Digital RF phase shifters fabricated using additive manufacturing processes are presented and studied. The purpose is to explain the performance differences between phase shifters fabricated using additive manufacturing and those fabricated with conventional subtractive techniques. All phase shifters are designed to operate at a center frequency of 2.45 GHz with a 100 MHz bandwidth. The 1-bit 45° switched line phase shifters have an average insertion loss of 1.3 dB and a 220 mm2 footprint, while the 1-bit 180° high-pass low-pass phase shifters have an insertion loss 1.56 dB and a 180 mm2 footprint. The 4-bit high-pass low-pass, switched line hybrid phase shifters on the other hand show an average state insertion loss of 5.4 dB and have a 660 mm2 foot print. By carefully analyzing the performance of the various phase shifter designs it is shown that the limiting factors of additive manufacturing technology are the low conductivity of CB028 silver ink in comparison to copper, and the inability to print dielectrics with low surface roughness. Finally, parallel plate capacitors and a spiral inductor designed to be fabricated using additive manufacturing techniques are studied. This is done in order to better understand the advantages and disadvantages of such a design. By analyzing the component’s simulated performance it is shown that 3D printed capacitors and inductors are feasible as long as the capacitance or inductance values needed are low. Large value 3D printed components are impractical for RF applications due to their large size.

The thesis deals with the dependence of mechanical characteristics on the anisotropy of polymers Nylon 12 and Ultem 9085 made by a 3D printing technology Fused Deposition Modeling (FDM). The evaluation of the material characteristics was performed on the basis of tensile and non-instrumental impact tests. It was proven that the material characteristics are strongly dependent on anisotropy, i.e. on layer thickness and raster angle for both types of polymers.

The project explores the possibilities of using additive manufacturing (3d-printing) to build architecture. Through a combination of theoretical research and practical experiments a building system has been developed which has the capabilities to create houses with great geometric flexibilities to a affordable price today. The construction system Perimeter is demonstrated in a pavilion situated at Norra Djurgården in Stockholm. / Projektet undersöker möjligheterna att använda additiv tillverkning (3d-printning) för att bygga arkitekturen. Genom en kombination av teoretisk forskning och praktiska experiment har ett byggsystem utvecklats som har kapacitet att skapa hus med stora geometriska flexibilitet till ett överkomligt pris i dag. Konstruktionssystemet Perimeter demonstreras i en paviljong belägen på Norra Djurgården i Stockholm.

