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Can the final product (device) be printed on a 3D printer?
This year, using a 3D printer in an apartment, I designed a device (mechanism) for attaching a cable to a cable by wrapping it with wire.
This device is necessary for laying cables through large spans "by air". You can learn more about this mechanism in a series of videos:
SteelWorm (Part 1 - Business Case)
SteelWorm (Part 2 - Design and Features)
SteelWorm (Part 3 - Usage Example)
This article, as you might have guessed from the title, is not about that. Here I want to try to break the stereotype that 3D printed products cannot be reliable and usable by the end user. I will start with common questions that I get asked about my mechanism:
1. Plastic housing? It is fragile, the mechanism will quickly break.
Of course, on average plastic is less durable than metal. Although it is immediately worth noting here that there are a lot of types of plastics and metals! If, for example, we compare ABS plastic and steel grade Ct. 3, then steel will be about 5 times stronger, but 8 times heavier, so the simplest answer to this question is a counter-question:
Do you have an electric screwdriver, grinder or drill? What material is their body made of?
Of course it's plastic! No major manufacturer of tools and household appliances can do without plastic products.
I remind you that there are a lot of types of plastics! Each has its own physical and chemical properties, so for each specific case, the manufacturer chooses his own.
As a rule, 90% of ordinary people are eliminated after this question, but more knowledgeable ones make the following argument:
2. 3D printed plastic is less durable than the injection molded plastic used by most manufacturers!
Indeed, products printed on an FDM 3D printer without additional processing are less durable in one of the directions, unlike injection molded plastic.
I won’t write about 3D printing using the SLS method now, because it is not so common, and practically devoid of this drawback.
The diagram above shows the breaking strength of 3D printed hooks depending on the direction of the layers and the thickness of the printed layers. Test results taken from the CNC Kitchen channel (full video available at: https://youtu.be/fbSQvJJjw2Q)
It can be seen from the diagram that plastic can withstand 3 times less load across the layers.
In scientific terms, a product printed on a 3D printer is an anisotropic material, but this is not a reason to give up on it.
Wood is also an anisotropic material, but to this day houses are built from it, moreover, as part of the elements of load-bearing structures. Therefore, a design engineer who develops a mechanism must perform strength calculations and make sure that there is a sufficient margin of safety in all nodes. You also need to study the features of the material in advance and arrange the layers so that the loads act along them. If this is not possible, then it is necessary to use additional reinforcement with fiberglass or, as in my case, metal tubes.
It is important to note that at temperatures above 50℃, most plastics begin to lose their strength properties drastically; in the sun, black elements can easily heat up to this temperature, the calculations must be rechecked. Thin body elements first of all begin to deform from the effects of temperature, therefore it is better not to make walls thinner than 1.
6 mm, or it is necessary to strengthen them with stiffeners. If the device is used outdoors, attention should be paid to UV resistance and hygroscopicity so that the case does not become brittle under the influence of the sun and the shape of the product does not lead to moisture. In my project, I used PETG plastic, which is devoid of these shortcomings and can be used in the temperature range from -40 to +70℃.
As a result, if all the strength conditions are met and tests are carried out, then nothing prevents the use of products printed on a 3D printer in the final device.
3. If the parts on a 3D printer are strong enough and stable, why do large manufacturers still use casting or stamping?
Economic feasibility! It all depends on the circulation of products. If you need more than 100 cases, then it will be more profitable to make a mold and quickly cast a batch, and if less, then you already need to calculate the economy. Moreover, each product (detail) separately, because The cost of 3D printing, mold making and casting can vary greatly depending on the size and geometry of the part, as well as surface requirements and manufacturing precision.
I won't go into details of economic analysis now, and sometimes Customers don't need it. It is enough to request a quotation for the manufacture of parts in various organizations involved in casting or 3D printing. Good specialists will quickly estimate the cost of the product according to your 3D model and its circulation, all that remains is to choose the most profitable option.
4. Plastic gears wear out quickly and become unusable.
Another stereotype that leads to confusion. As I noted above, any node of the mechanism is subject to calculation: both strength and work resource. In household appliances, you can often find both plastic gears and metal gears, and even a combination of them. For example, in the figure below, the plastic gear of the Bosch MFM-45020 meat grinder.
Naturally, the greater the load on the gear (speed and torque) and the longer the duration of the load, the faster wear will occur. Accordingly, to reduce wear, the gear must be made larger, or rather, the engagement area should be increased, or a more durable material should be used.
