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3D printed hybrid-dimensional electrodes for flexible micro-supercapacitors with superior electrochemical behaviours Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-11-11 Kang Tang; Hui Ma; Yujia Tian; Zixian Liu; Hongyun Jin; Shuen Hou; Kun Zhou; Xiaocong Tian
ABSTRACT Micro-supercapacitors (MSCs) with excellent electrochemical behaviours and flexibility possess great promise for portable and wearable electronic devices. A novel type of hybrid-dimensional Fe2O3/graphene/Ag ink is developed and extruded into MSC electrodes through the direct ink writing-based three-dimensional (3D) printing. The optimal solid-state MSC device exhibits a maximum areal capacitance
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A highly stretchable and intrinsically self-healing strain sensor produced by 3D printing Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-10-19 Binbin Guo; Xinzhu Ji; Xiaoteng Chen; Gang Li; Yongguang Lu; Jiaming Bai
ABSTRACT One common issue when implementing wearable strain sensors for health-monitoring is the limited service time when they are inevitably subjected to mechanical operation in practical applications. Therefore, integrating multi-functionality with reliable performance is a long-term pursing target. To this end, we have developed a promising strain sensor utilising a facile 3D printing technology
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Ordered nitrogen complexes overcoming strength–ductility trade-off in an additively manufactured high-entropy alloy Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-11-11 Dandan Zhao; Quan Yang; Dawei Wang; Ming Yan; Pei Wang; Mingguang Jiang; Changyong Liu; Dongfeng Diao; Changshi Lao; Zhangwei Chen; Zhiyuan Liu; Yuan Wu; Zhaoping Lu
ABSTRACT Strength and ductility were simultaneously enhanced in the additively manufactured CoCrFeMnNi high-entropy alloy by laser powder bed fusion (LBPF) under reactive N2 atmosphere. It was found that nitrogen atoms picked up during additive manufacturing line-up to form ordered nitrogen complexes (ONCs) in the octahedral interstitial position of the HEA matrix. Dislocation multiplication is then
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Effect of volumetric energy density on microstructure and tribological properties of FeCoNiCuAl high-entropy alloy produced by laser powder bed fusion Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-12-07 Yaojia Ren; Luxin Liang; Quan Shan; Anhui Cai; Jingguang Du; Qianli Huang; Shifeng Liu; Xin Yang; Yingtao Tian; Hong Wu
ABSTRACT A near-equiatomic FeCoNiCuAl High-entropy alloy (HEA) was produced using laser powder bed fusion (L-PBF) pre-alloy powder. Microstructural characteristics and tribological properties of L-PBF specimens under various volumetric energy densities (VEDs) were investigated in detail. The results showed that the phase of L-PBF specimen consisted of BCC matrix + Cu-rich B2 precipitate. The microstructure
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Additively manufactured oxide dispersion strengthened nickel-based superalloy with superior high temperature properties Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-12-07 Liming Tan; Guowei Wang; Yu Guo; Qihong Fang; Zecheng Liu; Xiangyou Xiao; Wuqiang He; Zijun Qin; Yong Zhang; Feng Liu; Lan Huang
ABSTRACT With excellent radiation resistance and high temperature strength, the oxide dispersion strengthened (ODS) nickel-based superalloys are deemed as candidate materials for advanced fission and fusion reactor. Since conventional manufacturing processes are difficult to produce components with complex shapes, additive manufacturing becomes an alternative method. In this work, ODS nickel-based
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A novel experimental method for in situ strain measurement during selective laser melting Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-12-07 Yaojie Wen; Baicheng Zhang; Shuying Liu; Wei Cai; Pei Wang; Coryl Jing Jun Lee; Junda Ma; Xuanhui Qu
ABSTRACT Selective laser Melting (SLM), a powder bed-based additive manufacturing technology, has been developed and applied in multiple industrial fields in the last decade. However, the distortion and swelling in the SLM process resulting from thermal stress cannot be predicted subject to measurement. In this work, an in situ distortion measurement system applied to the SLM process is presented.
