Massimo Martorelli

The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer

Purpose – This study aims to quantify the ultimate tensile strength and the nominal strain at break (ɛf) of printed parts made from polylactic acid (PLA) with a Replicating Rapid prototyper (Rep-Rap) 3D printer, by varying three important process parameters: layer thickness, infill orientation and the number of shell perimeters. Little information is currently available about mechanical properties of parts printed using open-source, low-cost 3D printers. Design/methodology/approach – A computer-aided design model of a tensile test specimen was created, conforming to the ASTM:D638. Experiments were designed, based on a central composite design. A set of 60 specimens, obtained from combinations of selected parameters, was printed on a Rep-Rap Prusa I3 in PLA. Testing was performed using a JJ Instruments – T5002-type tensile testing machine and the load was measured using a load cell of 1,100 N. Findings – This study investigated the main impact of each process parameter on mechanical properties and the effe...

Stereolithography in oral implantology: a comparison of surgical guides.

This article presents the use of stereolithography in oral implantology. Stereolithography is a new technology that can produce physical models by selectively solidifying an ultraviolet-sensitive liquid resin using a laser beam, reproducing the true maxillary and mandibular anatomic dimensions. With these models, it is possible to fabricate surgical guides that can place the implants in vivo in the same places and same directions as those in the planned computer simulation. A 70-year-old woman, in good health, with severe mandibular bone atrophy was rehabilitated with an over-denture supported by 2 Branemark implants. Two different surgical planning methods were considered: 1) the construction of a surgical guide evaluating clinical aspects, and 2) the surgical guide produced by stereolithographic study. The accuracy of surgical planning can reduce the problems related to bone density and dimensions. Furthermore, the stereolithographic study assured the clinicians of a superior location of fixtures in bone. Surgical planning based on stereolithographic technique is a safe procedure and has many advantages. This technologic advance has biologic and therapeutic benefits because it simplifies anatomic surgical management for improved implant placement.

Numerical fatigue 3D-FE modeling of indirect composite-restored posterior teeth

OBJECTIVE In restored teeth, stresses at the tooth-restoration interface during masticatory processes may fracture the teeth or the restoration and cracks may grow and propagate. The aim was to apply numerical methodologies to simulate the behavior of a restored tooth and to evaluate fatigue lifetimes before crack failure. MATERIALS AND METHODS Using a CAD-FEM procedure and fatigue mechanic laws, the fatigue damage of a restored molar was numerically estimated. Tessellated surfaces of enamel and dentin were extracted by applying segmentation and classification algorithms, to sets of 2D image data. A user-friendly GUI, which enables selection and visualization of 3D tessellated surfaces, was developed in a MatLab(®) environment. The tooth-boundary surfaces of enamel and dentin were then created by sweeping operations through cross-sections. A class II MOD cavity preparation was then added into the 3D model and tetrahedral mesh elements were generated. Fatigue simulation was performed by combining a preliminary static FEA simulation with classical fatigue mechanical laws. RESULTS Regions with the shortest fatigue-life were located around the fillets of the class II MOD cavity, where the static stress was highest. SIGNIFICANCE The described method can be successfully adopted to generate detailed 3D-FE models of molar teeth, with different cavities and restorative materials. This method could be quickly implemented for other dental or biomechanical applications.

Mechanical behavior of bulk direct composite versus block composite and lithium disilicate indirect Class II restorations by CAD-FEM modeling

OBJECTIVES To study the influence of resin based and lithium disilicate materials on the stress and strain distributions in adhesive class II mesio-occlusal-distal (MOD) restorations using numerical finite element analysis (FEA). To investigate the materials combinations in the restored teeth during mastication and their ability to relieve stresses. METHODS One 3D model of a sound lower molar and three 3D class II MOD cavity models with 95° cavity-margin-angle shapes were modelled. Different material combinations were simulated: model A, with a 10μm thick resin bonding layer and a resin composite bulk filling material; model B, with a 70μm resin cement with an indirect CAD-CAM resin composite inlay; model C, with a 70μm thick resin cement with an indirect lithium disilicate machinable inlay. To simulate polymerization shrinkage effects in the adhesive layers and bulk fill composite, the thermal expansion approach was used. Shell elements were employed for representing the adhesive layers. 3D solid CTETRA elements with four grid points were employed for modelling the food bolus and tooth. Slide-type contact elements were used between the tooth surface and food. A vertical occlusal load of 600 N was applied, and nodal displacements on the bottom cutting surfaces were constrained in all directions. All the materials were assumed to be isotropic and elastic and a static linear analysis was performed. RESULTS Displacements were different in models A, B and C. Polymerization shrinkage hardly affected model A and mastication only partially affected mechanical behavior. Shrinkage stress peaks were mainly located marginally along the enamel-restoration interface at occlusal and mesio-distal sites. However, at the internal dentinal walls, stress distributions were critical with the highest maximum stresses concentrated in the proximal boxes. In models B and C, shrinkage stress was only produced by the 70μm thick resin layer, but the magnitudes depended on the Youngs modulus (E) of the inlay materials. Model B mastication behavior (with E=20GPa) was similar to the sound tooth stress relief pattern. Model B internally showed differences from the sound tooth model but reduced maximum stresses than model A and partially than model C. Model C (with E=70GPa) behaved similarly to model B with well redistributed stresses at the occlusal margins and the lateral sides with higher stress concentrations in the proximal boxes. Models B and C showed a more favorable performance than model A with elastic biomechanics similar to the sound tooth model. SIGNIFICANCE Bulk filling resin composite with 1% linear polymerization shrinkage negatively affected the mechanical behavior of class II MOD restored teeth. Class II MOD direct resin composite showed greater potential for damage because of higher internal and marginal stress evolution during resin polymerization shrinkage. With a large class II MOD cavity an indirect composite or a lithium disilicate inlay restoration may provide a mechanical response close to that of a sound tooth.