<p>Additive manufacturing (AM) can be an advantageous substitute to various traditional manufacturing techniques. Due to the ability to rapidly create products, AM has been traditionally used to prototype more efficiently. As the industry has progressed, however, use cases have gone beyond prototyping into production of complex parts with unique geometries. Amongst the most popular of AM processes is fused deposition modeling (FDM). FDM fabricates products through an extrusion technique where plastic filament is heated to the glass transition temperature and extruded layer by layer onto a build platform to construct the desired part. The purpose of this research is to elaborate on the potential of this technology, while considering environmental impact as it becomes more widespread throughout industry, research, and academia.</p> <p>Although AM consumes resources more conservatively than traditional methodologies, it is not free from having environmental impacts. Several studies have shown that additive manufacturing can affect human and environmental health by emitting particles of a dynamic size range into the surrounding environment during a print. To begin this study, chapters investigate emission profiles and characterization of emissions from FDM 3D printers with the intention of developing a better understanding of the impact from such devices. Background work is done to confirm the occurrence of particle emission from FDM using acrylonitrile butadiene styrene (ABS) plastic filament. An aluminum bodied 3D printer is enclosed in a chamber and placed in a Class 1 cleanroom where measurements are conducted using high temporal resolution electrical low-pressure impactor (ELPI), scanning mobility particle sizer (SMPS), and optical particle sizer (OPS), which combined measure particles of a size range 6-500nm. Tests were done using the NIST standard test part and a honeycomb infill cube. Results from this study show that particle emissions are closely related to filament residence time in the extruder while less related to extruding speed. An initial spike of particle concentration is observed immediately after printing, which is likely a result of the long time required to heat the extruder and bed to the desired temperature. Upon conclusion of this study, it is theorized that particles may be formed through vapor condensation and coagulation after being released into the surrounding environment.</p> <p>With confirmation of FDM ultrafine particle emission at notable concentrations, an effort was consequently placed on diagnosing the primary cause of emission and energy consumption based on developed hypotheses. Experimental data suggests that particle emission is mainly the result of condensing and agglomerating semi-volatile organic compounds. The initial emission spike occurs when there is dripping of semi-liquid filament from the heated nozzle and/or residue left in the nozzle between prints; this supports the previously stated hypothesis regarding residence time. However, the study shows that while printing speed and material flow influence particle emission rate, the effects from these factors are relatively insignificant. Power profile analysis indicates that print bed heating and component temperature maintaining are the leading contributors to energy consumption for FDM printers, making time the primary variable driving energy input.</p> <p>To better understand the severity of FDM emissions, further investigation is necessary to diligence the makeup of the process output flows. By collecting exhaust discharge from a Makerbot Replicator 2x printing ABS filament and diffusing it through a type 1 water solution, we are able to investigate the chemical makeup of these compounds. Additional exploration is done by performing a filament wash to investigate emissions that may already be present before extrusion. Using solid phase micro-extraction, contaminants are studied using gas chromatography mass spectrometry (GCMS) thermal desorption. Characterization of the collected emission offers more comprehensive knowledge of the environmental and human health impacts of this AM process.</p> <p>Classification of the environmental performance of various manufacturing technologies can be achieved by analyzing their input and output material, as well as energy flows. The unit process life cycle inventory (UPLCI) is a proficient approach to developing reusable models capable of calculating these flows. The UPLCI models can be connected to estimate the total material and energy consumption of, and emissions from, product manufacturing based on a process plan. The final chapter focuses on using the knowledge gained from this work in developing UPLCI model methodology for FDM, and applying it further to the second most widely used AM process: stereolithography (SLA). The model created for the FDM study considers material input/output flows from ABS plastic filament. Energy input/output flows come from the running printer, step motors, heated build plate, and heated extruder. SLA also fabricates parts layer by layer, but by the use of a photosensitive liquid resin which solidifies when cured under the exposure of ultraviolet light. Model material input/output flows are sourced from the photosensitive liquid resin, while energy input/output flows are generated from (i) the projector used as the ultraviolet light source and (ii) the step motors. As shown in this work, energy flow is mostly time dependent; material flows, on the other hand, rely more on the nature of the fabrication process. While a focus on FDM is asserted throughout this study, the developed UPLCI models show how conclusions drawn from this work can be applied to different forms of AM processes in future work.</p>

<p>  </p> <p>This thesis is motivated by the author’s observation that no systematic methodology is available to characterize and model mechanical behaviors of 3D printed parts in terms of their elastic modulus and critical loading capacities. Note that the more controlled and steadier printing process is, the easier the mechanical properties parts can be predicted. This research focuses on the methods for the prediction and validation of mechanical properties of 3D printed parts, and the focus is the responses of the printed parts subjected to tensile loads. The mathematic models are derived to characterize the mechanical properties of a part along three principal directions, and the models are validated experimentally by following the American Society for Testing and Materials (ASTM) D638 testing standards. It is assumed that a unidirectional plane stress occurs to each lamina to (1) simplify a compliance matrix with a size 3 by 3 and (2) characterize the mechanical properties by the elastic modules and strengths in three principal directions. Two mathematical models are developed using the experimental data from the classical laminate theory and finite element analysis (FEA) by the SolidWorks. Both of the developed models are used to predict the ultimate tensile strength and Young’s modulus of the specimens that are printed by setting different raster angles on different layers. This thesis work aims to (1) gain a better understanding of the impact of printing parameters on the strengths of printed parts and (2) explore the feasibility of using the classical laminate theory to predict the mechanical properties of the parts printed with different raster angles and patterns. To validate the proposed mathematic models, parts by FDM are tested by following the ASTM testing standards; moreover, it testifies if the selected ASTM-D638 is suitable to test 3D printed parts by FDM. </p>

No description available.

