Beruflich Dokumente
Kultur Dokumente
PROCESSES:
from materials to applications, from
micro- to macro-simulations
F. Auricchio
Computational Mechanics and Advanced Material Group
Dipartimento di Ingegneria Civile e Architettura
Università di Pavia
ECONOMIC IMPACT
STEP 1
From CAD to .STL
STEP 2
Virtual Slicing
STEP 3
Printing
Ø Waste material
ü The advantages of 3D printing over
APPLICATIONS
3D printed ABS
Ø Automotive & Mechanic propellers
3D printed house
model
Ø Design & Planning
APPLICATIONS IN MEDICINE
Regenerative
Regenerative Medical Devices Prosthesis &
Medicine
Medicine Orthosis
• Expensive process;
• Material: metal alloys (Ni, Co, Fe, Al, Steel);
• Lower precision but higher speed than
• Curing: high power electron laser other metal technologies.
beam;
• Post-processing required
APPLICATIONS
First 3D printed car
Ø Automotive & Mechanic engine
3D printed front-
bearing housing
Ø Aeronautical & Defense
APPLICATIONS
3D-printed gold ring
Ø Jewelry & Luxury
3D-printed mold
APPLICATIONS IN MEDICINE
Regenerative
Regenerative Medical Devices Prosthesis &
Medicine
Medicine Orthosis
3D Printing technologies
Prototyping
Standard technologies
Production
3D Printing technologies
Prototyping
3D Printing technologies
Production
Standard technologies
Production
PRINCIPAL ALLOYS
Ø Cobalt-Chrome (CoCr)
Ø Stainless Steel (e.g. 316L)
Ø Maraging Steel
Ø Aluminum (AlSi12)
Aluminum powder
Ø Titanium (TiAl16V4)
Ø Copper (Cu)
Ø Gold (Au)
Ø Inconel (Ni - In718)
Titanium powder
ALLOYS PROPERTIES
Data from:
ALLOYS PROPERTIES
Data from:
Line behavior
influenced by the
Energy Density
SLM:
• More Resistance
• Less Ductility
CAST:
• Less Resistance
• More Ductility
Stress on Elongation.
Comparison between
the behaviour on
deposition plane and in
the normal direction.
Anisotropy Behaviour
of the Tensile:
• More Ductility on XY
• Same Tensile Strength
Kempen, Karolien, et al. "Mechanical properties of AlSi10Mg produced
by selective laser melting." Physics Procedia 39 (2012): 439-446.
ALLOYS PROPERTIES
Data from:
ALLOYS PROPERTIES
Data from:
Printing setting
influences final density
of the Part !!!
Printing setting
influences final density
of the Part !!!
From:
ALLOYS PROPERTIES
Data from:
ALLOYS PROPERTIES
Data from:
SLM:
• More Resistance
• Less Ductility
CAST:
• Less Resistance
• More Ductility
Fracture Strain in function of temperature for SLM (a) and REFERENCE Material(b).
Completely different
Vrancken, Bey, et al. "Heat treatment of Ti6Al4V produced by
response to Heat Selective Laser Melting: Microstructure and mechanical
Treatment !!! properties." Journal of Alloys and Compounds 541 (2012): 177-185.
Yield Stress in function of temperature for SLM (a) and REFERENCE Material(b).
Completely different
Vrancken, Bey, et al. "Heat treatment of Ti6Al4V produced by
response to Heat Selective Laser Melting: Microstructure and mechanical
Treatment !!! properties." Journal of Alloys and Compounds 541 (2012): 177-185.
From:
TRADITIONAL 3D PRINTED
ELONGATION AT
15% 4%
BREAK
From:
Internal
Study
V1: 2 s-1
V2: 1 s-1
V3: 0.2 s-1
V4: 0.03 s-1
Strain rate dependence V5: 0.01 s-1
V6: 0.001 s-1
Load (N)
• T1: 40°C
• T2: 50°C
• T3: 60°C
Louche, Hervé, et al. "An experimental and modeling study of the thermomechanical behavior of an ABS polymer
structural component during an impact test." International Journal of Impact Engineering 36.6 (2009): 847-861.
