Article
Chemistry, Multidisciplinary
Olav U. Bjorken, Benjamin Andresen, Sindre W. Eikevag, Martin Steinert, Christer W. Elverum
Summary: The limitations of DfAM lie in the knowledge of materials and production parameters. By studying the effects of layer temperature, the concept of thermal layer design (TLD) was introduced to increase strength in selected regions. Implementing TLD represents a major advancement in designing high-performance polymer components.
APPLIED SCIENCES-BASEL
(2022)
Review
Engineering, Manufacturing
Jose Luis Perez-Castillo, Enrique Cuan-Urquizo, Armando Roman-Flores, Oscar Olvera-Silva, Victor Romero-Munoz, Alfonso Gomez-Espinosa, Rafiq Ahmad
Summary: This paper provides an overview of the state-of-the-art in curved layered fused filament fabrication (CLFFF), covering topics such as upgrading FFF machines, slicing algorithms, and mechanical property characterization. Additionally, potential future research directions and the application of CLFFF in lattice metamaterial fabrication are discussed, along with concluding remarks and recommendations for the use of CLFFF.
ADDITIVE MANUFACTURING
(2021)
Review
Computer Science, Interdisciplinary Applications
Yongjie Zhang, Seung Ki Moon
Summary: The advent of additive manufacturing has opened up new possibilities in design and manufacturing, but finding the optimal combination of design and process parameters remains challenging. Data-driven strategies are becoming increasingly important in design, helping to achieve optimal part design.
JOURNAL OF COMPUTATIONAL DESIGN AND ENGINEERING
(2021)
Article
Chemistry, Multidisciplinary
Joerg Luechtenborg, Felix Burkhardt, Julian Nold, Severin Rothlauf, Christian Wesemann, Stefano Pieralli, Gregor Wemken, Siegbert Witkowski, Benedikt C. Spies
Summary: Additive manufacturing, particularly vat polymerization systems like SLA and DLP, are commonly used for dental restorations. However, the less common FFF technology, such as FDM, shows promise in the dental field for its cost-effective and straightforward approach. Using FFF for in-house production of nearly ready-to-use parts with minimal post-processing can be advantageous.
APPLIED SCIENCES-BASEL
(2021)
Review
Engineering, Manufacturing
Yanzhou Fu, Austin Downey, Lang Yuan, Avery Pratt, Yunusa Balogun
Summary: This paper presents a summary of research on real-time monitoring of additive manufacturing processes to ensure product quality and improve printing efficiency. It discusses different methods, devices, and achievements in monitoring systems for 3D printing, as well as sensor types and devices used for monitoring printer health state and printing process product quality. The review concludes with a discussion of current and future research directions in this field.
ADDITIVE MANUFACTURING
(2021)
Article
Polymer Science
Rafael Guerra Silva, Maria Josefina Torres, Jorge Zahr Vinuela, Aristides Gonzalez Zamora
Summary: By utilizing fused filament fabrication technology, it is possible to produce 3D miniature polymer lattice structures with complex topologies, even though there may be some difficulties and restrictions in the production process.
Article
Materials Science, Ceramics
Zhiheng Guan, Xiaole Yang, Peng Liu, Xiewen Xu, Yuanbing Li, Xianfeng Yang
Summary: This study optimized a thermoplastic elastic binder based on styrene ethylene butylene styrene (SEBS) to prepare flexible filaments with a solid loading of 43 vol%. The rheology, stress-strain behavior, and printing performance of the filament were evaluated, and the feasibility of fabricating complex-shaped parts was verified. Zirconia ceramics with a relative density of 99.1% and a flexural strength of 492.8 ± 40 MPa were obtained by the FFF method.
CERAMICS INTERNATIONAL
(2023)
Article
Engineering, Manufacturing
Muhammad Haris Rais, Ye Li, Irfan Ahmed
Summary: This paper explores four new sabotage attacks on the fused filament fabrication (FFF)-based 3D printing process, manipulating printing parameters or temperature profiles to alter the physical properties of printed objects, making them difficult to detect.
