Laser polished fused deposition poly-lactic acid objects for personalized orthopaedic application

Chai, Young Suck; Chen, Xiaobo; Zhang, Donghai; Lynch, Joseph P.; Birbilis, Nick; Qin, Qing Hua; Smith, Paul N.; Li, Rachel

doi:10.1007/s42452-020-03637-7

Cited by 13 publications

(8 citation statements)

References 37 publications

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“…Laser polishing had shown significant improvement in the surface properties of FFF parts. [131][132][133] The key process variable that impacts the surface quality is laser power. The laser power and beam size of 3 W and 200 μm respectively are the optimal process conditions for the FFF PLA specimen.…”

Section: Hot Air Jettingmentioning

confidence: 99%

Property enhancement approaches of fused filament fabrication technology: A review

Pazhamannil

Govindan

et al. 2022

Polymer Engineering & Sci

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The shift from rapid prototyping to rapid manufacturing using 3D printing is prominent after the development of volumetric 3D printing, multi-material printing, and functional materials development. Fused filament fabrication (FFF) is a fast-growing additive manufacturing technology with widespread end-user applications. The key constraints to its growth are the lower surface and mechanical properties compared to conventional manufacturing paradigms. The goal of this review is to look at the numerous pre-processing and post-processing parameters for the property enhancement of FFF. Preprocessing methods included optimization of process parameters (infill percentage, pattern, layer height, nozzle and platform temperature, raster angle and width, build orientation, and air gap) and adaptive slicing techniques.Mechanical (hot air jetting, barrel finishing, sand blasting, laser polishing, etc.), chemical (vapor smoothing, dipping, plating, and painting), and thermal (thermal annealing and normalizing) post-processing techniques were successful in improving the mechanical strength and surface finish of fused filament fabricated parts. This paper outlines the various methodologies a FFF user could incorporate for enhancing the final finished product's properties. The potential future prospects for the development of the 3D printing sector are also examined.

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Section: Hot Air Jettingmentioning

confidence: 99%

Property enhancement approaches of fused filament fabrication technology: A review

Pazhamannil

Govindan

et al. 2022

Polymer Engineering & Sci

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“…The material in this research was PLA filament produced by Sunhokey technology, Guangdong, China. Blue PLA filaments were selected in diameter due to their good thermal performance and environmentally friendly nature [16]. PLA has 1.24 g/cm 3 density, 48.5 MPa tensile strength, 82.7 MPa bending strength, and 150-165°C melting point.…”

Section: A Materialsmentioning

confidence: 99%

“…After the pelletising process, the pellets were extruded with a 60 rpm screw speed, a 55 rpm filament puller speed, and a temperature profile set to 175°C, 175°C, 175°C, 180°C, 170°C, 170°C (for the different zones from the hopper to the die-head, respectively) to obtain the samples from the extrusion. Before recycling, the samples were re-pelletised and dried for 2 hours at 35°C, below the glass transition temperature (Tg), to reduce the water content as much as possible and avoid hydrolytic degradation [16]. The PLA material was then re-extruded under the same conditions in the first processing step to obtain a recycled PLA sample.…”

Section: B Polylactic Acid Recyclingmentioning

confidence: 99%

The Effect of Multi-Extrusion Process of Polylactic Acid on Tensile Strength and Fracture Morphology of Filament Product

Syaifuddin

Suryanto²,

Suprayitno³

2021

JMEST

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Polylactic acid (PLA) is one of the most used materials in FDM 3D Printing. Large-scale consumption of PLA on an industrial scale could cause environmental and efficiency problems. Thus, PLA waste and industry waste need to be recycled to limit excessive waste. This study aimed to investigate the change in mechanical property, morphology, and structure of mechanically recycled PLA. Recycling was performed 12 times using the extrusion process with an extrusion temperature nozzle of 170°C. The SEM, structural analysis, and amorphous-crystalline analysis used XRD. The results showed a gradual decrease of tensile strength from each recycle with a total of 20% (13.22 MPa). The decrease percentage equalled the number of recycling. After the 9 th recycle, PLA experienced a drastic tensile strength decrease, in which the 12 th recycle tensile strength had a 14% (8.17 MPa) reduction. The morphology analysis of the tensile test sample presented significant morphology change, in which morphology defects such as void, flakes, and cracks appeared after the 6 th recycle. Although, until 12 times extrusion, it did not significantly affect the PLA phase shape. Mechanical recycle using a multi-extrusion process is not recommended exceeding six times.