Louche, Hervé, et al. "An experimental and modeling study of the thermomechanical behavior of an ABS polymer
structural component during an impact test." International Journal of Impact Engineering 36.6 (2009): 847-861.
Stress concentration
Internal study
Ferdinando Auricchio CompMech Group September, 2017
FDM 3D Printed ABS
Internal study
Ferdinando Auricchio CompMech Group September, 2017
FDM 3D Printed ABS
0.3 x 0.6
0.3 x 0.6
Internal study
Ferdinando Auricchio CompMech Group September, 2017
FDM 3D Printed ABS
23 24 25 26 14 15 16 17 18
MPa
MPa
Internal study
Díez-Pascual, Ana María, et al. "Novel nanocomposites reinforced with hydroxylated poly (ether ether
ketone)-grafted carbon nanotubes." Journal of Materials Chemistry 20.38 (2010): 8247-8256.
Ferdinando Auricchio CompMech Group September, 2017
Molded PEEK
Electrical conductivity:
Thermal conductivity:
CNT content increases both
electrical and thermal
conductivity
TENSILE PROPERTIES
Comparison between ABS and PEEK,
injection molded and FDM 3D printed
COMPRESSIVE PROPERTIES
Comparison between ABS and PEEK,
injection molded and FDM 3D printed
BENDING PROPERTIES
Comparison between ABS and PEEK,
injection molded and FDM 3D printed
Wu, Wenzheng, et al. "Influence of layer thickness and raster angle on the mechanical properties of 3D-printed
PEEK and a comparative mechanical study between PEEK and ABS." Materials 8.9 (2015): 5834-5846.
Temperature increasing:
• Young’s modulus decreases Temperature weakens
• Yield stress decreases FDM 3D printed Ultem
• Ductility decreases
Li, H., et al. "Modeling and characterization of fused deposition modeling tooling for vacuum
assisted resin transfer molding process." Additive Manufacturing 7 (2015): 64-72.
Ferdinando Auricchio CompMech Group September, 2017
FDM 3D Printed Ultem 9085
THERMOMECHANICAL PROPERTIES
Temperature increasing effect
Above 320°F
Chen, Bor‐Kuan, Yu‐Ting Fang, and Jing‐Ru Cheng. "Synthesis of low dielectric constant
polyetherimide films." Macromolecular symposia. Vol. 242. No. 1. WILEY‐VCH Verlag, 2006.
Ferdinando Auricchio CompMech Group September, 2017
Materials for SLS technology
Source: http://www.ec21.com
Ferdinando Auricchio CompMech Group September, 2017
SLS 3D printed Nylon and PCL
B
SLS printed Nylon: brittle
behavior
SLS printed PCL: ductile
behavior with softening
C
Young’s modulus increases
Effect of vapor-smoothing Yield strength increases
of SLS printed PCL (nearly four times than
unsmoothed PCL)
Kinstlinger, Ian S., et al. "Open-source selective laser sintering (OpenSLS) of nylon and
biocompatible polycaprolactone." PloS one 11.2 (2016): e0147399.
Effect of blending
Storage moduli of PA12/HDPE blends lower
than those for the pure components
Hypothesis: low
PA12/HDPE 50/50 chemical affinity
blend: lowest b e t w e e n PA 1 2
storage modulus and HDPE phases
Salmoria, G. V., et al. "Selective laser sintering of PA12/HDPE blends: Effect of
components on elastic/plastic behavior." Polymer Testing 27.6 (2008): 654-659.
