E. Bassoli

3D printing technique applied to rapid casting

Purpose – The purpose of this paper is to verify the feasibility and evaluate the dimensional accuracy of two rapid casting (RC) solutions based on 3D printing technology: investment casting starting from 3D‐printed starch patterns and the ZCast process for the production of cavities for light‐alloys castings.Design/methodology/approach – Starting from the identification and design of a benchmark, technological prototypes were produced with the two RC processes. Measurements on a coordinate measuring machine allowed calculating the dimensional tolerances of the proposed technological chains. The predictive performances of computer aided engineering (CAE) software were verified when applied to the ZCast process modelling.Findings – The research proved that both the investigated RC solutions are effective in obtaining cast technological prototypes in short times and with low costs, with dimensional tolerances that are completely consistent with metal casting processes.Practical implications – The research a...

Structural characterization of biomedical Co-Cr-Mo components produced by direct metal laser sintering.

Direct metal laser sintering (DMLS) is a technique to manufacture complex functional mechanical parts from a computer-aided design (CAD) model. Usually, the mechanical components produced by this procedure show higher residual porosity and poorer mechanical properties than those obtained by conventional manufacturing techniques. In this work, a Co-Cr-Mo alloy produced by DMLS with a composition suitable for biomedical applications was submitted to hardness measurements and structural characterization. The alloy showed a hardness value remarkably higher than those commonly obtained for the same cast or wrought alloys. In order to clarify the origin of this unexpected result, the sample microstructure was investigated by X-ray diffraction (XRD), electron microscopy (SEM and TEM) and energy dispersive microanalysis (EDX). For the first time, a homogeneous microstructure comprised of an intricate network of thin ε (hcp)-lamellae distributed inside a γ (fcc) phase was observed. The ε-lamellae grown on the {111}γ planes limit the dislocation slip inside the γ (fcc) phase, causing the measured hardness increase. The results suggest possible innovative applications of the DMLS technique to the production of mechanical parts in the medical and dental fields.

Effects of thermal treatments on microstructure and mechanical properties of a Co-Cr-Mo-W biomedical alloy produced by laser sintering.

Direct Metal Laser Sintering (DMLS) technology based on a layer by layer production process was used to produce a Co-Cr-Mo-W alloy specifically developed for biomedical applications. The alloy mechanical response and microstructure were investigated in the as-sintered state and after post-production thermal treatments. Roughness and hardness measurements, and tensile and flexural tests were performed to study the mechanical response of the alloy while X-ray diffraction (XRD), electron microscopy (SEM, TEM, STEM) techniques and microanalysis (EDX) were used to investigate the microstructure in different conditions. Results showed an intricate network of ε-Co (hcp) lamellae in the γ-Co (fcc) matrix responsible of the high UTS and hardness values in the as-sintered state. Thermal treatments increase volume fraction of the ε-Co (hcp) martensite but slightly modify the average size of the lamellar structure. Nevertheless, thermal treatments are capable of producing a sensible increase in UTS and hardness and a strong reduction in ductility. These latter effects were mainly attributed to the massive precipitation of an hcp Co3(Mo,W)2Si phase and the contemporary formation of Si-rich inclusions.

Direct metal rapid casting: mechanical optimization and tolerance calculation

Purpose – The purpose of this paper is to optimize the mechanical performances of parts produced by the ZCast Direct Metal Casting process varying the thermal treatment parameters. Adopting the optimized settings, a specific dimensional evaluation is planned to calculate the international tolerance (IT) grade ensured by the process.Design/methodology/approach – Cylindrical ZCast samples are manufactured and heat treated varying time and temperature. The baked parts underwent compression tests and the rupture surfaces are observed using the scanning electron microscopy. A regression analysis is performed on the results to optimize the baking process. For the dimensional assessment, a specific benchmark is designed, built and treated. It is measured before and after baking using a coordinate measuring machine and the results are processed to obtain the IT grade.Findings – The results proved that in the heat treatment of ZCast parts time has a negligible effect on the compressive strength, whereas temperatur...

Ex situ bioengineering of bioartificial endocrine glands: A new frontier in regenerative medicine of soft tissue organs

Ex situ bioengineering is one of the most promising perspectives in the field of regenerative medicine allowing for organ reconstruction outside the living body; i.e. on the laboratory bench. A number of hollow viscera of the cardiovascular, respiratory, genitourinary, and digestive systems have been successfully bioengineered ex situ, exploiting biocompatible scaffolds with a 3D morphology that recapitulates that of the native organ (organomorphic scaffold). In contrast, bioengineering of entire soft tissue organs and, in particular endocrine glands still remains a substantial challenge. Primary reasons are that no organomorphic scaffolding for endocrine viscera have as yet been entirely assembled using biocompatible materials, nor is there a bioreactor performance capable of supporting growth within the thickness range of the regenerating cell mass which has proven to be reliable enough to ensure formation of a complete macroscopic gland ex situ. Current technical options for reconstruction of endocrine viscera include either biocompatible 3D reticular scaffolds lacking any organomorphic geometry, or allogenic/xenogenic acellular 3D matrices derived from a gland similar to that to be bioengineered, eventually recellularized by autologous/heterologous cells. In 2007, our group designed, using biocompatible material, an organomorphic scaffold-bioreactor unit for bioengineering ex situ the human thyroid gland, chosen as a model for its simple anatomical organization (repetitive follicular cavities). This unit reproduces both the 3D native geometry of the human thyroid stromal/vascular scaffold, and the natural thyrocyte/vascular interface. It is now under intense investigation as an experimental tool to test cellular 3D auto-assembly of thyroid tissue and its related vascular system up to the ex situ generation of a 3D macroscopic thyroid gland. We believe that these studies will lay the groundwork for a new concept in regenerative medicine of soft tissue and endocrine organs; i.e. that the organomorphism of a biocompatible scaffold-bioreactor complex is essential to both the 3D organization of seeded stem cells/precursor cells and their phenotypic fate as glandular/parenchymal/vascular elements, eventually leading to a physiologically competent and immuno-tolerant bioconstruct, macroscopically suitable for transplantation and clinical applications.