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“…It is also useful to offer 3D printed physical models to surgeons/students/trainees/nurses/patients/their families for their education and training purposes. [6]…”

Section: Introductionmentioning

confidence: 99%

“…It is also useful to offer 3D printed physical models to surgeons/students/trainees/nurses/ patients/their families for their education and training purposes. [6] Recent technological advances have seen the emergence of 3D printing being adapted for interventional clinical application and a Trauma and Orthopaedic Research Laboratory, Department of Surgery, The Medical School, The Australian National University, Canberra, ACT, Australia, b Trauma and Orthopaedic Research Unit, Clinical Orthopaedic Surgery, The Canberra Hospital, Garran, ACT, Australia, c The Medical School, and John Curtin School of Medical Research, The Australian National University, Canberra, ACT, Australia, d National Computational Infrastructure, The Australian National University, Canberra, ACT, Australia; and e The Medical School, and John Curtin School of Medical Research, The Australian National University, Acton, ACT, Australia. medical education.…”

Section: Introductionmentioning

confidence: 99%

Comparison of 2 open-sourced 3-dimensional modeling techniques for orthopaedic application

Chai¹,

Šimić²,

Smith³

et al. 2022

OTA International: The Open Access Journal of Orthopaedic Trauma

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Objectives: Although 3-dimensional (3D) printing is becoming more widely adopted for clinical applications, it is yet to be accepted as part of standard practice. One of the key applications of this technology is orthopaedic surgical planning for urgent trauma cases. Anatomically accurate replicas of patients' fracture models can be produced to guide intervention. These high-quality models facilitate the design and printing of patient-specific implants and surgical devices. Therefore, a fast and accurate workflow will help orthopaedic surgeons to generate high-quality 3D printable models of complex fractures. Currently, there is a lack of access to an uncomplicated and inexpensive workflow.Methods: Using patient DICOM data sets (n = 13), we devised a novel, simple, open-source, and rapid modeling process using Drishti software and compared its efficacy and data storage with the 3D Slicer image computing platform. We imported the computed tomography image directory acquired from patients into the software to isolate the model of bone surface from surrounding soft tissue using the minimum functions. One pelvic fracture case was further integrated into the customized implant design practice to demonstrate the compatibility of the 3D models generated from Drishti.Results: The data sizes of the generated 3D models and the processing files that represent the original DICOM of Drishti are on average 27% and 12% smaller than that of 3D Slicer, respectively (both P < 0.05). The time frame needed to reach the stage of viewing the 3D bone model and the exporting of the data of Drishti is 39% and 38% faster than that of 3D Slicer, respectively (both P < 0.05). We also constructed a virtual model using third-party software to trial the implant design.Conclusions: Drishti is more suitable for urgent trauma cases that require fast and efficient 3D bone reconstruction with less hardware requirement. 3D Slicer performs better at quantitative preoperative planning and multilayer segmentation. Both software platforms are compatible with third-party programs used to produce customized implants that could be useful for surgical training.Level of Evidence: Level V.

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Laser polished fused deposition poly-lactic acid objects for personalized orthopaedic application

Cited by 13 publications

References 37 publications

Property enhancement approaches of fused filament fabrication technology: A review

Property enhancement approaches of fused filament fabrication technology: A review

The Effect of Multi-Extrusion Process of Polylactic Acid on Tensile Strength and Fracture Morphology of Filament Product

Comparison of 2 open-sourced 3-dimensional modeling techniques for orthopaedic application

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