Ferdinando Auricchio CompMech Group September, 2017
SLS 3D printed polymeric blends
CREEP TEST
Creep test: percentage deformation related
to the maximum strain amplitude in the
stress–strain curves
Elastic recovery and plastic deformation
measured after removing applied stress
Effect of blending
PA 1 2 / H D P E PA 1 2 / H D P E
80/20 blend: 20/80 blend:
elastic recovery highest plastic
similar pure deformation
PA12 (32%)
FATIGUE ANALYSIS
Fatigue curves obtained at 50% of maximum
strain amplitude: stress variation as function of
number of cycles
Effect of blending
PA12/HDPE 80/20 à lower fatigue strength
than pure PA12
PA12/HDPE 20/80 à similar fatigue behavior to
pure HDPE
PHYSICAL PROBLEM
ü Microscopic Simulation is principally adopted for SLM SIMULATION
ü Aim is to investigate the physical problem at the PARTICLE LEVEL
500 µm
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
PHYSICAL PROBLEM
ü Microscopic Simulation is principally adopted for SLM SIMULATION
ü Aim is to investigate the physical problem at the PARTICLE LEVEL
Ø Main effects:
• Heat conduction
• Absorption
• Convection
• Melting/Solidification
• Wetting
• Gravity
• Capillary Forces
Ø Secondary effects:
• Radiation
• Vaporization
• Marangoni convection At present, no analyses have been
• Solidification shrinkage carried out including all this effects
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
PHYSICAL PROBLEM
• Heat conduction and Absorption:
• Laser modeling:
Gaussian model of
laser heat distribution
• Fluid dynamics:
With some adjustments
can reproduce wetting
and capillarity
Including convection
and diffusion term
• Marangoni effect:
Marangoni number evaluates the
ratio between surface tension and
viscous forces
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
Ø Particles Method
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
Principal codes:
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
ü Kinetic approach:
• Discrete Particles System
• Particles Streaming and Propagation
ü Solving CFD problems using:
ü Explicit method:
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
NEWTON LAWS e
where:
• : position of the i-th particle
• : momentum of the i-th particle
• : force on the i-th particle
HYPOTHESIS:
1. Ergodic System
MICROSCOPIC LEVEL
LIOUVILLE
EQUATION
e
HYPOTHESIS: con: e
1. where :
probability to have ‘N’ particles at the • : derivative of position of the i-th particle
• : derivative of momentum of the i-th particle
time ‘t’ with velocity and position: • : Hamiltonian formulation of the system
(LBE)
BOLTZMANN
EQUATION with:
where:
• LHS : DIFFUSIVE part + CONVECTIVE
• RHS : COLLISION OPERATOR
HYPOTHESIS:
1. BGK approximation of the collision MESOSCOPIC LEVEL
term
2. Chapman-Enskog expansion
3. Consider finite numbers of momentum
distribution
4. Integration in the phase space
where:
• 1° EQUATION: continuity equation (mass conservation)
• 2° EQUATION : momentum balance equation
NAVIER-STOKES
EQUATIONS MACROCOPIC LEVEL
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
where : where :
1. : is the particle probability distribution 1. : is a time temperature coefficient
• Using the total derivative formulation we can finally write BOLTZMANN EQUATION
as follows:
: RELAXATION TIME
• Integrating over time we obtain the following analytical solution of Boltzmann Eq.
• Performing the First Order Taylor Expansion around = 0 and inserting it in the
analytical solution we obtain the final expression of Boltzmann Equation:
Where :
1. : ei is the i-th vector of the space base of the problem
2. : is the light velocity
3. : is the Gaussian weight for i-th velocity
VELOCITIES VELOCITIES
W W
H H
E E
I I
G G
H H
T T
S S
Ferdinando Auricchio CompMech Group September, 2017
Microscopic Simulations
STREAMING COLLISION
New distribution is
New distribution is
evaluated at the same
evaluated from previous
position at incremented
position at the same time
time
Ø DENSITY
Continuum
Discrete
Ø MOMENTUM
Continuum
Discrete
Ø BOUNCE BACK
BOUNDARY CONDITIONS
Used to simulate particle collision with
walls or rigid obstacles. Perfectly
BEFORE COLLISION AFTER COLLISION
elastic collisions are considered.