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Automatic determination of part build orientation for laser powder bed fusion Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-10-15 Yuchu Qin; Qunfen Qi; Peizhi Shi; Paul J. Scott; Xiangqian Jiang
ABSTRACT In this paper, an automatic determination method of part build orientation for laser powder bed fusion is presented. This method includes two steps. First, an existing facet clustering-based approach is applied to automatically generate the alternative orientations of a laser powder bed fusion part. Second, support volume, volumetric error, surface roughness, build time and build cost are
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Rapid surface defect identification for additive manufacturing with in-situ point cloud processing and machine learning Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-10-15 Lequn Chen; Xiling Yao; Peng Xu; Seung Ki Moon; Guijun Bi
ABSTRACT Surface monitoring is an essential part of quality assurance for additive manufacturing (AM). Surface defects need to be identified early in the AM process to avoid further deterioration of the part quality. In this paper, a rapid surface defect identification method for directed energy deposition (DED) is proposed. The main contribution of this work is the development of an in-situ point
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A review on the state-of-the-art of surface finishing processes and related ISO/ASTM standards for metal additive manufactured components Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-10-12 Jian-Yuan Lee; Arun Prasanth Nagalingam; S. H. Yeo
ABSTRACT The current state-of-the-art metal additive manufacturing (AM) process still cannot meet the high industry requirements in terms of surface roughness. In addition, there are limited ISO/ASTM standards on the post-processing of metal AM components. Considerable efforts have been made to close these current gaps and challenges for standardization. In this review, First, all the existing ISO/ASTM
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Editorial Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-10-04 Chua CK
(2020). Editorial. Virtual and Physical Prototyping: Vol. 15, No. 4, pp. 371-372.
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3D/4D-printed bending-type soft pneumatic actuators: fabrication, modelling, and control Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-08-03 Ali Zolfagharian; M. A. Parvez Mahmud; Saleh Gharaie; Mahdi Bodaghi; Abbas Z. Kouzani; Akif Kaynak
ABSTRACT This article reviews soft pneumatic actuators (SPAs) that are manufactured entirely via additive manufacturing methods. These actuators are known as four-dimensional (4D)-printed SPAs and can generate bending motions in response to either pressurised or vacuum (negative pressure) air stimulus after fabrication. They are characterised by geometrical and material factors that determine their
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A PCL/cellulose coil-shaped scaffold via a modified electrohydrodynamic jetting process Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-08-19 Young Eun Choe; Geun Hyung Kim
ABSTRACT Scaffolds are regarded as a key factor for tissue engineering as they provide a three-dimensional structural frame for host cells to attach, proliferate, and differentiate. Recently, 3D bioprinting has enabled the quick and versatile fabrication of various architectures of micro/macroscale scaffolds, but there remain obstacles to successful tissue regeneration, such as large strut diameter
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Melt-based, solvent-free additive manufacturing of biodegradable polymeric scaffolds with designer microstructures for tailored mechanical/biological properties and clinical applications Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-08-17 Zijie Meng; Jiankang He; Jiaxin Li; Yanwen Su; Dichen Li
ABSTRACT Biodegradable scaffolds are considered as the key component of tissue engineering which serve as temporary structural supports for tissue regeneration. The mechanical/biological properties of artificial synthetic polymeric scaffolds are highly dependent on their structural organisations. Additive manufacturing (AM) techniques have provided unprecedented opportunities to customise patient-specific
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Effect of post-deposition heat treatment on laser-TIG hybrid additive manufactured Al-Cu alloy Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-09-17 Dehua Liu; Dongjiang Wu; Guangyi Ma; Chongliang Zhong; Fangyong Niu; Andres Gasser; Johannes Henrich Schleifenbaum; Guijun Bi
ABSTRACT After solution + artificial aging treatment (T6 heat treatment) of 2219 aluminum alloy fabricated by laser-tungsten inert gas (TIG) hybrid method, more interestingly, we found that both the strength and elongation were improved. The strengthening mechanism has been analysed in details. Results showed that each layer was divided into the arc zone (AZ) and laser zone (LZ) before and after heat
