Aurrichio PDF

ADDITIVE MANUFACTURING
PROCESSES:
from materials to applications, from
micro- to macro-simulations
F. Auricchio
Computational Mechanics and Advanced Material Group
Dipartimento di Ingegneria Civile e Architettura
Università di Pavia
Ferdinando Auricchio CompMech Group September, 2017

Outline
Ø  3D Printing: The 4th industrial revolution: Additive Manufacturing

ü  Economic impact
ü  How does it work?
ü  Technologies & Workflow
ü  Applications
Ø  3D Printing: Additive Manufacturing: Materials

ü  Metal 3D printing
ü  Plastic 3D prinitng
Ø  3D Printing: Microscopic Simulations

ü  Physical problem
ü  State of art and available codes
ü  Lattice Boltzmann Method Markl, Matthias, and Carolin Körner. "Multiscale Modeling of Powder
Bed–Based Additive Manufacturing." Annual Review of Materials
ü  Some benchmarks Research
Ø  3D Printing: Macroscopic Simulations

ü  The importance of simulation
ü  State of art and commercial codes
ü  Abaqus simulations
ü  Digimat simulations

Outline
Ø  3D Printing: 3D@UniPV as strategic research theme

ü  Medicine: surgery support
ü  Regenerative medicine: scaffolds
ü  Bio-printing
ü  Architecture
ü  Micro-waves

Outline

ü  Applications


ü  Lattice Boltzmann Method
ü  Some benchmarks


Additive Manufacturing
February 2011 April 2012

3D printing is very popular

since 2011 …
… but it is not a brand new

technology
SLA-1, 3D Systems Corporation

1987

ECONOMIC IMPACT
Ø  Analysis from Wanted Analytics, also published on Forbes (2014)

ü  35% of USA job advertisements ask for engineers…experts of 3D
printing!!!
ü  Demand of candidates with 3D printing expertise: +1843% in the last four
years
Ø  Whooler Report (2014)

ü  The worldwide 3D printing industry is now expected to grow worldwide from
$3.07B in revenue in 2013 to $12.8B by 2018, and exceed $21B by 2020
Ø  McKinsey Report (2014)

ü  The advantages of 3D printing over other manufacturing technologies could
lead to profound changes in the way many things are designed,
developed, produced, and supported

Industry 4.0

HOW DOES IT WORK?

Additive manufacturing Creates objects through a sequential
layering process
STEP 1
From CAD to .STL
STEP 2
Virtual Slicing
STEP 3
Printing

HOW DOES IT WORK?

layering process

Virtual Model Slicing Printed Model

HOW DOES IT WORK?

layering process
Some advantages:
Ø  Very complex shapes in a single

manufacturing process
ü  Architectured materials and lattice

ü  Optimized components
Ø  No assembling procedures needed

ü  Printing assemblies in one shot
Ø  No more need to stock components

ü  Possibility of printing functional components
Ø  Waste material
ü  The advantages of 3D printing over

AM Technologies
FDM (Fused Deposition Modeling) uses a thermo-plastic filament, pushed

through a heating chamber and extruded through a small nozzle.
•  Material: thermoplastic filaments •  Inexpensive process;

(PLA, ABS, HIPS,TPU, TPE, PETG,Nylon,
reinforced materials);
•  Low resolution with respect to
•  Curing: temperature gradient; other processes.

AM Technologies
Vat – Polymerization or SLA uses a container of liquid photopolymer, that

is cured through UV laser.
•  Material: photo-polymeric resins; •  Quite expensive process;
•  Curing: UV laser; •  High accuracy and good finish;
•  Only one material at a time

AM Technologies
Material Jetting uses with photopolymers that are dropped

through small nozzles.
•  Material: photo-polymeric resins •  Highly expensive;
•  Curing: UV lamp; •  Multiple materials & colours with high

accuracy.

AM Technologies
Binder Jetting employs a powder base material and a liquid binder.
•  Material: chalk-like or plastic •  Fast process and good finish;

powder;
•  Parts can be made with a wide range of
•  Curing: binder (glue); different colours (milions);

The 4th industrial revolution
APPLICATIONS
3D printed ABS
Ø  Automotive & Mechanic propellers
3D printed house
model
Ø  Design & Planning
3D printed ULTEM air vent

Ø  Aeronautical & defense

APPLICATIONS IN MEDICINE
Implants Surgical Planning

Surgical Planning Medical Training
Medical Training
Regenerative
Regenerative Medical Devices Prosthesis &
Medicine
Medicine Orthosis

AM Technologies
Power bed fusion uses a laser source to melt powder on a

printing plate.
•  Expensive process;
•  Material: metal alloys (Ni, Co, Fe, Al,
Steel);
•  Higher precision but lower speed than
other metal technologies.
•  Curing: CO2 laser;
•  Post-processing required

AM Technologies
Directed energy deposition uses an electron beam source to melt
powder while it is deployed.
•  Expensive process;
•  Material: metal alloys (Ni, Co, Fe, Al, Steel);
•  Lower precision but higher speed than
•  Curing: high power electron laser other metal technologies.
beam;
•  Post-processing required

APPLICATIONS
First 3D printed car
Ø  Automotive & Mechanic engine
3D printed front-
bearing housing
Ø  Aeronautical & Defense
Customized 3D-printed lower jaw

Ø  Medical & Bio Medic

APPLICATIONS
3D-printed gold ring
Ø  Jewelry & Luxury
3D-printed mold
Ø  Casting, Patterns & Molds
Partially 3D printed watch

Ø  Watchmaking

APPLICATIONS IN MEDICINE
Implants Surgical Planning

Surgical Planning Medical Training
Medical Training
Regenerative
Medicine
Medicine Orthosis

Prototyping vs Production

3D Printing technologies Prototyping

Standard technologies Production


Prototyping vs Production

3D Printing technologies Prototyping

3D Printing technologies Production

Standard technologies Production


Outline

ü  Applications




Metal 3DP: MATERIALS
PRINCIPAL ALLOYS
Ø  Cobalt-Chrome (CoCr)
Ø  Stainless Steel (e.g. 316L)
Ø  Maraging Steel
Ø  Aluminum (AlSi12)
Aluminum powder
Ø  Titanium (TiAl16V4)
Ø  Copper (Cu)
Ø  Gold (Au)
Ø  Inconel (Ni - In718)
Titanium powder

ALLOYS PROPERTIES
Aluminum AlSi12 •  Method of fabrication: Air atomization

•  Density: 2,65 ton /m3
•  Mean particle size (Diameter): 30 - 40 µm
•  Chemical Composition: Al: 88 %
Principal powder Si: 11 – 13%
properties Residual: < 0,6%
•  Thermal Conductivity: 120 – 130 W/mK
•  Specific Heat: 963 J/KgK
•  Thermal Expansion: 21e-6 1/K
•  Melting Point: 580 °C
•  Heat of Fusion: 390 kJ/Kg
Data from:

ALLOYS PROPERTIES
Aluminum AlSi12 Mechanical Properties

PARAMETER TRADITIONAL PART 3D PRINTED 3D PRINTED AFTER
PART HEAT TREATMENT
Yield Strength 131 MPa 270 MPa 180 MPa

Ultimate Tensile
290 MPa 480 MPa 240 MPa
Strength
Elongation at
3,5 % 5,5 % 20 %
break
Hardness 80 HB 137 HB 90 HB
Data from:

ALLOYS PROPERTIES & MECHANICAL BEHAVIOUR
Aluminum AlSi12 Process Properties

Nominal stress on a
3D printed part for
different heating
conditions during the
process
Line behavior
influenced by the
Energy Density
Siddique, Shafaqat, et al. "Influence of process-induced microstructure and imperfections on

mechanical properties of AlSi12 processed by selective laser melting." Journal of Materials Processing
Technology 221 (2015): 205-213.

Aluminum AlSi12 Process Comparison

True stress on True
strain for the same
part realized with
different process.
SLM:
•  More Resistance
•  Less Ductility
CAST:
•  Less Resistance
•  More Ductility
Prashanth, K. G., et al. "Microstructure and mechanical properties of Al–12Si produced

by selective laser melting: Effect of heat treatment." materials Science and Engineering:
A 590 (2014): 153-160.

Aluminum AlSi12 Building Comparison
Yield strength for different

inclination angle of between
SLM specimens and
substrate plate.
Yield strength not

influenced by
inclination. Prashanth, K. G., et al. "Microstructure and mechanical properties of Al–12Si
produced by selective laser melting: Effect of heat treatment." Materials
Science and Engineering: A 590 (2014): 153-160.

Aluminum AlSi12 Elongation Test
Stress on Elongation.
Comparison between
the behaviour on
deposition plane and in
the normal direction.
Anisotropy Behaviour
of the Tensile:
•  More Ductility on XY
•  Same Tensile Strength
Kempen, Karolien, et al. "Mechanical properties of AlSi10Mg produced
by selective laser melting." Physics Procedia 39 (2012): 439-446.

Aluminum AlSi12 Post Process Treatment
Room temperature tensile

test curves of the SLM
samples annealed at
different temperatures:
Yield Strength and

Tensile Strength
influenced by annealing
temperature
Yield Strength and

Tensile Strength follow Prashanth, K. G., et al. "Microstructure and mechanical properties of
same trend line ! Al–12Si produced by selective laser melting: Effect of heat
treatment." Materials Science and Engineering: A 590 (2014): 153-160.

ALLOYS PROPERTIES
CoCrMo (Ni-free) •  Method of fabrication: Air atomization

Suitable for
MEDICAL •  Mean particle size (Diameter): 30 µm
APPLICATIONS •  Chemical Composition: Cr: 28 %
Mo: 6 %
Co: Balance
Principal powder
•  Solidification Shrinkage: 0,5 – 1,1%
proprieties
•  Thermal Conductivity: 13 W/mK
•  Thermal Expansion: 12e-6 1/K
•  Melting Point (variable !): ~1500 °C
•  Thermal diffusivity: 3,2 m2/s
Data from:

ALLOYS PROPERTIES
CoCrMo (Ni-free) Mechanical Properties

PART HEAT TREATMENT
Yield Strength 560 MPa ------ 450 MPa

Ultimate Tensile
655 MPa ------ 960 MPa
Strength
Elongation at Not
8% 20 %
break applicable
Hardness 30 HRC 47 HRC 34 HRC
Data from:

CoCrMo (Ni-free) Density Variation
Relative Density variation

for different Ratio of Laser
Power (P) on Laser
Velocity (V)
Printing setting
influences final density
of the Part !!!
Song, Changhui, et al. "Research on rapid manufacturing of CoCrMo

alloy femoral component based on selective laser melting." The
International Journal of Advanced Manufacturing Technology 75.1-4
(2014): 445-453.

CoCrMo (Ni-free) Density Variation
Relative Density variation

for different Ratio of Laser
Power (P) on Laser
Velocity (V)
Printing setting
influences final density
of the Part !!!
Song, Changhui, et al. "Research on rapid manufacturing of CoCrMo

alloy femoral component based on selective laser melting." The
International Journal of Advanced Manufacturing Technology 75.1-4
(2014): 445-453.

