An official website of the United States government
Additive manufacturing (AM) of polymer composites with continuous fibers could play a major role in the future of aerospace and beyond but will require printed materials to achieve new levels of reliability. This study characterized the strength distribution of selected thermoplastic matrix composites as a func- tion of printing via fused filament fabrication (FFF). Experimental and commercial composite filaments of continuous carbon or Kevlar fibers were printed with volume fraction (Vf) ranging from approximately 28 to 56 %. The strength was evaluated under uniaxial tension after specific stages of printing and Weibull statistics were applied to characterize the strength distribution. There was a significant reduction in strength of the printed material with respect to the unprinted condition, regardless of reinforcement type, fiber volume fraction or printer used. Damage introduced by feed extrusion of the filament, and fiber failures induced at material deposition were most detrimental. For carbon fiber filaments, the reduc- tion ranged from approximately 10 % for an experimental material to over 60 % for a commercial filament. There was no correlation in the strength degradation or variability with Vf. The prevention of process-related fiber damage is key to advancing AM for continuous fiber composite and application to designs intended for stress-critical applications.
more »
« less
Additive Manufacturing of Biomechanically Tailored Meshes for Compliant Wearable and Implantable Devices
Abstract Additive manufacturing (AM) of medical devices such as orthopedic implants and hearing aids is highly attractive because of the potential of AM to match the complex form and mechanics of individual human bodies. Externally worn and implantable tissue‐support devices, such as ankle or knee braces, and hernia repair mesh, offer a new opportunity for AM to mimic tissue‐like mechanics and improve both patient outcomes and comfort. Here, it is demonstrated how explicit programming of the toolpath in an extrusion AM process can enable new, flexible mesh materials having digitally tailored mechanical properties and geometry. Meshes are fabricated by extrusion of thermoplastics, optionally with continuous fiber reinforcement, using a continuous toolpath that tailors the elasticity of unit cells of the mesh via incorporation of slack and modulation of filament–filament bonding. It is shown how the tensile mesh mechanics can be engineered to match the nonlinear response of muscle. An ankle brace with directionally specific inversion stiffness arising from embedded mesh is validated, and further concepts for 3D mesh devices are prototyped.
more »
« less
- Award ID(s):
- 1724135
- PAR ID:
- 10460206
- Publisher / Repository:
- Wiley Blackwell (John Wiley & Sons)
- Date Published:
- Journal Name:
- Advanced Functional Materials
- Volume:
- 29
- Issue:
- 32
- ISSN:
- 1616-301X
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Abstract The ability of living species to transition between rigid and flexible shapes represents one of their survival mechanisms, which has been adopted by various human technologies. Such transition is especially desired in medical devices as rigidity facilitates the implantation process, while flexibility and softness favor biocompatibility with surrounding tissue. Traditional thermoplastics cannot match soft tissue mechanics, while gels leach into the body and alter their properties over time. Here, a single‐component system with an unprecedented drop of Young's modulus by up to six orders of magnitude from the GPa to kPa level at a controlled temperature within 28–43 °C is demonstrated. This approach is based on brush‐like polymer networks with crystallizable side chains, e.g., poly(valerolactone), affording independent control of melting temperature and Young's modulus by concurrently altering side chain length and crosslink density. Softening down to the tissue level at the physiological temperature allows the design of tissue‐adaptive implants that can be inserted as rigid devices followed by matching the surrounding tissue mechanics at body temperature. This transition also enables thermally triggered release of embedded drugs for anti‐inflammatory treatment.more » « less
-
Abstract Additive manufacturing (AM), also known as 3D printing, has significantly advanced in recent years, especially with the introduction of multifunctional 3D-printed parts. AM fabricated monolith has multiple material capabilities, thus various functionalities are well-perceived by the manufacturing communities. As an example, a traditional fused filament fabrication (FFF) 3D printer fabricates multi-material thermoplastic parts using a dual extrusion system to increase the functionality of the part including variable stiffening and gradient structures. In addition to the multiple thermoplastic feedstocks in a dual extrusion system, multifunctional AM can be achieved by embedding electronics or reinforcing fibers within the fabricated thermoplastic parts, which significantly impacts the rapid prototyping of hybrid components in manufacturing industries. State-of-the-art techniques such as coextrusion systems, ultrasonic welding