Additive manufacturing and mechanical properties of lattice-curved structures

Song

J Food Process Engineering

et al. 2022

Three‐dimensional (3D) printing has promising application potentials in improving food product manufacturing, increasingly helping in simplifying the supply chain, as well as expanding the utilization of food materials. To further understand the current situation of 3D food printing in providing food engineering solutions with customized design, the authors checked recently conducted reviews and considered the extrusion‐based type to deserve additional literature synthesis. In this perspective review, therefore, we scoped the potentials of 3D extrusion‐based printing in resolving food processing challenges. The evolving trends of 3D food printing technologies, fundamentals of extrusion processes, food printer, and printing enhancement, (extrusion) food systems, algorithm development, and associated food rheological properties were discussed. The (extrusion) mechanism in 3D food printing involving some essentials for material flow and configuration, its uniqueness, suitability, and printability to food materials, (food material) types in the extrusion‐based (3D food printing), together with essential food properties and their dynamics were also discussed. Additionally, some bottlenecks/concerns still applicable to extrusion‐based 3D food printing were brainstormed. Developing enhanced calibrating techniques for 3D printing materials, and designing better methods of integrating data will help improve the algorithmic representations of printed foods. Rheological complexities associated with the extrusion‐based 3D food printing require both industry and researchers to work together so as to tackle the (rheological) shifts that make (food) materials unsuitable. Practical Applications As a processing technology with digital additive manufacturing methodology, 3D food printing over the decades has evolved greatly with the extrusion‐based type increasingly studied. This perspective review scoped the potentials of 3D extrusion‐based printing in resolving food processing challenges. In this work, we demonstrated how this extrusion‐based technique increasingly contributes to situate the 3D food printing as among innovative technologies with an upscale dimension. To fully embrace the extrusion‐based 3D printing, the food industry needs to primarily understand the potentials this technology would provide in enhancing food material properties/types.

Section: D Printing Software/algorithm and Key Food Rheological Prope...mentioning

confidence: 99%

Potentials of3Dextrusion‐based printing in resolving food processing challenges: A perspective review

Song

J Food Process Engineering

et al. 2022

“…The algorithm consisted of converting the analytical surface in a grid XY following the points in order and calculating z for dynamic movements. McCaw and Cuan Urquizo [6] presented the procedure to fabricate non-planar lattice-shells on nonplanar equation-defined surfaces (parametric Bèzier surfaces of arbitrary order), whereas Cuan-Urquizo et al [40] generated and fabricated a lattice using rectangular equations and studied the mechanical behavior when force is applied. McCaw and Cuan-Urquizo [41] presented a mathematical approach to parametrize lattices onto Bèzier surfaces to fabricate non-planar chirality lattices and studied them under cyclic loading.…”

Section: Non-planar Path Planning For 3d Printingmentioning

confidence: 99%

“…A limited number of works were focused on the generation of more complex trajectories, such as those needed for the manufacturing of lattices or specific paths for the deposition of fibers or conductive materials. Complex trajectories or patterns, such as sinusoidal lattices, were reported, and these were printed on analytical surfaces (mathematically parametrized) but not using tessellated surfaces [40,41]. Complex freeforms, such as those encountered in biomedical applications (normally obtained from scanned data), may not be mathematically parametrized.…”

Section: Non-planar Path Planning For 3d Printingmentioning

confidence: 99%

Algorithm for the Conformal 3D Printing on Non-Planar Tessellated Surfaces: Applicability in Patterns and Lattices

et al. 2021

Self Cite

In contrast to the traditional 3D printing process, where material is deposited layer-by-layer on horizontal flat surfaces, conformal 3D printing enables users to create structures on non-planar surfaces for different and innovative applications. Translating a 2D pattern to any arbitrary non-planar surface, such as a tessellated one, is challenging because the available software for printing is limited to planar slicing. The present research outlines an easy-to-use mathematical algorithm to project a printing trajectory as a sequence of points through a vector-defined direction on any triangle-tessellated non-planar surface. The algorithm processes the ordered points of the 2D version of the printing trajectory, the tessellated STL files of the target surface, and the projection direction. It then generates the new trajectory lying on the target surface with the G-code instructions for the printer. As a proof of concept, several examples are presented, including a Hilbert curve and lattices printed on curved surfaces, using a conventional fused filament fabrication machine. The algorithm’s effectiveness is further demonstrated by translating a printing trajectory to an analytical surface. The surface is tessellated and fed to the algorithm as an input to compare the results, demonstrating that the error depends on the resolution of the tessellated surface rather than on the algorithm itself.

“…Three-dimensional (3D) printing, or additive manufacturing (AM), has aroused research interest significantly when it is widely applied for directly manufacturing complex 3D components and structures (Chu et al, 2008;Ding et al, 2014), such as non-planar lattice structures (Cuan-Urquizo et al, 2019;McCaw and Cuan-Urquizo, 2018), multi-plane objects (Ishak and Larochelle, 2019) and support-free parts (Dai et al, 2018;Xu et al, 2019). Generally, most traditional AM processes involve planar slicing and flat layer deposition with a uniform layer thickness (Ding et al, 2016b;Sun et al, 2007;Zhang et al, 2013Zhang et al, , 2003.…”

Section: Introductionmentioning

confidence: 99%

“…Ultimaker, Makerbot, Zortrax, Prusai3MK2 and Kossel Delta arm) with X, Y and Z motions, also known as three-DOF, have been developed. Although three axes 3D printer based on Cartesian coordinates has been used in slightly curved parts (Cuan-Urquizo et al, 2019;Etienne et al, 2019;Jin et al, 2017), it fails to meet the requirement that the axis of the printing nozzle should coincide with the normal direction of the deposited path on the curved surface (Chakraborty et al, 2008). So, the multi-DOF 3D printer has been applied to CLFDM.…”

Section: Introductionmentioning

confidence: 99%

A multi-DOF rotary 3D printer: machine design, performance analysis and process planning of curved layer fused deposition modeling (CLFDM)

Zhao

Shen

et al. 2020

RPJ

Purpose The purpose of this paper is to design and develop a rotary three-dimensional (3D) printer for curved layer fused deposition modeling (CLFDM), and discuss some technical challenges in the development. Design/methodology/approach Some technical challenges include, but are not limited to, the machine design and control system, motion analysis and simulation, workspace and printing process analysis, curved layer slicing and tool path planning. Moreover, preliminary experiments are carried out to prove the feasibility of the design. Findings A rotary 3D printer for CLFDM has been designed and developed. Moreover, this printer can function as a polar 3D printer for flat layer additive manufacturing (AM). Compared with flat layer AM, CLFDM weakens the staircase effect and improves geometrical accuracy and mechanical properties. Hence, CLFDM is more suitable for parts with curved surfaces. Research limitations/implications Double extruders have brought improved build speed. However, this paper is restricted to complex process planning and mechanical structures, which may lead to collisions during printing. Meanwhile, the rotation range of the nozzle is limited by mechanical structures, affecting the manufacturing capability of complex curved surfaces. Originality/value A novel rotary 3D printer, which has four degrees of freedom and double extruders, has been designed and manufactured. The investigation on the prototype has proved its capability of CLFDM. Besides, this rotary 3D printer has two working modes, which brings the possibility of flat layer AM and CLFDM.