TOP WALL
Ø PERIODIC BOUNDARY
CONDITIONS
Used to simulate an infinite domain. BOTTOM WALL
In a periodic domain the mass outgoing
from one side must enter from the
opposite side
Ø INLET BOUNDARY
CONDITIONS
Used to simulate the input of mass in
a domain
Ø OUTLET BOUNDARY
CONDITIONS
Used to simulate the outgoing of
mass in a domain
Zou & He model 1997
Advantages: Disadvantages:
Ø Numerical stability Ø High Computational Costs
Ø Feasible for High Re Numbers Ø Difficult to choose right parameters
Boltzmann Equation can be re written as follows:
where:
Ø is the particular collision matrix
Ø is transformation matrix
Ferdinando Auricchio CompMech Group September, 2017
Microscopic Simulations
• There is a linear relationship between the vector of moments and the vector of the
distribution functions:
• Introduce now the particular collision matrix so we can write the collision step in
the moments space
Ferdinando Auricchio CompMech Group September, 2017
Microscopic Simulations
t = t + δt
COLLISION
STREAMING
MACROSCOPIC QUANTITIES
EQUILIBRIUM DISTRIBUTION
Governing equations:
Navier-Stokes Equations
Ferdinando Auricchio
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
Microscopic Simulations
HORIZONTAL ISOLINEES
• Carnahan-Starling:
Ø The Adhesion Force between the fluid and the solid walls:
Introducing now, for example, the Carnahan-Starling EoS, Free Energy Potential can be
rewritten as follows:
Where
t = t + δt
STREAMING
MACROSCOPIC QUANTITIES
Carnahan-Starling
EQUATION OF STATE EOS
ADHESION FORCE
COLLISION
BOUNDARY CONDITIONS
Adhesion Force
LBM Data:
• LX : 51 [lu] (X axis)
• LY : 51 [lu] (Y axis)
• LZ : 41 [lu] (Z axis)
• r: 15 [lu] (droplet radius)
• R: 1 [lu2/(ts2*tu)] (Gas constant)
• a: 1 [lu5/(mu*ts2)] (EOS parameter)
• b: 3
4 [lu /mu] (EOS parameter)
• c: 0.3773 [---] (EOS parameter)
• Using the same lattice structure a parallel system of distribution for temperature is
set: up
• Thermal Lattice Boltzmann Model can written as follows:
COLLISION
STREAMING
Ferdinando Auricchio CompMech Group September, 2017
Microscopic Simulations
Continuum
Discrete
• Viscosità:
DISTRIBUTION INITIALIZATION
• Conduttività termica: • t: 0 initial time
• Ux Uy: 0 initial velocity
• Freq. Ril. NS: • Equilibrium distribution NS:
• Equilibrium distribution T:
• Freq. Ril. T: • =
• =
t = t + δt
COLLISION
STREAMING
MACROSCOPIC QUANTITIES
EQULIBRIUM DISTRIBUTIONS
IDEA:
• When the temperature is equal to Phase
Change Temperature, we evaluate Enthalpy
• When Enthalpy is equal to the Latent Heat,
the particle is considered melted.
• Viscosità:
DISTRIBUTION INITIALIZATION
• Conduttività termica: • t: 0 initial time
• Ux Uy: 0 initial velocity
• Freq. Ril. NS: • Equilibrium distribution NS:
• Equilibrium distribution T:
• Freq. Ril. T: • =
• =
• LIQUID FRACTION Initialization
t = t + δt
NS COLLISION
STREAMING
TEMPERATURE EVALUATION
Internal LOOP
k=k+1
TEMPERATURE EVALUATION
ENTHALPY EVALUATION
LIQUID FRACTION
T COLLISION
NO TOLERANCE CHECK
CONVERGE ?
