2^nd International Conference on 3D Printing Technology and Innovations March 19-20, 2018 London, UK

Biography:

Tomasz Kurzynowski completed his PhD 6 years ago from the Wroclaw University of Science and Technology and a professional development program from the Stanford University. He is the manager of Metal Additive Manufacturing Technology & Materials Laboratory, a member of the board of the Science Infrastructure Management Society. He has published more than 20 papers in reputed journals and over 150 industrial experises. His current research interest include additive manufacturing technologies and design methods for functional optimization or weight reduction of designed or reengineered parts, especially for the aerospace industry.

Abstract:

Additive Manufacturing (3D printing) offers the possibility of producing individually designed products that perfectly fulfill their functions – even the most complex ones. AM uses layered production techniques to produce functional finished parts. This process facilitates building of a part from materials that are difficult to machine and enables the production of complex parts for demanding industries such as aerospace. This direction of AM technology development is related to the ability of producing any geometric structure and to use a wide range of processing materials, including typical “aerial” materials used to reduce mass, such as aluminum, magnesium and titanium alloys.

It clearly shows the growing impact on the cost of two main factors:

• use increasingly advanced and expensive materials
• technological, construction and assembly work.

The use of magnesium for aviation applications is an opportunity to meet the high requirements and mass reduction of parts. The density of magnesium (1.77 g/cm³) is almost twice as low as conventional aluminum (2.77 g/cm³). Considering mechanical properties of magnesium (E = 34 GPa, hardness 0.6-0.95 GPa), it is characterized by excellent strength-to-weight ratio (specific strength). This is the reason why in advanced areas of industry where the mass of products is crucial, magnesium alloys are the desired materials.

Additive technologies (AMs) processing metals, plastics and composites that are currently in advanced development stage (or even commercially availabe) may have a huge impact on the cost of aircraft components by reducing the “buy-to-fly” ratio and eliminating some production, assembly and logistics activities.

This is closely related to the capabilities of additive technologies, including:

• the ability to create extremely complex shapes, spatial internal structures, etc., which reduce the weight of a product by up to 50% compared to conventional methods
• the possibility of producing one component that replaces a functional collection of several or even a dozen components made using traditional methods
• raw material savings – the amount of material needed (e.g. titanium or aluminum alloy) is only slightly larger than the volume of produced parts; additive technologies do not generate material waste as opposed to traditional technologies like machining, where losses can reach as much as 90% of the input material.

Biography:

Bernd Schob graduated his mechanical engineering studies at Westsächsische Hochschule Zwickau in 2007 and graduated his economics studies at Technische Universität Freiberg in 2015. Since 2016, he is a research assistant at Technische Universität Chemnitz, Department of Mechanical Engineering. His research focus is on Additive Manufacturing

Abstract:

In the last few years Additive Manufacturing has established itself in many branches of business. Especially in the automotive industry, the technology of powder-based laser additive melting (LAM) is eminently suitable for the production of customized, high-performance lightweight parts and geometrically complex components. Currently the range of usable materials is limited to a few titanium, nickel, aluminium, cobalt-chromium alloys, as well as some stainless steels and tool steels. Therefore, development of new powder alloys for the LAM - process is required. Medium manganese steel alloys are distinguished materials due to adjustable mechanical properties, such as high strength and significant ductility, which are beneficial for automotive applications. However, the comparatively difficult processing of a medium manganese steel is bounded by the resulting densities, among other limitations.

The aim of the work was to develop suitable and robust LAM process parameters for medium manganese steel combined with heat treatment to create microstructures that possess advanced mechanical properties.

During the development, material densities of approx. 99.98 % could be achieved (Figure 1). The mechanical investigations are determined by static load in the second step.

Due to the processing of the new manganese steel alloy and the resulting mechanical properties, new application potentials can be realised e.g. in automotive future body-in-whites structures.

Biography:

Camilo Zopp graduated his mechanical engineering studies at Dresden University of Technology in 2013.  Since 2014, he is research assistant at Chemnitz University of Technology, Department of Mechanical Engineering. He is working in the Germany’s first and only Federal Cluster of Excellence “MERGE” in the field of lightweight structures. His research focus is on additive manufacturing, selective laser melting (SLM). Especially in processing of new materials and development of material parameters. Another research topic is the production of thermoplastic-based hybrid laminats.

