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In this study, we tested the function of a replica of the over 500-year-old original of the
famous Franconian Imperial Knight Götz von Berlichingen’s first “iron hand”, which we
reconstructed by computer-aided design (CAD) and recently printed using a multi-material
3D printer. In different everyday tasks, the artificial hand prosthesis proved to be remarkably
helpful. Thus, the hand could hold a wine glass, some grapes, or a smartphone. With a
suitable pencil, even writing was possible without any problem. Although for all these
functions the healthy other hand was necessary to assist at the beginning, the artificial hand
is an astonishing mechanical aid with many possibilities. Therefore, in certain cases, the
non-invasive approach of a passive mechanical hand replacement, which is an individual,
quick and cheap solution due to modern 3D printing, may always be worth considering
also for today’s requirements.
The visualization of heart rhythm disturbance and atrial fibrillation therapy allow the optimization of new cardiac catheter ablations. With the simulation software CST (Computer Simulation Technology, Darmstadt) electromagnetic and thermal simulations can be carried out to analyze and optimize different heart rhythm disturbance and cardiac catheters for pulmonary vein isolation. Another form of visualization is provided by haptic, three-dimensional print models. These models can be produced using an additive manufacturing method, such as a 3D printer. The aim of the study was to produce a 3D print of the Offenburg heart rhythm model with a representation of an atrial fibrillation ablation procedure to improve the visualization of simulation of cardiac catheter ablation.
The basis of 3D printing was the Offenburg heart rhythm model and the associated simulation of cryoablation of the pulmonary vein. The thermal simulation shows the pulmonary vein isolation of the left inferior pulmonary vein with the cryoballoon catheter Arctic Front AdvanceTM from Medtronic. After running through the simulation, the thermal propagation during the procedure was shown in the form of different colors. The three-dimensional print models were constructed on the base of the described simulation in a CAD program. Four different 3D printers are available for this purpose in a rapid prototyping laboratory at the University of Applied Science Offenburg. Two different printing processes were used: 1. a binder jetting printer with polymer gypsum and 2. a multi-material printer with photopolymer. A final print model with additional representation of the esophagus and internal esophagus catheter was also prepared for printing.
With the help of the thermal simulation results and the subsequent evaluation, it was possible to make a conclusion about the propagation of the cold emanating from the catheter in the myocardium and the surrounding tissue. It could be measured that already 3 mm from the balloon surface into the myocardium the temperature drops to 25 °C. The simulation model was printed using two 3D printing methods. Both methods as well as the different printing materials offer different advantages and disadvantages. While the first model made of polymer gypsum can be produced quickly and cheaply, the second model made of photopolymer takes five times longer and was twice as expensive. On the other hand, the second model offers significantly better properties and was more durable overall. All relevant parts, especially the balloon catheter and the conduction, are realistically represented. Only the thermal propagation in the form of different colors is not shown on this model.
Three-dimensional heart rhythm models as well as virtual simulations allow a very good visualization of complex cardiac rhythm therapy and atrial fibrillation treatment methods. The printed models can be used for optimization and demonstration of cryoballoon catheter ablation in patients with atrial fibrillation.
The visualization of heart rhythm disturbance and atrial fibrillation therapy allows the optimization of new cardiac catheter ablations. With the simulation software CST (Computer Simulation Technology, Darmstadt) electromagnetic and thermal simulations can be carried out to analyze and optimize different heart rhythm disturbance and cardiac catheters for pulmonary vein isolation. Another form of visualization is provided by haptic, three-dimensional print models. These models can be produced using an additive manufacturing method, such as a 3d printer. The aim of the study was to produce a 3d print of the Offenburg heart rhythm model with a representation of an atrial fibrillation ablation procedure to improve the visualization of simulation of cardiac catheter ablation. The basis of 3d printing was the Offenburg heart rhythm model and the associated simulation of cryoablation of the pulmonary vein. The thermal simulation shows the pulmonary vein isolation of the left inferior pulmonary vein with the cryoballoon catheter Arctic Front Advance™ from Medtronic. After running through the simulation, the thermal propagation during the procedure was shown in the form of different colors. The three-dimensional print models were constructed on the base of the described simulation in a CAD program. Four different 3d printers are available for this purpose in a rapid prototyping laboratory at the University of Applied Science Offenburg. Two different printing processes were used and a final print model with additional representation of the esophagus and internal esophagus catheter was also prepared for printing. With the help of the thermal simulation results and the subsequent evaluation, it was possible to draw a conclusion about the propagation of the cold emanating from the catheter in the myocardium and the surrounding tissue. It was measured that just 3 mm from the balloon surface into the myocardium the temperature dropped to 25 °C. The simulation model was printed using two 3d printing methods. Both methods, as well as the different printing materials offer different advantages and disadvantages. All relevant parts, especially the balloon catheter and the conduction, are realistically represented. Only the thermal propagation in the form of different colors is not shown on this model. Three-dimensional heart rhythm models as well as virtual simulations allow very clear visualization of complex cardiac rhythm therapy and atrial fibrillation treatment methods. The printed models can be used for optimization and demonstration of cryoballoon catheter ablation in patients with atrial fibrillation.
