Garrett W. Melenka

Evaluation of Dimensional Accuracy and Material Properties of the MakerBot 3D Desktop Printer

Purpose – This paper aims to evaluate the material properties and dimensional accuracy of a MakerBot Replicator 2 desktop 3D printer. Design/methodology/approach – A design of experiments (DOE) test protocol was applied to determine the effect of the following variables on the material properties of 3D printed part: layer height, per cent infill and print orientation using a MakerBot Replicator 2 printer. Classical laminate plate theory was used to compare results from the DOE experiments with theoretically predicted elastic moduli for the tensile samples. Dimensional accuracy of test samples was also investigated. Findings – DOE results suggest that per cent infill has a significant effect on the longitudinal elastic modulus and ultimate strength of the test specimens, whereas print orientation and layer thickness fail to achieve significance. Dimensional analysis of test specimens shows that the test specimen varied significantly (p < 0.05) from the nominal print dimensions. Practical implications – Although desktop 3D printers are an attractive manufacturing option to quickly produce functional components, this study suggests that users must be aware of this manufacturing process’ inherent limitations, especially for components requiring high geometric tolerance or specific material properties. Therefore, higher quality 3D printers and more detailed investigation into the MakerBot MakerWare printing settings are recommended if consistent material properties or geometries are required. Originality/value – Three-dimensional (3D) printing is a rapidly expanding manufacturing method. Initially, 3D printing was used for prototyping, but now this method is being used to create functional final products. In recent years, desktop 3D printers have become commercially available to academics and hobbyists as a means of rapid component manufacturing. Although these desktop printers are able to facilitate reduced manufacturing times, material costs and labor costs, relatively little literature exists to quantify the physical properties of the printed material as well as the dimensional consistency of the printing processes.

An investigation into the mechanical characteristics of select self-ligated brackets at a series of clinically relevant maximum torquing angles: loading and unloading curves and bracket deformation

Edgewise orthodontic treatment utilizes a force couple in order to achieve labial-lingual tooth angulation. Two self-ligating brackets (Damon Q and Speed) were examined across a range of clinically relevant torques in order to assess the loading and unloading curves and bracket deformation. A previously developed torquing and load measurement system was utilized to rotate a 0.199 × 0.25 in stainless steel wire in a fixed bracket slot to the following angles: 16, 20, 24, 28, 32, and 40 degrees. The torque on the bracket was measured during both wire loading and unloading cycles. The torque play for the Damon brackets was determined to increase by less than 0.4 degrees when torqued to 70 Nmm, whereas the increase for the Speed brackets was 2.1 degrees at the same torque magnitude. The deformation curves for the Damon and Speed brackets were found to be different for loading and unloading. Speed brackets were found to start to plastically deform when torqued to 24 degrees (26 Nmm of torque), while Damon brackets did not plastically deform until 28 degrees (38 Nmm of torque). Damon brackets were found not to plastically deform as easily and to have a smaller increase in torque play than Speed brackets. Both the Damon and the Speed brackets demonstrated minimal effect of plastic deformation and torque play at maximum angles of twist less than 20 degrees. Torque measured in the brackets was different for loading and unloading.

Manufacturing processes for braided composite materials

Braiding is not being used as a manufacturing process as much as would be expected based on its well-known advantages. Fabricating consistent, high-quality braided composite materials has been challenging. The range of available processes and selecting the right one for the right component has perplexed researchers and engineers. Herein, production processes and methods, as well as alternatives, for the production of two-dimensional and three-dimensional braided composites are discussed.

Modeling Stress-Relaxation Behavior of the Periodontal Ligament During the Initial Phase of Orthodontic Treatment

The periodontal ligament is the tissue that provides early tooth motion as a result of applied forces during orthodontic treatment: a force-displacement behavior characterized by an instantaneous displacement followed by a creep phase and a stress relaxation phase. Stress relaxation behavior is that which provides the long-term loading to and causes remodelling of the alveolar bone, which is responsible for the long-term permanent displacement of the tooth. In this study, the objective was to assess six viscoelastic models to predict stress relaxation behavior of rabbit periodontal ligament (PDL). Using rabbit stress relaxation data found in the literature, it was found that the modified superposition theory (MST) model best predicts the rabbit PDL behavior as compared to nonstrain-dependent and strain-dependent versions of the Burgers four-parameter and the five-parameter viscoelastic models, as well as predictions by Schaperys viscoelastic model. Furthermore, it is established that using a quadratic form for MST strain dependency provides more stable solutions than the cubic form seen in previous studies.

Advanced testing of braided composite materials

Abstract Braided composite materials are one of the oldest textiles, but their adoption in industry, for mass-market or high-end products, is limited. The braiding process allows for versatility in the production of end products; such an advantage in the production process requires stringent assessment and quality control of the end product, or accurate modeling and design of components. However, the development of fully validated models to predict the large range of required material properties that would be highly beneficial for a priori design of braided component is hampered by the lack of consistent use of accurate testing methodology. Testing protocols specific to braided composites in terms of sample geometry, material quality, and mechanical properties do exist, but are often combined with those for other textile composites. This lack of concise information and list of key testing protocols for two- or three-dimensional braided composites, of flat or of complex shape, are hindering potential material engineers or researchers from assessing their properties. Herein, the most applicable standard and nonstandard testing procedures for braided composite materials and structures are concisely assembled.