Abstract:

In recent years the demand for additive manufactured components has experienced a considerable boost due to increased technical, economic and geometrical requirements. Above all for the aerospace industry, the additive production technology is predestined for the production of tailor-made and geometrically complex components. In particular, laser powderbed fusion (LPB-F) is characterized as an innovative and directional production process with enormous potential.

Aluminum alloys are excellent lightweight materials due to their comparatively high stiffness and strength combined with low weight. However, the current use in the additive production process is limited by the comparatively difficult processing and which can lead to undesired low material densities.

The focus of the work was the development of suitable LPB-F process parameters for higher strength and low oxygen aluminum alloy AlSi7Mg0.6 (SilmagAl^®). In this context, material densities of approx. 99.98 % could be achieved (Figure 1). In the second step, mechanical investigations were carried out under static load. A comprehensive trade-off and comparison was made between different heat treatments (Figure 2). In the static range, yield stresses of up to 300 MPa and tensile strengths of up to 430 MPa have been achieved. The fracture elongation at break could be adjusted accordingly with values up to 20 %. Hence processing of this improved aluminum alloy and the generated mechanical properties, new application potentials in the aerospace sector will open up, e.g. for future hydraulic components.

Biography:

Phd Marta Flisykowska An independent designer, lecturer, reasercher. She works at the Academy of Fine Arts at Faculty of Architecture and Design in the Experimental Design unit. Her interests revolve around various aspects of designing, particularly in the social context. She uses her passion for the Universe, anthropology, and futurology in her projects, exhibitions, and publications. She approaches design holistically as the meeting of local and global cultural spaces.  She actively participates in various project undertakings, she’s been a curator at numerous exhibitions and workshops, her works were displayed at international fairs and exhibitions such as Milan, Paris, Munich, Las Vegas, or Beijing.

Abstract:

In 2017, NASA published the results of the Human Research Program study. It involved conducting a comparison of two organisms which are as similar to each other as possible — those of Scott and Mark Kelly, identical twins. The whole project was to address the question of how very long space travel, similar to that required for humans to get to Mars, will affect the human body. There is a multitude of examples showing that mankind is preparing to travel to Mars. The recent test flight of the Falcon Heavy, developed by SpaceX, bears witness to the fact that this moment is right around the corner. These events thus encourage us to view ourselves from a different perspective.

The human body will have to change if we are to adapt to new physical conditions, such as lower temperature. The average temperature would be -63 °C but it may drop as low as -140 °C. The lowest temperature on Earth was -89.2 °C, recorded in Antarctica. The atmosphere of Mars consists mainly of carbon dioxide, the gravitational acceleration on Mars equals just over a third of that on Earth.

Research conducted in 2017 by the University of Pennsylvania indicates that the human body has been evolving over the centuries in order to genetically adapt to existing climatic conditions. The record of this process can be physically observed based on the example of our noses. 
It has been ascertained that the width of our nostrils correlates with the temperatures and humidity of the local climate in which our ancestors lived.

For the 3D printing conferences, I have prepared speculative designs of noses. How the nose could change in order to adapt to the conditions present on Mars. Flexible prints made of liquid photopolymer solidified using UV light. The various shapes of noses refer to the process of adaptation to the conditions which man will have to face if the Earth's environment were to change. Perhaps speculations on this issue will become an inspiration for science and will allow us to make breathing easier here on Earth — even before we set out to conquer Mars.

Biography:

Chao Zhu graduated with his Bachelor’s degree from Northwestern Polytechnical University. And he will get a Meng degree from The University of Manchester next year.