<p dir="ltr">The present work expands the state of the art in the design of soft actuators and flexible sensors manufactured through fused deposition modelling (FDM) and direct ink writing (DIW). The first design consisted of flexible sensors for rehabilitation. Three different designs were tested and compared according to their sensitivity and accuracy. The flexible sensor successfully responded to deformation by changing its resistance. The first design of soft actuator was the Closed Dual Pneumatic Bellow Actuator. The soft actuator was manufactured using FDM and included an inner chamber in which the input air flows through and produces the actuation. The actuator also included dielectric electroactive polymer (DEAP) that showed response to pressure between the actuator and the object to be grasped. The electrodes of the DEAP were manufactured using commercial conductive TPU. A second soft actuator was designed with a circular shape and embedded DEAP. The electrodes in the DEAP consisted of conductive carbon grease. Previous tests were performed to assess the functionality of a DEAP structure using conductive carbon grease. The DEAP showed an increase in capacitance as pressure was applied on one side of the structure parallel to the electrodes and computational simulations validated such response. Future work using the sensors and actuators presented includes the implementation of a closed-loop system to the soft actuators, using the readouts of the sensors to adjust the input pressure and apply precise pressure on objects. The flexible sensor for rehabilitation has the potential to be implemented in each of the fingers of the hand and use the data to characterize the movement of the hand under different configurations providing feedback to patients in task-oriented therapy.</p>