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Additive manufacturing of a shift block via laser powder bed fusion: the simultaneous utilisation of optimised topology and a lattice structure Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-09-15 Sang Hoon Kim; Si-Mo Yeon; Jae Hyang Lee; Young Won Kim; Hyub Lee; Jiyong Park; Nak-Kyu Lee; Joon Phil Choi; Clodualdo Aranas Jr.; Yong Jin Lee; Seouk An; Kyunsuk Choi; Yong Son
ABSTRACT The precise shape of a shift block support for the turbine blade of a hovercraft was additively manufactured using 17–4 precipitation-hardened stainless steel (STS 630) powder through laser powder bed fusion (LPBF). Subsequently, heat treatment under the H900 condition increased the yield strength and fracture strain of the shift block to 1313 MPa and 11.5%, respectively, and enhanced its
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Contactless reversible 4D-printing for 3D-to-3D shape morphing Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-09-23 Amelia Yilin Lee; Aiwu Zhou; Jia An; Chee Kai Chua; Yi Zhang
ABSTRACT 4D printing provides a means to create dynamic structures for self-actuating devices fabricated by additive manufacturing techniques. Most existing 4D printing processes are only capable of one-way shape morphing using a single mechanism for stimulation. In the limited successful reversible 4D-printing studies, most only demonstrate 2D-to-3D shape morphing. This study introduces a contactless
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On friction factor of fluid channels fabricated using selective laser melting Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-09-22 Yi Zhu; Lei Zhou; Shuai Wang; Chao Zhang; Cong Zhao; Lei Zhang; Huayong Yang
ABSTRACT The fabrication quality of horizontal fluid channels without supports using SLM is low, which further affects friction loss in channels. In the paper, circular fluid channels with diameters from 2 to 14 mm were built horizontally using 316L SS. The surface roughness on the top inner channel is 50–80 μm, while the rest part is approximately 10 μm. The cylindricity is around 0.2 and circularity
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Effect of melting modes on microstructure and tribological properties of selective laser melted AlSi10Mg alloy Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-09-28 Hong Wu; Yaojia Ren; Junye Ren; Anhui Cai; Min Song; Yong Liu; Xiaolan Wu; Qingxiang Li; Weidong Huang; Xiaoteng Wang; Ian Baker
ABSTRACT This paper focuses on the effect of melting modes on microstructural evolution and tribological properties of AlSi10Mg alloy fabricated by selective laser melting (SLM). The results showed that the microstructures of SLM AlSi10Mg consisted of primary α-Al surrounded by cellular Si networks (∼500 nm) when fabricated in conduction mode, but has a finer cellular-like Si phase (∼200 nm) when fabricated
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Material modelling and property mapping for structural FEA of thin-walled additively manufactured components Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-09-24 Sigfrid-Laurin Sindinger; David Marschall; Christoph Kralovec; Martin Schagerl
Additive manufacturing is progressively paving the way for optimised lightweight components that, due to their typically complex shape, would hardly be feasible with traditional production methods. However, the peculiar mechanical properties of additively manufactured materials limit the accuracy of structural analyses. In this research, a strategy for the implementation of thickness dependent anisotropy
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The self-induced electric-field-driven jet printing for fabricating ultrafine silver grid transparent electrode Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-09-24 Zhi Wang; Guangming Zhang; Hui Huang; Lei Qian; Xiaoling Liu; Hongbo Lan
To overcome the mandatory requirement of nozzle conductivity in the conventional electrohydrodynamic (EHD) jet printing, this paper proposed a self-induced electric-field-driven jet printing for fabricating ultrafine silver grids. In this method, only a copper foil is mounted on an insulating glass nozzle to serve as an extraction electrode for producing an electric field with substrate by electrostatic
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Melt-based, solvent-free additive manufacturing of biodegradable polymeric scaffolds with designer microstructures for tailored mechanical/biological properties and clinical applications Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-08-17 Zijie Meng; Jiankang He; Jiaxin Li; Yanwen Su; Dichen Li
Biodegradable scaffolds are considered as the key component of tissue engineering which serve as temporary structural supports for tissue regeneration. The mechanical/biological properties of artificial synthetic polymeric scaffolds are highly dependent on their structural organisations. Additive manufacturing (AM) techniques have provided unprecedented opportunities to customise patient-specific scaffolds