ADDITIVE MANUFACTURING
(2021)
Article
Polymer Science
Patrick Consul, Kai-Uwe Beuerlein, Genc Luzha, Klaus Drechsler
Summary: This study investigates the impact of extrusion parameters on fiber alignment in additive manufacturing using short fiber reinforced composite materials. The flow conditions during extrusion shaping have a significant influence on fiber alignment. Strength and stiffness are reduced by 41% and 54%, respectively, when the fiber alignment is lowest.
Article
Materials Science, Ceramics
Maria Vozarova, Erich Neubauer, Lubos Baca, Michael Kitzmantel, Jozef Feranc, Veronika Trembosova, Peter Peciar, Michaela Kritikos, Martina Orlovska, Marian Janek, Marian Matejdes
Summary: This study successfully prepared boron carbide ceramics using a composite filament containing 65 wt% micron-sized boron carbide powder. Complex-shaped green bodies were manufactured using a commercial FFF desktop printer, and fully dense boron carbide ceramics with high relative density were obtained after sintering. Thermal analysis and micro-CT imaging confirmed the good performance and shape retention of the printed parts.
JOURNAL OF THE EUROPEAN CERAMIC SOCIETY
(2023)
Article
Materials Science, Multidisciplinary
Ahmad Naqi, Zachary Swain, Michael E. Mackay
Summary: This study demonstrates a fused filament fabrication (FFF) die design capable of extruding two thermoplastics simultaneously to produce composite structures. The use of polyethylene terephthalate glycol (PETG) and high-density polyethylene (HDPE) filaments in core-shell 3D printing results in improved impact resistance and toughness. The die design allows for the fabrication of high-performance materials suitable for various applications.
ACS APPLIED POLYMER MATERIALS
(2023)
Article
Materials Science, Multidisciplinary
Ahmad Naqi, Zachary Swain, Michael E. Mackay
Summary: This study demonstrates a fused filament fabrication (FFF) die design that enables the simultaneous extrusion of two thermoplastics in a core-shell configuration, enabling the production of composite structures in a single step. The use of high-density polyethylene (HDPE) as a shell material, along with polyethylene terephthalate glycol (PETG) as a core material, results in enhanced impact resistance and toughness in the produced objects. The die design can open up new avenues for fabricating high impact resistance materials suitable for high performance applications and utilizing HDPE in 3D printed objects due to its superior solvent resistance.
ACS APPLIED POLYMER MATERIALS
(2023)
Article
Engineering, Manufacturing
Jingdong Chen, Douglas E. Smith
Summary: This study presents a low-cost device and measuring procedure for characterizing filament materials in FFF based on pressure drop through an FFF nozzle. The device utilizes an analytical pressure drop model and is validated by comparing results with a commercial rotational rheometer. Additionally, a Filament Flow Index (FFI) is proposed for assessing material extrusion in FFF part fabrication.
ADDITIVE MANUFACTURING
(2021)
Review
Polymer Science
Ans Al Rashid, Muammer Koc
Summary: This study provides a comprehensive review of scientific achievements in numerical simulations of the FFF process for polymers and their composites, discussing the physical phenomena and research efforts with a focus on numerical simulation techniques.
Article
Engineering, Manufacturing
Tilen Kosir, Janko Slavic
Summary: This research presents the design principles of a functional, single process, dynamic piezoelectric sensor using the FFF technique, which overcomes the limitations of traditional manufacturing methods and enables the embedding of piezoelectric sensing elements into various complex 3D-printed structures.
ADDITIVE MANUFACTURING
(2022)
Article
Construction & Building Technology
Anja Kunic, Roberto Naboni, Aljaz Kramberger, Christian Schlette
Summary: The field of architecture is increasingly turning to wood as a sustainable solution for new buildings while reducing carbon emissions. Research in Robotic Timber Construction (RTC) has rapidly evolved to focus on improving production efficiency through automated assembly, aided by human-robot collaboration. This paper presents an original workflow for automated design and assembly of reversible timber structures, enhancing the material life cycle of wood and its carbon store.
AUTOMATION IN CONSTRUCTION
(2021)
Article
Construction & Building Technology
Narendrakrishnan Neythalath, Asbjorn Sondergaard, Bhavatarini Kumaravel, Jakob Andreas Baerentzen, Roberto Naboni
Summary: Visual Programming Language (VPL) is increasingly used in the AEC industries and robotic research. While VPL has advantages, there are limitations for developing commercial-grade robotic applications. To overcome these challenges, utilizing software design patterns could be a potential solution.