Comparison of deformation and torque expression of the orthos and orthos Ti bracket systems

Orthodontic torque expression is the result of axial rotation of rectangular archwires within a rectangular bracket slot. This study investigates the effect of bracket material on torque expression. Torque exerted by a rotating archwire on each bracket will be measured as well as the relative deformation of each bracket slot. A total of 60 tests were performed where archwires were rotated within a bracket slot to produce torque within a bracket. Thirty Ormco Orthos Ti and 30 Orthos SS were compared to investigate the effect of torque on bracket material. Each bracket was mounted on a six-axis load cell that measured forces and moments in all directions. The archwire was rotated from an initial angle of 0 degree in 3 degrees increments to maximum angle of 51 degrees and then returned to the initial position. An overhead camera took images at each 3 degrees increment. The bracket images were post-processed using a digital image correlation technique to measure the relative deformation of each bracket slot. The maximum torque expressed at 51 degrees was 99.8 Nmm and 93.0 Nmm for Orthos Ti and Orthos SS, respectively. Total plastic deformation measured at 0 degrees post-torquing of the Orthos SS was 0.038 mm compared to 0.013 mm for Orthos Ti. The Orthos Ti brackets plastically deformed less than the Orthos SS brackets after torquing. The Orthos SS bracket plastic deformation was 2.8 times greater than that of Orthos Ti brackets. The Orthos Ti brackets expressed more torque than the stainless steel brackets but exhibited substantial variation.

Introduction to braided composite material behavior

Braided composites can fulfill the needs of a great number of applications. Yet their use is sparse at best in industrial applications compared to other composite material production methods. Herein we assess the state of braided composites, provide general insight in their history, geometry, behavior, and provide a road map to predicting their behavior.

Three-dimensional deformation comparison of self-ligating brackets

INTRODUCTION Archwire rotation is used in orthodontic treatment to alter the labiolingual orientation of a tooth. Measurement of the 3-dimensional (3D) motion of the orthodontic brackets requires a new configuration of the orthodontic torque simulator. METHODS The orthodontic torque simulator was coupled with a stereo microscope and 2 cameras to allow for the 3D bracket motion to be determined during wire twisting. The stereo camera images were processed with a 3D digital image correlation technique to determine the 3D deformation of the orthodontic brackets. Three self-ligating brackets (Damon Q, Ormco, Orange, Calif; In-Ovation R, GAC, Bohemia, NY; and Speed, Strite Industries, Cambridge, Ontario, Canada) were compared by using the 3D digital image correlation method to demonstrate the difference in 3D motion of self-ligating brackets components. RESULTS Contour plots of the 3 brackets demonstrate the 3D motion of the bracket tie-wings and the archwire retentive component. The 3D motion of the bracket tie-wings and archwire retentive component were quantified. The displacement values of the archwire retentive component measured with the 3D orthodontic torque simulator were found to be 2.0 and 3.5 times less for the In-Ovation and Damon Q brackets than the values in previous studies that examined the compliance of the archwire retentive component. CONCLUSIONS The 3D digital image correlation method used to quantify bracket deformation showed the 3D motion of the bracket tie-wings and the motion of the archwire retentive component. The use of a 3D optical measurement system is useful to understand the motion of the archwire retentive component but is not necessary to quantify bracket tie-wing motion. This measurement technique can be used to evaluate brackets of varying designs.

Characterizing short-fiber-reinforced composites produced using additive manufacturing

Abstract Material extrusion additive manufacturing (MEAM), a sub-branch of three-dimensional (3D) printing is growing in popularity. Test specimens were 3D-printed using commercial polylactic acid (PLA) filament, and PLA filament reinforced with short-carbon fibers (PLA/CF). As-printed specimens and specimens that were annealed at three different temperatures, then subjected to tensile testing. The internal microstructures of the samples were also examined. The effects of the short-carbon fiber fillers on the mechanical properties of 3D-printed PLA were investigated, and the effects of the annealing process on polymer crystallinity and mechanical properties. The annealing process was shown to increase the crystallinity of both sample groups, though no statistically significant effect of annealing on mechanical properties was observed. The tensile properties of the PLA and PLA/CF filaments showed that the addition of carbon fibers to the PLA filament led to a significant increase in elastic modulus of the MEAM samples.

Design of braided composite materials

Abstract In an industrial world aiming to improve processes and end-products, the use of braided composites has been minimal compared to other composite materials. Considering the well-known advantages of braided composites, this is surprising. However, the complex nature of braiding production, modeling, and design processes have been contributing factors. In this work, we present a discussion of the fundamental steps and considerations for designing braided composites and successful examples where they have been used. This work is intended to guide junior designers through a thorough design process and lay out a road map for experienced designers.