tools, and thermal embedding tools have been implemented to automate the process of embedding conductive material within the 3D-printed thermoplastic substrate. The goal of this tool development effort is to embed wires within 3D 3D-printed plastic substrate. This research consisted of developing a wire embedding tool that can be integrated into an FFF desktop 3D printer to deposit conductive as well as resistive wires within the 3D-printed thermoplastic substrate. By realizing the challenges for discrete materials interaction at the interface such as nichrome wires and Acrylonitrile Butadiene Styrene (ABS) plastics and polylactic acid (PLA), the goal of this tool was to immerse wire within ABS and PLA substrate using transient swelling mechanisms under non-polar solvent. A proof-of-concept test stands with a wire feed system and the embedding wheel was first designed and manufactured using 3D printing to examine if a traditional roller-guided system, primarily used for plastic extrusion, would be sufficient for wire extrusion. The development of the integrated wire embedding tool was initiated based on the success of the proof-of-concept wire extrusion system. The design of the integrated wire embedding tool consisted of three sub-assemblies: wire delivery assembly, wire shearing assembly, and swivel assembly. The wire delivery assembly is responsible for feeding the wire towards the thermoplastic using the filament delivery system seen within FFF printers. For the wire shearing mechanism, a cutting Tungsten carbide blade in conjunction with a Nema-17 external stepper motor was used to shear the wire. For the wire embedding assembly, a custom swivel mount was fabricated with a bearing housing for a ball bearing that allowed for a 360-degree motion around the horizontal plane. A wire guide nozzle was placed through the mount to allow for the wire to be fed down into a brass embedding wheel in a tangential manner. Additionally, the solvent reservoir was mounted such that an even layer of solution was dispensed onto the thermoplastic substrate. Through this tool development effort, the aim was to develop technologies that will enable 3D printing of wire-embedded monolith for various applications including a self-heating mold of thermoset-based composite manufacturing as well as smart composites with embedded sensors.more » « less
-
In this research, we propose a Multi-Filament Fused Deposit Modelling (MFFMD) printer and a respective generator that can be used to produce structural parts with locally tailored functional properties. 3D-printed structural components can highly benefit from multi-material printing with tuneable functional properties. Currently, multi-material printing is mainly achieved using multiple separate nozzles, leading to discontinuous flow in switching materials. This limitation results in material interface delamination, minimal control in the continuous transition of material properties, and longer production time.To address this, we first design and build an MFFMD printer with a single customized nozzle allowing seamless switching between multiple filaments. We then develop a method that generates a continuous toolpath of a given geometry and differentiates materials based on various stress conditions at particular regions. To illustrate, we fabricate a Pratt truss as an example of a tension-compression structure as a case study. In one go, the MFFMD printer deposits resistant filament, respectively, at tension- or compression-concentrated regions based on local stress conditions. Comparative load tests are conducted to validate the performance enhancement of multi-filament prints against single-filament prints. Our proposed method is a prototypical study conducted on a small scale. While it mainly uses thermal plastic filaments, it can be expanded to other construction materials and scales in the future.more » « less
-
Abstract Actin filament assembly and mechanics are crucial for maintenance of cell structure, motility, and division. Actin filament assembly occurs in a crowded intracellular environment consisting of various types of molecules, including small organic molecules known as osmolytes. Ample evidence highlights the protective functions of osmolytes such as trimethylamine‐N‐oxide (TMAO), including their effects on protein stability and their ability to counteract cellular osmotic stress. Yet, how TMAO affects individual actin filament assembly dynamics and mechanics is not well understood. We hypothesize that, owing to its protective nature, TMAO will enhance filament dynamics and stiffen actin filaments due to increased stability. In this study, we investigate osmolyte‐dependent actin filament assembly and bending mechanics by measuring filament elongation rates, steady‐state filament lengths, and bending persistence lengths in the presence of TMAO using total internal reflection fluorescence microscopy and pyrene assays. Our results demonstrate that TMAO increases filament elongation rates as well as steady‐state average filament lengths, and enhances filament bending stiffness. Together, these results will help us understand how small organic osmolytes modulate cytoskeletal protein assembly and mechanics in living cells.more » « less
