

Remanufacturing Of Precision Metal Components Using Additive Manufacturing Technology, Xinchang Zhang

Doctoral Dissertations

"Critical metallic components such as jet engine turbine blades and casting die/mold may be damaged after servicing for a period at harsh working environments such as elevated temperature and pressure, impact with foreign objects, wear, corrosion, and fatigue. Additive manufacturing has a promising application for the refurbishment of such high-costly parts by depositing materials at the damaged zone to restore the nominal geometry. However, several issues such as pre-processing of worn parts to assure the repairability, reconstructing the repair volume to generate a repair tool path for material deposition, and inspection of repaired parts are challenging. The current research aims …

Rasters Vs Contours For Thin Wall Ultem 9085 Fdm Applications, Vausman Kota

Browse all Theses and Dissertations

Currently many components are additively manufactured via fused deposition modeling (FDM). However, FDM results in gaps between passes which produces a poor surface finish and porous material that is difficult to hold pressure. Commercial scale air systems require a pressure to be maintained within thin walled components with minimal post processing and clean up after fabrication. A design of experiments (DOE) was created to identify the optimal raster vs contour ratio for UTLEM 9085 CG fabricated using FDM at different build angles and wall thicknesses. A custom-built pressurized test system was developed, the leak rates were calculated and the surfaces …

Characterization And Quality Assessment Of Smart Polymer Systems Fabricated By Using 3d Printing Technique, Carlos Alejandro Garcia Rosales

Open Access Theses & Dissertations

Shape memory polymers (SMPs) are classified as smart materials due to their inherent stimulus-induced response. SMP is capable of recovering its original shape from a high degree of deformation by applying an external stimulus such as thermal energy. Other stimuli are electricity, light, chemical, and magnetic field. Shape memory polymers (SMPs) and its fabrication process has recently attracted much attention as a result of their potential application as soft active materials. Demonstration of SMP systems fabricated via 3D printing technologies has been one of the most popular attempts. This Dissertation presents an integration of two commercial SMP materials (DiAPLEX and …