CoCrMo (Ni-free) Thermal Behaviour
Stress-Strain curves for

different laser power and
spot diameter:
a)  200W – 0,1 mm

b)  150W – 0,1 mm
c)  100W – 0,1 mm
d)  200W – 0,2 mm
e)  150W – 0,2 mm
f)  100W – 0,2 mm
Laser Power and Spot

Takaichi, Atsushi, et al. "Microstructures and mechanical properties of
diameter not influences to Co–29Cr–6Mo alloy fabricated by selective laser melting process for
much Stress-Strain Curve !!! dental applications." Journal of the mechanical behavior of biomedical
materials 21 (2013): 67-76.

CoCrMo (Ni-free) Fatigue Test

Rotating Beam Fatigue Test
SLM Part shows a good

response to Fatigue test.
From:

ALLOYS PROPERTIES
Ti6Al4V •  Method of fabrication: Air atomization

•  Mean particle size (Diameter): 30 µm
•  Chemical Composition: Ti: 89,7 %
Principal powder Al: 6 %
properties V: 4 %
•  Thermal Conductivity: 7,2 W/mK
•  Latent Heat of fusion: 370 kJ/Kg
•  Thermal Expansion: 8,9e-6 1/K
•  Melting Point : 1880 °C
Data from:

ALLOYS PROPERTIES
Ti6Al4V Mechanical Properties

PART HEAT TREATMENT
Yield Strength 860 MPa 950 MPa Not Performed

Ultimate Tensile
930 MPa 1020 MPa Not Performed
Strength
Elongation at
> 10 % 14 % Not Performed
break
Hardness ----- 33 HRC Not Performed
Data from:

Ti6Al4V Mechanical Behaviour

Stress-Strain curves for
different SLM part and
Reference Material:
SLM:
•  More Resistance
•  Less Ductility
CAST:
•  Less Resistance
•  More Ductility
Vrancken, Bey, et al. "Heat treatment of Ti6Al4V produced by Selective

Laser Melting: Microstructure and mechanical properties." Journal of
Alloys and Compounds 541 (2012): 177-185.

Ti6Al4V Post Process Treatment

SLM REFERENCE
Fracture Strain in function of temperature for SLM (a) and REFERENCE Material(b).
Completely different
Vrancken, Bey, et al. "Heat treatment of Ti6Al4V produced by
response to Heat Selective Laser Melting: Microstructure and mechanical
Treatment !!! properties." Journal of Alloys and Compounds 541 (2012): 177-185.

Ti6Al4V Heat treating Process

SLM
SLM REFERENCE
REFERENCE
Yield Stress in function of temperature for SLM (a) and REFERENCE Material(b).
Completely different
Vrancken, Bey, et al. "Heat treatment of Ti6Al4V produced by
response to Heat Selective Laser Melting: Microstructure and mechanical
Treatment !!! properties." Journal of Alloys and Compounds 541 (2012): 177-185.

Ti6Al4V Fatigue Test

High cycle Fatigue Test
SLM Part shows a good

response to Fatigue test.
From:

Materials for FDM technology: ABS
ABS (ACRYLONITRILE BUTADIENE STYRENE): PROPERTIES
Density: 1.07 g/cm3

Viscosity: 255000 cP
Tensile Modulus: 2300 MPa
Tensile Yield Strength: 43 MPa
Elongation at Break: 15%
Hardness, Rockwell R: 107
Heat Deflection Temperature at 0.46 MPa: 94.9°C
Heat Deflection Temperature at 1.8 MPa: 89.2°C
Source: https://en.wikipedia.org
Glass Transition Temperature: 107°C
Melt Temperature: 217°C
ABS chemical structure Coefficient of Linear Thermal Expansion: 85.8 µm/m-°C
Thermal Conductivity: 0.176 W/m-K
Source: http://www.essentialchemicalindustry.org Source: http://www.matweb.com
Chemical Formula: (C8H8·C6H4·C3H3N)n

Materials for FDM technology: ABS
ABS MECHANICAL PROPERTIES: 3D PRINTED VS TRADITIONAL
TRADITIONAL 3D PRINTED
TENSILE MODULUS 2300 MPa 1800 MPa
YIELD STRENGTH 43 MPa 30 MPa
ELONGATION AT
15% 4%
BREAK
From:
Internal
Study

Molded ABS
MECHANICAL RESPONSE DEPENDS ON STRAIN RATE

Global mechanical response for
various strain rates Vn at the same
room temperature
ABS: elastoplastic behavior, with

ductile failure mode
V1: 2 s-1
V2: 1 s-1
V3: 0.2 s-1
V4: 0.03 s-1
Strain rate dependence V5: 0.01 s-1
V6: 0.001 s-1
Young’s modulus not drastically

changed by strain rate increment Louche, Hervé, et al. "An experimental and modeling study of the
thermomechanical behavior of an ABS polymer structural component during an
impact test." International Journal of Impact Engineering 36.6 (2009): 847-861.
Interesting viscous effects: mechanical Yield stress increases

properties affected by strain increment Plastic flow decreases

Molded ABS
MECHANICAL RESPONSE DEPENDS ON TEMPERATURE
Global mechanical response

for various room temperatures
at a constant strain rate of 0.1
s-1:
Load (N)
•  T1: 40°C
•  T2: 50°C
•  T3: 60°C
Material softening increases

with room temperature
0
0
Displacement (mm)
Temperature increment Young’s modulus not affected

influence on mechanical Yield stress decreases
properties
Louche, Hervé, et al. "An experimental and modeling study of the thermomechanical behavior of an ABS polymer
structural component during an impact test." International Journal of Impact Engineering 36.6 (2009): 847-861.

Molded ABS
STRAIN RATE AND TEMPERATURE INFLUENCE ON STRENGTH
Yield stress vs logarithm of axial

strain rate, for various imposed
room temperatures:
•  T1: 27°C
•  T2: 40°C
•  T3: 50°C
•  T4: 60°C
Strength influenced by strain

rate and temperature
Strain rate increment Material hardening
Temperature increment Material softening
Louche, Hervé, et al. "An experimental and modeling study of the thermomechanical behavior of an ABS polymer
structural component during an impact test." International Journal of Impact Engineering 36.6 (2009): 847-861.

FDM 3D Printed ABS
MECHANICAL PROPERTIES: STRESS – STRAIN CURVE

•  Dog-bone specimen
•  ASTM D638 standard test method
•  Cross-ply layers (±45°) disposition
Source: http://www.mse.mtu.edu Internal study
Dog-bone shape problems
Discretization of radius in Premature failure of

curved zones tested specimen
Stress concentration
Source: Ahn, Sung-Hoon, et al. "Anisotropic material properties of fused

deposition modeling ABS." Rapid prototyping journal 8.4 (2002): 248-257.
FDM 3D Printed ABS
MECHANICAL RESPONSE DEPENDS ON FIBER ORIENTATION

•  Rectangular shape
•  ASTM D3039 standard test method
Dog-bone shape issues •  Unidirectional layer disposition
•  FDM printed objects à Anisotropic mechanical
and failure behavior
Internal study
FDM 3D Printed ABS
MECHANICAL RESPONSE DEPENDS ON FIBER ORIENTATION

Mechanical behavior strongly depends on fiber orientation θ
Internal study
FDM 3D Printed ABS
INFLUENCE OF EXTRUDED FILAMENT WIDTH

AND THICKNESS ON ELASTIC MODULUS
Filament
Configurations Filament Width
Thickness
thickness
1 0,2 0,4
2 0,25 0,5
3 0,3 0,6 width
Elastic modulus at 0° orientation Elastic modulus at 90° orientation
0.3 x 0.6
0.3 x 0.6
0.25 x 0.5 0.25 x 0.5
0.2 x 0.4 0.2 x 0.4
1500 1600 1700 1800 1900 2000 2100 2200

1500 1600 1700 1800 1900 2000 2100 2200
MPa
MPa
Internal study
FDM 3D Printed ABS
INFLUENCE OF EXTRUDED FILAMENT WIDTH

AND THICKNESS ON YIELD STRENGTH
Filament
Configurations Filament Width
Thickness
thickness
1 0,2 0,4
2 0,25 0,5
3 0,3 0,6 width
Uniaxial tensile strength at 0° Uniaxial tensile strength at 90°

orientation orientation
0.3 x 0.6 0.3 x 0.6
0.25 x 0.5 0.25 x 0.5
0.2 x 0.4 0.2 x 0.4
23 24 25 26 14 15 16 17 18
MPa
MPa
Internal study

Materials for FDM technology: PEEK
PEEK (POLY-ETHER ETHER KETONE): PROPERTIES

PEEK, Unreinforced
Density: 1.35 g/cm3

Viscosity: 183000 cP
Source: http://www.plasticsnewseurope.com Heat Deflection Temperature at 0.46 MPa: 195°C
Heat Deflection Temperature at 1.8 MPa: 159°C
Glass Transition Temperature: 145°C
Melt Temperature: 383°C
Coefficient of Linear Thermal Expansion: 50.7 µm/m-°C
Source: http://www.matweb.com
Source: Najeeb, Shariq, et al. "Nanomodified peek

dental implants: Bioactive composites and surface
modification—A review." International journal of
dentistry 2015 (2015.

Molded PEEK
MECHANICAL RESPONSE DEPENDS ON STRAIN RATE
Mechanical behavior of PEEK under

compression at different strain rates,
under the same room temperature
PEEK sensitivity to strain rate and

temperature under tension and
compression is very similar
Strain rate influence on FDM 3D

printed PEEK mechanical properties
Yield stress increases

Strain rate increment
Young’s modulus slightly increases
Garcia-Gonzalez, D., et al. "Mechanical impact behavior of polyether–ether–ketone

(PEEK)." Composite Structures 124 (2015): 88-99.
Molded PEEK
MECHANICAL RESPONSE DEPENDS ON TEMPERATURE
Mechanical behavior of PEEK under

compression at different
temperatures, under the same strain
rate of 0.001 s-1
PEEK sensitivity to strain rate and

temperature under tension and
compression is very similar
Temperature influence on FDM 3D

printed PEEK mechanical properties
Yield stress drastically decreases

Temperature increment
Plastic strain increases
Garcia-Gonzalez, D., et al. "Mechanical impact behavior of polyether–ether–ketone

(PEEK)." Composite Structures 124 (2015): 88-99.
Molded PEEK
PEEK WITH CARBON NANOTUBES: MECHANICAL RESPONSE

Te n s i l e t e s t e x e c u t e d a t r o o m
temperature
Pre-testing annealing: 3h at 200°C
HPEEK-CNT: hydroxilated PEEK

covalently attached to a carbon
nanotubes (CNT) surface
PEEK/HPEEK-CNT(%): hydroxilated
PEEK reinforced with carbon
nanotubes, inserted into a PEEK matrix
Maximum modulus and strength, but

less ductility, for hydroxylated PEEK
grafted carbon nanotubes
Effect of HPEEK-CNT percentage Young’s modulus increases

into a PEEK matrix with respect to
Yield strength increases (up to 25%)
unfilled PEEK
Díez-Pascual, Ana María, et al. "Novel nanocomposites reinforced with hydroxylated poly (ether ether
ketone)-grafted carbon nanotubes." Journal of Materials Chemistry 20.38 (2010): 8247-8256.
Molded PEEK
PEEK WITH CNT: TGA ANALYSIS
TGA curve obtained under nitrogen

atmosphere at a heating rate of 10°C/
min
TGA goal: investigate FDM 3D printed

PEEK degradation temperature as a
function of CNT percentage
CNT percentage increment
Thermal conductivity Heat dissipation FDM 3D printed PEEK

increases much facilitated thermal behavior improved
Molded PEEK
PEEK WITH CNT: ELECTRICAL AND THERMAL CONDUCTIVITY
Electrical and thermal conductivity,

as function of CNT content, of PEEK
nanocomposites tested at room
temperature
Comparison between CNT in PEEK

matrix and HPEEK-CNT in PEEK
matrix
Electrical conductivity:
Thermal conductivity:
CNT content increases both
electrical and thermal
conductivity
Increasing CNT content à difference CNT content more than 0.3 à

in electrical conductivity between thermal conductivity of HPEEK-CNT
CNT in PEEK matrix and HPEEK-CNT in PEEK matrix becomes greater than
in PEEK matrix decreases CNT in PEEK matrix
FDM 3D Printed PEEK
TENSILE PROPERTIES
Comparison between ABS and PEEK,
injection molded and FDM 3D printed
FDM 3D printed PEEK: superior

tensile properties with respect to FDM
3D printed ABS plastic (PEEK tensile
strength 108% higher than ABS)
FDM 3D printed ABS and PEEK:

lower tensile properties than
injection molded
Gaps between filaments weaken

FDM 3D printed specimens
Especially true for PEEK (due to

printing difficulties)
Wu, Wenzheng, et al. "Influence of layer thickness and raster angle on the mechanical properties of 3D-printed
PEEK and a comparative mechanical study between PEEK and ABS." Materials 8.9 (2015): 5834-5846.