Abstract:

The Fused Deposition Modelling, which is one of the main additive manufacturing technologies, is widely used in many fields with multiple materials. Additive manufacturing shows a rapid development over the last decade and hence FDM printing machines have been improved remarkablely. In this work, the effects of several set parameters on 3D printed samples’ mechanical properties and their printing quality were explored. It seems that the fill density affects samples’ mechanical properties significantly and the variation of maximum load stress and the Young’s modulus changed linearly with increased density. Moreover, the fill pattern affects fibre’s structure and determines the products’ structural properties. The mechanical properties of samples and the printing time were also affected significantly with different layer thicknesses. Samples with different fill patterns showed highly varying properties; e.g. samples with linear fill pattern showed the best tensile properties where samples with “diamond” fill pattern can have a large deformation during tests. Furthermore, the effects of different materials (e.g. PLA, ABS, carbon fibre reinforced PLA/ABS) on the properties 3D printed structures were also observed and the results showed that the samples with both carbon reinforced PLA and ABS are better in tensile properties than pure PLA and ABS. However, they were found to be more brittle in nature. Moreover, the smaples printed from carbon fibre reinforced materials showed a 45-55% increase in tensile properties and a 40-55% increase in Young’s modulus comapted to pure PLA and ABS.

Biography:

Sara Varetti is a PhD student at the Department of Applied Science and Technology (DISAT) of Politecnico di Torino. Her reaserch activity is focused on characterization of materials used for Selective Laser Melting and in particular on Aluminum alloys. Among her activities there is the design and characterization of an innovative anti-ice system for aircraft, that is patented. This study is carried out in collaboration with the Department of Mechanical Engineering and Aerospace (DIMEAS) of Politecnico di Torino.

Abstract:

Additive Manufacturing (AM) technology offers the possibility to build strong and light components with complex structures, as lattice, optimizing the strength/mass ratio. The goal of this work is the characterization of an innovative sandwich panel with trabecular core made by Selective Laser Melting (SLM), used as heat exchanger for many industrial applications, for example in aerospace field [1]. In this case study, the panel is integrated into the leading edges of aircraft wings and acts as hot air anti-icing system and, at the same time, as impact absorber (Figure 1). The system, due to its lightness and shape, leads to the optimization of the heat exchange, the improvement of the thermal efficiency, and the reduction of fuel use and gas emission.

A set of experimental and numerical tests is conducted on lattice specimens through a Design of Experiment (DOE). Different design parameters were varied to understand how they affect the mechanical and thermal behavior: six different cell shapes (Figure 2), varying cell size and volume fraction, were tested. The same experimental program is carried out for two different metal alloys: AlSi10Mg and Ti6Al4V.

Mechanical tests involve compression test on single core and on the whole panel, flexural and impact test. Further analisys on failure mechanism is carried out by observation with Optical Microscope. Thermal behavior of the system is also investigated by preliminary thermal simulations, whose results are validated by experimental measuraments of the temperature gradients on the external surface.

Biography:

Jehad Nasereddin completed his BSc in Pharmacy from the University of Petra, Amman, Jordan in 2015. He then joined the Master of Science in Pharmaceutical Technology Program at the University of Bradford, and graduated with distinction in December 2016. In April 2017, he started his PhD at the University of East Anglia, under the supervision of Dr. Sheng Qi, his project focuses on investigating the process parameters involved in Fused Deposition Modeling.

Abstract:

The advent of additive manufacturing techniques, namely Fused Deposition Modeling (FDM), holds many promising prospects for medical applications, from tailored polypills for personalized medicine to patient-specific implants. However, the lack of pharmaceutically-acceptable materials that possess suitable properties for FDM is the main issue standing in the way of turning FDM into a commercially viable process. And although a number of research efforts has demonstrated the feasibility of using blends of pharmaceutically relevant polymers to print pharmaceutical dosage forms, there remains little-to-no investigation into the critical parameters that govern the feasibility of an FDM process. Mechanical properties of the filament used in FDM is one such critical parameter; part of the filament feeding process involves rotating gears pushing the filament into a pinhole slit that leads on to the heating element of the printer. Trial and error attempts at feeding various in-house prepared filaments to the printer revealed that filaments need to possess specific mechanical properties; filaments which are too brittle will fracture inside the print head causing a blockage, filaments which are too deformable will coil around the conveyer gears without threading into the melting zone.