EQUILIBRIUM DITRIBUTIONS
LBM Data:
• Grid 151x151 [lu]
• Gravity: 10-7 [lu/tu]
• Viscosity 0,011[mu/(tu*lu)]
• Thermal diffusivity 0,081 [lu2/tu]
• Latent heat 0,3 [lu2/tu2]
• Initial temperature 0,664 [Tu]
• Fusion temperature 1,625 [Tu]
• Imposed temperature 2 [Tu]
Fourier Equation
Adhesion force
FUTURE DEVELOPMENTS
• To set up a complete
framework for to simulate
droplets phase change for
a 3D model with FREE
SURFACE technique.
Ø Plastic deformations
ü Inducing tolerances and geometry alterations
Principal codes:
ü Platform for Non linear modeling: ü Solutions for engineering: ü Full integrated tool
§ Material Modeling § Non-linear coupling § Microscopic analysis
§ Testing and Prototyping § Thermo-mechanical problem § Mesoscopic analysis
§ Design & Manufacture § Fracture problems § Macroscopic analysis
From: http://www.mscsoftware.com/product/ From: https://www.3ds.com/it//abaqus/ From: http://www.geonx.com/index-3.html
Replicator G
Pre-processing
GCODE
THERMAL
GCODE containing:
ANALYSIS
• Nozzle movements
• Print pattern velocity
MECHANICAL • Environmental
ANALYSIS machine setup
STL
Ri-elaborated Gcode
THERMAL code to extract • Time of bead deposition
ANALYSIS needed • Position of the bead
informations deposition
MECHANICAL
ANALYSIS
Gcode example Used during Simulation
• Heat conduction
GCODE • Heat convection
• Emissivity
THERMAL
ANALYSIS
MECHANICAL
ANALYSIS
TEMPERATURE DISTRIBUTION
GCODE
THERMAL
ANALYSIS
MECHANICAL
ANALYSIS
RESIDUAL STRESS DISTRIBUTION
Geometry:
• Length: 120 mm
• Width: 12 mm
• Height: 0,8 mm
Ø Goal
To virtually reproduce the real* printing process of the specimen and compare
experimental findings with analysis results
*real: material parameters, printing path, environmental setup
Ø Specific Goal
Mesh:
• Type: 8-nodes
• Elements: 144000
• Nodes: 183305
• Layers: 4
Simulation Parameters:
• Build Tray Temperature: 90 °C
• Ambient Temperature: 45 °C
• Molten Temperature: 240 °C
• Convection Film coefficient: 8 W/m2C
• Emissivity: 0,0
Filament Cross-Section:
• Width: 0,4 mm
• Height: 0,2 mm
Material Parameters:
• Type: ABS
• Constitutive Model: ELASTIC LINEAR
• Density: Fixed
• Convection: Temperature Dependent
• Specific Heat: Temperature Dependent
• Expansion: Temperature Dependent
Ferdinando Auricchio CompMech Group September, 2017
Abaqus Simulation -- FDM
Deposition process
• Temperature Evolution
• Heat Conduction
Deposition process
• Residual Stresses Evolution
200
Big time increments
180
160
140
Loose of
accuracy of the
120
0,04 0,1 0,5 1,0
temperature field
2,0
Time Increment [s]
Δt1 Δt2 Δt3 Δt4
Δt1 = 0,04 s
Δt2 = 0,5 s
Δt3 = 1,0 s
Orientation
Δt4 = 2,0 s
ü EXPERIMENTAL: separation between part and the base arise during the printing process
ü SIMULATION: separation has been performed by removing the part after the printing process
Corner Displacement
simulation
~ 1,9 mm
~ 1,5 mm
Corner Displacement
experimental
Input Data:
Stresses Analysis
• Mesh type: 8-nodes
• Thermal analysis time* 1,30h
• Stress analysis time* 2h
• Density: Fixed
• Conductivity: Temp. dependent
• Emissivity: Fixed
• Convection coeff.: Fixed
* on 4 core machine
Ferdinando Auricchio CompMech Group September, 2017
Abaqus Simulation -- FDM
Displacements Distribution
Retraction effect
from the expected
final shape
Geometry:
• Length: 120 mm
• Width: 65 mm
• Height: 60 mm
Ø Goal
To virtually reproduce the real* printing process of the specimen and compare