FDM 3D Printed PEEK
COMPRESSIVE PROPERTIES
FDM 3D printed PEEK: superior

compressive strength with respect to
FDM 3D printed ABS plastic
ABS and PEEK: compressive modulus
very similar
FDM 3D printed ABS and PEEK:

lower compressive properties
than injection molded
Gaps between filaments weaken

FDM 3D printed specimens
Especially true for PEEK (due to

printing difficulties)

FDM 3D Printed PEEK
BENDING PROPERTIES
FDM 3D printed PEEK: very similar

bending properties with respect to ABS
plastic
FDM 3D printed PEEK: lower

bending properties than
injection molded
Main cause: weak interlayer

bonding in FDM 3D printed
PEEK specimens
FDM 3D printed ABS: similar

bending properties with respect
to injection molded ABS

Materials for FDM technology: Ultem
Ultem (POLYETHERIMIDE - PEI): PROPERTIES

Ultem® 1000 PEI
Density: 1.28 g/cm3
Viscosity: N/A
Source: https://clever3d.de Heat Deflection Temperature at 0.46 MPa: N/A
Heat Deflection Temperature at 1.8 MPa: 204°C
Ultem (PEI) chemical structure Glass Transition Temperature: 210°C
Melt Temperature: N/A
Coefficient of Linear Thermal Expansion: 55.8 µm/m-°C
Source: Zhu, Haitao, et al. "Effect of MIL-53 on phase
inversion and gas separation performance of mixed Source: http://www.matweb.com
matrix hollow fiber membranes." RSC Advances 6.73
(2016): 69124-69134.

FDM 3D Printed Ultem 9085
MECHANICAL PROPERTIES DEPEND ON TEMPERATURE

Compressive tests on FDM 3D
printed cylindrical coupons, at
various temperatures
Four stages in stress-strain curve:

A.  Linear elastic phase
B.  Non-linear behavior, due to
viscous effects
C.  B e g i n n i n g o f b a r r e l i n g ,
coincident with peak load
D.  N o n - u n i f o r m d e f o r m a t i o n ,
barreling more prominent
Temperature increasing:
•  Young’s modulus decreases Temperature weakens
•  Yield stress decreases FDM 3D printed Ultem
•  Ductility decreases
Li, H., et al. "Modeling and characterization of fused deposition modeling tooling for vacuum
assisted resin transfer molding process." Additive Manufacturing 7 (2015): 64-72.
FDM 3D Printed Ultem 9085
THERMOMECHANICAL PROPERTIES
Temperature increasing effect
Decreasing of mechanical properties
Above 320°F
Modulus and strength drastically

lowered
Temperature effect on specific heat
FDM 3D printed Ultem specific heat

increasing with temperature
Rapid increase till 120°F

Li, H., et al. "Modeling and characterization of fused deposition modeling tooling for vacuum
assisted resin transfer molding process." Additive Manufacturing 7 (2015): 64-72.

Synthetized PEI
MECHANICAL PROPERTIES OF PEI WITH DIAMINES

Mechanical response of PEI synthetized
with diamines (chemical components
with two amino groups)
Three types of diamines, varying in

chemical unit length
Mechanical properties Young’s modulus decreases Possible cause: increment

variation as function of of flexibility in the polymer
diamine unit length Tensile strength decreases
chain
Chen, Bor‐Kuan, Yu‐Ting Fang, and Jing‐Ru Cheng. "Synthesis of low dielectric constant
polyetherimide films." Macromolecular symposia. Vol. 242. No. 1. WILEY‐VCH Verlag, 2006.
Materials for SLS technology
PLASTIC POWDERS: SOME EXAMPLES

Sintered part density: 1.33 g/cm3 0.78 g/cm3 1.03 g/cm3
Tensile Modulus: 3720 MPa 5 MPa 1880 MPa
Tensile Yield Strength: 45 MPa 2 MPa 32 MPa
Elongation at Break: 2.8% 200% 20%
Hardness: 73 (Shore D) 59 (Shore A) 73 (Shore D)
Heat Deflection Temperature at 0.46 MPa: 180°C N/A 194°C
Heat Deflection Temperature at 1.8 MPa: 129°C N/A 70°C
Thermal Conductivity: 0.33 W/m-K N/A N/A
Main features: High strength Rubber-like Flame retardant
High stiffness Tear resistant High toughness
Glass filled Easily Low smoke
composite processed toxicity
DuraForm DuraForm® DuraForm®

® ProX® TPU FR 100
GF Plastic Elastomer Plastic
Source: https://www.3dsystems.com
Source: http://www.ec21.com
SLS 3D printed Nylon and PCL
SLS PRINTED LATTICE STRUCTURES: MECHANICAL RESPONSE

A Uniaxial compression test
of Nylon (fig. A),
unsmoothed PCL (fig. B)
and vapor-smoothed PCL
(fig. C) lattice structures
B
SLS printed Nylon: brittle
behavior
SLS printed PCL: ductile
behavior with softening
C
Young’s modulus increases
Effect of vapor-smoothing Yield strength increases
of SLS printed PCL (nearly four times than
unsmoothed PCL)
Kinstlinger, Ian S., et al. "Open-source selective laser sintering (OpenSLS) of nylon and
biocompatible polycaprolactone." PloS one 11.2 (2016): e0147399.

SLS 3D printed polymeric blends
SLS PRINTED POLYMERIC BLENDS: MECHANICAL RESPONSE

Dynamic mechanical analysis of sintered PA12
(polyamide 12), HDPE (high density polyethylene) and
their blends
Elastic modulus, strength and elongation values for

different PA12/HDPE blends:
Highest elastic modulus: 80% PA12 – 20% HDPE

Highest strength: 20% PA12 – 80% HDPE (HDPE
phase provides greater toughness)
Salmoria, G. V., et al. "Selective laser sintering of PA12/HDPE blends: Effect of

components on elastic/plastic behavior." Polymer Testing 27.6 (2008): 654-659.

STORAGE MODULUS AS FUNCTION OF TEMPERATURE

Storage modulus: measure of material stored
energy during a vibration test à material
elastic portion
Temperature increment: from -50°C to

60/70°C: rapid decrease of storage modulus
for every blend and pure component
Effect of blending
Storage moduli of PA12/HDPE blends lower
than those for the pure components
Hypothesis: low
PA12/HDPE 50/50 chemical affinity
blend: lowest b e t w e e n PA 1 2
storage modulus and HDPE phases
CREEP TEST
Creep test: percentage deformation related
to the maximum strain amplitude in the
stress–strain curves
Elastic recovery and plastic deformation
measured after removing applied stress
Pure HDPE à lower elastic recovery than

pure PA12
Effect of blending
PA 1 2 / H D P E PA 1 2 / H D P E
80/20 blend: 20/80 blend:
elastic recovery highest plastic
similar pure deformation
PA12 (32%)

FATIGUE ANALYSIS
Fatigue curves obtained at 50% of maximum
strain amplitude: stress variation as function of
number of cycles
Pure HDPE: greater stress variation than pure

PA12 (up to four times) à fatigue strength of
PA12 greater than HDPE
Effect of blending
PA12/HDPE 80/20 à lower fatigue strength
than pure PA12
PA12/HDPE 20/80 à similar fatigue behavior to
pure HDPE
Low influence of PA12 in blend matrix under

fatigue test conditions
PA12/HDPE 50/50 Low chemical

blend: lowest affinity of 50/50
toughness blend Salmoria, G. V., et al. "Selective laser sintering of PA12/HDPE blends: Effect of
Outline

ü  Applications




Microscopic Simulations
PHYSICAL PROBLEM
ü  Microscopic Simulation is principally adopted for SLM SIMULATION
ü  Aim is to investigate the physical problem at the PARTICLE LEVEL
500 µm
Ferdinando Auricchio
Alberto Cattenone CompMech Group
Compmech Group September, 2017
September 2017
PHYSICAL PROBLEM
ü  Microscopic Simulation is principally adopted for SLM SIMULATION
ü  Aim is to investigate the physical problem at the PARTICLE LEVEL
Ø  Main effects:
•  Heat conduction
•  Absorption
•  Convection
•  Melting/Solidification
•  Wetting
•  Gravity
•  Capillary Forces
Ø  Secondary effects:
•  Radiation
•  Vaporization
•  Marangoni convection At present, no analyses have been
•  Solidification shrinkage carried out including all this effects
September 2017
PHYSICAL PROBLEM
•  Heat conduction and Absorption:
•  Laser modeling:
Gaussian model of
laser heat distribution
•  Fluid dynamics:
With some adjustments
can reproduce wetting
and capillarity
•  General balance equation:
Including convection
and diffusion term
•  Marangoni effect:
Marangoni number evaluates the
ratio between surface tension and
viscous forces
September 2017
STATE OF ART & COMMERCIAL CODES
Ø  Lattice Boltzmann Method (LBM)

ü  Chen, Shiyi, and Gary D. Doolen. "Lattice Boltzmann method for fluid flows." Annual review of
fluid mechanics 30.1 (1998): 329-364.
ü  Körner, Carolin, Elham Attar, and Peter Heinl. "Mesoscopic simulation of selective beam melting
processes." Journal of Materials Processing Technology211.6 (2011): 978-987.
ü  Ammer, Regina, et al. "Simulating fast electron beam
melting with a parallel thermal free surface lattice
Boltzmann method." Computers & Mathematics
with Applications 67.2 (2014): 318-330.
Ø  Particles Method
ü  Zohdi, T. I. "Additive particle deposition and selective laser processing-a computational

manufacturing framework." Computational Mechanics 54.1 (2014): 171-191.
ü  Ganeriwala, Rishi, and Tarek I. Zohdi. "Multiphysics modeling and simulation of selective laser
sintering manufacturing processes." Procedia CIRP 14 (2014): 299-304.
ü  Ganeriwala, Rishi, and Tarek I. Zohdi. "A coupled discrete element-finite difference model of
selective laser sintering." Granular Matter 18.2 (2016): 21.
September 2017