The engagement area can be increased by:
- tooth modulus increase;
- gear width increase;
- helical gear application.
Unfortunately, there are no simplified methods for calculating the resource of plastic gears. In my model, I only performed a static strength analysis. When starting, the maximum force of 2.1 kg acts on the teeth for a short time, but even with this load, the safety margin for PETG plastic is 38 times!
Further, 99% of the operating time occurs with a load 12 times less, solely to overcome the friction force in the bearings, while the maximum rotation speed is 480 rpm. Therefore, we can say with confidence that under such loads, the gear train will last a very long time.
Nylon is considered the best material for plastic gear due to its strength and low surface friction.
From personal experience, if the operating temperature is not more than 50℃, then PLA gears perform well: it also has a low surface friction coefficient and high abrasion resistance.
Try to take a file and grind off a part of the PLA part and everything will immediately become clear.
5. Is the 3D printed case waterproof?
There is a standard for protecting the device against water and dust - IP. The case printed on a 3D printer can easily provide the maximum degree of protection of the IP69 standard, i.e. prevent dust from entering the case completely, ensure immersion in water to a depth of more than 1 meter for more than 30 minutes, and also withstand high pressure and high temperature water jets. You can get acquainted with the detailed decoding of the standard at the link: https://ru.wikipedia.org/wiki/IP_(envelope_protection_degree).
In many ways, the result depends on the literacy of the designer. For example, if you print the body of the product in 1 layer, then there can be no talk of any water permeability. And if you print a hollow cube 100x100mm with a 5mm wall thickness of nylon, it will provide IP69, but how do you put useful stuffing inside? Of course, the body must be collapsible! And this is how the parts of the body will be joined and fastened together - the task of the designer, and here I will share my experience:
I usually use screws and bolts to fasten the body parts together.
For reliable fixation, I developed the following rules:
1. Bolts and screws are used only with a flat head, i.e. not with a hidden head! Especially if the hole is made along the layers. Otherwise, when you tighten the hardware, the part may simply crack.
2. The holes for the screws must be made smaller than diameter D to engage the thread with the plastic:
If perpendicular to the layers - 0.89*D;
If parallel to the layers - 0.95*D;
If you do less, the screw will be hard to screw in and the plastic may break.
3. Holes for self-tapping screws must be made smaller than diameter D to engage the thread with plastic:
If perpendicular to layers 0.83*D
If parallel to layers 0.87*D
4. If you need a simple and strong connection of 2 large parts with a tight compression between them, then use the connection on bolts and flanges.
For free play of the bolt, the hole diameter must be increased by 0.
2mm.
5. To ensure that parts fit into each other, I use the following rule:
Fits (gaps) for "Plastic-Plastic" in 3D model:
• Loose (walks easily, dangles) - 0.3 mm;
• Medium (with little effort) - 0.2 mm;
• Thick (forced in) - 0.1 mm.
If the parts are large and the area of their contact is large (>5cm2), then it is desirable to increase the gaps.
"Plastic-metal", the same, just the gaps are 2 times smaller.
Unlike metal, plastic has large tolerances. As can be seen from the diagram above, this is due to the influx of layers. Therefore, in order to achieve the IP65 standard for a prefabricated printed case, it will be necessary to use rubber washers and gaskets, which can also be printed on a 3D printer from elastic filaments.
Conclusion
I hope the article turned out to be equally useful for Contractors and Customers. I tried to dispel the fears of Customers about products printed on a 3D printer, and I also shared my personal experience in designing cases, which means that this article should be useful for beginners in 3D printing.
Dear readers - Customers, I wish high-quality and responsible Contractors, whose products will be manufactured and reliably designed on time, and to Contractors - solvent and adequate Customers who have an idea about the pros and cons of 3D printing!
Printing organs: how ears, skin and noses are made with a 3D printer
- Natalka Pisnya
- BBC Russian Service, USA
: she will help you understand the events.
Photo copyright, Masela family archive
Photo caption,Luc Masela with his parents one month after the artificial bladder transplant. year 2001.
Now 27, Luc Masela is an athlete with a degree in economics, works for a large exhibition company, travels a lot and recently met, in his words, "the most beautiful girl in the world." Both she and most of his current friends were extremely surprised when they learned that 17 years ago he survived a dozen and a half operations.
Luke was born with spina bifida - and although he was able to walk, his bladder was severely damaged. By the age of 10, he almost did not leave hospitals: due to improper functioning of the bladder, fluid began to return to the boy's kidneys, doctors diagnosed an irreversible pathology of the organ.
