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Abstract The majority of 3D‐printed biodegradable biomaterials are brittle, limiting their application to compliant tissues. Poly(glycerol sebacate) acrylate (PGSA) is a synthetic biocompatible elastomer and compatible with light‐based 3D printing. In this article, digital‐light‐processing (DLP)‐based 3D printing is employed to create a complex PGSA network structure. Nature‐inspired double network (DN) structures consisting of interconnected segments with different mechanical properties are printed from the same material in a single shot. Such capability has not been demonstrated by any other fabrication techniques so far. The biocompatibility of PGSA is confirmed via cell‐viability analysis. Furthermore, a finite‐element analysis (FEA) model is used to predict the failure of the DN structure under uniaxial tension. FEA confirms that the DN structure absorbs 100% more energy before rupture by using the soft segments as sacrificial elements while the hard segments retain structural integrity. Using the FEA‐informed design, a new DN structure is printed and tensile test results agree with the simulation. This article demonstrates how geometrically‐optimized material design can be easily and rapidly constructed by DLP‐based 3D printing, where well‐defined patterns of different stiffnesses can be simultaneously formed using the same elastic biomaterial, and overall mechanical properties can be specifically optimized for different biomedical applications.
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Enhancing the Structural Performance of 3D Printed Objects Through G Code Optimization via FEA in the FDM Process
Abstract Additive manufacturing, an innovative process that assembles materials layer by layer from 3D model data, is recognized as a transformative technology across diverse industries. Researchers have extensively investigated the impact of various printing parameters of 3D printing machines, such as printing speed, nozzle temperature, and infill, on the mechanical properties of printed objects. Specifically, this study focuses on applying Finite Element Analysis (FEA) in G code modification in Fused Deposition Modeling (FDM) 3D Printing. FDM involves extruding a thermoplastic filament in layers over a build plate to create a three-dimensional object. In the realm of load-bearing structures, the Finite Element Analysis (FEA) process is initiated on the target object, employing the primary load to identify areas with high-stress concentrations. Subsequently, optimization techniques are used to strategically assign printing parameter combinations to improve mechanical properties in potentially vulnerable regions. The ultimate objective is to tailor the G code, a set of instructions for the printer, to strengthen particular areas and improve the printed object’s overall structural integrity. To evaluate the suggested methodology’s efficacy, the study conducts a comprehensive analysis of printed objects, both with and without the optimized G code. Simultaneously, mechanical testing, such as tensile testing, demonstrates quantitative data on structural performance. This comprehensive analysis aims to identify the impact of G code alteration on the finished product. Preliminary experimental results using simple tensile specimens indicate notable improvements in structural performance. Importantly, these improvements are achieved without any discernible mass increase, optimizing material usage and reducing the cost of additive manufacturing. The modified G code targets to strengthen critical areas using updated printing parameters without a net increase in the overall material consumption of the object. This finding holds significant implications for industries reliant on additive manufacturing for load-bearing components, offering a promising avenue for improved efficiency and durability. Integrating advanced techniques, such as G code modification and finite element analysis (FEA), as the additive manufacturing landscape evolves presents a pathway toward optimizing mechanical properties. By contributing valuable insights and laying the groundwork for further exploration and refinement of these methodologies, this study paves the way for enhanced structural performance in various additive manufacturing applications. Ultimately, it encourages innovation and progress in the field, propelling the industry toward new heights of efficiency and reliability.
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- Award ID(s):
- 2107140
- PAR ID:
- 10630128
- Publisher / Repository:
- American Society of Mechanical Engineers
- Date Published:
- ISBN:
- 978-0-7918-8860-5
- Format(s):
- Medium: X
- Location:
- Portland, Oregon, USA
- Sponsoring Org:
- National Science Foundation
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Conference Paper:
- https://doi.org/10.1115/IMECE2024-143962