ü  Lattice Boltzmann Method (LBM) is the most common approach
ü  Full integrated codes from Micro- to Macroscopic Simulations are emerging
Principal codes:
ü  Full integrated tool: ü  Full integrated tool

ü  Multiphysics Simulations :
§  Eulerian-Lagrangian §  Microscopic analysis
§  LBM approach §  Multiphysics simulations §  Mesoscopic analysis
§  Fluid dynamics
§  Broad range of length and §  Macroscopic analysis
§  Heat conduction problems time scales
From: http://walberla.net/ From: https://wci.llnl.gov/simulation/ From: http://www.geonx.com/index-3.html
September 2017
LATTICE BOLTZMANN METHOD

Why Lattice Boltzmann Method for SLM ?
Ø  Ideal for evolving domain problems
Ø  Easy to set boundary conditions
Ø  Suitable for complex geometries
Ø  Easy to parallelize
Ø  Stability
Ø  Accuracy from: Open LBM
Principal method features
Ø  Explicit method
Ø  Mechanical-statistical approach
Ø  Easy to recover Navier-Stokes equations
Ø  Easy to recover convection-diffusion
equation
Fields of LBM application Ø  Adaptable for phase change problems
Ø  Fluid dynamics
Ø  Heat conduction
Ø  Geophysics
Ø  Astronomy
Ø  Biomedical Droplets collision
September 2017
LATTICE BOLTZMANN METHOD --- Overview

Ø  Basis of Lattice Boltzmann method
ü  Kinetic approach:
•  Discrete Particles System
•  Particles Streaming and Propagation
ü  Solving CFD problems using:
Boltzmann Equation instead of the Navier-Stokes Equations
Navier-Stokes Equations Boltzmann’s Equation
ü  Fixed Lattice Mesh (VOF based):
ü  Explicit method:
September 2017
BOLTZMANN vs. NAVIER-STOKES EQUATIONS
NEWTON LAWS e
where:
•  : position of the i-th particle
•  : momentum of the i-th particle
•  : force on the i-th particle
HYPOTHESIS:
1.  Ergodic System
MICROSCOPIC LEVEL
LIOUVILLE
EQUATION
e
HYPOTHESIS: con: e
1.  where :
probability to have ‘N’ particles at the •  : derivative of position of the i-th particle
•  : derivative of momentum of the i-th particle
time ‘t’ with velocity and position: •  : Hamiltonian formulation of the system
2.  Consider only the lowest momentum

distributions MICROSCOPIC LEVEL
3.  Assume the MOLECULAR CHAOS
September 2017
BOLTZMANN vs. NAVIER-STOKES EQUATIONS
(LBE)
BOLTZMANN
EQUATION with:
where:
•  LHS : DIFFUSIVE part + CONVECTIVE
•  RHS : COLLISION OPERATOR
HYPOTHESIS:
1.  BGK approximation of the collision MESOSCOPIC LEVEL
term
2.  Chapman-Enskog expansion
3.  Consider finite numbers of momentum
distribution
4.  Integration in the phase space
where:
•  1° EQUATION: continuity equation (mass conservation)
•  2° EQUATION : momentum balance equation
NAVIER-STOKES
EQUATIONS MACROCOPIC LEVEL
September 2017
LATTICE BOLTZMANN METHOD --- Goal
Since under certain conditions it is possible that Boltzmann Equation is an

alternative formulation of the Navier-Stokes Equations, the method goal is:
Ø  To solve NAVIER STOKES EQUATION indirectly by
Solving the BOLTZMANN EQUATION
LATTICE BOLTZMANN METHOD --- Ingredients
What we need to easily solve the Boltzmann Equation?
1.  A manageable form of the COLLISION OPERATOR

2.  To solve the equilibrium BOLTZMANN EQUATION
3.  A Discretization of the continuum form of BOLTZMANN EQUATION
September 2017

1.  COLLISION OPERATOR
This formulation is too complicated
to be used for practical purposes
where :
1.  MOLECULAR CHAOS HYPOTHESIS is assumed:
2.  The superscript “ ‘ “ refers to quantities before collision, while the

others are quantities after the collision
3.  : is the solid part of the domain where the collision happens
We adopt an APPROXIMATE
4.  The subscript “1” and “2” are the two colliding particles
FORMULATION
Equilibrium distribution, following

Adopt the Bhatnagar-Gross-Krook Boltzmann H theorem, has the form of a
(BGK) approximation: Maxwellian Distribution
where : where :
1.  : is the particle probability distribution 1.  : is a time temperature coefficient
2.  is the EQUILIBRIUM DISTRIBUTION 2.  : is the dimension of the problem

3.  is the typical time of the problem


2.  ANALITYCAL SOLUTION OF BOLTZMANN EQUATION
•  Starting from: (neglecting forcing term) we introduce the

collision operator and we obtain:
•  Using the total derivative formulation we can finally write BOLTZMANN EQUATION
as follows:
: RELAXATION TIME
•  Mathematically speaking, this equation as the following characteristics:

Ø  Linear
Ø  Non homogeneous ORDINARY DIFFERENTIAL EQUATION
Ø  Constant coefficient
We can evaluate the ANALITYCAL SOLUTION of

the homogeneous associated ODE

2.  ANALITYCAL SOLUTION OF BOLTZMANN EQUATION
•  Consider now the homogeneous associated ODE:
•  Integrating over time we obtain the following analytical solution of Boltzmann Eq.
•  Performing the First Order Taylor Expansion around = 0 and inserting it in the
analytical solution we obtain the final expression of Boltzmann Equation:
with Equilibrium Distribution written as follows:


3.  DISCRETIZATION
•  Considering all the infinite configuration of velocity the particles can assume in
the domain would make impossible the resolution of the problem
•  Fix a set of possible velocity the particles and rewrite Boltzmann Equation as
follows:
where is the i-th DISCRETE VELOCITY
•  In analogous way the Equilibrium Distribution is discretized as follows:
Where :
1.  : ei is the i-th vector of the space base of the problem
2.  : is the light velocity
3.  : is the Gaussian weight for i-th velocity


3.  DISCRETIZATION --- SCHEMES
Schemes are generally indicated in the following format: DmQn
Where m is the dimension of the problem and n is the number of selected velocities
SCHEME D2Q9 SCHEME D3Q19
VELOCITIES VELOCITIES
W W
H H
E E
I I
G G
H H
T T
S S
LATTICE BOLTZMANN METHOD --- APPLICATION

In order to make easier the application of the method we can SPLIT the
equation as follows:
STREAMING COLLISION
New distribution is
New distribution is
evaluated at the same
evaluated from previous
position at incremented
position at the same time
time

LATTICE BOLTZMANN METHOD --- BOUNDARY CONDITIONS

A very important point, from the physical point of view, is the possibility to
recover the MACROSCOPIC QUANTITIES of the problem:
Ø  DENSITY
Continuum
Discrete
Ø  MOMENTUM
Continuum
Discrete

LATTICE BOLTZMANN METHOD --- BOUNDARY CONDITIONS
•  Examples of the most common BOUNDARY CONDITIONS for fluid

dynamic problems
Ø  BOUNCE BACK
BOUNDARY CONDITIONS
Used to simulate particle collision with
walls or rigid obstacles. Perfectly
BEFORE COLLISION AFTER COLLISION
elastic collisions are considered.
TOP WALL
Ø  PERIODIC BOUNDARY
CONDITIONS
Used to simulate an infinite domain. BOTTOM WALL
In a periodic domain the mass outgoing
from one side must enter from the
opposite side

LATTICE BOLTZMANN METHOD --- BOUNDARY CONDIDITONS
•  Examples of the most common BOUNDARY CONDITIONS for fluid

dynamic problems
Ø  INLET BOUNDARY
CONDITIONS
Used to simulate the input of mass in
a domain
Zou & He model 1997
Ø  OUTLET BOUNDARY
CONDITIONS
Used to simulate the outgoing of
mass in a domain
Zou & He model 1997

LATTICE BOLTZMANN METHOD --- EXTENSIONS

MULTIPLE RELAXATION TIME
Idea: to use different relaxation times for the i-th distributions
Advantages: Disadvantages:
Ø  Numerical stability Ø  High Computational Costs
Ø  Feasible for High Re Numbers Ø  Difficult to choose right parameters
Boltzmann Equation can be re written as follows:
where:
Ø  is the particular collision matrix
Ø  is transformation matrix

MULTIPLE RELAXATION TIME D2Q9 case
•  First, elementary independent moments are evaluated and written as a matrixial
system as follows:
•  There is a linear relationship between the vector of moments and the vector of the
distribution functions:
•  Introduce now the particular collision matrix so we can write the collision step in
the moments space

MULTIPLE RELAXATION TIME D2Q9 case
•  Collision can be written in this form: or in an external
formulation as follows:
•  Finally we can move again to the classical distribution formulation:

LATTICE BOLTZMANN METHOD --- GENERAL WORKFLOW

PARAMETER DEFINITION •  Re: example: 400
•  Ux: example: 1m/s
•  ρ: example: 1000 Kg/m3
•  δt: example: 1s
•  Nx: example: 301
DISTRIBUTION INITIALIZATION •  Ny: example: 301
•  t: 0 initial time •  relaxation parameter
•  Ux : 0 initial X velocity
•  Uy : 0 initial Y velocity •  kinematic viscosity
•  equilibrium distribution
•  Imposing : =
t = t + δt
COLLISION
STREAMING
BOUNDARY CONDITIONS •  Bounce-back on 3 sides

•  Imposed velocity on the top wall
MACROSCOPIC QUANTITIES
EQUILIBRIUM DISTRIBUTION

LATTICE BOLTZMANN METHOD --- BENCHMARKS

LID DRIVEN CAVITY
Ø  Bounce back boundaries are imposed on bottom,
left and right layer
Ø  Imposed velocity on the top layer
Ø  Re = 400
Ø  Grid = 351x351 units
Governing equations:
Navier-Stokes Equations
September 2017

BACKWARD FACING STEP Governing equations:
Ø  Bounce back on top and bottom layer Navier-Stokes Equations

Ø  Imposed velocity on the left wall
Ø  Outlet on right side
Ø  Re = 500
Ø  Grid = 801x81 units
INLET VELOCITY PROFILE
HORIZONTAL ISOLINEES
The two classical vortexes are recovered


PIPE WITH OBSTACLE Governing equations:
Ø  Bounce back on top and bottom layer Navier-Stokes Equations

Ø  Imposed velocity on the left wall
Ø  Outlet on right side
Ø  Re = 600
Ø  Grid = 601x51 units INLET VELOCITY PROFILE
VON KARMAN VORTEXES

LATTICE BOLTZMANN METHOD --- MULTIPHASE APPROACH

SHAN & CHEN Multi-Phase Model (GAS/LIQUID Single Component)
Three additional components are needed in this model:
Ø  Equation of State used to link the DENSITY to the PRESSURE:
•  Van der Walls: REPULSIVE TERM
•  Redlich-Kwong: ATTRACTIVE TERM
•  Carnahan-Starling:
Ø  Forcing model used to impose external forces:
External force is converted into

imposed velocity during
macroscopic quantities evaluation
He & al. model 1998

LATTICE BOLTZMANN METHOD --- MULTIPHASE APPROACH

SHAN & CHEN Multi-Phase Model Model (GAS/LIQUID Single Component)
Three additional components are needed in this model:
Ø  The Adhesion Force between the fluid and the solid walls:
Benzi & al. 1993
Where α is the i-th discrete velocity
1.  G is equal to 1/3 He& Doolen