Um medizinische Behandlungsverfahren in der Praxis besser verstehen und anwenden zu können, gewinnt die Visualisierung der Prozesse an immer größerer Bedeutung. Durch Anwendung der Computer-Simulationssoftware CST können elektromagnetische und thermische Simulationen zur Analyse verschiedener Herzrhythmusstörungen durchgeführt werden. Eine weitere Form der Visualisierung erfolgt durch haptische, dreidimensionale Druckmodelle. Diese Modelle können mit einem generativen Herstellungsverfahren, wie z. B. einem 3D-Drucker, in kürzester Zeit hergestellt werden.
Dieser Beitrag stellt die Möglichkeiten des 3D-Druckes unter der Berücksichtigung von Mensch-Roboter-Kollaborations-Anforderungen dar. Dabei werden die Vorteile mit besonderem Fokus auf die zusätzliche Gestaltungsfreiheit erläutert. Anhand von Beispielen wird der Stand der Technik bereits eingesetzter Sensorik sowie deren Notwendigkeit in Greifsystemen erläutert. Im weiteren Verlauf dieses Beitrags werden allgemeine Verfahren für die additive Verarbeitung von leitfähigen Materialien vorgestellt. Daran angeknüpft sind Beispiele speziell zur 3D-gedruckten Sensorik. Abgerundet wird der Beitrag mit einem Ausblick bezüglich 3D-gedruckter Sensorik in MRK-Greifsystemen.
This paper presents a method for supporting the application of Additive Tooling (AT)-based validation environments in integrated product development. Based on a case study, relevant process steps, activities and possible barriers in the realisation of an injection-moulded product are identified and analysed. The aim of the method is to support the target-oriented application of Additive Tooling to obtain physical prototypes at an early stage and to shorten validation cycles.
In 4D printing an additively manufactured component is given the ability to change its shape or function under the influence of an external stimulus. To achieve this, special smart materials are used that are able to react to external stimuli in a specific way. So far, a number of different stimuli have already been investigated and initial applications have been impressively demonstrated, such as self-folding bodies and simple grippers. However, a methodical specification for the selection of the stimuli and their implementation was not yet in the foreground of the development.
The focus of this work is therefore to develop a methodical approach with which the technology of 4DP can be used in a solution- and application-oriented manner. The developed approach is based on the conventional design methodology for product development to solve given problems in a structured way. This method is extended by specific approaches under consideration of the 4D printing and smart materials.
To illustrate the developed method, it is implemented in practice using a problem definition in the form of an application example. In this example, which represents the recovery of an object from a difficult-to-access environment, the individual functions of positioning, gripping and extraction are implemented using 4D printing. The material extrusion process is used for additive manufacturing of all components of the example. Finally, the functions are successfully tested. The developed approach offers an innovative and methodical approach to systematically solve technical complex problems using 4DP and smart materials.
Various rapid prototyping methods have been available for the production of physical architectural models for a few years. This paper highlights in particular the advantages of 3D printing and Fused Layer Modeling for the production of detailed architectural models. In addition, the current challenges for the creation and transfer of CAAD-data are explained. Furthermore, new methods are being developed in order to improve both the technical and economic boundary conditions for the application of 3DP und FLM. This makes the production of models with very detailed interior rooms possible. The internal details are made visible by dividing the complex overall model into individual models connected by means of an innovative plug-in system. In addition, three case studies are shown in which the developed methods are applied in order to implement detailed architectural models. Finally manufacturing time and costs of the architectural models in the three case studies are compared.