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Automatic generation of alternative build orientations for laser powder bed fusion based on facet clustering Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-05-12 Yuchu Qin; Qunfen Qi; Peizhi Shi; Paul J. Scott; Xiangqian Jiang
ABSTRACT In this paper, a novel facet clustering based method is proposed to generate alternative build orientations for laser powder bed fusion. This method consists of two steps. First, a hierarchical clustering algorithm is applied to divide facets of the design model in standard tessellation language format into different clusters, each of which shares a similar normal vector. Second, alternatives
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Effect of defocusing distance on laser powder bed fusion of high strength Al–Cu–Mg–Mn alloy Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-05-14 Xiaojia Nie; Ze Chen; Yang Qi; Hu Zhang; Changchun Zhang; Zhongxu Xiao; Haihong Zhu
The influence of the defocusing distance on melt pool morphology, defect, microstructure and mechanical properties of the laser powder bed fusion (L-PBF) of high strength Al–Cu–Mg–Mn alloy was studied. It is found that because of the different laser energy distribution, the defocusing distance has significant effects on melt pool morphology, defects, microstructure and mechanical properties of the
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Deep learning for fabrication and maturation of 3D bioprinted tissues and organs Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-06-01 Wei Long Ng; Alvin Chan; Yew Soon Ong; Chee Kai Chua
Bioprinting is a relatively new and promising tissue engineering approach to solve the problem of donor shortage for organ transplantation. It is a highly-advanced biofabrication system that enables the printing of materials in the form of biomaterials, living cells and growth factors in a layer-by-layer manner to manufacture 3D tissue-engineered constructs. The current workflow involves a myriad of
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Laser powder bed fusion for metal additive manufacturing: perspectives on recent developments Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-06-25 S. L. Sing; W. Y. Yeong
While significant progress has been made in laser powder bed fusion (L-PBF) for metal additive manufacturing (AM), there is still limited large scale adoption of this advanced manufacturing technique by the industry. This paper covers the recent developments in L-PBF with discussions from the materials and process perspectives. High entropy alloys and high strength aluminium alloys have been identified
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Acoustic absorptions of multifunctional polymeric cellular structures based on triply periodic minimal surfaces fabricated by stereolithography Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-03-19 Wenjing Yang; Jia An; Chee Kai Chua; Kun Zhou
Polymeric cellular structures based on triply periodic minimal surfaces (TPMS) have been widely studied for applications in multiple disciplines due to their multifunctionality. However, there is limited acoustic application by TPMS-based structures as their acoustic properties remain largely unknown. In this paper, TPMS-based structures are fabricated by additive manufacturing and investigated as
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A review of geometric sensitivities in laser metal 3D printing Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-02-25 Vedant Chahal; Robert M. Taylor
This paper examines the relationships in laser metal additive manufacturing between part geometry and as-built part quality, including residual stresses, deformations, process induced porosity, surface roughness, and microstructural variations. A comprehensive review of these defects and their relationships with the geometric features are provided along with a brief discussion of the involved physical
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Graphene oxide-driven interfacial coupling in laser 3D printed PEEK/PVA scaffolds for bone regeneration Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-02-12 Pei Feng; Jiye Jia; Shuping Peng; Wenjing Yang; Shizhen Bin; Cijun Shuai
Blending Polyetheretherketone (PEEK) with Polyvinyl alcohol (PVA) is promising to obtain a composite scaffold combining the excellent biomechanical properties of PEEK and the remarkable degradability of PVA. However, the weak interfacial bonding between nonpolar PEEK and polar PVA would result in poor mechanical properties. In this study, owing to its unique amphiphilic properties, graphene oxide (GO)
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On-demand additive manufacturing of functionally graded concrete Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-02-07 Z.Y. Ahmed; F.P. Bos; M.C.A.J. van Brunschot; T.A.M. Salet
ABSTRACT The rapid development of additive manufacturing of cementitious materials has enabled the emergence of a new design paradigm, namely functional grading of material properties by location. Target performance parameters could be material weight and insulation value or (particularly important) ductility. A generic concept to achieve this, is through the selective addition of fibres or aggregates