The effects of cavity-margin-angles and bolus stiffness on the mechanical behavior of indirect resin composite class II restorations

OBJECTIVE To study the influence of the different class II mesio-occlusal-distal (MOD) cavity shape on the stress and strain distributions in adhesive indirect restorations, using numerical finite element analysis (FEA). To investigate the relationship between restored teeth failure and stiffness of food, three values of Youngs modulus were used for the food. METHODS A 3D model of a sound lower molar and three class II MOD cavities with different shape were created. Slide-type contact elements were used between tooth surface and food. An adhesive resin-based cement, modeled with fixed-type contact elements, and a single restorative filling materials were considered. To simulate polymerization shrinkage effect, which is basically restricted to the thin composite cement layer, shell elements were employed and the thermal expansion approach was used. A vertical occlusal load of 600N was applied, while assigning fixed zero-displacements on the cutting surfaces below the crevices. All the materials were assumed to be isotropic and elastic. A static linear analysis was carried out. RESULTS In the lingual cusp, the displacements increased as the values of the stiffness food increased. In the restored teeth, the stress near the restoration-tooth interface was strongly dependent on the MOD cavity shape. The stress peaks were mainly located along the enamel-dentin interface at the lingual side; wedge-shaped MOD cavity with a low angle, in combination with the lowest food stiffness provided the best results. SIGNIFICANCE A more complex load application on the occlusal surfaces was introduced. Food stiffness slightly affected the stress distribution of the restored and sound teeth. Teeth with adhesive class II MOD indirect resin composite restorations were potentially more susceptible to damage if the class II MOD cavity-margin-angle was higher than 95°. Restored teeth with a higher cavity-margin-angle led to considerable stress concentration in the lingual cusp along the enamel-dentin interface. These models were more susceptible to fracture in the lingual cusps when compared to the buccal ones.

Further Theoretical Insight into the Mechanical Properties of Polycaprolactone Loaded with Organic–Inorganic Hybrid Fillers

Experimental/theoretical analyses have already been performed on poly(ε-caprolactone) (PCL) loaded with organic–inorganic fillers (PCL/TiO2 and PCL/ZrO2) to find a correlation between the results from the small punch test and Young’s modulus of the materials. PCL loaded with Ti2 (PCL = 12, TiO2 = 88 wt %) and Zr2 (PCL = 12, ZrO2 = 88 wt %) hybrid fillers showed better performances than those obtained for the other particle composition. In this context, the aim of current research is to provide further insight into the mechanical properties of PCL loaded with sol–gel-synthesized organic–inorganic hybrid fillers for bone tissue engineering. For this reason, theoretical analyses were performed by the finite element method. The results from the small punch test and Young’s modulus of the materials were newly correlated. The obtained values of Young’s modulus (193 MPa for PCL, 378 MPa for PCL/Ti2 and 415 MPa for PCL/Zr2) were higher than those obtained from a previous theoretical modelling (144 MPa for PCL, 282 MPa for PCL/Ti2 and 310 MPa for PCL/Zr2). This correlation will be an important step for the evaluation of Young’s modulus, starting from the small punch test data.

