Several active methods, which requires external control systems and moving parts, have been developed to control the fiber orientation during 3D printing. Active mechanisms like rotating nozzle, impeller, and magnetic field have been integrated to realize complex internal fiber structures. In this study, instead of using active methods, I investigate a passive method for controlling the fiber orientation without any moving parts or additional mechatronics added in the printing process. Composites of polydimethylsiloxane (PDMS) and glass fibers (GF) are 3D printed. Channels, such as helicoid, are designed and integrated to guide the ink flow and passively result in different pre-alignment of fibers before the ink flow into narrow nozzle space. While passing through the designed channels, the fibers orient due to the shear between channel walls and the ink. The effect of helicoids with different pitch sizes are investigated via mechanical experiments, microstructural analysis, and numerical simulations. The results show that both surface to volume ratio and helix angle of the channel affect pre-alignment of fiber orientation at the entry of nozzle. The internal fiber structures lead to enhanced and tunable mechanical properties of printed composites. Pitch size 7-9 mm (helix angle of 7.92- 10.15o) is found to be optimal for the 3D printed PDMS-GF composites. Stiffness and strength can be tuned up to 77.6% and 47.8%, respectively, compared with the case without helicoid channel. Channels of parallel holes, parallel holes with taper end and gradually changing pitch helicoids are experimentally tested, showing further enhancement in mechanical properties.

In this report, my work on 3D-printing will be presented. This project is what constitutes my examination project in the education of industrial design engineering.   3D-printers are tools that have undergone great development in recent years. Through this development, the machines have become increasingly accessible to private individuals thanks to reduced prices, easyer use and higher quality. Through an increased use of the tool on a more private level, new opportunities are created for how we manufacture products, as well as how our attitude to its components are viewed.   The purpose of the work was to investigate how 3D-printing can be used to create more efficient and sustainable products with a focus on users, manufacturers and the environment. The goal was to develop an approach to utilize the function of a 3D-printer in a way that contributes to higher sustainability and efficiency, where the end result should contribute to this without forcing the user to make any decisive sacrifices.   The work has been carried out with a three-part process, divided into the phases Inspiration, Ideation and implementation, which together constitute an iterative design process. Initially in the inspiration phase, inspiration was created for the work with the help of a literature study, theory collection and a context analysis. Then began the ideation phase, whose purpose was to start creating ideas and conceptualize the inspiration that has previously been collected in the inspiration phase. To implement these ideas and concepts, the implementation phase was carried out to achieve a more completed and implemented concept.   The work resulted in the concept TonePrint. TonePrint is a speaker and a pair of headphones that work together in a form of ecosystem to make the interaction smoother for the user when changing audio source. The product TonePrint is a product that the user 3D-prints by oneself. This contributes to a more efficient and sustainable product as well as production. The product is designed in a way that enables the user to configure the product based on their own needs, which contributes to increased personalization. It allows the user to reuse components from previous devices that would otherwise be discarded, or select components based on their own liking and taste. / I den här rapporten kommer mitt arbete rörande 3D-printeing presenteras. Det här projektet är det som utgör mitt examensarbete i utbildningen högskoleingenjör inom teknisk design.   3D-printers är verktyg som har genomgått stor utveckling de senaste åren. Genom den här utvecklingen har maskinerna blivit allt mer tillgängliga för privatpersoner tack vare lägre priser, smidigare användning och högre kvalitet. Genom en ökad användning av verktyget på mer privata plan skapas nya möjligheter för hur vi tillverkar produkter, samt hur vi ser på produkter och dess uppbyggande komponenter.   Syftet med arbetet var att undersöka hur 3D-printing kan användas för att skapa mer effektiva och hållbara produkter med fokus på användare, tillverkare och miljön. Målet var att ta fram ett tillvägagångssätt att nyttja de egenskaper en 3D-printer medför på ett sätt som bidrar till en högre hållbarhet och effektivitet, där det slutliga resultatet ska bidra till detta utan att tvinga användaren att göra några avgörande uppoffringar.    Arbetet har genomförts med en tre delad process, indelad i faserna Inspiration, Ideation och implementation som tillsammans utgör en iterativ designprocess. Initialt i inspirationsfasen skapades inspiration för arbetet med hjälp av en litteraturstudie, teoriinsamling samt en kontextanalys. Därefter påbörjades ideationsfasen, vars syfte var att börja skapa idéer och konceptualisera den inspirationen som tidigare blivit insamlad i inspirationsfasen. För att implementera dessa idéer och koncept utfördes implementationsfasen för att nå ett mer färdigställt och förverkligat koncept.   Arbetet resulterade i konceptet TonePrint. TonePrint är en högtalare och ett par hörlurar som samverkar i ett form av ekosystem för att göra interaktionen smidigare för användaren vid byte av ljudkälla. Produkten TonePrint är en produkt som användaren själv 3D-printar. Detta bidrar till en mer effektiv och hållbar produkt samt produktion. Produkten är utformad på ett sätt som möjliggör för användaren att konfigurera produkten utifrån eget behov vilket bidrar till en ökad personalisering. Det möjliggör för användaren att återanvända komponenter från tidigare enheter som annars skulle slängas, eller välja komponenter utifrån eget tycke och smak.

