Han Tong Loh

Fabrication of 3D chitosan–hydroxyapatite scaffolds using a robotic dispensing system

Abstract A new robotic desktop rapid prototyping (RP) system was designed to fabricate scaffolds for tissue engineering applications. The experimental setup consists of a computer-guided desktop robot and a one-component pneumatic dispenser. The dispensing material (chitosan and chitosan–hydroxyapatite (HA) dissolved in acetic acid) was stored in a 30-ml barrel and forced out through a small Teflon-lined nozzle into a dispensing medium (sodium hydroxide–ethanol in ratio of 7:3). Layer-by-layer, the chitosan was fabricated with a preprogramed lay-down pattern. Neutralization of the chitosan forms a gel-like precipitate, and the hydrostatic pressure in the sodium hydroxide (NaOH) solution keeps the cuboid scaffold in shape. Comparison of the freeze-dried scaffold to the wet one showed linear and volumetric shrinkage of about 31% and 62%, respectively. A good attachment between layers allowed the chitosan matrix to form a fully interconnected channel architecture. Results of in vitro cell culture studies revealed the scaffold biocompatibility. The results of this preliminary study using the rapid prototyping robotic dispensing (RPBOD) system demonstrated its potential in fabricating three-dimensional (3D) scaffolds with regular and reproducible macropore architecture.

Multi‐objective optimization of part‐ building orientation in stereolithography

In rapid prototyping, such as SLA (stereolithography apparatus) and FDM (fused deposition modelling), the orientation of the part during fabrication is critical as it can affect part accuracy, reduce the production time, and minimize the requirement for supports and, thus, the cost of building the model. Presents a multi‐objective approach for determining the optimal part‐building orientation. Considers different objectives such as part accuracy and building time. Objective functions have been developed based on known sources of errors affecting part accuracy and the requirements of good orientations during the building of a model. The objective functions employ weights assigned to various surface types affecting part accuracy. The primary objective is to attain the specified accuracy achievable with the process. The secondary objective is to minimize the building time. Gives examples to illustrate the algorithm for deriving the optimal orientation which can assure better part quality and higher building efficiency.

Imbalanced text classification: A term weighting approach

The natural distribution of textual data used in text classification is often imbalanced. Categories with fewer examples are under-represented and their classifiers often perform far below satisfactory. We tackle this problem using a simple probability based term weighting scheme to better distinguish documents in minor categories. This new scheme directly utilizes two critical information ratios, i.e. relevance indicators. Such relevance indicators are nicely supported by probability estimates which embody the category membership. Our experimental study using both Support Vector Machines and Naive Bayes classifiers and extensive comparison with other classic weighting schemes over two benchmarking data sets, including Reuters-21578, shows significant improvement for minor categories, while the performance for major categories are not jeopardized. Our approach has suggested a simple and effective solution to boost the performance of text classification over skewed data sets.

Benchmarking for comparative evaluation of RP systems and processes

A geometric benchmark part is proposed, designed and fabricated for the performance evaluation of rapid prototyping machines/processes. The benchmark part incorporates key shapes and features of better‐known benchmark parts. It also includes new geometric features, such as freeform surfaces, certain mechanical features and pass‐fail features that are increasingly required or expected of RP processes/systems. The part is suitable for fabrication on a typical RP machines. In this paper, the application of the benchmark part is demonstrated using relatively common RP processes. The ability of the benchmark part to determine achievable geometric features and accuracy by the aforementioned RP processes is presented and discussed.

Considerations and selection of optimal orientation for different rapid prototyping systems

The ability to evaluate and determine the best part building orientation for different rapid prototyping (RP) processes is important for building a satisfactory part/prototype within the limits of manufacturing time and building cost. It is also an essential step towards the identification of the most suitable RP process with a given RP application. This paper discusses the selection of building direction for four RP processes, namely stereolithography (SL), selective laser sintering (SLS), fusion deposition modelling (FDM) and laminated object manufacturing (LOM). Main differences in the four processes are first examined with emphasis on the effects of these differences with regard to the building inaccuracy, the surface finish, the manufacturing time and cost. An optimal orientation algorithm is demonstrated on a part considered for processing with one of the four RP processes. The influence of the process characteristics on the selection of appropriate orientation with different RP processes is illustrated in the example.

Determination of optimal cutting conditions using design of experiments and optimization techniques

Abstract In process planning or NC part programming, optimal cutting conditions are to be determined using reliable mathematical models representing the machining conditions of a particular work-tool combination. The development of such mathematical models requires detailed planning and proper analysis of experiments. In this paper, the mathematical models for TiN-coated carbide tools and Rochling T4 medium carbon steel were developed based on the design and analysis of machining experiments. The models developed were then used in the formulation of objective and constraint functions for the optimization of a multipass turning operation with such work-tool combinations.

Optimal orientation with variable slicing in stereolithography

Accuracy and building time are two important concerns in rapid prototyping (RP). Usually there exists a trade‐off between these two aspects pertaining to model building in RP. The use of variable thickness slicing can satisfy these two requirements to some extent. Introduces an adaptive variable thickness slicer implemented on a solid CAD modeller. The slicer employs a genetic algorithm to find the minimum layer thickness allowed at referenced height with a given cusp height tolerance. By introducing the variable thickness slicing technique, the optimal orientation for part building in RP systems is considered. Seeks to obtain the optimal orientation with adaptive slicing for part building in stereolithography (SLA) systems. Takes into consideration building time, accuracy and stability of the part when determining the optimal orientation. Results show that the proposed approach gives an effective and practical solution for building parts with curved surfaces.

Direct laser sintering of a copper-based alloy for creating three-dimensional metal parts

Abstract Direct laser sintering of metal, as one of the important developments in rapid prototyping technologies, is discussed in this paper. A special copper-based alloy is used for this rapid prototyping process. Experiments on the sintering conditions of this material had been conducted in a self-developed high temperature metal sintering machine. The mechanism of laser sintering for this kind of material was disclosed by SEM analysis of microstructures of sintered parts. The density, surface roughness and mechanical properties of the laser sintering parts due to variation of process parameters were measured and analysed. The effect of process parameters to the accuracy of sintered parts was also investigated. Thus, optimum parameters were obtained for direct laser sintering of three-dimensional metal parts.

Equidistant path generation for improving scanning efficiency in layered manufacturing

Path generation is an important factor that affects the quality and efficiency of most laminated manufacturing processes such as SLS, SLA and FDM. This paper introduces an efficient path generation algorithm. The principle of the algorithm and its implementation are presented. A comparative study is used to analyze the effectiveness of this method. The results of comparison on both path length and processing time between the traditional method and the proposed method are discussed.

Toward generic models for comparative evaluation and process selection in rapid prototyping and manufacturing

Selection of the most suitable rapid prototyping and manufacturing (RP&M) process for a specific part creation is a difficult task due to the proliferation of RP/s&M processes and materials. Multiple considerations such as good dimensional accuracy, fine surface finish, short building time, and low building cost are all desired objectives, and no one process is superior in all aspects. For a software tool to assist in making such a selection, a systematic study is first required to compare pertinent attributes among the different RP&M processes. It is also necessary to design appropriate models that can be used to characterize these attributes and that can be modified for existing and future RP&M machines. This paper studies the four dominant RP&M processes currently in the market—stereolithography (SL), selective laser sintering (SLS), fused deposition modeling (FDM), and laminated object manufacturing (LOM)—through a benchmark part. Generic models for surface roughness, building time, and building cost are also presented.