Additive manufacturing is a rapidly growing manufacturing process for which many new processes and materials are currently being developed. The biggest advantage is that almost any shape can be produced, while conventional manufacturing methods reach their limits. Furthermore, a lot of material is saved because the part is created in layers and only as much material is used as necessary. In contrast, in the case of machining processes, it is not uncommon for more than half of the material to be removed and disposed of. Recently, new additive manufacturing processes have been on the market that enables the manufacturing of components using the FDM process with fiber reinforcement. This opens up new possibilities for optimizing components in terms of their strength and at the same time increasing sustainability by reducing materials consumption and waste. Within the scope of this work, different types of test specimens are to be designed, manufactured and examined. The test specimens are tensile specimens, which are used both for standardized tensile tests and for examining a practical component from automotive engineering used in student project. This project is a vehicle designed to compete in the Shell Eco-marathon, one of the world’s largest energy efficiency competitions. The aim is to design a vehicle that covers a certain distance with as little fuel as possible. Accordingly, it is desirable to manufacture the components with the lowest possible weight, while still ensuring the required rigidity. To achieve this, the use of fiber-reinforced 3D-printed parts is particularly suitable due to the high rigidity. In particular, the joining technology for connecting conventionally and additively manufactured components is developed. As a result, the economic efficiency was assessed, and guidelines for the design of components and joining elements were created. In addition, it could be shown that the additive manufacturing of the component could be implemented faster and more sustainably than the previous conventional manufacturing.
The fast and cost-effective manufacturing of tools for thermoforming is an essential requirement to shorten the development time of products. Thus, additive processes are used increasingly in tooling for thermoforming of plastic sheets. However, a disadvantage of many additive methods is that they are highly cost-intensive, since complex systems based on laser technology and expensive metal powders are needed. Therefore, this paper examines how to work with favorable additive methods, e.g. Binder Jetting, to manufacture tools, which provide sufficient strength for thermoforming. The use of comparatively low-priced inkjet technology for the layer construction and a polymer plaster as material can be expected to result in significant cost reductions. Based on a case study using a cowling (engine bonnet) for an Unmanned Aerial Vehicle (UAV), the development of a complex tool for thermoforming is demonstrated. The object in this study is to produce a tool for a complex-shaped component in small numbers and high quality in a short time and at reasonable costs. Within the tooling process, integrated vacuum channels are implemented in additive tooling without the need for additional post-processing (for example, drilling). In addition, special technical challenges, such as the demolding of undercuts or the parting of the tool are explained. All process steps from tool design to the use of the additively manufactured tool are analyzed. Based on the manufacturing of a small series of cowlings for a UAV made of plastic sheets (ABS), it is shown, that the Binder Jetting offers sufficient mechanical and thermal strength for additive tooling. In addition, an economic evaluation of the tool manufacturing and a detailed consideration of the required manufacturing times for the different process steps are carried out. Finally, a comparison is made with conventional and alternative additive methods of tooling.
The present-day methods of numerical simulation offer a great variety of options for optimizing metal forming processes. Although it is possible to simulate complex forming processes, the results are typically available only as 2D projections on screens. Some forming processes have reached a level of complexity beyond the level of spatial sense, which makes it necessary to use physical 3D representations to develop a deeper understanding of the material flow, microstructural processes, process and design limits, or to design the required tooling. Physical 3D models can be produced in a short amount of time using 3D printing, and indexed with a wide range of colors. In this paper, the additive manufacturing of 3D color models based on simulation results are explored by means of examples from metal forming. Different 3D-printing processes are compared on the basis of quality as well as technical and economic criteria. Other examples from the fields joining by upset-bulging of tubes and microstructure simulation are also analyzed. This paper discusses the possibilities offered by the rapid progress and wide availability of 3D printers for the design and optimization of complex metal forming processes.