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Improving surface finish quality in extrusion-based 3D concrete printing using machine learning-based extrudate geometry control Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-02-05 Wenxin Lao; Mingyang Li; Teck Neng Wong; Ming Jen Tan; Tegoeh Tjahjowidodo
3D Concrete Printing (3DCP) has been gaining popularity in the past few years. Due to the nature of line-by-line printing and the slump of the material deposition in each extruded line, 3D printed structures exhibit obvious lines or marks at the layer interface, which affects surface finish quality and potentially affect bonding strength between layers. This makes it necessary to control the extrudate
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Additive manufacturing of lightweight and high-strength polymer-derived SiOC ceramics Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-01-17 Ziyong Li; Zhangwei Chen; Jian Liu; Yuelong Fu; Changyong Liu; Pei Wang; Mingguang Jiang; Changshi Lao
ABSTRACT Lightweight and high-strength polymer-derived SiOC ceramics with varied lattice structures have been successfully produced using different polysiloxanes as preceramic polymers (PCPs) via photopolymerisation-based digital-light-processing 3D printing and pyrolysis. Photocurable precursor resins were prepared by simple mixing of polysiloxanes with photosensitive acrylate monomers, achieving
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A survey of design methods for material extrusion polymer 3D printing Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-01-14 Jiaqi Huang; Qian Chen; Hao Jiang; Bin Zou; Lei Li; Jikai Liu; Huangchao Yu
In recent years, additive manufacturing technology has been highly focused on its strong capability in complex geometry manufacturing and great suitability for customised product fabrication. Researchers have recognised the key role of additive manufacturing in leading the next-generation manufacturing, and have conducted extensive research from different aspects, including product design, process
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Multi-material additive manufacturing of low sintering temperature Bi2Mo2O9 ceramics with Ag floating electrodes by selective laser burnout Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-01-06 Reza Gheisari; Henry Chamberlain; George Chi-Tangyie; Shiyu Zhang; Athanasios Goulas; Chih-Kuo Lee; Tom Whittaker; Dawei Wang; Annapoorani Ketharam; Avishek Ghosh; Bala Vaidhyanathan; Will Whittow; Darren Cadman; Yiannis C. Vardaxoglou; Ian M. Reaney; Daniel S. Engstrøm
ABSTRACT Additive manufacturing (AM) of co-fired low temperature ceramics offers a unique route for fabrication of novel 3D radio frequency (RF) and microwave communication components, embedded electronics and sensors. This paper describes the first-ever direct 3D printing of low temperature co-fired ceramics/floating electrode 3D structures. Slurry-based AM and selective laser burnout (SLB) were used
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Editorial Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-03-15 Chee Kai Chua
(2020). Editorial. Virtual and Physical Prototyping: Vol. 15, No. 2, pp. 131-132.
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Metal-doped polymer-derived SiOC composites with inorganic metal salt as the metal source by digital light processing 3D printing Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-04-17 Cong Ma; Chong He; Weilin Wang; Xiaoyan Yao; Liwen Yan; Feng Hou; Jiachen Liu; Anran Guo
Metal-doped polymer derived ceramics (PDCs) exhibits multifunctional properties due to the introduction of special metal element; however as one of the cheapest metal element carriers, metal inorganic salts have rarely been reported for the fabrication of metal-doped PDCs. In this article, a novel hydrophilic photosensitive γ-methacryloxypropyl trimethoxy modified polyhydroxymethylsiloxane preceramic
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Laser additive manufacturing of Mg-based composite with improved degradation behaviour Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-04-05 Youwen Yang; Changfu Lu; Shuping Peng; Lida Shen; Di Wang; Fangwei Qi; Cijun Shuai
Magnesium (Mg) alloy shows great potential as bone implant owing to its favourable biocompatibility and degradability. In the present work, bioglass-reinforced Mg-based composite was manufactured via laser additive manufacturing. The results showed that too low a volumetric energy density (Ev ) resulted in the appearance of open pores on the surface, which significantly deteriorated the densification
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Compressive properties of 3D printed auxetic structures: experimental and numerical studies Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-07-23 Amer Alomarah; Syed H. Masood; Igor Sbarski; Batool Faisal; Zhanyuan Gao; Dong Ruan
