@article{ZentgrafNuetzelMuehlbaueretal., author = {Zentgraf, Jan and N{\"u}tzel, Florian and M{\"u}hlbauer, Nico and Schultheiss, Ulrich and Grad, Marius and Schratzenstaller, Thomas}, title = {Surface Treatment of Additively Manufactured Polyetheretherketone (PEEK) by Centrifugal Disc Finishing Process: Identification of the Key Parameters}, series = {Polymers}, volume = {16}, journal = {Polymers}, publisher = {MDPI}, address = {Basel}, issn = {2073-4360}, doi = {10.3390/polym16162348}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-73959}, abstract = {Polyetheretherketone is a promising material for implants due to its good mechanical properties and excellent biocompatibility. Its accessibility to a wide range of applications is facilitated by the ability to process it with an easy-to-use manufacturing process such as fused filament fabrication. The elimination of disadvantages associated with the manufacturing process, such as a poor surface quality, is a main challenge to deal with. As part of the mass finishing process, centrifugal disc finishing has demonstrated good results in surface optimization, making it a promising candidate for the post-processing of additively manufactured parts. The objective of this study is to identify the key parameters of the centrifugal disc finishing process on the waviness of additively manufactured PEEK specimens, which has not been investigated previously. The waviness of the specimen was investigated by means of confocal laser scanning microscopy (CLSM), while weight loss was additionally tracked. Six parameters were investigated: type, amount and speed of media, use of compound, amount of water and time. Type of media, time and speed were found to significantly influence waviness reduction and weight loss. Surface electron microscopy images demonstrated the additional effects of deburring and corner rounding. Results on previous studies with specimens made of metal showed similar results. Further investigation is required to optimize waviness reduction and polish parts in a second post-processing step.}, language = {en} } @article{KuettnerRathsFischeretal., author = {Kuettner, Andreas and Raths, Max and Fischer, Samuel and Laumer, Tobias}, title = {Heat staking of polymer parts generated by fused layer modeling}, series = {The International Journal of Advanced Manufacturing Technology}, volume = {128}, journal = {The International Journal of Advanced Manufacturing Technology}, publisher = {Springer Nature}, doi = {10.1007/s00170-023-11850-y}, pages = {547 -- 562}, abstract = {Heat staking is a joining technology by which thermoplastic pins are formed by force and temperature to create a form- and force-fitting connection between components. This paper examines the characteristics of 3D printed pins in comparison to conventionally turned pins for heat staking applications. The 3D printed pins are created using fused layer modeling, with variations in horizontal and vertical building directions, as well as different layer thicknesses. The study investigates the impact of significant factors on the heat staking process, including the forming force and temperature. Tensile tests, micrographs, and micro-CT measurements were conducted to determine the properties of the heat-staked joints. Additionally, a stage plan was developed to enhance the understanding of the forming process of both printed and conventionally turned materials. The findings suggest that, under specific process parameters, 3D printed pins exhibit comparable strength to conventionally manufactured pins. The research also demonstrates that the anisotropy resulting from the layer-by-layer construction of the pins significantly influences the strength of the connection. Furthermore, the study reveals that 3D printed pins exhibit good forming accuracy during the heat staking process, and the cavities formed during printing can be substantially reduced.}, language = {en} } @inproceedings{Laumer, author = {Laumer, Tobias}, title = {The influence of micro-sized structures on the compound strength of multi-material components built by Simultaneous Laser Beam Melting of Polymers}, series = {Proceedings of LPM2016 - the 17th International Symposium on Laser Precision Microfabrication, 2016, Xian, China}, booktitle = {Proceedings of LPM2016 - the 17th International Symposium on Laser Precision Microfabrication, 2016, Xian, China}, abstract = {Simultaneous laser beam melting (SLBM) allows the direct realization of multi-material components consisting of different polymer materials by a single Additive Manufacturing (AM) process. To achieve a high compound strength between different materials by adhesive bonding, a common boundary zone based on diffusion of the macromolecules is necessary and thus, both materials needs to be compatible regarding their specific adhesion compatibility. However, by SLBM also incompatible polymers can be