The present Master thesis is focused on innovation and verification of the functionality of a 3D RepRap. The theoretical part of the thesis characterizes individual additive technologies. The practical part is focused on the design of the technical modifications of the printer in order to achieve the quality of the printing, while the current 3D printer design is compared with the innovative solution. The practical part tests the setting of print parameters, various materials for 3D printing and necessary finishing operations. The thesis is completed

The goal of the thesis was to design a piston manufactured by conventional method and subsequently adjusted one for additive manufacturing. Beside the designs, thermo-structural model was created for both pistons, considering maximal loading of the engine. Analysis evaluation showed the possibility of further application of the new technology in comparison to current one, within automotive industry.

Master’s thesis deals with an issue of 3D printing and of using a topological optimization for editing a shape of a 3D printed product. First part of this thesis provides a general description of a subtractive manufacturing technology, specifically its use in CNC milling machines, and of an additive manufacturing technology which is used in 3D printing. Second part of this thesis describes the topological optimization per se and specific methods which are used in the topological optimization. In the third and the fourth part of this thesis, topological optimization modules of software Ansys and SolidWorks are described. In the fifth part of this thesis, the topological optimization capabilities for 3D printed product on a specific embodiments of a design lightning and a cross-beam are demonstrated.

The diploma thesis focuses on risk assessment in the area of occupational health and safety, specifically on the risks in the implementation of 3D printing into the production process. The introductory part of the work introduces theoretical background in the area of occupational health and safety, together with the knowledge of 3D printing and methods for identification and risk management. In the following part, the identification, analysis and assessment of risks is carried out on a concrete example. Appropriate measures for their minimization, including financial evaluation, are proposed for the assessed risks.

The asymmetrical arrangement of cellular structure allows for an accurate functional adaptation at all levels of hierarchy, which derives excellent features for the development of new materials. The main objective of introducing a hierarchy into cellular structures is to improve the mechanical behaviour of the material while maintaining its elastic properties. A part of this work is devoted to the literature review related to the lightened cellular polymeric materials with hierarchical cellular structure. The rest is focused on the preparation of PLA based polymer structures using 3D printing, followed by a saturation in CO2 and a foaming in a silicon oil at elevated temperature. Samples were prepared from natural and white PLA filaments. Based on a series of experiments, optimal conditions for the saturation and foaming process were identified. Through 3D printing and foaming, a one-, two- and three-level hierarchy was introduced into the beam-shaped samples and the effect of the internal cell arrangement on the strain response of the material was examined by the means of a mechanical three-point bending test. Increasing the level of the hierarchy led to an increase in material resistance, which resulted in high values of strength and strain energy (toughness) based on the samples density. The best results were achieved by samples with “sandwich” structure with three levels of hierarchy and 30% filling. Despite the shorter plateau, there was a significant increase in strength and strain energy compared to gradient structures. At the same time, the contribution of the polymer structures prepared in this field of research was demonstrated by comparison with the theoretical model.

The diploma thesis deals with the influence of colouring additives and setting of the process parameters of 3D printing on the mechanical and surface properties of samples made of PLA material. The work describes the process of filament production, as well as the printing of normalized samples on a 3D printer using the additive method Fused Deposition Modeling. The impact of 3 types of colouring additives is evaluated on the basis of tensile test, hardness test and surface analysis. The evaluated quantities are primarily tensile strength, hardness, surface texture, roughness and corrugation. The work also evaluates the influence of the percentage of sample filling, the direction of the fibres of the inner filling and the orientation of the samples in the printing chamber of the 3D printer on the mechanical properties. The results are evaluated on the basis of the tensile test and the evaluated quantities are mainly the tensile strength, the ultimate stress and the modulus of elasticity in traction. The work is completed by evaluating the results and overall recommendations for filament manufacturers and users.

The diploma thesis deals with the production process of optical part of headlamp module produced by additive technology. The thesis contains the characteristics of headlamp, current manufacturing technology and description of additive manufacturng methods. The practical part is focused on the production of a reflector using 3D printing. The conclusion of the thesis is dedicated to the measuring of light output and its evaluation.

The thesis deals with the possible use of additive technology in the production of strong thermally exposed components of turbine engines. The first part of the thesis is dedicated to the issue of processing heat-resistant materials by SLM method, introduction of conventional production of selected part and outline of currently used progressive methods in precision casting technology. These theoretical findings are further applied in the practical part of the thesis, which deals with the analysis of mechanical properties of cast and printed material IN 939. Experimental part also includes production of the blisk of the first stage turbine of the auxiliary power unit S5L by SLM additive technology. The thesis also includes analysis of fracture surfaces and metallographic analysis of samples using light and scanning electron microscopy. The thesis ends with the evaluation of the achieved results.