experimental findings with analysis results
*real: material parameters, printing path, environmental setup
Ø Specific Goal
Mesh:
• Type: 8-node
• Elements: 196407
• Nodes: 285601
• Layers: 20
Simulation Parameters:
• Build Tray Temperature: 300 °C
• Ambient Temperature: 125 °C
• Convection Film coefficient: 18 W/m2C
• Emissivity: 0,25
Laser Parameters:
• Laser Power 200 W
Material Parameters:
• Type: Ti6Al4V
• Constitutive Model: ORTHOTROPIC
• Density: Fixed
• Convection: Temperature Dependent
• Specific Heat: Temperature Dependent
• Expansion: Temperature Dependent
Ferdinando Auricchio CompMech Group September, 2017
Abaqus Simulation -- SLM
ü POWDER DEPOSITION
ü LASER PATH
STL
GCODE
THERMAL
ANALYSIS
MECHANICAL
ANALYSIS
ü POWDER DEPOSITION
ü LASER PATH
STL
GCODE
THERMAL
ANALYSIS
MECHANICAL
ANALYSIS
• Temperature Evolution
ü Appropriate time
increment is needed
to correctly evaluate
the temperature of
elements activation
• Stresses Evolution
ü Appropriate time
increment is needed
to correctly evaluate
the temperature of
elements activation
~ 0,03 mm
Horizontal displacements
~ 0,025 mm
Ferdinando Auricchio CompMech Group September, 2017
Abaqus Simulation -- FDM
SENSITIVITY ANALYSIS
Ø MATERIAL
Ø LASER POWER
Ø GEOMETRY
COSTS TO PAY
ü Increasing of Computation Time
ü Bigger Memory needed
Thermal Analysis
Mechanical Analysis
Influence of the Laser Spot Radius on the temperature distribution. LASER POWER: 400W
Thermal Analysis
Influence of the Laser Spot Radius on the temperature distribution. LASER POWER: 400W
Partially Melted
NOT Melted
Influence of the Laser Spot Radius on the temperature distribution. LASER POWER: 400W
Influence of the Time Increment on the temperature distribution. LASER POWER: 400W
Time Increment = 0,04E-3 s
Laser Spot = 0,02 mm
Thermal Analysis
Influence of the Time Increment on the temperature distribution. LASER POWER: 400W
Time Increment = 0,04E-3 s
Influence of the Ambient Temperature on the temperature distribution. LASER POWER: 400W
Ambient Temperature = 26°
Influence of the Ambient Temperature on the temperature distribution. LASER POWER: 400W
Ambient Temperature = 26°
Influence of the Ambient Temperature on the temperature distribution. LASER POWER: 400W
Ambient Temperature = 26°
Influence of the Laser Penetration Depth on the temperature distribution. LASER POWER: 400W
Laser Penetration Depth = 0,05 mm
Influence of the Laser Penetration Depth on the temperature distribution. LASER POWER: 400W
Laser Penetration Depth = 0,05 mm
Influence of the Laser Penetration Depth on the temperature distribution. LASER POWER: 400W
Laser Penetration Depth = 0,05 mm
Macroscale approach:
Main benefits:
ü Extremely fast computational time
ü Simple test to evaluate Inherent Strain Parameters From: MSC Digimat
ü Temperature distribution
ü Residual stresses
ü Part distortions after support remove
Ø Inherent strain values are defined for each layer are used to calculate
the residual stresses and thus the distortion of the part From: MSC Digimat
Technique: FDM
Material: ABS
Simulation Parameters:
• Build Tray Temperature: 90 °C
• Ambient Temperature: 45 °C
• Molten Temperature: 240 °C
• Convection Film coefficient: 8 W/m2C
• Emissivity: 0,0
Goal:
Compare numerical predictions with experimental evidences in terms of deformed
configuration due to residual stresses induced by the printing process.
