With the rapid increase in utilization of the cheap and user friendly Fused Filament Fabrication, FFF 3D printer, a deeper knowledge about the technique is needful. The frame restricting the 3D printers for prototyping purposes is fading and a new phase of endless application possibilities is emerging. To bridge the gap in possible applications from prototypes to real products it is key to know and improve the factors affecting durability. With over a hundred settings and parameters to tweak the FFF 3D printing process there are a lot of opportunities, opportunities to optimize for durability.The tensile properties of some of the most used FFF 3D printing materials together with a few nylon based materials are examined, which are popular in engineering applications. The materials tested are ranging from rigid to flexible, rubber like materials. The most common failure scenario of a FFF 3D printed product is layer bonding failure. The factors affecting layer bonding performance are studied.The measurements are carried out using tensile testing equipment at Blekinge Institute of Technology. All tested specimens are manufactured at Creative Tools AB Halmstad with the FFF 3D printers Flashforge Dreamer and Makerbot Replicator 2X.The tensile strength of 3D printed PLA is found to be 51 MPa. PET has a tensile strength of 40 MPa and ABS 34 MPa. Stress-strain behavior of the materials shows that ABS is slightly softer than PLA and PET are slightly softer than ABS. PLA being the hardest material in the test. ISO 527-2 tensile testing standard is used but the tests diverge from the standard in several ways. The measurement data presented in this study can be very useful to guide the design engineer to choose the most durable plastic for the unique application.Five basic 3D printing settings are evaluated for layer bonding performance, by measuring the load capacity of a PLA specimen loaded transversally relative to the layers. Four of the settings show to possibly affect the layer bond’s load capacity by 50 % or more individually.The results of this study are presented in graphs, diagrams and pictures. These may help the 3D printer user to tweak basic settings to increase layer bonding performance and ultimately the durability of the product significantly.

Proton therapy, a relatively young modality in radiation therapy, has proven useful in cases where a sharp dose gradient or low secondary irradiation is required. In Canada proton therapy it was performed at the TRIUMF Proton Therapy Facility in the treatment of large or difficultly positioned ocular melanomas. This rare primary malignant cancer of the eye has a poor prognosis if untreated. Patient vision sparing is critical for quality of life and is strongly affected by the accuracy of the chosen treatment. Reduction in irradiation of critical structures is a proven strength of proton therapy due to the high dose-gradient and finite range in tissue. But, with the advantage of steep dose gradients, comes the requirement of precision target positioning and planning. Monte Carlo particle transport software is a valuable tool for understanding treat- ment doses in cases where measurement is time consuming or difficult. Accurate simulation of primary proton dose to water aids in the evaluation of beam charac- teristics and allows for study into improving dose application for patient treatment. In this work, a full Monte Carlo model of the TRIUMF proton therapy facility was developed. Measurements were taken in water to validate simulated results within 2% over the treatment depth for a wide range of beam modulations. The second advantage of proton therapy lies in its reduced dose bath to healthy tissue. This is especially important in pediatric cases where extraneous dose comes with a high risk of secondary carcinogenesis. Whereas multi-angle photon treatments necessarily irradiate large volumes of healthy tissue to produce a flat target dose, proton treatments may irradiate a target with a single beam. With this advantage comes a trade-off - protons produce a large number of neutrons as they are prepared for patient treatment. These neutrons are the largest contributor to secondary dose in proton therapy and must be well modeled and shielded to ensure patient safety. The second part of this work involves the measurement of secondary neutron doses in the TRIUMF treatment room. Measurements were validated within 20% of simulated values with uncertainties dominated by calibration of the detector. Neutron doses to an anatomic human model showed that calibrated secondary doses were in line with similar treatment facilities reporting globally. Simulations indicated that the source of neutrons was primarily in the unshieldable region of the beamline opening. Thus the total treatment time was the determining factor in secondary dose to the patient. With primary proton dose well modeled, it became possible to study the pre- cision of treatment and possible avenues for improvement. The beam modulation wheels and optimization scheme was developed in the late 90‘s when computational and manufacturing technologies were less developed. Updated optimization methods indicated that moving to a smooth scheme of energy modulation, as opposed to a stepped modulation wheel, could improve distal dose sharpness. This was contrary to the long-held belief that there was an optimal number of steps for modulation. The third portion of this work explored the use of 3D printers to enable the fabri- cation of smoothly transitioning modulator wheels. Materials and printer methods were studied, indicating a strong candidate in the PolyJet TM method for beam mod- ulation. Both stepped and newly-optimized smooth modulator wheels were printed and validated. Total turnaround time for modulator production was under 24 hours - proving the feasibility of patient-specific beam modulation. The last portion of this work explored the use of positron emitting isotopes for dose validation. Protons traversing tissue or plastic generate β + emitting isotopes via nuclear interactions. The resulting back-to-back annihilation photons can be re- constructed into the isotope distribution produced by the beam. This can potentially provide information about beam position in the target and hence position of a phan- tom or patient. An anatomic 3D printed eye phantom was designed and irradiated to test the feasibility of this method. While a strong isotope signal was reconstructed, the test did not yield a viable technique due to the low resolution of the phantom scan. The phantom position was poorly reconstructed using the transmission scan. Despite this, it could be possible to improve this method by using other methods for phantom position registration. / Graduate

