Recently, the demand for lightweight open-pore lattice structures with specific stiffness is increasing in many fields, such as the aeronautical, automotive, mechanical and bone tissue engineering sectors. For each concrete application, there is a need to predict its mechanical properties precisely and efficiently. There are several methods used to analyze the mechanical properties of lattice structures. Among them, the asymptotic expansion homogenization method is a more advantageous approach over the experimental, theoretical, and finite element methods, because it handles some of their limitations such as the time-consuming process, size effect, and the high amount of computational resources needed. Therefore, in this work, we use the asymptotic expansion homogenization method to perform a systematic parametric study to calculate the effective stiffness of different open-pore lattice structures. In addition, the designed models were fabricated using an SLA 3D printer, and the effective stiffness of the fabricated specimens was tested via UTM experiment to validate the numerical results computed by the asymptotic expansion homogenization method. Consequently, it was proved that this method is precise and effective for predicting the mechanical properties of lattice structures.
A microfluidics chip is a miniature analytical system that injects a small amount of reagent into microchannels formed in the chip. It controls fluid flow to perform pretreatment, detection, reaction, mixing, separation, and analysis in parallel. In this study, polygonal microchannel structures were fabricated using a microstereolithography 3D printer based on an LCoS microdisplay projector. In the experiment, the width of the microchannel structure was changed from 50 ㎛ to 500 ㎛, and the output and width of the structure were measured. Inspection of the shape of the resulting microchannel structure showed that the tip of the structure was elliptical instead of the expected rectangular shape, and the fabrication width error increased as the channel width decreased to 200 ㎛ or less. Nevertheless, it was possible to fabricate microfluidics chip structures with widths less than 100 ㎛. The results of this study demonstrate the applicability of an LCoS microdisplay project-based 3D printer for the fabrication of microfluidic channel structures.
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Recently, competition in the manufacturing industry related to the preoccupation of new markets has drastically changed due to the increase in small quantity batch production products. Besides, business models utilizing 3D printing technology suitable for flexible manufacturing are gaining interest. As 3D printing technology is becoming more common, Design for Additive Manufacturing is also in the spotlight. However, the productivity of 3D printing technology is still insufficient in terms of mass production. In this study, the possibility of innovation in mass production process that combines 3D printing technology is presented through the case of innovation in manufacturing productivity of medium-speed engine cylinder head through the integration of sand 3D printing technology. It outlines how sand 3D printing technology is applied to cylinder head mass production processes, how the quality of cylinder head products can be improved compared to conventional pattern-based molding methods, and how productivity can be maximized by reducing process time and human error through hybrid production method with sand 3D printed integrated design cores. In conclusion, this paper presents the effectiveness of sand 3D printing technology which can secure product competitiveness by increasing the production capacity of mass production process, reducing production costs, improving quality, and reducing loss.
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Three-dimensional printing technology has technical limitations limited to the development of prototypes focusing on functional realization. Because of these limitations, there are problems such as mechanical strength and rigidity in entering the commercialization market. However, the industry is working to overcome these obstacles in the future and apply them directly to the field for mass production in the manufacturing process. In particular, research to secure physical properties such as mechanical strength, the major problem of 3D printing products, has been initiated in the automobile industry, aviation, and medical fields. Thus, this study focused on the mechanical strength required for commercialization of 3D printing technology. To achieve this goal, a tensile specimen was fabricated by an FDM (Fused Deposition Modeling) type 3D printer. Tensile specimens were produced of round bar type and the deposition direction, layer height, and printing speed of the layers were considered. Finally, the effects of variables for each printing condition on tensile strength and fracture behavior were compared and analyzed. Also, the fracture surface of the tensile specimen was observed to investigate the effect of the deposition direction on the fracture behavior.
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Recent manufacturing methods for fabricating flexible devices have attracted a keen interest, with a strong demand by industrial manufactures. For thin film application on flexible devices, slot-die coating was found to be the most suitable method having excellent uniformity. Optimization of the reservoir of slot-die coater should be prioritized, since it is an important parameter affecting the uniformity of the final outcome of the coated layer. However, the numerous designs of reservoir makes prototyping difficult, and also results in high manufacturing cost. This study analyzed the velocity deviation of the slot-die coater outlet using CFD analysis, and shape optimization was performed by contour map. We introduce a facile and low-cost fabrication method for a slot-die coater, using polydimethylsiloxane materials and three-dimensional printing technique. The fabricated polymer slot-die coater was further evaluated by the leakage test of solution.
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