3D printing a CAD modelnormally requires conversion into a polygon mesh, usually an STL-file, in orderto be able to load the model in the slicer. This conversion destroys roundsurfaces and replaces them with flat surfaces. Slicing a polygon mesh resultsin one or more polygons, consisting of a number of straight lines. This canaffect both dimensional accuracy and surface smoothness. Modern 3D-printerscan, in addition to straight lines, handle arcs. However, today’s commonslicers can not generate arcs as the input does not contain any curvedfeatures. This project aims at finding an alternative solution. By directslicing of CAD models the slices can contain arcs, and the slicer can producearc commands for the 3D-printer. During this project a prototype slicer isconstructed as a proof of concept. The prototype handles STEP-files as inputand creates both linear and circular movement for the 3D-printer. The resultsshow that both the intermediate files (STEP/STL) and the resulting G-code filescan get smaller, yet preserving the original shape, by using this method. Theproposed solution has a positive effect on the 3D-printing workflow as well, asthe intermediate files can be imported back into the CAD system. The projectconcludes that there is possibly a bright future for direct slicing, but thereare more problems to solve before it can become reality.

A indústria de cerâmica branca de objetos decorativos e utilitários, produz diariamente um contingente significativo de resíduo de gesso, oriundo do descarte dos moldes, cuja vida útil é extremamente curta. A deposição desse material via de regra é feita em aterros sanitários, sem qualquer tipo de isolamento em células e sem observar as recomendações da Lei da Política Nacional de Resíduos Sólidos. De acordo com a hierarquia estabelecida pela lei, a supressão da geração dos resíduos sólidos aparece como alternativa prioritária do ponto de vista das boas práticas ambientais. É nessa perspectiva que a tecnologia de produção industrial computadorizada de objetos tridimensionais por deposição de matéria prima, surge como alternativa. A intenção desse trabalho é apresentar conceitos de produtos que potencializem o uso dessa tecnologia através de configurações formais inovadoras para o setor, eliminando a utilização do gesso em seu processo de fabricação além de avaliar os resultados obtidos através da análise dos protótipos fabricados. / White ceramic industry of decorative and utilitarian objects, produces daily a significant contingent of waste gypsum, originated from the disposal of moulds, whose lifespan is extremely short. Deposition of this material usually is made in landfills without any type of isolation cells and without observing the recommendations of the Law of the Brazilian solid waste Policy. According to the ranking established by law, the elimination of solid waste generation appears as a priority alternative in terms of good environmental practices. In this perspective, the technology of computerized industrial production of three-dimensional objects by deposition of raw material, is an alternative. The aim of this paper is to present product concepts that enhance the use of this technology through innovative formal settings for the sector and make an analysis about the results.

O uso da digitalização e da impressão tridimensional (3D) com a produção de biomodelos que possam ser usados em aulas práticas das disciplinas de anatomia veterinária no Brasil é uma ferramenta inovadora. O acesso dos alunos a essa material didático pode representar um aspecto importante no aprendizado da anatomia de animais domésticos. Neste estudo, foi utilizado um scanner que faz a captura tridimensional das imagens e uma impressora 3D que realiza a impressão por deposição de material fundido (FDM) para produzir modelos esqueléticos de do membro torácico do equino. Foram usados a escápula, o úmero, radio e ulna, ossos do carpo e falanges usada para produzir modelos digitais. Estes foram então usados para produzir modelos físicos através da impressão, realizada em várias escalas. As características anatômicas dos modelos impressos tridimensionais (3D) foram então comparadas com as dos ossos do esqueleto original. Os resultados deste estudo demonstraram que os biomodelos de animais podem ser rapidamente produzidos usando a tecnologia de impressão 3D. Em termos de precisão entre os biomodelos e as peças anatômicas originais não houve diferença significativa na estatística. Todas as características, exceto o forame nutrício, puderam ser identificadas nas cópias impressas em 3D. / The use of three-dimensional (3D) scanning and printing for the production of biomodels that can be used in practical classes of veterinary anatomy disciplines in Brazil is an innovative tool. The students ease of access to this teaching material can be an important aspect of learning the anatomy of domestic animals. In this study, a scanner was used to capture three-dimensional images and a 3D printer that performs die-cast printing (FDM) was used to produce skeletal models of equines thoracic limb. The scapula, humerus, radius and ulna, carpal bones and phalanges were used to produce digital models and physical models for 3D impressions. The anatomical characteristics of the three-dimensional printed models were then compared with those of the original skeletal bones. The results of this study demonstrated that animal biomodels can be rapidly produced using 3D printing technology. In terms of precision between the biomodels and the original anatomical parts, there was no significant statistical difference. All the characteristics, except for the foramen nutritium, were successfully identified in the 3D printed copies.