2.  is the Free Energy Potential Potential 1998
3.  subscript indicates the solid nodes
4.  is a bit function assuming value of 1
for solid nodes and 0 for liquid nodes Where
Introducing now, for example, the Carnahan-Starling EoS, Free Energy Potential can be
rewritten as follows:
Where

LATTICE BOLTZMANN METHOD --- MULTIPHASE WORKFLOW

PARAMETER DEFINITION •  Nx •  Liquid phase density
•  Ny •  Gas phase density
•  Nz •  Equation of state (EOS)
•  Diameter •  EOS Parameters
•  Wall density
DISTRIBUTION INITIALIZATION
•  t: 0 initial time
•  Ux, Uy,Uz : initial velocity
•  Node Identification (Wall vs. Liquid/Gas)
•  equilibrium distribution
•  Imposing : =
t = t + δt
STREAMING
FREE ENERGY POTENTIAL He& Doolen Potential 1998

LATTICE BOLTZMANN METHOD --- MULTIPHASE WORKFLOW
Carnahan-Starling
EQUATION OF STATE EOS
Choice of the parameters α and β (from literature)
ADHESION FORCE
Benzi & al.1993

Here we use the Node Identification !!
EXTERNAL FORCES
He & al. 1998
EQUILIBRIUM DISTRIBUTION External forces are converted into imposed velocity
COLLISION
BOUNDARY CONDITIONS

LATTICE BOLTZMANN METHOD --- EXAMPLES

DROPLET WETTING
Adhesion Force
Free Energy Potential
LBM Data:
•  LX : 51 [lu] (X axis)
•  LY : 51 [lu] (Y axis)
•  LZ : 41 [lu] (Z axis)
•  r: 15 [lu] (droplet radius)
•  R: 1 [lu2/(ts2*tu)] (Gas constant)
•  a: 1 [lu5/(mu*ts2)] (EOS parameter)
•  b: 3
4 [lu /mu] (EOS parameter)
•  c: 0.3773 [---] (EOS parameter)

THERMAL LATTICE BOLTZMANN METHOD

•  Lattice Boltzmann Method is applicable also to Fourier’s Equation in fact this
equation is mathematically similar to Navier-Stokes Equations
•  Convective and diffusive parts are clearly evident
•  Using the same lattice structure a parallel system of distribution for temperature is
set: up
•  Thermal Lattice Boltzmann Model can written as follows:
•  In this case a different relaxation time can be chosen.

•  Analogous decomposition in a Collision and a Streming term can be performed:
COLLISION
STREAMING
THERMAL LATTICE BOLTZMANN METHOD

How to link LBM to TLBM ???
Ø  Temperature as a Forcing Term:
Ø  Forcing Term is included in LBM by the Streaming operator:
•  Workflow is completely similar to the classic LBM workflow

•  Also TEMPERATURE can be recovered as a MACROSCOPIC QUANTITY:
Continuum
Discrete

THERMAL LATTICE BOLTZMANN METHOD --- WORKFLOW

•  Nx
PARAMETER DEFINITION •  Ny
•  ρ: Density
•  g: Gravity
•  Pr: Prandtl Number
LATTICE PARAMETERS •  Ra: Rayleigh Number
•  T_high
•  Time-step: •  T_low
•  Viscosità:
•  Conduttività termica: •  t: 0 initial time
•  Ux Uy: 0 initial velocity
•  Freq. Ril. NS: •  Equilibrium distribution NS:
•  Equilibrium distribution T:
•  Freq. Ril. T: •  =
•  =
t = t + δt
COLLISION
Temperature FORCING TERM

THERMAL LATTICE BOLTZMANN METHOD --- WORKFLOW
STREAMING
Boundary conditions for NS and T

distributions:
•  Bounce back NS
•  Periodic NS BOUNDARY CONDITIONS
•  Adiabatic T
•  Imposed Temperature T x
EQULIBRIUM DISTRIBUTIONS

THERMAL LATTICE BOLTZMANN METHOD --- EXAMPLES

RAYLEIGH – BERNARD CONVECTION
LBM Data:
Governing equations: •  Grid: 162x81 [lu]
•  Prandtl’s number: 1
Navier-Stokes Equations •  Rayleigh’s number: 20000
•  High temperature: 100 °C
Fourier Equation •  Low temperature: 25 °C
•  Bounce back and periodicity for flow
Temperature isolines Velocity isolines

THERMAL LATTICE BOLTZMANN METHOD --- PHASE CHANGE

In order to insert Phase Change, we have to consider the physics of the problem:
IDEA:
•  When the temperature is equal to Phase
Change Temperature, we evaluate Enthalpy
•  When Enthalpy is equal to the Latent Heat,
the particle is considered melted.
•  We introduce the concept of LIQUID FRACTION:

•  Physically it evaluates the ratio between Enthalpy and Latent Heat
where:
SOLID
•  Hs: Solid Enthalpy
TRANSITION •  Lf: Latent Heat
•  cp: Specific heat
LIQUID •  n: Node counter
•  k: Iteration counter


•  Nx
WORKFLOW
PARAMETER DEFINITION •  Ny
•  ρ: Density
•  g: Gravity
•  Pr: Prandtl Number
LATTICE PARAMETER •  Ra: Rayleigh Number
•  T_high
•  Time-step: •  T_low
•  Viscosità:
•  Conduttività termica: •  t: 0 initial time
•  Ux Uy: 0 initial velocity
•  Freq. Ril. NS: •  Equilibrium distribution NS:
•  Equilibrium distribution T:
•  Freq. Ril. T: •  =
•  =
•  LIQUID FRACTION Initialization
t = t + δt
NS COLLISION
Temperature FORCING TERM


WORKFLOW
STREAMING
Boundary conditions for NS and T

distributions:
•  Bounce back NS BOUNDARY CONDITIONS
•  Periodic NS
•  Adiabatic T
•  Imposed Temperature T x
TEMPERATURE EVALUATION
Internal LOOP
k=k+1
TEMPERATURE EVALUATION
ENTHALPY EVALUATION


WORKFLOW
LIQUID FRACTION
T COLLISION
NO TOLERANCE CHECK
CONVERGE ?
YES MACROSCOPIC QUANTITIES
EQUILIBRIUM DITRIBUTIONS


PHASE CHANGE 2D
T
e
Navier-Stokes Equations m
p
Fourier Equation
e
r
a
Liquid fraction t
u
r
e
LBM Data:
•  Grid 151x151 [lu]
•  Gravity: 10-7 [lu/tu]
•  Viscosity 0,011[mu/(tu*lu)]
•  Thermal diffusivity 0,081 [lu2/tu]
•  Latent heat 0,3 [lu2/tu2]
•  Initial temperature 0,664 [Tu]
•  Fusion temperature 1,625 [Tu]
•  Imposed temperature 2 [Tu]
Data in Lattice Units referring to Ti6AlV4


WETTING + TEMPERATURE EVOLUTION
Fourier Equation
Adhesion force
Free energy potential
Droplet wetting coupled with heat

conduction: LBM Data:
ü  High temperature on bottom wall •  LX : 51 [lu] (X axis)
ü  Low temperature on top wall •  LY : 51 [lu] (Y axis)

•  LZ : 41 [lu] (Z axis)
FUTURE DEVELOPMENTS •  r: 15 [lu] (droplet radius)

•  R: 1 [lu2/(ts2*tu)] (Gas constant)
INCLUDE THE PHASE CHANGE IN THE •  a: 1 [lu5/(mu*ts2)] (EOS parameter)

•  b: 3
4 [lu /mu] (EOS parameter)
3D MULTIPHASE WETTING PROBLEM
•  c: 0.3773 [---] (EOS parameter)

LATTICE BOLTZMANN METHOD --- FINAL CONSIDERATIONS
PROBLEMS AND DIFFICULTIES
•  Principal difficulty is to include the phase change in a multiphase Lattice

Boltzmann model
FUTURE DEVELOPMENTS
•  To set up a complete
framework for to simulate
droplets phase change for
a 3D model with FREE
SURFACE technique.
Ammer, Regina, et al. "Simulating fast electron

beam melting with a parallel thermal free surface
lattice Boltzmann method." Computers &
Mathematics with Applications 67.2 (2014):
318-330.

Outline

ü  Applications


ü  Lattice Boltzmann Method
ü  Some benchmarks


Macroscopic Simulations
THE IMPORTANCE OF SIMULATION

To Capture:
Ø  Residual stresses
ü  Inducing stuctural effects in terms of additional stresses
Ø  Plastic deformations
ü  Inducing tolerances and geometry alterations
Ø  Detachment from the build tray

ü  Inducing macroscopic defects (waste of time and material)
Ø  Presence of microscopic defects

ü  Inducing weaker components
Possibility of tuning the additive manufacturing process to

avoid the supramentioned negative effects


ü  F.E.M. approach is the most used for Macroscopic Simulations
Principal codes:
ü  Platform for Non linear modeling: ü  Solutions for engineering: ü  Full integrated tool
§  Material Modeling §  Non-linear coupling §  Microscopic analysis
§  Testing and Prototyping §  Thermo-mechanical problem §  Mesoscopic analysis
§  Design & Manufacture §  Fracture problems §  Macroscopic analysis
From: http://www.mscsoftware.com/product/ From: https://www.3ds.com/it//abaqus/ From: http://www.geonx.com/index-3.html


ADOPTED CODE
ü  Solutions for engineering:

§  Non-linear coupling
§  Thermo-mechanical problem
§  Fracture problems
From: https://www.3ds.com/it//abaqus/

Abaqus Simulation framework
SIMULATION WORKFLOW Carried out with:
Replicator G
CAD STL GCODE
Pre-processing
ü  Geometry definition ü  Elements activation ü  Elements activation
ü  Slicing ü  Extrusion temperature ü  Temperature as

predefined field
ü  Gcode Ri-elaboration ü  Room temperature
ü  Build tray temperature

CAD ü  CAD generated using
•  Computer Aided Design

•  Vector graphics
•  Easy to modify
STL
Standard Sprocket
GCODE
ü  STL conversion using
THERMAL
ANALYSIS
•  Vector graphics
•  Triangular surface
discretization
MECHANICAL •  Most common format
ANALYSIS used in AM simulation

CAD ü  GCODE generated using
STL Slicing Process
GCODE
THERMAL
GCODE containing:
ANALYSIS
•  Nozzle movements
•  Print pattern velocity
MECHANICAL •  Environmental
ANALYSIS machine setup

GCODE is a very file complex, but we need just few informations

CAD to perform analysis
TIME X Y Z
STL
GCODE Home made
Ri-elaborated Gcode
THERMAL code to extract •  Time of bead deposition
ANALYSIS needed •  Position of the bead
informations deposition
MECHANICAL
ANALYSIS
Gcode example Used during Simulation

Thermal analysis performed in

CAD
ü  Sequential elements activation
TIME X Y Z
following Ri-elaborated GCODE
STL ü  Considered effects:
•  Heat conduction
GCODE •  Heat convection
•  Emissivity
THERMAL
ANALYSIS
MECHANICAL
ANALYSIS
TEMPERATURE DISTRIBUTION

Mechanical analysis performed in

CAD
ü  Sequential elements activation
TIME X Y Z
following Ri-elaborated GCODE
STL ü  Temperature results are imported

as predefined field
GCODE
THERMAL
ANALYSIS
MECHANICAL
ANALYSIS
RESIDUAL STRESS DISTRIBUTION