Metamaterials that exhibit negative Poisson’s ratio (NPR) are known as auxetics. They laterally expand or contract when they are axially tensioned or compressed. A re–entrant chiral auxetic structure (RCA) is a recently developed structure, which combines the topological features of re–entrant and chiral honeycombs. Comparative study between the RCA structure and popular benchmarks subjected to uniaxial
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Parametric studies and manufacturability experiments on smooth self-supporting topologies Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-07-23 Yun-Fei Fu; Bernard Rolfe; Louis N. S. Chiu; Yanan Wang; Xiaodong Huang; Kazem Ghabraie
This paper aims to explore the effects of optimisation parameters (the filter radius, mesh size, and target volume fraction) on the compliance and manufacturability of smooth self-supporting topologies for additive manufacturing (AM); and conduct manufacturability experiments of selected simulation results with the Selective Laser Melting (SLM) technology. In this study, smooth self-supporting topologies
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Stress-constrained shell-lattice infill structural optimisation for additive manufacturing Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-08-07 Huangchao Yu; Jiaqi Huang; Bin Zou; Wen Shao; Jikai Liu
This paper presents a numerical study on stress-constrained shell-lattice infill structural optimisation. This problem is inherently challenging for several reasons: (i) different stress measures have to be used for the solid shell and the porous lattice infill, and the two types of stress constraints make the problem extremely complex to solve and (ii) involvement of the shell layer further complicates
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Residual stress analysis of thin AlSi10Mg parts produced by Laser Powder Bed Fusion Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-08-04 Alessandro Salmi; Eleonora Atzeni
Among the various Additive Manufacturing (AM) technologies available for metal part production, powder bed processes are the most promising for industrial mass production. However, one obstacle to the widespread adoption of AM technologies is the effect of the residual stress state on the integrity and lifetime of parts. The residual stress state is influenced to a great extent by the geometry and
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Electrohydrodynamic printing of sub-microscale fibrous architectures with improved cell adhesion capacity Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-09-10 Bing Zhang; Jiankang He; Qi Lei; Dichen Li
A solution-based electrohydrodynamic (EHD) printing strategy was developed to fabricate sub-microscale biopolymeric fibres to mimic the tiny architectures of native extracellular matrix (ECM) for enhanced cellular performance. It was found that when the working voltage was significantly reduced to 500 V, sub-microscale fibres as well as user-specific patterns with an average fibre size of 193 ± 51 nm
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Laser 3D printed bio-inspired impact resistant structure: failure mechanism under compressive loading Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-10-09 Jiankai Yang; Dongdong Gu; Kaijie Lin; Chenglong Ma; Rui Wang; Hongmei Zhang; Meng Guo
This work presents a comprehensive failure mechanism study of the bi-directionally corrugated panel (DCP) structures inspired by the telson of mantis shrimp. The DCP structures were fabricated by selective laser melting (SLM) with AlSi10Mg powder. The influence of key structural parameters, namely wave number (N), on the compressive behaviours, stress distribution, deformation modes and fracture mechanism
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Microstructure modelling for metallic additive manufacturing: a review Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-10-23 Joel Heang Kuan Tan; Swee Leong Sing; Wai Yee Yeong
The microstructure of metals depends on the additive manufacturing (AM) process and the process parameters. However, experimentation on different process parameters for different materials is costly and time-consuming. To overcome these challenges, numerical simulations provide insights that allow prediction of microstructure formed under different process parameters. Microstructure modelling requires
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Multi-objective optimisation of bio-inspired lightweight sandwich structures based on selective laser melting Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-11-20 Liang Meng; Jian Zhao; Xinqiang Lan; Huihui Yang; Zemin Wang
Multi-objective optimisation of the bio-inspired lightweight structure is developed by response surface methodology (RSM) and non-dominated sorting genetic algorithm II (NSGA-II) for future applications in the aerospace and military fields. Multilayer bio-inspired sandwich structures of Ti6Al4V alloy are designed and fabricated by selective laser melting (SLM). Results show that the bio-inspired sandwich
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Microstructure evolution and mechanical property response via 3D printing parameter development of Al–Sc alloy Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-12-03 C. N. Kuo; C. K. Chua; P.C. Peng; Y. W. Chen; S. L. Sing; S. Huang; Y. L. Su
