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Analytical Modelling and Optimization of the Temperature-Dependent Dynamic Mechanical Properties of Fused Deposition Fabricated Parts Made of PC-ABS.

ABSTRACT: Fused deposition modeling (FDM) additive manufacturing has been intensively used for many industrial applications due to its attractive advantages over traditional manufacturing processes. The process parameters used in FDM have significant influence on the part quality and its properties. This process produces the plastic part through complex mechanisms and it involves complex relationships between the manufacturing conditions and the quality of the processed part. In the present study, the influence of multi-level manufacturing parameters on the temperature-dependent dynamic mechanical properties of FDM processed parts was investigated using IV-optimality response surface methodology (RSM) and multilayer feed-forward neural networks (MFNNs). The process parameters considered for optimization and investigation are slice thickness, raster to raster air gap, deposition angle, part print direction, bead width, and number of perimeters. Storage compliance and loss compliance were considered as response variables. The effect of each process parameter was investigated using developed regression models and multiple regression analysis. The surface characteristics are studied using scanning electron microscope (SEM). Furthermore, performance of optimum conditions was determined and validated by conducting confirmation experiment. The comparison between the experimental values and the predicted values by IV-Optimal RSM and MFNN was conducted for each experimental run and results indicate that the MFNN provides better predictions than IV-Optimal RSM.

SUBMITTER: Mohamed OA

PROVIDER: S-EPMC5457216 | biostudies-other | 2016 Nov

REPOSITORIES: biostudies-other

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Project description:A microneedle (MN) array is a novel biomedical device adopted in medical applications to pierce through the stratum corneum while targeting the viable epidermis and dermis layers of the skin. Owing to their micron-scale dimensions, MNs can minimize stimulations of the sensory nerve fibers in the dermis layer. For medical applications, such as wound healing, biosensing, and drug delivery, the structure of MNs significantly influences their mechanical properties. Among the various microfabrication methods for MNs, fused deposition modeling (FDM), a commercial 3D printing method, shows potential in terms of the biocompatibility of the printed material (polylactic acid (PLA)) and preprogrammable arbitrary shapes. Owing to the current limitations of FDM printer resolution, conventional micron-scale MN structures cannot be fabricated without a post-fabrication process. Hydrolysis in an alkaline solution is a feasible approach for reducing the size of PLA needles printed via FDM. Moreover, weak bonding between PLA layers during additive manufacturing triggers the detachment of PLA needles before etching to the expected sizes. Furthermore, various parameters for the fabrication of PLA MNs with FDM have yet to be sufficiently optimized. In this study, the thermal parameters of the FDM printing process, including the nozzle and printing stage temperatures, were investigated to bolster the interfacial bonding between PLA layers. Reinforced bonding was demonstrated to address the detachment challenges faced by PLA MNs during the chemical etching process. Furthermore, chemical etching parameters, including the etchant concentration, environmental temperature, and stirring speed of the etchant, were studied to determine the optimal etching ratio. To develop a universal methodology for the batch fabrication of biodegradable MNs, this study is expected to optimize the conditions of the FDM-based fabrication process. Additive manufacturing was employed to produce MNs with preprogrammed structures. Inclined MNs were successfully fabricated by FDM printing with chemical etching. This geometrical structure can be adopted to enhance adhesion to the skin layer. Our study provides a useful method for fabricating MN structures for various biomedical applications.

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Analytical Modelling and Optimization of the Temperature-Dependent Dynamic Mechanical Properties of Fused Deposition Fabricated Parts Made of PC-ABS.

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