Dataset Information

Influences of Material Selection, Infill Ratio, and Layer Height in the 3D Printing Cavity Process on the Surface Roughness of Printed Patterns and Casted Products in Investment Casting.

ABSTRACT: As 3D-printed (3DP) patterns are solid and durable, they can be used to create thin wall castings, which is complicated with wax patterns because of the wax's fragility and high shrinkage ratio. According to this study's experiment results, polylactic acid (PLA), polyvinyl butyral (PVB), and castable wax (CW) are suitable materials for preparing investment casting (IC) cavities. The results indicate that the casting product with the highest-quality surface is obtained using a cavity prepared using a CW-printed pattern. PLA- and PVB-printed patterns provide a good surface finish for casted products. In addition, the roughness of both the printed and casted surfaces increases as the printing layer height increases. The roughness of the casted surface varies from 2.25 μm to 29.17 μm. This investigation also considers the correlation between the infill ratio and mechanical properties of PLA-printed patterns. An increase in the infill ratios from 0% to 100% leads to a significant increase in the tensile properties of the PLA-printed pattern. The obtained results can be practically used.

SUBMITTER: Nguyen TT

PROVIDER: S-EPMC9965826 | biostudies-literature | 2023 Feb

REPOSITORIES: biostudies-literature

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Influences of Material Selection, Infill Ratio, and Layer Height in the 3D Printing Cavity Process on the Surface Roughness of Printed Patterns and Casted Products in Investment Casting.

Nguyen Thanh Tan TT Tran Van Tron VT Pham Thi Hong Nga THN Nguyen Van-Thuc VT Thanh Nguyen Chi NC Thi Hong Minh Nguyen HMN Duy Nguyen Vu Anh NVA Thanh Duy Nguyen DN Nguyen Van Thanh Tien VTT

Micromachines 20230205 2

As 3D-printed (3DP) patterns are solid and durable, they can be used to create thin wall castings, which is complicated with wax patterns because of the wax's fragility and high shrinkage ratio. According to this study's experiment results, polylactic acid (PLA), polyvinyl butyral (PVB), and castable wax (CW) are suitable materials for preparing investment casting (IC) cavities. The results indicate that the casting product with the highest-quality surface is obtained using a cavity prepared usi ...[more]

PMID: 36838095

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Project description:The mechanical and rheological characterizations of flexible investment casting patterns capable of 3D printing are reported. The wax pattern was composed of microcrystalline hydrocarbon wax (DMW7478), Piccotex 75 (a copolymer of α-methyl-styrene and vinyl toluene with a 75/25 molar ratio, respectively) and Escorene (a copolymer of ethylene and vinyl acetate with a 72/28 mass ratio, respectively). It was found that in order to obtain a wax pattern with appreciable mechanical properties, the content of the microcrystalline hydrocarbon wax in these blends should not exceed 30% (m/m). Thus, a series of patterns with 28% (m/m) wax and varying Piccotex and Escorene contents spanning from 0 to 72% (m/m) was prepared. The dependence of the dynamic viscosities of the wax patterns on the composition was described using a stretched exponential model, whereas their variations with the temperature were interpreted in terms of the Arrhenius-Guzman equation. Furthermore, the slopes of the lines fitted to the viscosity versus temperature curves at the pour point decreased linearly with the Piccotex content. Non-Newtonian changes in the shear stress with the shear rate and shear stress crystallization were observed at temperatures near the pour points. The mechanical properties were evaluated using the uniaxial tensile mode and by three-point bending experiments. It was found that the stress (σ) versus the relative elongation (ε) curves can effectively be rendered by means of the standard linear solid (SLS) viscoelastic model. In addition, it was also established that the Young's modulus varied according to a sigmoid-type curve with the piccotex content, while the yield stress decreased linearly with the concentration of Piccotex. In addition, based on the spooling suitability and printability, the patterns were rated and it was found that the most appropriate wax pattern compositions for 3D printing were those which contained 30% (m/m) and 35% (m/m) Piccotex.

Project description:BackgroundFor difficult or rare procedures, simulation offers an opportunity to provide education and training. In developing an adequate model to utilize in simulation, 3D printing has emerged as a useful technology to provide detailed, accessible, and high-fidelity models. Nasal osteotomy is an essential step in many rhinoplasty surgeries, yet it can be challenging to perform and difficult to receive adequate exposure to this nuanced portion of the procedure. As it currently stands, there are limited opportunities to practice nasal osteotomy due to the reliance on cadaveric bones, which are expensive, difficult to obtain, and require appropriate facilities and personnel. While previous designs have been developed, these models leave room for improvement in printing efficiency, cost, and material performance. This manuscript aims to describe the methodology for the design of an updated nasal osteotomy training model derived from anatomic data and optimized for printability, usability, and fidelity. Additionally, an analysis of multiple commercially available 3D printing materials and technologies was conducted to determine which offered superior equivalency to bone.MethodsThis model was updated from a first-generation model previously described to include a more usable base and form, reduce irrelevant structures, and optimize geometry for 3D printing, while maintaining the nasal bones with added stabilizers essential for function and fidelity. For the material comparison, this updated model was printed in five materials: Ultimaker Polylactic Acid, 3D Printlife ALGA, 3DXTECH SimuBone, FibreTuff, and FormLabs Durable V2. Facial plastic surgeons tested the models in a blinded, randomized fashion and completed surveys assessing tactile feedback, audio feedback, material limitation, and overall value.ResultsA model optimizing printability while maintaining quality in the area of interest was developed. In the material comparison, SimuBone emerged as the top choice amongst the evaluating physicians in an experience-based subjective comparison to human bone during a simulated osteotomy procedure using the updated model.ConclusionThe updated midface model that was user-centered, low-cost, and printable was designed. In material testing, Simubone was rated above other materials to have a more realistic feel.

Dataset Information

Influences of Material Selection, Infill Ratio, and Layer Height in the 3D Printing Cavity Process on the Surface Roughness of Printed Patterns and Casted Products in Investment Casting.

Publications

Influences of Material Selection, Infill Ratio, and Layer Height in the 3D Printing Cavity Process on the Surface Roughness of Printed Patterns and Casted Products in Investment Casting.

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