Today, thermoforming moulds are mostly produced using conventional mould-building technologies (e.g. milling and drilling) and are made of metal (e.g. aluminium or steel) or hardwood. The tools thus produced are very robust, but are only cost-effective in mass production. For the production of small batches of thermoformed parts, there is a need for moulds which can be produced quickly and economically. A new approach which significantly reduces the production time and cost is the 3D printing process (3DP). The use of this technology to produce thermoforming moulds offers many new options in the geometries which can be manufactured, and in manufacturing time and costs. In a case study of a thermoformed part (a scaled automotive model), the pre-processing of the CAD model of a mould is demonstrated. The mould can be printed within a few hours, and is sufficiently heat-resistant for moulding processes. The important advantages of moulds printed in 3D, in comparison to moulds built using conventional technologies, are the ability to create any shape of channels for the vacuum and the simplification in the production of tool mock-ups. This paper also discusses the economics of the technique, such as a comparison of material costs and manufacturing costs in relation to conventional production technologies and materials.
4D printing (4DP) is an evolutionary step of 3D printing, which includes the fourth dimension, in this case the time. In different time steps the printed structure shows different shapes, influenced by external stimuli like light, temperature, pH value, electric or magnetic field. The advantage of 4DP is the solution of technical problems without the need for complex internal energy supply via cables or pipes. Previous approaches to 4D printing with magnetoresponsive materials only use materials with limited usability (e.g. hydrogels) and complex programming during the manufacturing process (e.g. using magnets on the nozzle). The 4D printing using unmagnetized particles and the later magnetization allows the use of a standard 3D printer and has the advantage of being easily reproducible and relatively inexpensive for further application. Therefore, a magnetoresponsive feedstock filament is produced which shows elastic and magnetic properties. In a first step, pellets are produced by compounding polymer with magnetic particles. In a second step, those pellets are extruded in form of filament. This filament is printed using a conventional printing system for Material Extrusion (MEX-TRB/P). Various prototypes have been printed, deformed and magnetized, which is called programming. In comparison to shape memory polymers (SMP) the repeatability of the movement is better. The results show the possibilities of application and function of magnetoresponsive materials. In addition, an understanding of the behaviour of this novel material is achieved.
Application of Polymer Plaster Composites in Additive Manufacturing of High-Strength Components
(2015)
Today, 3D-printing with polymer plaster composites is a common method in Additive Manufacturing. This technique has proven to be especially suitable for the production of presentation models, due to the low cost of materials and the possibility to produce color-models. But nowadays it requires refinishing through the manual application of a layer of resin. However, the strength of these printed components is very limited, as the applied resin only penetrates a thin edge layer on the surface. This paper develops a new infiltration technique that allows for a significant increase in the strength of the 3D-printed component. For this process, the components are first dehydrated in a controlled two-tier procedure, before they are then penetrated with high-strength resin. The infiltrate used in this process differs significantly from materials traditionally used for infiltration. The result is an almost complete penetration of the components with high-strength infiltrate. As the whole process is computer-integrated, the results are also easier to reproduce, compared to manual infiltration. On the basis of extensive material testing with different testing specimen and testing methods, it can be demonstrated that a significant increase in strength and hardness can be achieved. Finally, this paper also considers the cost and energy consumption of this new infiltration method. As a result of this new technology, the scope of applicability of 3D-printing can be extended to cases that require significantly more strength, like the production of tools for the shaping of metals or used for the molding of plastics. Furthermore, both the process itself and the parameters used are monitored and can be optimized to individual requirements and different fields of application.
A number of design rules must be adhered to in the development and manufacturing of unmanned aerial vehicles. In this, additive manufacturing, particularly in the implementation of requirements with respect to light-weight construction and sustainability, offers several advantages compared to conventional manufacturing methods. Therefore, this article will primarily introduce and compare current concepts for sustainable design using additive manufacturing. These will, above all, consist of the production of complete fuselages and wings by means of rapid prototyping or also rapid tooling. In addition, a new concept will be introduced in which a UAV using AM can be implemented through the combination of very light components and a preferably resource-saving manufacturing method. In this process, a three-dimensional spaceframe is used in combination with a covering in the construction of the wing. Hereby, the development process for sustainable design using additive manufacturing will be analyzed and the results will be explained by means of concrete case studies. In conclusion, the results of these case studies will be compared to the latest technology regarding wing span load.