Three-dimensional (3D) printed Sc-modified Al alloy by powder bed fusion (PBF) provides significant strength and ductility without hot tearing during the process. This kind of 3D-printable high specific strength materials exhibits great potential in lightweight applications. Due to the lesser design limitation through the 3D printing process, the degree of lightweight is greatly affected by the specific
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Direct printing of performance tunable strain sensor via nanoparticle laser patterning process Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-03-12 Ji-Hyeon Song; Ho-Jin Kim; Min-Soo Kim; Soo-Hong Min; Yan Wang; Sung-Hoon Ahn
Flexible electronics are attractive because of flexibility and portability. The circuits are printed on flexible substrates, which are delicate and heat-sensitive. Traditional photolithography, which uses high temperatures and corrosive chemicals, easily causes damages in flexible substrates. Here, we develop a low-cost nanoparticle based laser patterning process for fabrication of flexible electronics
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Effect of defects and specimen size with rectangular cross-section on the tensile properties of additively manufactured components Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2020-03-04 Pan Wang; Min Hao Goh; Qiang Li; Mui Ling Sharon Nai; Jun Wei
To evaluate specimen size dependence on the tensile properties of additively manufactured (AM) components, various rectangular specimens, ranging from miniaturised to ASTM standard specimens, are machined from electron beam melted Ti-6Al-4V and used for the tensile testing. It is found that the elongation is strongly related to the sample size while the yield and ultimate tensile strengths exhibit
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Editorial Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-07-24 Chee Kai Chua
(2019). Editorial. Virtual and Physical Prototyping: Vol. 14, No. 4, pp. 307-307.
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Design and experimental validation of self-supporting topologies for additive manufacturing Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-07-24 Yun-Fei Fu, Bernard Rolfe, Louis N. S. Chiu, Yanan Wang, Xiaodong Huang, Kazem Ghabraie
Incorporating additive manufacturing (AM) constraints in topology optimisation can lead to performance optimality while ensuring manufacturability of designs. Numerical techniques have been previously proposed to obtain support-free designs in AM, however, few works have verified the manufacturability of their solutions. Physical verification of manufacturability becomes more critical recalling that
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Influence of surface pores on selective laser melted parts under lubricated contacts: a case study of a hydraulic spool valve Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-06-30 Y. Zhu, Y. Yang, P. Lu, X. Ge, H. Yang
Hydraulic valve spools can be produced with hollow structures using SLM to increase dynamic response. The contact between the valve spool and body is crucial and relates to the performance of a hydraulic valve, which has not been studied. This paper investigates the reciprocating contact of an SLM-fabricated spool valve from a tribological aspect. By varying the process parameters, porous and standard
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Effects of TiO2 doping on microstructure and properties of directed laser deposition alumina/aluminum titanate composites Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-05-30 Dongjiang Wu, Yunfei Huang, Fangyong Niu, Guangyi Ma, Shuai Yan, Chaojiang Li, Jun Ding
Al2O3-based composite ceramics have excellent high temperature performance and are ideal materials for preparing hot end components. However, poor fracture toughness and thermal shock resistance limit its applications. Based on the excellent low thermal expansion characteristics and thermal shock resistance of Al2TiO5 ceramic, different composition ratios of Al2O3/Al2TiO5 composite ceramics were prepared
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A comprehensive study on variability of relative density in selective laser melting of Ti-6Al-4V Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-05-22 Amir Mahyar Khorasani, Ian Gibson, AmirHossein Ghasemi, Alireza Ghaderi
In this research, the effects of Selective Laser Melting (SLM) process parameters comprising laser power, scan speed, hatch space and scan pattern angle on the formation of porosity and subsequently density have been analysed. To improve the mechanical properties, post-processes (heat treatment) must be performed. Therefore, heat treatment was added to the design of experiment to analyse the effect
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Compressive behaviour of Neovius Triply Periodic Minimal Surface cellular structure manufactured by fused deposition modelling Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-05-20 Sohaib Z. Khan, S. H. Masood, Essam Ibrahim, Zaini Ahmad