Deep drilling of aluminium die-cast parts: surface roughness, dimensional tolerance and tool-chip interaction

Many automotive applications require deep drilling on pressure die-cast parts in Aluminium alloys. The aim of the research was to understand if common cutting practices, usually determined on raw materials, can be successful on semimanufactured parts as well, having an inhomogeneous microstructure. A specific investigation was carried out on deep drilling of an EN AB-46000 cylinder block, varying technological parameters (cutting speed, feed, tool, lubrication). Dimensional tolerance and surface roughness were measured and statistically analyzed. The quantitative analysis of the process macroscopic performances was combined with an investigation of microstructural aspects of the material, their effects on chip formation and tool-chip interaction.

A combined additive layer manufacturing / indirect replication method to prototype 3D vascular-like structures of soft tissue and endocrine organs: A combined additive layer manufacturing (ALM)/ indirect replication method to prototype 3D vascular-like structures of soft tissue and endocrine organs is presented in this paper

We describe an innovative methodology combining Additive Layer Manufacturing (ALM) and indirect replication to reconstruct reticular-like, three-dimensional (3D) structures mimicking the vascular network of soft tissue and endocrine organs. Using a fractal-like algorithm capable of modelling the intraparenchymal vascular distribution of these viscera, single intraglandular branches of the human thyroid arteries were prototyped with synthetic resin, based on the algorithmic standard to layer (STL) output and ALM techniques. Satisfactory dimensional accuracy was obtained for these models, which were used as masters to evaluate protocols for their indirect replication, through both single and double procedures. Additional studies were conducted using casts of the human kidney arteries, obtained by injection / corrosion of the isolated organ. Satisfactory 3D reproduction of the external morphology of the kidney vessels was achieved. We conclude that our approach has the potential to develop up to the reconstruction with biomaterials of an entire, intraparenchymal vascular tree of soft tissue and endocrine organs.

Dimensional Tolerances and Assembly Accuracy of Dental Implants and Machined Versus Cast-On Abutments

BACKGROUND The clinical application of prosthetic components obtained by different manufacturing processes lacks technological foundation: the dimensional tolerance of individual parts and their assembly accuracy are not known. The rotational misfit (RM) of the hexagonal connection is critical in single-tooth implant restorations, but no standard control procedures are available for its evaluation. PURPOSE The research aimed at proposing a new protocol for the dimensional assessment of implant-abutment connections, based on noncontact measurement and statistical data processing. The procedure was applied to machined- and cast-on abutments, as well of the matching implants. MATERIALS AND METHODS Three groups of five abutments each were studied: machined titanium abutments, pre-machined calcinable abutments before casting procedures and the same specimens after casting. A group of five corresponding implants was considered as well. Twice the apothem was measured on each hexagon through an optical measuring microscope. The data were processed to obtain the international tolerance (IT) grade. The RM was then calculated using the apothems of the external and the internal hexagon. RESULTS All the components were classified between IT8 and IT9, and the maximum RM was around 3-4° for all the assemblies, inferior to the critical limits for the screw joint stability. CONCLUSION An original measuring protocol was developed, independent of parts assembly and based on ITs. An objective dimensional characterization of prosthetic components and assemblies has been achieved, which is the basis for their reliability in clinical applications.

Study of the EDM process effects on aluminium alloys

Till now aluminium moulds have been employed only for pre-production; with the alloys A12219 and A17050, which have outstanding properties, we can think about medium productions of plastic components obtained by injection moulding. To evaluate the machinability of these alloys and understand the correlations among process parameters, dimensional tolerances, surface finish and electrode wear, some tests have been made by Electro Discharge Machining. The electrodes and the machined surfaces have been also observed at OM, SEM to understand the EDM mechanisms. Comparison tests have also been done on A17075, commonly employment for pre-production moulds, to have precise control data.

Multi-disciplinary approach in engineering education: learning with additive manufacturing and reverse engineering

Purpose – The purpose of this paper is to report an interdisciplinary, cooperative-learning project in a second-year course within the “Enzo Ferrari” Master of Science Degree in Mechanical Engineering. The work aims to raise awareness of the educational impact of additive manufacturing and reverse engineering. Design/methodology/approach – Students are asked to develop, concurrently, the design and the manufacturing solution for an eye-tracker head mount. A digital head model is reverse engineered from an anatomical mannequin and used as an ergonomic mock-up. The project includes prototype testing and cost analysis. The device is produced using additive manufacturing techniques for hands-on evaluation by the students. Findings – Results of the presented case study substantiate the authors’ belief in the tremendous potential of interdisciplinary project-based learning, relying on innovative technologies to encourage collaboration, motivation and dynamism. Originality/value – The paper confirms a spreading ...