Abaqus Simulation -- FDM
INVESTIGATED PHYSICAL PROBLEM Carried out with:
Geometry:
•  Length: 120 mm
•  Width: 12 mm
•  Height: 0,8 mm
Ø  Goal
To virtually reproduce the real* printing process of the specimen and compare
experimental findings with analysis results
*real: material parameters, printing path, environmental setup
Ø  Specific Goal
Compare the specimen deformations with analysis prediction

SIMULATION PARAMETERS Carried out with:
Mesh:
•  Type: 8-nodes
•  Elements: 144000
•  Nodes: 183305
•  Layers: 4
Simulation Parameters:
•  Build Tray Temperature: 90 °C
•  Ambient Temperature: 45 °C
•  Molten Temperature: 240 °C
•  Convection Film coefficient: 8 W/m2C
•  Emissivity: 0,0
Filament Cross-Section:
•  Width: 0,4 mm
•  Height: 0,2 mm
Material Parameters:
•  Type: ABS
•  Constitutive Model: ELASTIC LINEAR
•  Density: Fixed
•  Convection: Temperature Dependent
•  Specific Heat: Temperature Dependent
•  Expansion: Temperature Dependent
THERMAL ANALYSIS Carried out with:
Ø  Goal Evaluate temperature distribution during printing process
Deposition process
•  Temperature Evolution
Temperature distribution: DETAIL
•  Elements Activation following

GCDOE
•  Heat Convection
•  Heat Conduction

MECHANICAL ANALYSIS Carried out with:
Ø  Goal Evaluate stresses distribution during printing process
Deposition process
•  Residual Stresses Evolution
Residual Stresses Distribution:

DETAIL
•  Elements Activation following

GCDOE
•  Residual stresses following
deposition path

TIME INCREMENT INFLUENCE Carried out with:
ü  Appropriate time increment is needed to correctly evaluate the

temperature of elements activation
Temperature of elements activation

240
Expected activation temperature
220
Temperature [°C]
200
Big time increments
180
160
140
Loose of
accuracy of the
120
0,04 0,1 0,5 1,0
temperature field
2,0
Time Increment [s]
Δt1 Δt2 Δt3 Δt4

TIME INCREMENT INFLUENCE Carried out with:
ü  Appropriate time increment is needed to correctly evaluate the

temperature of elements activation
ü  Different time increment can influence Residual Stresses distribution
Δt1 = 0,04 s
Δt2 = 0,5 s
Δt3 = 1,0 s
Orientation
Δt4 = 2,0 s
ü  Max & Min Stress is NOT INFLUENCED by the time increment

ü  STRESS PATTERN clearly changes with time increment !!!
PROBLEM VALIDATION Carried out with:
To validate the simulation we compared:

SIMULATED DISPLACEMENTS vs EXPERIMENTAL DISPLACEMENTS
ü  EXPERIMENTAL: separation between part and the base arise during the printing process
ü  SIMULATION: separation has been performed by removing the part after the printing process
Corner Displacement
simulation
~ 1,9 mm
~ 1,5 mm
Corner Displacement
experimental

CONCLUSIONS Carried out with:
ü  19% error is detected between experimental results and simulations

ü  This mismatch is caused by physics and model reasons:
•  No adhesion between part and plate is considered
•  Material behavior is ELASTO-PLASTIC (elastic-linear is a
simplification)
•  During printing nozzle can touch the rising filament: this effect is
not considered in the simulation

SOME RESULTS Carried out with:
Shape Optimized BIKE CRANCK Thermal Analysis

Input Data:
•  Material: ABS
•  Melting temperature: 240°
•  Deposition temperature: 120°
•  Ambient temperature: 45°
•  Material type: Orthotropic
•  Thermal analysis: Transient
•  Mechanical analysis: Static
Input Data:
Stresses Analysis
•  Mesh type: 8-nodes
•  Thermal analysis time* 1,30h
•  Stress analysis time* 2h
•  Conductivity: Temp. dependent
•  Emissivity: Fixed
•  Convection coeff.: Fixed
* on 4 core machine
SOME RESULTS SPROCKET Carried out with:
Temperature Distribution Stress Distribution
Displacements Distribution
Retraction effect
from the expected
final shape

Abaqus Simulation -- SLM
INVESTIGATED PROBLEM Carried out with:
Geometry:
•  Length: 120 mm
•  Width: 65 mm
•  Height: 60 mm
Ø  Goal
To virtually reproduce the real* printing process of the specimen and compare
experimental findings with analysis results
*real: material parameters, printing path, environmental setup
Ø  Specific Goal
Compare the specimen deformations with analysis prediction

SIMULATION PARAMETERS Carried out with:
Mesh:
•  Type: 8-node
•  Elements: 196407
•  Nodes: 285601
•  Layers: 20
Laser Parameters:
•  Laser Power 200 W
Material Parameters:
•  Type: Ti6Al4V
•  Constitutive Model: ORTHOTROPIC
•  Convection: Temperature Dependent
•  Specific Heat: Temperature Dependent
•  Expansion: Temperature Dependent
Here Gcode is used in a FAKE MODE to define 2 activation

CAD tables
ü POWDER DEPOSITION
ü  LASER PATH
STL
GCODE
THERMAL
ANALYSIS
MECHANICAL
ANALYSIS

Here Gcode is used in a FAKE MODE to define 2 activation

CAD tables
ü  POWDER DEPOSITION
ü LASER PATH
STL
GCODE
THERMAL
ANALYSIS
MECHANICAL
ANALYSIS

THERMAL ANALYSIS Carried out with:
Deposition process &

Laser scan Path
•  Temperature Evolution
ü  Appropriate time
increment is needed
to correctly evaluate
the temperature of
elements activation

STRESS ANALYSIS Carried out with:
Deposition process &

Laser scan Path
•  Stresses Evolution
ü  Appropriate time
increment is needed
to correctly evaluate
the temperature of
elements activation

CONCLUSIONS Carried out with:
ü  SIMULATION: separation has been performed by removing the part after

the printing process
Vertical displacements
~ 0,03 mm
Horizontal displacements
~ 0,025 mm
SOME RESULTS SQUARE PLATE 400W Carried out with:
SENSITIVITY ANALYSIS
Sensitivity analysis has been carried out using the same:
Ø  MATERIAL
Ø  LASER POWER
Ø  GEOMETRY
We have investigated the influence of the following parameters:
Ø  LASER SPOT diameter

Ø  Analysis TIME INCREMENT
Ø  AMBIENT TEMPERATURE
Ø  LASER PENETRATION depth
On temperature and residual stress results

A MORE ACCURATE SOLUTION Carried out with:
We can have more precise solution in terms of:

ü  Temperature
ü  Stress
With some simple ‘tricks’:
ü  Using finer mesh 2 or 3 elements for a powder layer!!
ü  Using finer time increment
ü  Modeling Laser heat source Gaussian Distribution
COSTS TO PAY
ü  Increasing of Computation Time
ü  Bigger Memory needed
Laser Gaussian Distribution

SOME RESULTS SQUARE PLATE 400W Carried out with:
Thermal Analysis
Mechanical Analysis

SOME RESULTS SQUARE PLATE Carried out with:
Influence of the Laser Spot Radius on the temperature distribution. LASER POWER: 400W
Laser Spot = 0,02 mm
Thermal Analysis
Laser Spot = 0,1 mm

Partially Melted
Laser Spot = 0,1 mm
NOT Melted

Laser Spot = 0,1 mm

Influence of the Time Increment on the temperature distribution. LASER POWER: 400W
Time Increment = 0,04E-3 s
Thermal Analysis

Laser Spot = 0,1 mm

Influence of the Time Increment on the temperature distribution. LASER POWER: 400W

Influence of the Ambient Temperature on the temperature distribution. LASER POWER: 400W
Ambient Temperature = 26°



Influence of the Laser Penetration Depth on the temperature distribution. LASER POWER: 400W
Laser Penetration Depth = 0,05 mm




ADOPTED CODE
ü  Platform for Non linear modeling:

§  Material Modeling
§  Testing and Prototyping
§  Design & Manufacture
From: http://www.mscsoftware.com/product/

is a integrate software able to perform a complete

simulation from Micro- to Macro- scale.
Macroscale approach:
ü  Voxel technique up to millions of elements

ü  Inherent Strain Method
ü  Laser based simulation
ü  Automatic support structure generation From: MSC Digimat
Main benefits:
ü  Extremely fast computational time
ü  Simple test to evaluate Inherent Strain Parameters From: MSC Digimat
From: MSC Digimat

Results:
ü  Temperature distribution
ü  Residual stresses
ü  Part distortions after support remove

is a integrate software able to perform a complete

simulation from Micro- to Macro- scale.
About INHERENT STRAIN METHOD:
Ø  Heating and cooling down introduce strain in the build
Ø  These strains are depending on the scanning direction, material etc.

From: MSC Digimat
Ø  Inherent strain is a generic name given to such nonelastic strains as

thermal expansion, phase transformation, initial strains, plastic strains
and misfit strains
Ø  Inherent strain values are defined for each layer are used to calculate
the residual stresses and thus the distortion of the part From: MSC Digimat
Ø  One approach to get the parameters is to estimate them based on material

properties and process parameters
Ø  Simufact Additive uses the “Cantilever Test” results to get a better

prediction of the inherent strain values From: MSC Digimat

Technique: FDM
Geometry: PLANAR SPRING
Material: ABS
Thermal properties: Temperature Dependent

Constitutive model: Elastic-Orthotropic
Goal:
Compare numerical predictions with experimental evidences in terms of deformed
configuration due to residual stresses induced by the printing process.

SIMULATION RESULTS Carried out with:
WARPAGE RISK EVALUATION
VON MISES STRESS

CRITICAL ZONE !!! DISTRIBUTION
Max 5.5 Mpa

Min 2.8 Mpa
Courtesy of MSC Digimat

VERTICAL DISPLACEMENTS
Max 1.8 mm
SIMULATION RESULTS
Min -1.2 mm
Displacements have been

evaluated with a very precise
Laser Measurement
Courtesy of

Technique: FDM
Geometry: BRIDGE
Material: ABS
Thermal properties: Temperature Dependent

Constitutive model: Elastic-Orthotropic
•  Build Tray Temperature: 120°C
Goal:
Compare numerical predictions with experimental evidences in terms of deformed
configuration due to residual stresses induced by the printing process.