[ES] La fabricación aditiva, también llamada impresión 3D, ha tenido un gran impacto en la industria. La capacidad de fabricar modelos complejos y personalizados a bajo coste se adapta muy bien para algunas aplicaciones, sustituyendo procesos de fabricación tradicional y ofreciendo nuevas oportunidades. En medicina, la fabricación personalizada de modelos complejos ha encontrado muchas aplicaciones, desde réplicas de patologías para la educación hasta implantes hechos a medida y remplazo de órganos. De todas las posibilidades de esta tecnología en medicina, la fabricación de modelos anatómicos a partir de imágenes médicas ofrece un excelente balance entre facilidad de implementación y beneficio, esto la hace una aplicación perfecta para ser usada ampliamente en los hospitales. La fabricación aditiva de modelos anatómicos es un campo que ha suscitado considerable entusiasmo en los últimos años. La comunidad médica ve esta herramienta como el siguiente paso generacional en la visualización clínica, ofreciendo grandes beneficios para los pacientes y el sistema de salud. Debido al gran interés, hay muchos investigadores que han evaluado el impacto de esta tecnología en la práctica médica, midiendo los beneficios médicos que puedan tener estos modelos anatómicos. En general, los resultados muestran que hay reducción de tiempo de quirófano, menor morbilidad y mortalidad al igual que menor estrés y denuncias por parte de pacientes. A pesar de estos resultados prometedores, no hay muchos estudios realizados sobre cuál debe ser el proceso para garantizar la reproducibilidad y seguridad de estos modelos, un tema que es de gran importancia para poder cumplir con las regulaciones actuales, que exigen protocolos de fabricación y sistemas de calidad para este proceso. Debemos observar que, aunque el proceso para obtener modelos anatómicos es más fácil que otras aplicaciones de esta tecnología, no es un proceso trivial. Es un trabajo complejo con múltiples pasos que Involucra a varios especialistas para su correcta realización. Actualmente el hospital es el entorno ideal para poder fabricar estos modelos, permite un mayor control del proceso, facilita la colaboración multidisciplinar necesaria y reduce considerablemente los requisitos legales que rigen los dispositivos médicos. El objetivo de esta investigación es desarrollar un protocolo detallado y optimizado que cumpla con los requisitos técnicos, médicos y legales para poder implementar esta tecnología emergente de forma segura y eficiente en centros de salud. Para alcanzar este objetivo, las metodologías observadas fueron la revisión por literatura, la investigación doctrinal legal y la investigación acción empleada en los diferentes casos estudiados. Los casos se han elegido buscando la mayor diversidad posible bajo el criterio de conveniencia en el horizonte temporal contemplado, dada la diversidad compleja del estudio realizado. Gracias a la colaboración con varias instituciones médicas y de educación, este protocolo se pudo implementar en diversos contextos, mejorándolo progresivamente al ponerlo a prueba con casos reales, mediante el trabajo continuo con los expertos. El resultado es un protocolo que incluye varios años de experiencia y que ha sido aplicado en un amplio rango de especialidades. Este protocolo es relativamente sencillo de seguir y cumple con los principales requisitos para ser implementado en hospitales. / [CA] La fabricació additiva, també anomenada impressió 3D, ha tingut un gran impacte en la indústria. La capacitat de fabricar models complexos i personalitzats a baix cost s' adapta molt bé per a algunes aplicacions, substituint processos de fabricació tradicional i oferint noves oportunitats. En medicina, la fabricació personalitzada de models complexos ha trobat moltes aplicacions, des de rèpliques de patologies per a l'educació fins a implants fets a mida i òrgans. De totes les possibilitats d'aquesta tecnologia en medicina, la fabricació de models anatòmics a partir d'imatges mèdiques ofereix un excel·lent balanç entre facilitat d'implementació i benefici, això la fa una aplicació perfecta per ser usada àmpliament als hospitals. La fabricació additiva de models anatòmics és un camp que ha suscitat considerable entusiasme en els últims anys. La comunitat mèdica veu aquesta eina com el següent pas generacional en la visualització clínica, oferint grans beneficis per als pacients i el sistema de salut. A causa del gran interès, hi ha molts investigadors que han avaluat l'impacte d'aquesta tecnologia en la pràctica mèdica, mesurant els beneficis mèdics que puguen tenir aquests models anatòmics. En general, els resultats mostren que hi ha reducció de temps de quiròfan, menor morbiditat i mortalitat igual que menor estrès i denúncies per part de pacients. Malgrat aquests resultats prometedors, no hi ha molts estudis realitzats sobre quin ha de ser el procés per garantir la reproduïbilitat i seguretat d' aquests models, un tema que és de gran importància per poder complir amb les regulacions actuals, que exigeixen protocols de fabricació i sistemes de qualitat per a aquest procés. Hem d'observar que, tot i que el procés per obtenir models anatòmics és més fàcil que altres aplicacions d'aquesta tecnologia, no és un procés trivial. És un treball complex amb múltiples passos que Involucra diversos especialistes per a la seva correcta realització. Actualment l'hospital és l'entorn ideal per poder fabricar aquests models, permet un major control del procés, facilita la col·laboració multidisciplinària necessària i redueix considerablement els requisits legals que regeixen els dispositius mèdics. L'objectiu d'aquesta investigació és desenvolupar un protocol detallat i optimitzat que compleix amb els requisits tècnics, mèdics i legals per poder implementar aquesta tecnologia emergent de forma segura i eficient en centres de salut. Per assolir aquest objectiu, les metodologies observades van ser la revisió per literatura, la investigació doctrinal legal i la investigació acció emprada en els diferents casos estudiats. Els casos s' han triat buscant la major diversitat possible sota el criteri de conveniència en l' horitzó temporal contemplat, atesa la diversitat complexa de l' estudi realitzat. Gràcies a la col·laboració amb diverses institucions mèdiques i d'educació, aquest protocol es va poder implementar en diversos contextos, millorant-lo progressivament en posar-lo a prova amb casos reals, mitjançant el treball continu amb els experts. El resultat és un protocol que inclou diversos anys d' experiència i que ha estat aplicat en un ampli rang d' especialitats. Aquest protocol és relativament senzill de seguir i compleix amb els principals requisits per ser implementat en hospitals. / [EN] Additive manufacturing, also called 3D printing, has had a huge impact on the industry. The ability to manufacture complex and customized models at a low cost is well suited for some applications, replacing traditional manufacturing processes and offering new opportunities. In medicine, the custom manufacture of complex models has found many applications, from replicas of pathologies for education to custom-made implants and organ replacement. Of all the possibilities of this technology in medicine, the manufacture of anatomical models from medical images offers an excellent balance between ease of implementation and benefit, this makes it a perfect application to be widely used in hospitals. Additive manufacturing of anatomical models is a field that has attracted considerable enthusiasm in recent years. The medical community sees this tool as the next generational step in clinical visualization, offering great benefits for patients and the healthcare system. Due to the great interest, there are many researchers who have evaluated the impact of this technology on medical practice, measuring the medical benefits that these anatomical models may have. In general, the results show that there is a reduction in operating room time, lower morbidity and mortality as well as less stress and complaints from patients. Despite these promising results, there are not many studies conducted on what the process should be to guarantee the reproducibility and safety of these models, an issue that is of great importance to be able to comply with current regulations, which require manufacturing protocols and quality systems for this process. We should note that although the process for obtaining anatomical models is easier than other applications of this technology, it is not a trivial process. It is a complex work with multiple steps that involves several specialists for its correct realization. Currently the hospital is the ideal environment to be able to manufacture these models, it allows greater control of the process, facilitates the necessary multidisciplinary collaboration, and considerably reduces the legal requirements that govern medical devices. The objective of this research is to develop a detailed and optimized protocol that meets the technical, medical, and legal requirements to implement this technology in hospitals. To achieve this objective, the methodologies observed consisted of literature review, legal doctrinal research and action research used in the multiple cases studied. The cases have been selected seeking the greatest possible diversity under the criterion of convenience in the time horizon contemplated, given the complex diversity of the study carried out. Thanks to the collaboration with several medical and educational institutions, this protocol could be implemented in various contexts, progressively improving it by testing it with real cases, through continuous work with experts. The result is a protocol that includes several years of experience and has been applied in a wide range of specialties. It is relatively simple to follow and complies with most requirements to be implemented in hospitals. / De Rossi Estrada, M. (2022). Investigación para el desarrollo de un protocolo para fabricación aditiva de modelos anatómicos en centros de salud [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/183303 / TESIS