Supercapacitors, also known as electrochemical capacitors, have shown great potential as energy storage devices; and 3D printing likewise as a manufacturing technique. This research progressively investigates combining these two technologies to fabricate 3D-printed, electrochemical double-layer capacitors (EDLCs). Small EDLCs were designed in a sandwich structure with an FDM-printed plastic frame and carbon electrodes. Inkjet printing was initially combined with FDM printing to produce a pilot sample with a silver ink current collector, however this performed poorly (Cs = 6 mF/g). Henceforth a paste extrusion system was added to the FDM printer to deposit the current collectors and electrodes, fabricating the entire device in a single continuous process. This process was progressively developed and tested, ultimately attaining specific capacitances of 200 mF/g. The fully integrated 3D printing process used to manufacture the EDLCs was a novel approach. Combining the FDM printer with a paste extruder allowed for a high degree of dimensional accuracy, as well as simplifying the production process. This aspect of the design functioned successfully, without significant faults, and proved a reliable fabrication method. The later designs used in this study provided the EDLCs extendable by incorporating connection jacks. This was to create the possibility to increase capacitance simply by connecting multiple EDLCs together. Tests of this feature showed that it worked well, with the extendable EDLCs delivering outputs very close to the theoretical maximum efficiency of the unit. Carbon conductive paint was applied as a current collector and electrode for the 3D printed EDLCs in an exploration of metal-free 3D printed supercapacitors. These metal-free EDLCs were found to provide around 60% of the specific capacitance of the best performing EDLC variant produced (silver paint current collectors with activated carbon and carbon paint mixture electrodes). Although considerable improvement is required to produce EDLC samples with comparable capacitances to existing commercial manufacturing techniques, this study lays important groundwork in this area, and has introduces effective and innovative design ideas for supercapacitors and integrated 3D printing processes.

The development of energy storage devices has represented a significant technological challenge for the past few years. Electrochemical double-layer capacitors (EDLCs), also named as supercapacitors, are a likely competitor for alternative energy storage because of their low-cost, high power density, and high fast charge/discharge rate. The recent development of EDLCs requires them to be lightweight and flexible. There are many fabrication techniques used to manufacture flexible EDLCs, and these methods can include pre-treatment to ensure more efficient penetration of activated carbon (AC) patterns onto the substrate, or those that utilise masks for the definitions of patterns on substrates. However, these methods are inconvenient for building cost-effective devices. Therefore, it was necessary to find a suitable process to reduce the steps of manufacture and to be able to print multiple materials uniformly. This research work describes the first use of a 3D printing technology to produce flexible EDLCs for energy storage. In this research work, the four essential elements for the EDLCs substrate, current collector, activated electrode, and gel electrolyte were investigated. The AC powder was milled by ball milling to optimise the paste deposition and the electrochemical performance. A flexible composite EDLC was designed and manufactured by 3D printing. The electrochemical performance of the flexible composite EDLCs was then examined. Being highly flexible is one of the critical demands for the recent development of EDLCs. Therefore, highly flexible EDLCs were designed and manufactured by only one single extrusion process. The 3D highly flexible EDLC maintains significant electrochemical performance under a mechanical bending test. To meet the power and energy requirements, the EDLCs were connected and tested in series and parallel circuits. A supercapacitor based on printed AC material displays an area specific capacitance of 1.48 F/cm2 at the scan rate of 20 mV/s. The coulombic efficiency for the flexible EDLC was found to be 59.91%, and the cycling stability was achieved to be 56% after 500 cycles. These findings indicate that 3D printing technology may be increasingly used to develop more sophisticated flexible wearable electronic devices.