Since the late 20th century, breakthroughs in technology have been occurring expeditiously. Indeed, technological innovations have provided the betterment of many aspects of life and ensured humans’ appropriate forms of evolution and civilization. It is safe to claim that medicine has advanced within the past few decades, especially with the upbringing of technological innovations. The world of medicine would not have experienced its recent breakthroughs and profound discoveries without utilizing the available technology. The improvements observed in medicine and technology resulted in better providing of healthcare. Customizing treatments for each patient is now possible. One method of applying customization is through 3D printing of materials such as artificial prosthetics, tissues, and organs. This literature review analyzes 3D printing by stating definitions, assessing its history, discussing its different applications and closing with evaluating future directions. 3D printing first appeared in the late 20th century, and its primary purpose was to design and manufacture products efficiently and accurately. Traditional production of structures involves subtractive manufacturing (carving, cutting, and other methods of reshaping materials) to achieve desired products, whereas 3D printers implement additive manufacturing (a layer-by-layer approach). This provides less time, greater accuracy, and labor-free fabrication of products. Computerized software is one of the essential parts of 3D printing, and functions include designing, scaling, visualizing, controlling production frequency, and many more. In medical applications, the software may require CT scans, cone beam computed tomography, and intraoral scanners (for dental applications). The 3D printing techniques identified in this review are generally applied in oral and maxillofacial procedures—stereolithography, which constructs a product layer-by-layer through curing liquid resin using a UV laser. Digital light projection is a method similar to stereolithography, with a few differences, such as using a UV light instead of a laser and using a liquid crystal display panel. Fused deposition modeling is a technique that melts plastic filaments and extrudes them through a nozzle to form a structure in a layer-by-layer fashion. Selective laser sintering is also similar to stereolithography, where it uses a laser to form an object layer by layer, but the material is a thin layer of plastic powder instead of liquid resin. The power binder printing technique applies droplets onto powdered materials, adhering and forming layers as designed via computerized software. Lastly, computed axial lithography is similar to digital light projection, except the light is projected from many angles at once instead of one layer at a time. The main objectives of this literature review are to investigate each technique, discuss the advantages and disadvantages, and list the commonly applied areas in medicine for each. Also, this review evaluates the current limitations experienced when using 3D printers and suggestions for overcoming them. Some limitations include, but are not limited to, excessive time allocated for producing specific structures, accurate capturing of surgical sites, use of appropriate materials that form printed structures, cost, and deficiencies of reported data. Lastly, this literature review assesses the future projections. The future holds promising breakthroughs in 3D printing technology, including the fabrication of dental stem cells, operating artificial organs, complex vascular tissues, customized artificial alveolar structures for oral and intracranial procedures, and regeneration of periodontal tissues. These projections may occur by overcoming the most reported limitations. Medicine is digitizing rapidly and will continue adapting to the latest technological inventions. The current efforts to advance 3D printing technology will likely positively impact the advancement of many fields, including healthcare, increase chances of positive postoperative outcomes, and potentially combat many health issues society faces today. Professionals across disciplines must come together to further research and educate curriculums to revolve around the innovative technologies to continuing education courses related to 3-D printing technologies.