This project was a test of concept for an external heating system for Big Area Additive Manufacturing (BAAM) Fused Deposition Modeling (FDM) 3D printers. To goal of the heating system was to prevent or mitigate delamination and warping in BAAM FDM prints by propelling warm air onto printed layers while not interfering with prior functions of the 3D printer.

Plastics contribute 2 GTons to the global carbon footprint, today, several countries have set targets to achieve carbon neutrality. Plastics, being a major contributor to global carbon footprint, would need to be reduced significantly from our daily life to achieve that or a way needs to be devised to recycle them. A big bottleneck in this process is to reduce the consumption of thermosetting plastics or to reduce the emissions associated with plastic and move towards economical and environmentally safe plastics having a longer lifespan and efficient recyclability. Fused filament fabrication (FFF) is the most commonly used 3D printed technology available today. Its applications range from production of prototypes to hollow shafts, and fully functional commercial components. This technology is revolutionary in a sense that it offers advantages such as cheaper raw materials, high degree of customizability, production in smaller batches at lower costs, decrease in material wastage, rapid prototyping, and complex geometry. A number of thermoplastic polymers can be used with FFF technology to produce parts, in addition research is on going to print materials not commonly used for FFF process. Polyoxymethylene (POM) could be a viable option for utilization as FFF basestock for the production of tribologically functional components. POM is an engineering thermoplastic that offers high resistance to wear, low friction, excellent impact resistance, and good chemical resistance. These properties render it suitable for production of gear wheels and low load bearings. It is currently processed using traditional manufacturing methods such as injection and compression moulding, while its printability has received very little attention in the openly available literature. An attempt has been made in this thesis to fill up this research gap by providing insight into POM filament quality, and the thermal, mechanical, and tribological behaviour of POM printed parts. The influence of overfill and layer height on the bulk properties of the printed samples, its play with counterface surface roughness and applied load has also been investigated.