WARPAGE RISK EVALUATION

CRITICAL ZONE !!!
Courtesy of
MSC Digimat
VON MISES STRESS DISTRIBUTION

Max 18.3 Mpa
Min 0.2 Mpa
Courtesy of
MSC Digimat

VERTICAL DISPLACEMENTS
Max 0.4 mm
SIMULATION RESULTS
Min 0,0 mm
Displacements have been

evaluated with a very precise
Laser Measurement
Courtesy of


ADOPTED CODE
ü  Full integrated tool

§  Microscopic analysis
§  Mesoscopic analysis
§  Macroscopic analysis
From: http://www.geonx.com/index-3.html

is a very powerful simulation platform suitable for

different manufacturing processes
To predict:
•  Residual Stresses
•  Residual
Distortions
•  Material quality of
the manufactured
component
From: Geonx


From: Geonx


VIRFAC WORKFLOW
From: Geonx

FDM parts meso-structure
Goal) Investigate how filament orientation

affect the FDM 3D-printed part
mechanical properties
Inner structure at a sub-millimeter scale

resulting from FDM extrusion process

Constitutive law for FDM parts
We use CLT and Tsai-Hill yielding criterion in finite element analysis

to predict FDM parts mechanical behavior. Both models are
calibrated using experimental data
Linear elastic mechanical Plastic mechanical behaviour
behaviour
Classical Lamination Theory (CLT) Tsai-Hill yielding surface
Four elastic constants required: Three admissible stresses required:

•  �↓1 = elastic tensile modulus in •  σ↓1 = maximum tensile stress in
material direction 1 material direction 1
•  �↓2 = elastic tensile modulus in •  σ↓2 = maximum tensile stress in
material direction 2 material direction 2
•  ν↓12 = ratio between strain in •  τ↓12 = maximum shear stress
direction 2 and strain in direction 1 value in plane 12
•  �↓12 = shear modulus in plane 12
Constitutive law for FDM parts
Classical Lamination Theory (CLT) Orthotropic fiber (layer) under
θ=0° E1 , ν12 plane stress
θ=90° E2
θ=45° G12
Elastic moduli for ABS 3D-printed specimen through Classical
Lamination Theory

Yielding criterion for FDM parts
Formulation of suitable yielding criteria, using Tsai-Hill approach
θ=0° sLt Tsai-Hill criterion: failure occurs in an

orthotropic lamina when
θ=90° sTt
θ=45° sLTs
Uniaxial tensile strength according to Tsai – Hill Theory

Validation: experimental data vs FEA
Plate with hole - two cases considered:
Circular hole
Elliptic hole
500 Layer sequence through the thickness
400
Force [N]
300
Experimental data
200 s
Finite element
100
analysis
0
0 0,2 0,4 0,6 0,8 1 1,2
Δl [mm]
FEA elements and constitutive model
Ansys commercial software – two type of elements considered

Solid 186: 3D 20-node layered element Shell 181: 4-node layered element
that exhibits quadratic displacement with six DOF at each node
behavior.
•  Large displacements
•  Plasticity with
isotropic hardening
rule

Validation - Plate with circular hole
Load [N] – displacement [mm] curve

450 450
400 400
350 350
300 hole_0°_A 300 hole_30_A
250 hole_0°_B 250 hole_30_B
200 hole_0°_C 200 hole_30_C
SHELL SHELL
150 150
SOLID SOLID
100 100
50 50
0 0
0 0,25 0,5 0,75 1 1,25 1,5 1,75 0 0,25 0,5 0,75 1 1,25 1,5 1,75
450 450
400 400
350 350
300 hole_60°_A 300
hole_90°_A
250 hole_60°_B 250 hole_90°_B
200 hole_60°_C 200 hole_90°_C
150 SHELL 150 SHELL
SOLID
100 SOLID 100
50 50
0 0
0 0,25 0,5 0,75 1 1,25 1,5 1,75 0 0,25 0,5 0,75 1 1,25 1,5 1,75
Validation - Plate with elliptical hole
Load [N] – displacement [mm] curve

450 450
400 400
350 350
300 ell_0°_A 300 ell_30°_A
250 ell_0°_B 250 ell_30°_B
200 ell_0°_C 200 ell_30°_C
150 SHELL 150 SHELL
SOLID SOLID
100 100
50 50
0 0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2
450 450
400 400
350 350
300 ell_60°_A 300
ell_90°_A
250 ell_60°_B 250 ell_90°_B
200 ell_60°_C 200 ell_90°_C
SHELL SHELL
150 150
SOLID
SOLID
100 100
50 50
0 0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2 0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2
Validation - Plate with elliptical hole
Using 8 elements through the tickness (1 element for each layer ) the
response curve is almost the same
Load-displacement ellipse 60°

450
400
350 ell_60°_A
300
Load [N]
ell_60°_B
250
200 ell_60°_C
150 SOLID1
100 SOLID_8el
50
0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2
Displacement [mm]

Validation
Conclusions:
•  CLT has seems to be accurate enough in predicting mechanical

response in elastic domain using both shell and solid elements.
•  In plastic region the simulated response curve does not accurately

match experimental data. Solid elements are more precise.
•  More accurate or different constitutive models are needed to capture

mechanical response in plastic region

3D printing applications
3D@Unipv
A strategic plan
for
University of Pavia

A Strategic Theme for UniPV

A Strategic Theme for UniPV
Involving Companies & Research Institutes

PROTOLAB 3D Printers
ObJet 260 Connex 3

Ø  PolyJet printer with photopolymer resins;
Ø  Different colors & materials (deformable and transparent);
Ø  Big/small models with fine details (20 µm);
Ø  3D printed models of the abdominal cavity;
FORM 2 Desktop SLA

Ø  Printer with photopolymer resins;
Ø  High precision (100/50/25 µm);
Ø  4 different transparent materials (1 deformable);
Ø  Medium/small (vascular) models with fine details;
3DSystems ProJet 460 Plus

Ø  Binder jetting technology;
Ø  High precision (100 µm) and low production times and costs;
Ø  2.8 milion colors;
Ø  Big/small models with fine details, especially bone structures;

PROTOLAB 3D Printers
3NTR A4v3
Ø  Professional FDM printer;
Ø  Triple bowden extruder (water cooled extruders up to 410°C);
Ø  Hot chamber (up to 70°C);
3NTR A4v2
Ø  Professional FDM printer;
Ø  Dual bowden extruder (water cooled extruders up to 410°C);
LeapFrog Creatr HS
Ø  FDM printer;
Ø  Dual bowden extruder;
Ø  Suitable for relatively high speeds printing of large objects;
LeapFrog Creatr Dual Extruder

Ø  FDM printer;
Ø  Dual direct extruder;
Ø  Suitable for low modulus filaments printing;

Medicine

3D Printing Applications: Medicine
Implants Surgical Planning Medical Training

Medicine Orthosis

How?
A new instrument for surgical planning
MDTC Scan Image Segmentation 3D Virtual Model
Minimally Invasive Surgical Planning 3D Printed Model

Surgery
To Whom?
Our 3D printed models are intended for all medical

specialities. To date, we have several years of
experience in the areas of:
•  Abdominal Surgery (Prof. Pietrabissa)
•  Otolaryngology and Maxillofacial

Surgery (Prof. M. Benazzo, Prof. P. Canzi)
•  Orthopedics (Prof. F. Benazzo)
•  Vascular Surgery (Prof. Marone, Prof. S. Trimarchi,

Prof. P. Quaretti)

Abdominal Surgery
General surgery clinical cases

(Prof. A. Pietrabissa, I.R.C.C.S. San Matteo of Pavia)
Clinical case # Cases
Kidney tumor 11
Spleen tumor 3
Pancreas tumor 3
Spleen (splenectomy) 13
Kidney (living donor procurement) 8
Splenic artery aneurysm 3
•  All of the cases have been planned only relying on 3D printed models
•  Intervenctions have been carried out through laparoscopic or robotic
surgery

Case studies: Kidney & Pancreas
Kidney donor procurement performed through robotic surgery &

pancreas tail tumor: robotic resection.

Vascular Surgery
Vascular clinical cases

(Prof. E. Marone, I.R.C.C.S. San Matteo of Pavia)
(Prof. S. Trimarchi, I.R.C.C.S. San Donato of San Donato)
(Prof. P. Quaretti, I.R.C.C.S. San Matteo of Pavia)
Clinical case # Cases
Aortic arch aneurysm 3

Aortic aneurysm 8
Aortic dissection 7
Endoprosthesis evaluation 8
Double aortic arch 1
Carotid plaques and calcifications 1
Auricola models 2
Cardiac cavity reconstruction 1
Case studies: Clinical evaluation
Pre - operative
Dissection of the aorta Aneurysm of the aortic arch Auricola models
Post - operative

Regenerative Medicine

Biocompa<ble materials for implantable scaffolds and 3D prinNng

Thermoplastic Setting of printing
biocompatible polymers parameters and 3D Stem Cells from Adipose
(PLA & PCL) printing Tissue
Implant Transfer Implant Incubation Implant Seeding

Biocompa<ble materials for 3D prinNng and implantable scaffolds

Produce a copolymeric PLA-PCL patch for esophageal tissue regeneration
In collaboration with: Prof. Bice Conti & Drug Science Department
PCL (polycaprolactone)
PLA (polylactic acid)
Setting of Biological
Thermoplastic Final
printing analysis and
biocompatible esophageal
parameters and mechanical
polymers patches
3D printing characterization

Goal : to find a compromise between biological and mechanical responses
Porosity variations by changing infill

percentage à to find the most suitable porosity
for the esophageal patch.
Infill 90%
Infill 50%
Infill 20%

SEM (Scanning Electron Microscopy) Analysis
Determinate internal
structure and
morphology
3D Printed patch Solvent casted patch

Informations about
morphological
aspects
Infill 20% Infill 50% Infill 90%

GPC Analysis: molecular weight determination
Determinate the
Molecular Weight
(Mw) of polymers
20-25% How polymer Mw

changes after the
extrusion process
Reduction of
20-25% of PLA-
PCL Mw after FDM
Mw = Molecular Weigth 3D printing
Mn = Number average Molecular weigth
PI = Polydispersity Index = Mw/Mn

MTT Analysis: cell viability and proliferation test

Total seeded Cells dropped Study cell
cells from patches proliferation rates
and viability
Analyse cell
viability and
engraftment on 3D
printed patches
30 – 40% of
seeded cells is
retained by
Cells retained patches
by patches

Mechanical Characterization: 3D printed patches stiffness
Study patch
stiffness and
mechanical
properties
Patches
with 20%
infill Reproduce
esophageal tissue
mechanical
features
Target

Bioprinting

Bio-printing
Bioprin<ng for the 3D prinNng of biological Nssues

Cell extraction from
Patient MDTC Scan Virtual Model specific patient
Bioprinted self tissue Incubation: tissue growth Bioprinting

Bio-printing
BioprinNng: State of Art
Common FDM 3D printers allow to … but they don’t allow to print highly
process thermoplastic filaments with viscous materials, such as:
softness > 50[shoreA], as:
  Hydrogels
  Thermoplastic polymers   Silicones
  Biocompatible polymers
  Elastomers So there is a need for a new extrusion
system!
Bioprinting

Bio-printing
BioprinNng: State of Art

Hydrogels Cells Bioink Bioprinting

3D networks made Biological Used in biomedical Layer by layer

of biocompatible components (cells) and tissue deposition of
thermoplastic are encapsulated engineering bioink
polymers in hydrogels applications
Goal
Customize a commercial FDM 3D printer
to extrude hydrogel suitable for bioink
and Bioprinting purpose
FDM Bioprinting

Bio-printing
Bioprin<ng for the 3D prinNng of biological Nssues

To develop a technological and multidisciplinary framework to create
biological tissue by 3D printing
In collaboration with: Experimental Surgery Lab (UniPV) & Ist. C.
Mondino (Pavia)
Bioink Bioplotter (Future) Tissue

Bio-printing
Goal: customize a commercial FDM 3D Printer to extrude hydrogel

suitable for bioink and Bioprinting purpose
Bioplotter: 3NTR FDM printer with hardware modifications
Peristaltic
Hardware modification pump
Elements set-up detection
•  Peristaltic pump
•  Silicon tube
•  Preloaded Syringe
•  Nozzle
•  Adapter Preloaded
syringe
Silicon tube
Software implementation Nozzle

Adapter
MATLAB function
implementation to
generate simple and
monolayer shape and G-
code

Bio-printing
Goal: customize a commercial FDM 3D Printer to extrude hydrogel

suitable for bioink and Bioprinting purpose
Bioprinted ink: Sodium Alginate
2%, 4% and 6% soldium alginate geometries extruded using customized FDM

printer to evaluate:
Resolution
Extrude different size standard
geometries
Ø  Circle
Ø  Square
Ø  Grid
Repeatability
Extrude 5 times standard
geometries
Ø  Circle
Ø  Square
Ø  Grid

New Biomaterials
For years we cooperate with different thermoplastic filaments producers.