VERTICAL DISPLACEMENTS
Max 1.8 mm
SIMULATION RESULTS
Min -1.2 mm
Courtesy of
Technique: FDM
Geometry: BRIDGE
Material: ABS
Simulation Parameters:
• Build Tray Temperature: 120°C
• Ambient Temperature: 45 °C
• Molten Temperature: 240 °C
• Convection Film coefficient: 8 W/m2C
• Emissivity: 0,0
Goal:
Compare numerical predictions with experimental evidences in terms of deformed
configuration due to residual stresses induced by the printing process.
Courtesy of
MSC Digimat
Courtesy of
MSC Digimat
VERTICAL DISPLACEMENTS
Max 0.4 mm
SIMULATION RESULTS
Min 0,0 mm
Courtesy of
To predict:
• Residual Stresses
• Residual
Distortions
• Material quality of
the manufactured
component
From: Geonx
From: Geonx
VIRFAC WORKFLOW
From: Geonx
θ=90° E2
θ=45° G12
Elastic moduli for ABS 3D-printed specimen through Classical
Lamination Theory
Circular hole
Elliptic hole
400
Force [N]
300
Experimental data
200 s
Finite element
100
analysis
0
0 0,2 0,4 0,6 0,8 1 1,2
Δl [mm]
Ferdinando Auricchio CompMech Group September, 2017
FEA elements and constitutive model
• Large displacements
• Plasticity with
isotropic hardening
rule
450 450
400 400
350 350
300 hole_60°_A 300
hole_90°_A
250 hole_60°_B 250 hole_90°_B
200 hole_60°_C 200 hole_90°_C
150 SHELL 150 SHELL
SOLID
100 SOLID 100
50 50
0 0
0 0,25 0,5 0,75 1 1,25 1,5 1,75 0 0,25 0,5 0,75 1 1,25 1,5 1,75
Ferdinando Auricchio CompMech Group September, 2017
Validation - Plate with elliptical hole
Using 8 elements through the tickness (1 element for each layer ) the
response curve is almost the same
ell_60°_B
250
200 ell_60°_C
150 SOLID1
100 SOLID_8el
50
0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2
Displacement [mm]
Conclusions:
3D@Unipv
A strategic plan
for
University of Pavia
3NTR A4v3
Ø Professional FDM printer;
Ø Triple bowden extruder (water cooled extruders up to 410°C);
Ø Hot chamber (up to 70°C);
3NTR A4v2
Ø Professional FDM printer;
Ø Dual bowden extruder (water cooled extruders up to 410°C);
LeapFrog Creatr HS
Ø FDM printer;
Ø Dual bowden extruder;
Ø Suitable for relatively high speeds printing of large objects;
Medicine
Kidney tumor 11
Spleen tumor 3
Pancreas tumor 3
Spleen (splenectomy) 13
Kidney (living donor procurement) 8
Splenic artery aneurysm 3
• All of the cases have been planned only relying on 3D printed models
• Intervenctions have been carried out through laparoscopic or robotic
surgery
Post - operative
Regenerative Medicine
PCL (polycaprolactone)
Setting of Biological
Thermoplastic Final
printing analysis and
biocompatible esophageal
parameters and mechanical
polymers patches
3D printing characterization
Infill 50%
Infill 20%
Determinate internal
structure and
morphology
Determinate the
Molecular Weight
(Mw) of polymers
Reduction of
20-25% of PLA-
PCL Mw after FDM
Mw = Molecular Weigth 3D printing
Mn = Number average Molecular weigth
PI = Polydispersity Index = Mw/Mn
Analyse cell
viability and
engraftment on 3D
printed patches
30 – 40% of
seeded cells is
retained by
Cells retained patches
by patches
Study patch
stiffness and
mechanical
properties
Patches
with 20%
infill Reproduce
esophageal tissue
mechanical
features
Target
Bioprinting
Common FDM 3D printers allow to … but they don’t allow to print highly
process thermoplastic filaments with viscous materials, such as:
softness > 50[shoreA], as:
Hydrogels
Thermoplastic polymers
Silicones
Biocompatible polymers
Elastomers
So there is a need for a new extrusion
system!
