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Design for additive manufacturing of customized cast with porous shell structures

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Abstract

Additive manufacturing (AM) recently has been changing from conventional Rapid prototyping (RP) to direct fabrication of functional parts. As a direct fabrication method, a promising application of AM is to make personalized or customized parts; biomedical applications customized to human’s bodies can provide improved functionalities for an example. In this study, a customized plastic cast is developed to replace traditional plaster casts. For customization, its basic shape is defined out of three-dimensional (3d) scan data of a human arm. This cast is designed to have a number of holes for lighter weight and better ventilation, and to be printed using a Material extrusion (ME) type 3d printer that uses thermoplastic polymer filaments. Finite element (FE) analyses are then performed to evaluate the structural safety and stiffness of the printed cast with porosity. Considering that the structural safety and stiffness are degenerated due to the porous structure, design reinforcements are suggested to improve the bending stiffness of the porous cast. FE analyses are then performed with variations of design parameters of the reinforcement structures, from which we obtain the best design candidate that provides higher specific stiffness than the conventional solid structure. A porous-customized cast with lighter weight and better ventilation can thereby be developed successfully.

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Authors and Affiliations

  1. Department of Mechanical System Design Engineering, Seoul National University Science and Technology, Seoul, 01811, Korea

    Yeong-Eun Lim, Na-Hyun Kim, Hye-Jin Choi & Keun Park

Authors
  1. Yeong-Eun Lim
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  2. Na-Hyun Kim
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  3. Hye-Jin Choi
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  4. Keun Park
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Corresponding author

Correspondence to Keun Park.

Additional information

Recommended by Editor Haedo Jeong

Yeong-Eun Lim is a master candidate in the Department of Mechanical Design and Robot Engineering at Seoul National University of Science and Technology, Korea. She received a B.S. from Seoul National University of Science and Technology in 2015. Her current research includes design and analysis of lightweight structure for additive manufacturing.

Keun Park received his B.S. and M.S. degrees in Precision Engineering and Mechatronics from KAIST, Korea, in 1992 and 1994, respectively. He then received his Ph.D. degree in Mechanical Engineering from KAIST in 1999. Dr. Park is currently a Professor of the Department of Mechanical System Design Engineering at Seoul National University of Science and Technology, Korea. His research interests include numerical analysis of material forming processes, micro-fabrication, and additive manufacturing.

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Lim, YE., Kim, NH., Choi, HJ. et al. Design for additive manufacturing of customized cast with porous shell structures. J Mech Sci Technol 31, 5477–5483 (2017). https://doi.org/10.1007/s12206-017-1042-z

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  • DOI: https://doi.org/10.1007/s12206-017-1042-z

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