processed to multi-material parts. If two incompatible polymers are processed, a positive locking between the different materials is necessary to achieve a connection between the materials. The positive locking results of a random mixture process of the different powder materials during the powder deposition process by a two chamber recoater system, which leads to the forming of undercuts of one material in the other during the melting and recrystallization. In this paper, thermoplastic elastomer (TPE) and polypropylene (PP) powders, which are incompatible, are processed to multi-material specimens. By qualifying basic material properties, their influence on the process and especially on the forming of undercuts in the boundary zone is analyzed. To also allow the analysis of the influence of both material and process parameters on the resulting part properties, tensile test specimens are built and their tensile strength is determined. Additionally, cross sections of the boundary zone are prepared and analyzed by microscope images.}, language = {en} } @article{PremChavezVegaBoehmetal., author = {Prem, Nina and Chavez Vega, Jhohan Harvey and B{\"o}hm, Valter and Sindersberger, Dirk and Monkman, Gareth J. and Zimmermann, Klaus}, title = {Properties of Polydimethylsiloxane and Magnetoactive Polymers with Electroconductive Particles}, series = {Macromolecular Chemistry and Physics}, volume = {219}, journal = {Macromolecular Chemistry and Physics}, number = {18}, publisher = {Wiley}, doi = {10.1002/macp.201800222}, abstract = {Magnetoactive polymers are intelligent materials whose mechanical and electrical characteristics are reversibly influenced by external magnetic stimuli. They consist of a highly elastic polymer matrix in which magnetically soft and/or hard particles are distributed by means of special fabrication processes. In addition to ferromagnetic particles such as carbonyl iron powder, electrically conductive particles may also be embedded into the polymer matrix. After characterizing a range of compounds, this work focuses on a comparison of the electrical properties and the suitability of various materials for applications, with particular emphasis on integration into 3D and 6D printing processes. 6D printing is based on the selective positioning of particles in a 3D polymer matrix with a further three degrees of freedom for a graduated dispersion of the particles at certain points and in desired directions. The aim is therefore to ensure that the polymers containing electroconductive tracks have the best possible electrical properties, that is, low resistivity but are still capable of being printed. A comparison between the traditionally used compounds containing graphite and carbon black is made for the first time. This latter is found to be greatly superior both in terms of electrical conductivity and applicability to 3D printing and 6D printing.}, language = {en} } @article{SindersbergerDiermeierPremetal., author = {Sindersberger, Dirk and Diermeier, Andreas and Prem, Nina and Monkman, Gareth J.}, title = {Printing of hybrid magneto active polymers with 6 degrees of freedom}, series = {Materials today communications}, volume = {15}, journal = {Materials today communications}, number = {June}, publisher = {Elsevier}, doi = {10.1016/j.mtcomm.2018.02.032}, pages = {269 -- 274}, abstract = {3D printing techniques offer a versatile method for the fabrication and structuring of magnetoactive polymer (MAP) components and devices for research prototype development. MAP materials enjoy an advantage in that the particulate content may be manipulated by external magnetic fields during the forming and curing processes. Controlled particle diffusion within the polymer matrix, by means of external fields applied during the printing process, influences a further three spatial dimensions. This permits control of the spatial particle concentration and makes free displacement of particle accumulations possible during the crosslinking phase. Particles which are susceptible to electric or magnetic fields can thereby be shifted into regions previously free of particles. The additional 3 graded dispersion axes effectively results in what can be described as 6 degrees of freedom (6DOF) printing. Electrically conductive polymers combined with non-conductive areas, provide an additional benefit for the production of complex hybrid structures. This may be augmented by the combination of magnetically active thermoplastics as inelastic structural components together with mechanically deformable elastomers. The combination of all fabrication methods in one hybrid printing process makes the production of complex sensor and actuator systems in one manufacturing sequence possible. This far exceeds the capabilities of conventional casting and machining operations and opens new possibilities for the fabrication of soft material elements.}, language = {en} }