Bioprinting
Hydrogels
Cells
Bioink
Bioprinting
Goal
Customize a commercial FDM 3D printer
to extrude hydrogel suitable for bioink
and Bioprinting purpose
FDM Bioprinting
Peristaltic
Hardware modification
pump
Elements set-up detection
• Peristaltic pump
• Silicon tube
• Preloaded Syringe
• Nozzle
• Adapter
Preloaded
syringe
Silicon tube
Resolution
Extrude different size standard
geometries
Ø Circle
Ø Square
Ø Grid
Repeatability
Extrude 5 times standard
geometries
Ø Circle
Ø Square
Ø Grid
PLA filament
NaCl
Water
Porous scaffold
Biocompatible Natural porogen
To dissolve NaCl
For regenerative
thermoplastic medicine purposes
polymer
Architecture
Shangai Italy
(Enrico Dini, WASP, ...) Netherlands
(10 3D-printed houses in 24 (canal house printing)
hours)
Ø Advantages:
ü less materials and energy used
ü possibility to use local materials
(e.g. clay in third world countries)
ü less injures and danger for
workers
ü low income and emergency
houses in collaboration with Uni Napoli Federico II & Stress
Ferdinando Auricchio CompMech Group September, 2017
House 3D-printing
Arnhem Station
(Arup)
Modular Architectural
elements purposes Optimization
3D printed brick for the Quake Beijing studio Laboratory for Creative 3D printed curve
Column designed by Emerging Object Design fabricated silkworm-inspired pavilion wall, University of
for the city's 2015 Design Week Southern California
Ferdinando Auricchio CompMech Group September, 2017
3D Printing of concrete elements
Micro-waves
Characterization
Methodologies
Narrow-band Broad-band
Waveguide Microstrip-lines
Measurement Measurement
Set-up Set-up
Standard WR-90
Biopolymers
Thermoplastic PCL
Polymers Polycaprolacton
e
Techno Polymers
Natural PLA
Peek
PLA – PCL
copolymer
Ultem
Elastomeric Polymers
Nylon
TPU based
polymers
Carbon
reinforced
nylon TPE based
polymers
Ferdinando Auricchio CompMech Group September, 2017
Micro-waves - FDM
Standard Slab
SIW SIW
Reduced
Losses
Session FR-4-B: Characterization and application of printed materials Friday, 22 September 2017,
16:20-18:00, Room B "Aula di Disegno"
Additive Manufacturing of a Chalk Powder NRD 3-Port Junction via Binder Jetting Technology
E. Massoni, P. F. Espín-López, M. Pasian, M. Bozzi, L. Perregrini, S. Marconi, G. Alaimo, F. Auricchio
Ferdinando Auricchio CompMech Group September, 2017
Micro-waves
Metallic WR-90
3D-printed WR-90
WR-90
3D-printed WR-90 prototype
after the metalization
procedure
EXPERIMENTAL
RESULTS
Architectured Materials
MATERIALS MATERIALS
BY CHANCE BY DESIGN
Laminates / Composites
4D-printing
3D PRINTING or ADDITIVE
MANUFACTURING: allows
the creation of 3D objects
with complex shapes
… to 4D printing