AUTOMATION IN CONSTRUCTION
(2021)
Article
Engineering, Civil
Soren Gustenhoff Hansen, Anja Kunic, Roberto Naboni
Summary: The research introduces a new concept of timber connections for use in automated robotic assembly and disassembly, featuring self-alignment, enhanced shear capacity, and ductile behavior. Experimental results validate the accuracy of the developed calculation models.
ENGINEERING STRUCTURES
(2021)
Article
Robotics
Aljaz Kramberger, Anja Kunic, Inigo Iturrate, Christoffer Sloth, Roberto Naboni, Christian Schlette
Summary: This paper presents a framework for the design and robotic assembly of timber structures. The study incorporates learning by demonstration to automate the complex assembly of wooden joints and enables new designs of construction elements previously only possible by skilled craftsmen. The research provides an overview of different focus levels, from digital twin integration to timber joint design and robotic assembly execution, and explores synergistic results in both robotic and construction design innovation, with a perspective on future developments.
FRONTIERS IN ROBOTICS AND AI
(2022)
Article
Green & Sustainable Science & Technology
Styrmir Gislason, Simon Bruhn, Luca Breseghello, Burak Sen, Gang Liu, Roberto Naboni
Summary: This paper investigates the potential environmental benefits of 3D concrete printing (3DCP) over conventional concrete construction for structural beams. The study shows that infill optimization for printed beams can help reduce material usage and offset the environmental impacts. Recommendations for future research on material- and recarbonation-efficient 3DCP design are also provided.
CLEAN TECHNOLOGIES AND ENVIRONMENTAL POLICY
(2022)
Article
Engineering, Manufacturing
Luca Breseghello, Roberto Naboni
Summary: This paper introduces a data-informed toolpath-based design approach for 3D Concrete Printing (3DCP) to fabricate architectural horizontal structures. By reducing material usage in structural beams through stress-based optimization and integrating Finite Element (FE) analysis, the workflow provides design flexibility and enhances the performance of the structures.
ADDITIVE MANUFACTURING
(2022)
Article
Engineering, Civil
Luca Breseghello, Hamed Hajikarimian, Henrik Broner Jorgensen, Roberto Naboni
Summary: This paper presents a workflow for the design, material testing, and numerical simulation of shape-optimised reinforced 3D Concrete Printed (3DCP) beams. The proposed method includes the development of a lossless data transfer tool and a Finite Element Analysis (FEA) model. The tests confirmed the reliability of the numerical model and showed that the proposed 3DLightBeam+ design has a higher flexural strength-to-weight ratio than comparable beams.
ENGINEERING STRUCTURES
(2023)
Proceedings Paper
Computer Science, Hardware & Architecture
Luca Breseghello, Roberto Naboni
Summary: The recent advancements in 3D Concrete Printing (3DCP) have a significant impact on architectural design, highlighting the disconnect between digital modeling and manufacturing processes. This paper introduces an interactive tool for previewing 3D printing toolpaths within Grasshopper, integrating geometric, physical, and design feedback. The developed tool is tested on full-scale printed prototypes, demonstrating its precision and contributing to bridging the gap between the digital environment and fabrication procedures in the construction industry.
COMPUTER-AIDED ARCHITECTURAL DESIGN: DESIGN IMPERATIVES: THE FUTURE IS NOW
(2022)
Article
Engineering, Manufacturing
Przemyslaw Golebiewski, Pawel Wienclaw, Jaroslaw Cimek, Pawel Socha, Dariusz Pysz, Adam Filipkowski, Grzegorz Stepniewski, Olga Czerwinska, Ireneusz Kujawa, Ryszard Stepien, Rafal Kasztelanic, Andrzej Burgs, Ryszard Buczynski
Summary: We report the development of a 3D printing process for producing soft glass optical fibers. The process involves direct printing using a miniaturized crucible and depositing straight horizontally-oriented lines to replace traditional assembly techniques. Experimental results demonstrate good performance of the printed photonic crystal fiber preform.
ADDITIVE MANUFACTURING
(2024)