This presentation outlines an in-house developed method to identify the desired mechanical properties for FDM filament: A TA.XT 2 Texture Analyzer fitted with an in-house prepared rig loosely based on the spaghetti flexure rig was used to quantify forces required to deform a number of commercial and in-house filaments. Principal Component Analysis (PCA) was used to sort the data collected from the texture analysis and categorize the various filaments into feedable and non-feedable. The method was then employed to evaluate the feedability of an ibuprofen formulation to verify its suitability as a method to test the mechanical properties of filaments.

Biography:

Sarah Gretzinger is a PhD student at the Karlsruhe Institute of Technology (KIT). She has completed her Master studies form the Ulm University in cooperation with the Biberach University of Applied Science.

Abstract:

The development of biocompatible 3D printing methods have pushed the limits in tissue engineering and regenerative medicine in the past years and is considered to be a key technology in these application fields. Since the processing of living materials represents a major increase in process complexity, a directed and systematic process development approach is highly recommended for 3D bioprinting of cells. Such an approach is, however, profoundly dependent on the availability of suitable and accurate cell characterisation methods.

In this study, we evaluated different state-of-the-art cell characterisation methods concerning applicability in 3D bioprinting process development. One metabolic assay, namely, PrestoBlue®  and one flow cytometry approach. The theoretical evaluation was based on method versatility and high-throughput screening (HTS) compatibility, as well as method robustness. Further, we have evaluated the performance of two methodes that differ in their corresponding mechanism. In this case study, INS-1E was used as model cell line. The evaluation was done with one non-invasive and one invasive cell characterisation method. As non-invasive strategy, the metabolic assay PrestoBlue® was chosen, since the colometric assay can be performed by analysing the supernatant. A flow cytometry strategy was chosen as invasive method. Here, a subsequent de-solubilisation of the 3D printed object is necessary, in order to gain a single cell suspension. Our study demonstrates the importance of analytical method evaluation, for a specific application, and will facilitate a guidance for method selection.

Biography:

Jiun-Hong Liu studies at Institute of Mechanical Engineering in Chung Yuan Christian University. Major research is in opto-mechatronics.

Abstract:

In this study, SLA method was used to fabricate three-dimensional micro-structures. A soft polymer such as PDMS was used as a mold to duplicate the pattern of the micro-structures. Polyaniline (PANI) films with micro-structures on the surface using PDMS molds were prepared as eletrodes of supercapacitor. A specific capacitance 391 F/g at a current density of 1 A/g was measured for the PANI micro-structures, while the specific capacitance of PANI plane is 304 F/g. To achieve higher energy storage, laser interference lithograpy was employed to fabricate nano-structures on the micro-structures. The specific capacitance 487 F/g was obtained for the micro/nano hierarchical structures due to increase the surface of PANI electrodes.

Biography:

Mohamed Aburaia is a PhD student at the University of Innsbruck. His PhD topic deals with the usage of industrial robot manipulators for freeform prinitng. He is the deputy program director of the Master program Mechatronics/Robotics at the University of Applied Sciences Technikum Wien. He is also the project manager of a research facility that uses industrial robots to simulate processes and value chains that are analyzed and optimized concerning Industry 4.0 and related challenges.

Abstract:

Whereas regular FDM (fused deposition modelling, FFF = fused filament fabrication) relies on layer-by-layer additive manufacturing, the authors demonstrate a freeform printing process using a robot and fibre reinforced biopolymers (PLA, PHB). As fibres, both conventional (glass fibre, aramid fiber, carbon fibre) and natural fibres (flax, hemp) are used. Also, nano-scaled cellulosic nano crystals (CNC) and/or carbonized biobased nanofillers are used as reinforcement. A new 5 axis/6 axis 3D printing method for load path oriented fibre placement on freeform surfaces (FFF- based and robot arm-based) was developed. A fourfold increase in tensile strength, compared to the non-reinforced polymer, was found for aramid in PLA. Current challenges are melt strand cooling and melt strand chopping. Further increase in mechanical strengthening is expected from optimization of the sizing agent. Freeform printing was demonstrated for up to 45°C of extruded strand angle, without the need for a support structure, using air cooling and regular extrusion speed. Tensile testing according to ISO 527 reveals that the print direction has a market influence of mechanical properties in tensile testing.