The focus of this thesis is on the transition from 2D character design to 3D model design, and how this transition affects the appeal, fluidity, and clarity of the 2D design. The source material for this project was an original screenplay entitled The Birds Work for Bea. Three characters from the material were selected for a process including ideation, research, 2D character and style exploration, 3D sculpting, and 3D printing and finishing. This project serves as a study in all aspects of the character concept development pipeline.

Additive manufacturing (AM), also called 3-dimensional printing (3DP), emerged as a disruptive technology affecting multiple organizations' business models and supply chains and endangering incumbents' financial health, or even rendering them obsolete. The world market for products created by AM has increased more than 25% year over year. Using Christensen's theory of disruptive innovation as a conceptual framework, the purpose of this multiple case study was to explore the successful strategies that 4 individual managers, 1 at each of 4 different light and high-tech manufacturing companies in the Netherlands, used to adopt AM technology into their business models. Participant firms originated from 3 provinces and included a value-added logistics service provider and 3 machine shops serving various industries, including the automotive and medical sectors. Data were collected through semistructured interviews, member checking, and analysis of company documents that provided information about the adoption of 3DP into business models. Using Yin's 5-step data analysis approach, data were compiled, disassembled, reassembled, interpreted, and concluded until 3 major themes emerged: identify business opportunities for AM technology, experiment with AM technology, and embed AM technology. Because of the design freedom the use of AM enables, in combination with its environmental efficiency, the implications for positive social change include possibilities for increasing local employment, improving the environment, and enhancing healthcare for the prosperity of local and global citizens by providing potential solutions that managers could use to deploy AM technology.

abstract: This dissertation aims at developing novel materials and processing routes using alkali activated aluminosilicate binders for porous (lightweight) geopolymer matrices and 3D-printing concrete applications. The major research objectives are executed in different stages. Stage 1 includes developing synthesis routes, microstructural characterization, and performance characterization of a family of economical, multifunctional porous ceramics developed through geopolymerization of an abundant volcanic tuff (aluminosilicate mineral) as the primary source material. Metakaolin, silica fume, alumina powder, and pure silicon powder are also used as additional ingredients when necessary and activated by potassium-based alkaline agents. In Stage 2, a processing route was developed to synthesize lightweight geopolymer matrices from fly ash through carbonate-based activation. Sodium carbonate (Na2CO3) was used in this study to produce controlled pores through the release of CO2 during the low-temperature decomposition of Na2CO3. Stage 3 focuses on 3D printing of binders using geopolymeric binders along with several OPC-based 3D printable binders. In Stage 4, synthesis and characterization of 3D-printable foamed fly ash-based geopolymer matrices for thermal insulation is the focus. A surfactant-based foaming process, multi-step mixing that ensures foam jamming transition and thus a dry foam, and microstructural packing to ensure adequate skeletal density are implemented to develop foamed suspensions amenable to 3D-printing. The last stage of this research develops 3D-printable alkali-activated ground granulated blast furnace slag mixture. Slag is used as the source of aluminosilicate and shows excellent mechanical properties when activated by highly alkaline activator (NaOH + sodium silicate solution). However, alkali activated slag sets and hardens rapidly which is undesirable for 3D printing. Thus, a novel mixing procedure is developed to significantly extend the setting time of slag activated with an alkaline activator to suit 3D printing applications without the use of any retarding admixtures. This dissertation, thus advances the field of sustainable and 3D-printable matrices and opens up a new avenue for faster and economical construction using specialized materials. / Dissertation/Thesis / Doctoral Dissertation Civil, Environmental and Sustainable Engineering 2019

