Indirect Additive Manufacturing of resin components using polyvinyl alcohol sacrificial moulds

Montero, Joaquin; Vitale, Pablo; Weber, Sebastian; Bleckmann, Matthias; Paetzold, Kristin

doi:10.1016/j.procir.2020.02.191

Cited by 9 publications

(6 citation statements)

References 22 publications

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“…WAAM possesses the capability to manufacture massive part with zero reliance on moulds via the use of CAD / CAM software. However, WAAM production is highly dependent upon additional positioning systems, such as a robot, or CNC milling machine [16]. Additionally, WAAM main components are motion system, material deposition system, and heat source [28].…”

Section: Wire Arc Additive Manufacturing (Waam)mentioning

confidence: 99%

The Innovation in wire arc additive manufacturing (WAAM): A review

Alaboudi

2023

Advanced Topics in Mechanics of Materials, Structures and Construction

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Abstract. This review or research paper is illustrated to analytically assess and address one of potential industrial revolutions, which is Wire Arc Additive Manufacturing (WAAM). WAAM is classified from Hybrid Manufacturing (HM) processes. Thus, one of the Hybrid Manufacturing ultimate goals has always been to transcend the limitation aspects associated with the tradition process. As Artificial Intelligence (AI) has evolved and expanded all over the globe, Additive Manufacturing (AM) has been gradually developed and introduced to the world to be one of a distinguished innovative impact in the history of manufacturing. Additive Manufacturing (AM) has been improved over the conventional methods in the manufacturing world due to its advanced complexity, consistency, quality of work, and various advantages and contribution that satisfy the costumers needs and requirements. Various applications in the industry have proven the AM applicability to replace the conventional processes such as casting and machining as it can deal with very coplex shapes [3]. In spite of the fact that there are numerous materials that can be manufactured in the modern technologies of AM, such as polymers, metals, ceramic, and composites, the contribution of Metal Additive Manufacturing (MAM) arguably has been a significant influence in the industries in comparison to the others [1]. In this review paper the detailed deliverable information and materials which will be established and communicated in this paper will concentrate on the history of (WAAM) including its pros and cons, latest contribution to the industries, AM classifications, materials, and primary materials and practices in industry.

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Section: Wire Arc Additive Manufacturing (Waam)mentioning

confidence: 99%

The Innovation in wire arc additive manufacturing (WAAM): A review

Alaboudi

2023

Advanced Topics in Mechanics of Materials, Structures and Construction

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“…Moreover, solvable molds allow the production of parts with complex overhangs. At the moment, this approach is mainly adopted in electronics, bioengineering or medical fields [18,19], but it could be suitable for all those applications that need high-performance composite complex shapes or heat resistance properties [20].…”

Section: Surface Finishing Implementation For New Applicationsmentioning

confidence: 99%

Composite Finishing for Reuse

Romani

Suriano

Mantelli

et al. 2022

Systemic Circular Economy Solutions for Fiber Reinforced Composites

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Coating processes are emerging for new applications related to remanufactured products from End-of-Life materials. In this perspective, their employment can generate interesting scenarios for the design of products and solutions in circular economy frameworks, especially for composite materials. This chapter would give an overview of coating design and application for recycled glass fiber reinforced polymers on the base of the experimentation made within the FiberEUse project. New cosmetic and functional coatings were developed and tested on different polymer composite substrates filled with mechanically recycled End-of-Life glass fibers. Afterwards, recycled glass fiber reinforced polymer samples from water-solvable 3D printed molds were successfully coated. Finally, new industrial applications for the developed coatings and general guidelines for the coating of recycled glass fiber reinforced polymers were proposed by using the FiberEUse Demo Cases as a theoretical proof-of-concept.

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“…An initial experiment was performed prior to the 3D printing process of the mold to identify the best 3D printing parameter variations, particularly mold thickness and travel speed (Haque, 2020;Azhikannickal & Uhrin, 2019).The best travel speed was determined to be 70 mm/s, and the mold thickness was determined to be 2.4 mm. Meanwhile, the other printing parameters were determined based on the literature (Montero et al, 2020;Tagami et al, 2017), such as printing speed of 50 mm/s, extruder and platform temperatures of 205 0 C and 45 0 C, infill of 0%, layer height of 0.2 mm, Then, the lumbar mold made of PVA was sliced and printed. Subsequently, the printed lumbar mold was drilled to add injection and excess holes.…”

Section: Casting Process Optimizationmentioning

confidence: 99%

“…Due to all the challenges faced in fabricating lumbar model, an indirect additive manufacturing approach can be used to obtain a better quality of the lumbar spine model. Indirect additive manufacturing can be performed by combining FDM and casting processes to produce the part (Montero et al, 2020). The combination can be implemented since the desired material to fabricate the part is only possible through the casting process, meanwhile traditional casting process is not recommended due to its low accuracy and a long period of time required for mold preparation.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Rigid Polyurethane Foam Lumbar Spine Model for Surgical Training using Indirect Additive Manufacturing

Asriyanti¹,

Saptaji²,

Khoiriyah³

et al. 2022

IJTech

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Lumbar model is an artificial bone that is commonly used in surgical training to simulate working with the human-like bone for the trainer. The common lumbar model is made of rigid polyurethane (PU) foam and is produced using casting. However, the current lumbar model is expensive and has limitations in representing the real human lumbar, especially in geometry, visuals, and haptics. Therefore, an alternative method of fabricating lumbar models made of rigid polyurethane for surgical training using indirect additive manufacturing will be investigated in this paper. The proposed indirect additive manufacturing is a combination of 3D printing and casting methods. The main process of this method is started by fabricating a mold made of polyvinyl alcohol (PVA) using fused deposition modeling (FDM) 3D printing and subsequently casting PU foam material into the 3D printed PVA mold. Accordingly, the aim of this study is to find the optimized casting process parameters, especially for injecting the material into the mold, to achieve a better quality of lumbar model. The study was conducted using a Design of Experiment (DoE) Taguchi Orthogonal Array to optimize the casting process. The geometrical measurements of middle endplate depth, upper end-plate width, spinal canal width, spinal canal depth, and lower pedicle length show the error ranged from 0.14% to 0.85%. The average porosity, measured from the body, lamina, and spinous, was found to be non-uniform. It is ranged from 19.58% to 21.94% on the middle part and 39.78% to 45.41% on the subsurface of lumbar model. The density was increased by 64.89% compared to the reference open molded PU foam.

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Indirect Additive Manufacturing of resin components using polyvinyl alcohol sacrificial moulds

Cited by 9 publications

References 22 publications

The Innovation in wire arc additive manufacturing (WAAM): A review

The Innovation in wire arc additive manufacturing (WAAM): A review

Composite Finishing for Reuse

Fabrication of Rigid Polyurethane Foam Lumbar Spine Model for Surgical Training using Indirect Additive Manufacturing

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