Within one of these partnerships, the idea of producing a biocompatible
PLA filament charged with NaCl was born.

PLA filament NaCl Water Porous scaffold

Biocompatible Natural porogen To dissolve NaCl For regenerative
thermoplastic medicine purposes
polymer
Goal: to obtain a scaffold with opportune macro and micro-porosity in order

to achieve optimal cell engraftment and proliferation rates, that is not possible
to obtain with standard materials processed through FDM technology.

Architecture

House 3D-printing
Ø  Same 3D printing technology, but concrete or other structural materials
Companies and research centers are taking on this technology all over the world
Shangai Italy
(Enrico Dini, WASP, ...) Netherlands
(10 3D-printed houses in 24 (canal house printing)
hours)
Ø  Advantages:
ü  less materials and energy used
ü  possibility to use local materials
(e.g. clay in third world countries)
ü  less injures and danger for
workers
ü  low income and emergency
houses in collaboration with Uni Napoli Federico II & Stress
House 3D-printing
Arnhem Station
(Arup)
Modular Architectural
elements purposes Optimization
3D printed brick for the Quake Beijing studio Laboratory for Creative 3D printed curve
Column designed by Emerging Object Design fabricated silkworm-inspired pavilion wall, University of
for the city's 2015 Design Week Southern California
3D Printing of concrete elements
The design concept

3D Printing of concrete elements
The final beam

Micro-waves

Micro-waves - characterization
Characterization
Methodologies
Narrow-band Broad-band
Waveguide Microstrip-lines
Measurement Measurement
Set-up Set-up
In collaboration with M.Bozzi, L.Perregrini, E.Massoni, L.Silvestri

Micro-waves – Narrow band
Narrow-band Analysis of 3D-printed Ninjaflex White Snow Filaments
Standard WR-90
X-band [8.2-12.4] GHz

Micro-waves – Broad band
Broad-band Analysis of 3D-printed Ninjaflex White Snow Filaments
Permittivity vs frequency Loss vs frequency

FDM available materials
Biopolymers
Thermoplastic PCL
Polymers Polycaprolacton
e
Techno Polymers
Natural PLA
Peek
PLA – PCL
copolymer
Ultem
Elastomeric Polymers
Nylon
TPU based
polymers
Carbon
reinforced
nylon TPE based
polymers
Micro-waves - FDM

Micro-waves - FDM
Tuning of Dielectric Properties

3D printing process allows tuning the dielectric characteristics of
substrate materials.
Different printing patterns and

filling factors can be adopted.
•  E. Massoni, L. Silvestri, M. Bozzi, L. Perregrini, G. Alaimo, S. Marconi, and F. Auricchio,

"Characterization of 3D-Printed Dielectric Substrates with Different Infill for Microwave Applications,"
IEEE MTT-S International Microwave Workshop Series on Advanced Materials and Processes for RF
and THz Applications (IMWS-AMP 2016), Chengdu, China, July 20-22, 2016.

Micro-waves - FDM

The dielectric permittivity of 3D printed
materials with partial infill is estimated
by the Maxwell-Garnett equation.
Permittivity vs infill percentage
Samples printed by using TPU filament. Loss vs infill percentage

Micro-waves - FDM
3D-printed Slab SIW

A substrate integrated slab waveguide (SISW) was implemented by
FDM by using TPU filament, by modifying the permittivity in the side
portions of the waveguide.
Standard 3D-printed SIW 3D-printed slab SIW
This approach allows increasing the single mode bandwidth, up to

50% bandwidth enhancement.
Micro-waves - FDM
3D-printed Slab SIW
Standard Slab
SIW SIW
Session WE-2-A “Additive manufacturing: innovative materials and applications” Wednesday, 20

September 2017, 11:00-12:40 Room A “Aula del ‘400”
E. Massoni, L. Silvestri, G. Alaimo, S. Marconi, M. Bozzi, L. Perregrini, and F. Auricchio, “3D-Printed
Substrate Integrated Slab Waveguide for Single-Mode Bandwidth Enhancement,” IEEE Microwave and
Wireless Components Letters, Vol.27, Issue 6, pp. 536-538, June 2017.
Micro-waves - FDM
Non radiative dielectric (NRD)-guide

PRO: high geometrical
freedom of design
Tuning of properties through

infill
CONS: High losses

Micro-waves – Binder Jetting
Reduced
Losses

Micro-waves – Binder Jetting

Reduced losses
Session FR-4-B: Characterization and application of printed materials Friday, 22 September 2017,
16:20-18:00, Room B "Aula di Disegno"
Additive Manufacturing of a Chalk Powder NRD 3-Port Junction via Binder Jetting Technology
E. Massoni, P. F. Espín-López, M. Pasian, M. Bozzi, L. Perregrini, S. Marconi, G. Alaimo, F. Auricchio
Micro-waves
Thermal and Mechanical Properties

Micro-waves – VAT photopolymerization
Is it possible to replace metal guides with plastic

3D printed ones?
Metallic WR-90
3D-printed WR-90

WR-90
3D-printed WR-90 prototype
after the metalization
procedure
3D-printed WR-90 prototype

prior to the metalization
procedure

EXPERIMENTAL
RESULTS
Very good agreement between

metal and 3D-printed metalized
behavior

Architectured Materials

Architectured materials
MATERIALS MATERIALS
BY CHANCE BY DESIGN
Laminates / Composites
Architectured materials: combinations of two or more

materials, or by one material and space (pores), designed
to display attributes not offered by one material alone

4D-printing

4D printing
From 3D printing …
3D PRINTING or ADDITIVE
MANUFACTURING: allows
the creation of 3D objects
with complex shapes
… to 4D printing
4D PRINTING: adding a new

capability (transformation) to
multi-material 3D printing
Thanks for Your Attention
Prof. Ferdinando Auricchio,
Computational Mechanics and Advanced Material Group
University of Pavia

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ADDITIVE MANUFACTURING

Ferdinando Auricchio CompMech Group September, 2017

Ø 3D Printing: The 4th industrial revolution: Additive Manufacturing

Ø 3D Printing: Additive Manufacturing: Materials

Ø 3D Printing: Microscopic Simulations

Ø 3D Printing: Macroscopic Simulations

Ferdinando Auricchio CompMech Group September, 2017

Ø 3D Printing: 3D@UniPV as strategic research theme

Ferdinando Auricchio CompMech Group September, 2017

Ø 3D Printing: The 4th industrial revolution: Additive Manufacturing

Ø 3D Printing: Additive Manufacturing: Materials

Ø 3D Printing: Microscopic Simulations

Ø 3D Printing: Macroscopic Simulations

Ferdinando Auricchio CompMech Group September, 2017

February 2011 April 2012

Ferdinando Auricchio CompMech Group September, 2017

3D printing is very popular

… but it is not a brand new

SLA-1, 3D Systems Corporation

Ferdinando Auricchio CompMech Group September, 2017

Ø Analysis from Wanted Analytics, also published on Forbes (2014)

Ø Whooler Report (2014)

Ø McKinsey Report (2014)

Ferdinando Auricchio CompMech Group September, 2017

Ferdinando Auricchio CompMech Group September, 2017

HOW DOES IT WORK?

Ferdinando Auricchio CompMech Group September, 2017

HOW DOES IT WORK?

Ferdinando Auricchio CompMech Group September, 2017

Virtual Model Slicing Printed Model

Ferdinando Auricchio CompMech Group September, 2017

HOW DOES IT WORK?

Ø Very complex shapes in a single

ü Architectured materials and lattice

Ø No assembling procedures needed

Ø No more need to stock components

Ferdinando Auricchio CompMech Group September, 2017

FDM (Fused Deposition Modeling) uses a thermo-plastic filament, pushed

• Material: thermoplastic filaments • Inexpensive process;

Ferdinando Auricchio CompMech Group September, 2017

Vat – Polymerization or SLA uses a container of liquid photopolymer, that

• Material: photo-polymeric resins; • Quite expensive process;

• Curing: UV laser; • High accuracy and good finish;

• Only one material at a time

Ferdinando Auricchio CompMech Group September, 2017

Material Jetting uses with photopolymers that are dropped

• Material: photo-polymeric resins • Highly expensive;

• Curing: UV lamp; • Multiple materials & colours with high

Ferdinando Auricchio CompMech Group September, 2017

Binder Jetting employs a powder base material and a liquid binder.

• Material: chalk-like or plastic • Fast process and good finish;

Ferdinando Auricchio CompMech Group September, 2017

3D printed ULTEM air vent

Ferdinando Auricchio CompMech Group September, 2017

Implants Surgical Planning

Ferdinando Auricchio CompMech Group September, 2017

Power bed fusion uses a laser source to melt powder on a

Ferdinando Auricchio CompMech Group September, 2017

Ferdinando Auricchio CompMech Group September, 2017

Customized 3D-printed lower jaw

Ferdinando Auricchio CompMech Group September, 2017

Ø Casting, Patterns & Molds

Partially 3D printed watch

Ø  3D Printing: The 4th industrial revolution: Additive Manufacturing

Ø  3D Printing: Additive Manufacturing: Materials

Ø  3D Printing: Microscopic Simulations

Ø  3D Printing: Macroscopic Simulations

Ø  3D Printing: 3D@UniPV as strategic research theme

Ø  3D Printing: The 4th industrial revolution: Additive Manufacturing

Ø  3D Printing: Additive Manufacturing: Materials

Ø  3D Printing: Microscopic Simulations

Ø  3D Printing: Macroscopic Simulations

Ø  Analysis from Wanted Analytics, also published on Forbes (2014)

Ø  Whooler Report (2014)

Ø  McKinsey Report (2014)

Ø  Very complex shapes in a single

ü  Architectured materials and lattice

Ø  No assembling procedures needed

Ø  No more need to stock components

•  Material: thermoplastic filaments •  Inexpensive process;

•  Material: photo-polymeric resins; •  Quite expensive process;

•  Curing: UV laser; •  High accuracy and good finish;

•  Only one material at a time

•  Material: photo-polymeric resins •  Highly expensive;

•  Curing: UV lamp; •  Multiple materials & colours with high

•  Material: chalk-like or plastic •  Fast process and good finish;

Ø  Casting, Patterns & Molds

Ø  3D Printing: The 4th industrial revolution: Additive Manufacturing

Ø  3D Printing: Additive Manufacturing: Materials

Ø  3D Printing: Microscopic Simulations

Ø  3D Printing: Macroscopic Simulations

Aluminum AlSi12 •  Method of fabrication: Air atomization

CoCrMo (Ni-free) •  Method of fabrication: Air atomization

a)  200W – 0,1 mm

Ti6Al4V •  Method of fabrication: Air atomization