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Indiana University-Purdue University Indianapolis (IUPUI) / Acrylonitrile Butadiene Styrene (ABS) is the most widely used thermoplastics in 3D printing for making models, prototypes, patterns, tools and end-use parts. However, there is a lack of systematic understanding of the mechanical properties of 3D printed ABS components, including orientation-dependent tensile strength, creep, and fatigue properties. These mechanical properties are critically needed for design and application of 3D printed components. The main objective of this research is to systematically characterize key mechanical properties of 3D printed ABS components, including tensile, creep, and fatigue properties. Additionally, the eff ects of printing orientation on the mechanical prop- erties are investigated. There are two research approaches employed in the thesis: rst, experimental investigation of the tensile, creep, and fatigue properties of the 3D printed ABS components; second, laminate based finite-element modeling of tensile test to understand the stress distributions in different printing layers. The major conclusions of the thesis work are summarized as follows. The tensile test experiments show that the 0 printing orientation has the highest Young's modulus, 1.81 GPa, and ultimate strength, 224 MPa. The tensile test simulation shows a similar Young's modulus as the experiment in elastic region, indicating the robustness of laminate based finite element model. In the creep test, the 90 printing orientation has the lowest k value of 0.2 in the plastics creep model, suggesting the 90 is the most creep resistant among 0 , 45 , and 90 printing orientations. In the fatigue test, the average cycle number under load of 30 N is 3796 revolutions. The average cycle number decreases to 128 revolutions when the load is below 60N. Using the Paris Law, with the crack size of 0.75 mm long and stress intensity factor is varied from 352 to 700 MN -m^3/2 , the predicted fatigue crack growth rate is 0.0341 mm/cycle.

Indiana University-Purdue University Indianapolis (IUPUI) / Bronze is a popular metal for many important uses. Currently, there are no economical 3D printers that can print Bronze powders. A recent product, Bronze Metal Clay (BMC) has arrived. Additionally, commercial metal 3D printers require laser or electron beam sources, which are expensive and not easily accessible. The objective of this research is to develop a new two-step processing technique to produce 3D printed metallic component. The processing step includes room temperature 3D printing followed by high-temperature sintering. Since no material data exists for this clay, the tensile strength and hardness properties of BMC are compared to wrought counterpart. In this research tests are completed to determine the mechanical properties of Cu89Sn11 Bronze Metal Clay. The author of this thesis compares the physical properties of the same material in two different formats: 3D printed clay and molded clay. Using measured stress-strain curves and derived mechanical properties, including Young's modulus, yield strength, and ultimate tensile strength, the two formats demonstrate inherit differences. The Ultimate tensile strength for molded BMC and 3D-printed specimens sintered at 960 C was 161.94 MPa and 157 MPa, respectively. A 3D printed specimen which was red at 843 C had 104.32 MPa tensile strength. Factory acquired C90700 specimen had an ultimate stress of 209.29 MPa. The Young's modulus for molded BMC and 3D-printed specimens sintered at 960 C was 36.41 GPa and 37.05 GPa, respectively. The 843 C 3D-printed specimen had a modulus of 22.12 GPa. C90700 had the highest modulus of 76.81 GPa. The Yield stress values for molded BMC and 3D-printed specimens sintered at 960 C was 77.81 MPa and 72.82 MPa, respectively. The 3D-printed specimen had 46.44 MPa. C90700 specimen had 115.21 MPa. Hand molded specimens had a Rockwell hardness HRB85, while printed samples had a mean of HRB69. Also, molded samples recorded a higher Young's Modulus of 43 GPa vs. 33 GPa for the printed specimens. Both samples were weaker than the wrought Cu88:8Sn11P0:2 which had a 72 GPa. Cu88:8Sn11P0:2 also was a harder material with an HRC45. The property di erence between 3D printed, molded, and wrought samples was explained by examining their micro structures. It shows that 3D printed sample had more pores than the molded one due to printing process. This study demonstrates the flexibility and feasibility of using 3D printing to produce metallic components, without laser or electron beam source.