Orientador: Paola Castro Moraes / Resumo: O escopo do presente trabalho visa a análise da reparação tecidual traqueal, viabilidade e biocompatibilidade de implante manufaturado tridimensionalmente por método de modelagem por fusão e deposição de co-poliamida associado a elastômero termoplástico aplicado por técnica de anastomose, em coelhos. Quinze animais foram divididos em três grupos homogêneos, referentes aos momentos das eutanásias programadas: sete, 15 e 30 dias. Sinais de caráter clinico e cirúrgico foram observados diariamente durante o tempo de sobrevida de cada grupo, indicando ausência de sinais respiratórios e complicações com a técnica de implantação. Avaliações macroscópicas foram realizadas, para verificar o comportamento tecidual perante a inserção do biomaterial por inspeção direta, assim como análise histopatológica em coloração hematoxilina-eosina para investigação das reações celulares locais. Os resultados dos estudos citado à cima foram aplicados ao teste Exato de Fisher, sob significância de 5% (p<0,05). Não houve deformidade traqueal, deiscência de sutura e luxação da prótese em nenhum animal do projeto. Processo inflamatório de padrão misto foi notado em todos os tempos explorados de forma decrescente, presença de crescimento tecidual sob implante conforme a reparação do organismo frente a prótese ocorreu de forma progressiva e houve escassez de células gigantes, comprovando ausência de reação tipo corpo estranho, revelando boa aceitação do implante e do material proposto na reparação de teci... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The scope of the present work aims at the analysis of the tracheal tissue repair, viability and biocompatibility of a three-dimensional manufactured implant by fusion molding and co-polyamide deposition associated with thermoplastic elastomer applied by anastomosis technique in rabbits. Fifteen animals were divided into three homogeneous groups, related to the euthanasia moments programmed: seven, 15 and 30 days. Signs of clinical and surgical character were observed daily during the survival time of each group, indicating absence of respiratory signs and complications with the implantation technique. Macroscopic evaluations were performed to verify the tissue behavior before insertion of the biomaterial by direct inspection, as well as histopathological analysis in hematoxylin-eosin staining to investigate the local cellular reactions. The results of the above-mentioned studies were applied to Fisher's exact test, in a significance of 5% (p <0.05). There was no tracheal deformity, suture dehiscence, and dislocation of the prosthesis in any animal of the project. Inflammatory process of mixed pattern was observed at all times explored decreasingly, presence of tissue growth under implant as the repair of the organism before the prosthesis occurred progressively and there was a shortage of giant cells, proving absence of foreign body type reaction, revealing good acceptance of the implant and of the proposed material in the repair of tracheal tissue. Thus, it is concluded that... (Complete abstract click electronic access below) / Mestre

This work develops and examines design strategies for reducing the stiffness of 3D-printed compliant mechanisms. The three aspects of a flexure that determine its stiffness are well known: material, boundary conditions, and geometry. In a highly constrained design space however, flexure stiffness may remain unacceptably high even while arriving at the limits of design constraints. In this work, changes to geometry and boundary conditions are examined that lead to drastically reduced stiffness behavior without changing flexure thickness, width, or length. Changes to geometry can result in very complex mechanisms. However, 3D printing enables almost arbitrarily complex geometries. This dissertation presents three design strategies for stiffness reduction: static balancing, lattice flexures, and compound joints. Static balancing refers to changes in the boundary conditions that result in a near-zero net change in potential energy storage over the useful deflection of a flexure. In this work, I present a method for static balancing that utilizes non-dimensional parameters to quickly synthesize a joint design with stiffness reduced by nearly 90%. This method is not only simple and straightforward, it is applicable to a wide range of flexure topologies. The only requirements on the joint to be balanced are that it must be approximated as a pin joint and torsion spring, and it must have a well-understood stiffness when subjected to a compressive load. Lattice flexures result from modifications to geometry that reduce cross-sectional area without changing width or thickness. However, the reduction in stiffness is greater than the reduction in cross sectional area. This can occur because the bending load is now carried by beams partially in torsion. Two lattice geometries are proposed and analyzed in detail using analytic and numeric techniques. It is shown that the off-axis stiffness behavior of lattice flexures can be better than that of conventional blade flexures while bending stiffness is reduced >60%. Compound joints are those that consist of arrays of flexures arranged co-axially. This arrangement provides increased range of motion, generally decreased stiffness, and improved stability. Additionally, a method is herein presented to reduce the parasitic center shift of a compound joint to nearly zero at a specified deflection. The penultimate chapter demonstrates how all three strategies can be used together, and includes new results to facilitate their combination.