Mechanical behavior of endodontically restored canine teeth: Effects of ferrule, post material and shape

OBJECTIVE To assess the effect of a ferrule design with specific post material-shape combinations on the mechanical behavior of post-restored canine teeth. METHODS Micro-CT scan images of an intact canine were used to create a 3-D tessellated CAD model, from which the shapes of dentin, pulp and enamel were obtained and geometric models of post-endodontically restored teeth were created. Two types of 15mm post were evaluated: a quartz fiber post with conical-tapered shape, and a carbon (C) fiber post with conical-cylindrical shape. The abutment was created around the coronal portion of the posts and 0.1mm cement was added between prepared crown and abutment. Cement was also added between the post and root canal and a 0.25mm periodontal ligament was modeled around the root. Four models were analysed by Finite Element (FE) Analysis: with/without a ferrule for both types of post material and shape. A load of 50N was applied at 45° to the longitudinal axis of the tooth, acting on the palatal surface of the crown. The maximum normal stress criterion was adopted as a measure of potential damage. RESULTS Models without a ferrule showed greater stresses (16.3MPa) than those for models with a ferrule (9.2MPa). With a ferrule, stress was uniformly distributed along the abutment and the root, with no critical stress concentration. In all models, the highest stresses were in the palatal wall of the root. Models with the C-fiber post had higher stress than models with the quartz fiber posts. The most uniform stress distribution was with the combination of ferrule and quartz fiber post. SIGNIFICANCE The FE analysis confirmed a beneficial ferrule effect with the combination of ferrule and quartz fiber post, with tapered shape, affording no critical stress concentrations within the restored system.

Flatness, circularity and cylindricity errors in 3D printed models associated to size and position on the working plane

The purpose of this paper is to assess the main effects on the geometric errors in terms of flatness, circularity and cylindricity based on the size of the printed benchmarks and according to the position of the working plane of the 3D printer. Three benchmark models of different sizes, with a parallelepiped and cylinder shape placed in five different positions on the working plane are considered. The sizes of models are chosen from the Renard series R40. Benchmark models are fabricated in ABS (Acrylonitrile Butadiene Styrene) using Zortrax M200 3D printer. A sample of five parts for each geometric category, as defined from the R40 geometric series of numbers, is printed close to each corner of the plate, and in the plate center position. Absolute Digimatic Height Gauge 0-450mm with an accuracy of ±0.03mm by Mitutoyo is used to perform all measurements: flatness on box faces, and circularity/cylindricity on cylinders. Results show that the best performances, in terms of form accuracy, are reached in the area center printable while they decrease with the sample size. Being quality a critical factor for a successful industrial application of the AM processes, the results discussed in this paper can provide the AM community with additional scientific data useful to understand how to improve the quality of parts which may be obtained through new generations of 3D printer.

Dynamic spinnaker performance through digital photogrammetry, numerical analysis and experimental tests

Sail manufacture has undergone significant development due to sailing races like the America’s Cup and the Volvo around the World Race. These competitions require advanced technologies to help increase sail performance. Hull design is fundamentally important but the sails (the only propulsion instrument) play a key role in dynamic of sailboats. Under aerodynamic loads, sail cloth deforms, the aerodynamic interaction is modified and the pressure on the sails is variously distributed resulting in performance inconsistencies. The interaction between fluid and structure necessitates a solution which combines aerodynamic and structural numerical simulations. Furthermore, in numerical simulations the aeroelastic sail characteristics must be known accurately. In this paper, the dynamic performance of a Spinnaker was studied. Digital photogrammetry was used to acquire the images, make the 3D reconstruction of the sail and validate the models in Computational Fluid Dynamics (CFD) analysis. Orthotropic constitutive characteristics of ten different sail cloths were measured by experimental test. The methodology allowed to compare dynamic performance in terms of forces, pressure and vibration for the different sail cloths and different fiber orientations.

Mechanical and Thermal Properties of Dental Composites Cured with CAD/CAM Assisted Solid-State Laser

Over the last three decades, it has been frequently reported that the properties of dental restorative composites cured with argon laser are similar or superior to those achieved with conventional halogen and light emitting diode (LED) curing units. Whereas laser curing is not dependent on the distance between the curing unit and the material, such distance represents a drawback for conventional curing units. However, a widespread clinical application of this kind of laser remains difficult due to cost, heavy weight, and bulky size. Recently, with regard to the radiation in the blue region of the spectrum, powerful solid-state lasers have been commercialized. In the current research, CAD (computer-aided design)/CAM (computer-aided manufacturing) assisted solid-state lasers were employed for curing of different dental restorative composites consisting of micro- and nanoparticle-reinforced materials based on acrylic resins. Commercial LED curing units were used as a control. Temperature rise during the photopolymerisation process and bending properties were measured. By providing similar light energy dose, no significant difference in temperature rise was observed when the two light sources provided similar intensity. In addition, after 7 days since curing, bending properties of composites cured with laser and LED were similar. The results suggested that this kind of laser would be suitable for curing dental composites, and the curing process does not suffer from the tip-to-tooth distance.