Compressive behaviour of Triply Periodic Minimal Surface type Neovius structure is investigated. The structure was manufactured by Fused Deposition Modelling (FDM) Additive Manufacturing technology in ABS material. The Neovius cellular structures with four different unit cell sizes of 8, 10, 12 and 14 mm with the volume fractions of 15%, 20% and 25% were investigated. Morphology of the samples was
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The influence of slicing parameters on the multi-material adhesion mechanisms of FDM printed parts: an exploratory study Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-04-23 Francesco Tamburrino, Serena Graziosi, Monica Bordegoni
The potentiality of the Fused Deposition Modeling (FDM) process for multi-material printing has not yet been thoroughly explored in the literature. That is a limitation considering the wide diffusion of dual extruders printers and the possibility of increasing the number of these extruders. An exploratory study, based on tensile tests and performed on double-material butt-joined bars, was thus conceived;
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Research progress of ceramic matrix composite parts based on additive manufacturing technology Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-04-23 Zhongliang Lu, Jiwei Cao, Zhaoqiang Song, Dichen Li, Bingheng Lu
Ceramic matrix composites (CMCs) are materials that can be engineered for high-temperature applications in various fields including aerospace, marine, etc. It is very difficult to fabricate CMCs using traditional moulding methods due to their brittleness and high hardness. Additive manufacture (AM) technology, a digital manufacturing technology, provides multiple advantages over traditional manufacturing
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3D food printing: a categorised review of inks and their development Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-04-15 Siew Li Voon, Jia An, Gladys Wong, Yi Zhang, Chee Kai Chua
3D food printing, or the use of food materials in additive manufacturing, has been a topic of interest to the commercial sector for the past decade. Recently, there has also been increased attention from the academic field, with a considerable volume of research being published. Most of these studies have focused on developing food inks for extrusion-based printing beyond conventional materials such
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Minimum length scale constraints in multi-scale topology optimisation for additive manufacturing Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-03-17 Jikai Liu, Yufan Zheng, Rafiq Ahmad, Jinyuan Tang, Yongsheng Ma
This paper performs a combined numerical and experimental study to explore the role of minimum length scale constraints in multi-scale topology optimisation. Multi-scale topology optimisation is generally performed without considering the actual unit cell size, while an arbitrary value considerably smaller than the part is selected afterwards. However, this procedure would be problematic if including
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In situ alloying of elemental Al-Cu12 feedstock using selective laser melting Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-03-15 Rafael Martinez, Iain Todd, Kamran Mumtaz
This investigation developed selective laser melting (SLM) processing parameters for the in situ fabrication of an Al-Cu12 alloy from pure elemental blends of aluminium and copper powders. Use of elevated pre-heat temperatures (400°C) created a coarser dendritic cell microstructure consisting of supersaturated Al-rich with a uniform Al2Cu phase granular microstructure compared to non-pre-heated samples
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Optimisation of multi-part production in additive manufacturing for reducing support waste Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-03-06 Jingchao Jiang, Xun Xu, Jonathan Stringer
Additive manufacturing (AM) is becoming increasingly popular because of its unique advantages. However, AM still suffers from support material waste during the fabrication process when overhanging features exist. Plenty of research has been carried out for minimising support usage. However, former studies only focused on the optimisation for a single part fabrication. In this paper, a four-step strategy
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Numerical and experimental assessment of the mechanical properties of 3D printed 18-Ni300 steel trabecular structures produced by Selective Laser Melting – a lean design approach Virtual Phys. Prototyp. (IF 7.31) Pub Date : 2019-03-01 Franco Concli, Andrea Gilioli
Lattice and trabecular structures are excellent candidates for energy absorbing applications such as personal protective equipment or any sort of bumper. Additive manufacturing technologies allow more freedom in the design of new topologies such as trabecular and lattice structures overcoming the limitation of the traditional manufacturing processes. In the present research, an investigation on the
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