Automatic altitude compensation has been a holy grail of rocket propulsion for decades. Current state-of-the-art bell nozzles see large performance decreases at low altitudes, limiting rocket designs, shrinking payloads, and overall increasing costs. Aerospike nozzles are an old idea from the 1960’s that provide superior altitude-compensating performance and enhanced performance in vacuum, but have survivability issues that have stopped their application in satellite propulsion systems. A growing need for CubeSat propulsion systems provides the impetus to study aerospike nozzles in this application. This study built two aerospike nozzles using modern 3D metal printing techniques to test aerospikes at a size small enough to be potentially used on a CubeSat. Results indicated promising in-space performance, but further testing to determine thermal limits is deemed necessary.

This research project primarily focuses on three major aspects: synthesis and inclusion of silver microparticles and nanowires within a polymer matrix, extrusion of composite filaments and, three-dimensional (3D) printing of multifunctional polymer composites. Since very few studies have explored the inclusion of silver nanoparticles in 3D printing materials, the findings from this study can be significant for additive manufacturing technology. Over the past few decades, the applications of additive manufacturing has been expanding considerably in several industries like automobile, biomechanics, aerospace, hardware engineering, to name a few. We are particularly interested in silver particles and nanowires because of their enhanced antimicrobial, mechanical and optical properties. The unique antimicrobial properties of the silver-polymer composite will especially be applicable in the food and meat industry, where microbial infection is a major concern because of the exposure of microbes in the polymer belts that are used to transfer and package the items in the factory. It costs the industries a considerable amount of time, money and labor to regularly clean and sanitize those belts. If we are able to develop polymer belts with embedded antimicrobial properties, it could have tremendous applications in the food and meat industries. The morphology of the particles will be studied using scientific techniques like Transmission electron microscopy (TEM) and Scanning Electron Microscopy (SEM). The idea is then to nanoparticles will be incorporated into PLA polymer pellets and extruded into composite filaments that can be used for 3D printing of dog-bone test structures. After the fabrication process, tensile tests and fracture surface analysis will be conducted to study the extent of enhancement of the mechanical properties as compared to neat polymer 3D printed specimens. The critical challenge in this project would be to ensure homogenous distribution of the nanoparticles throughout the polymer filaments. This project will integrate concepts and applications from three different fields: nanotechnology, material science, and additive manufacturing.

Orientador: Gustavo Franco Barbosa / Resumo: O presente projeto de pesquisa, tem como objetivo estudar a viabilidade técnica e financeira para implementação de um manipulador robótico colaborativo,para bioimpressão, utilizando seringas para aplicação da biotinta, definindo os parâmetros de impressão, materiais e equipamentos disponíveis. Propõe-se um estudo sobre os desafios da bioimpressão, tanto na área de desenvolvimento de novos equipamentos,processos e materiais, assim como os desafios sobre impressão de tecidos humanos com células vivas. O trabalho foi realizado com base na revisão da literatura, abordando os principais autores e empresas especializadas no tema proposto, de modo a alcançar o objetivo. O presente projeto estudará a viabilidade de implementação das seringas como efetuador em um manipulador robótico. A metodologia consiste em modelo teórico, seleção dos materiais disponíveis, dividido em quatro etapas, onde serão analisados: concepção, modelo 3D, validação da ideia com simulação em ambiente virtual e fabricação do protótipo em um momento futuro. Os métodos aplicados no projeto contam com um enfoque descritivo qualitativo, com o objetivo de estudar as características e equipamentos apresentados para a fabricação de arcabouços (scaffolds) e tecidos com o uso de robô colaborativo. / Abstract: This research project aims to study the technical and financial feasibility of implementing a collaborative robotic manipulator, for bioprinting, using syringes for bioinkapplication, defining the printing parameters, materials and equipment available. A study is proposed on the challenges of bioprinting, both in the area of development of new equipment, processes and materials, as well as the challenges of printing human tissues with living cells. The work was based on the literature review, approaching the main authors and companies specialized in the proposed theme, in order to reach the objective. This project will study the feasibility of implementing syringes as an effector in a robotic manipulator. The methodology consists of theoretical model, selection of available materials, divided into four stages, which will be analyzed: conception, 3D model, idea validation with simulation in virtual environment and prototypefabrication in a future moment. The methods applied in the project have a qualitative descriptive approach, aiming to study the characteristics and equipment presented for the manufacture of scaffolds and fabrics using a collaborative robot. / Mestre