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Video caption,"3D printed" organs are here
Doctors offered the family two solutions: lifelong dialysis or the creation of a new bladder from a segment of the intestine. This would guarantee Luke several years of medically supervised life and a high risk of developing cancer.
The urologist who was taking care of the boy invited the Masela family to take part in an experimental program: to grow a new bladder from his own cells. Then, in 2001, it sounded like science fiction: only nine people took part in the program before Luke.
Despite this, his family agreed.
"The essence of the operation was reduced to two stages: first, a piece of bladder tissue was taken from me and over the next two months cells were grown in the laboratory in order to grow a new healthy bladder from them," says Luke.
Photo copyright, Masela family archive
Photo caption,Luc Masela, 17 years after his artificial bladder transplant
Next came the transplant, which he said took 16 hours. “I opened my eyes and saw a cut through my entire stomach, tubes of all possible sizes were sticking out of me, except for them - four IVs and a bottle-feeding machine,” he recalls. “I stayed in the hospital for another month, I was prescribed bed rest, after that I stayed at home for another month.
The operation was performed by Dr. Anthony Atala, Pediatric Regenerative Surgeon. In two months, out of a hundred patient cells, scientists created one and a half billion. Further, an engineering structure was created on a collagen frame: the bladder was “sculpted” like a two-layer pie, the core of which dissolved over time, and it started working like an ordinary organ, taking root thanks to Luke’s own cells.
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Luke and Dr. Atala haven't seen each other for 10 years after being discharged from the hospital. Once a dying child became the champion of the school wrestling team and went to college.
The professor took charge of the Wake Forest Institute of Regenerative Medicine in North Carolina in those 10 years, but he never forgot about Luke: his bladder was one of the most challenging and most successful projects in his early practice.
By 2018, Atala won the Christopher Columbus Prize - for "work on a discovery that will have a significant impact on society"; The Times and Scientific American magazines at various times named him "Physician of the Year", he was also recognized as "one of the 50 scientists on the planet who in the next 10 years will change the way we live and work.
"
How to print a new face
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In the mid-2000s, Atala's team turned their attention to an ordinary household 3D printer and wrote special software for it, later specialized machines were created for the laboratory. Now the laboratory "grows" up to 30 different types of cells and organs, as well as cartilage and bones.
One of the team's latest achievements is ears and noses grown outside the human body.
The main customer and sponsor of Atala's developments is the US Department of Defense, and many of the patients are military victims of military operations.
It works like this: first, a CT scan of the ear or nose is done. One of Atala's assistants, Joshua Corpus, jokes that at this stage, people often ask to "improve" the shape of the nose if they thought theirs was too wide or hooked, and the ears if they were too wide.
After that, a special computer code is written, and the printing of the basis of the organs begins.
For this, a bioabsorbable polymer, polycaprolactam, is used. At the same time flexible and durable, in the human body it disintegrates within four years.
After printing, the layers of polycaprolactam resemble lace; after transplantation, their place will be taken by a person's own cartilage tissue in a few years.
Polycaprolactam is then saturated with a gel created from the patient's cells, cooled to -18 degrees Celsius - so the cells, according to scientists, are not damaged, they are "alive and happy."
Image caption,Printing a test kidney sample on a bioprinter
In order for the polymer and gel structure to take shape and become something more durable, ultraviolet is used in the laboratory - it does not damage cells.
The future implant is printed for 4-5 hours, then it is finally formed and inserted under the epidermis.
Skin can also be grown: children affected by the fires were the first to participate in the early trials of Atala - after the "printing" of the skin, scientists observed the patients for several more years. The new skin did not crack, did not burst, and grew with the children.
The most difficult job, according to the scientist, is facial wounds: it’s not enough just to stretch the skin, you need to accurately calculate the geometry, align swelling, bone structure, and understand how a person will look after that.
In addition to the skin and ears, Atala can "print" the bones of the jaws, grow blood vessels and cells of some organs - the liver, kidneys, lungs.
This technology is especially appreciated by oncologists: on the basis of patient cells, it is possible to recreate the body's response to various types of chemotherapy and observe the reaction to a particular type of treatment in the laboratory, and not on a living person.
But the liver, kidneys, lungs and heart are still being tested. Atala says he raised them in miniature, but creating organs from various tissues to real size requires a lot of additional research.
But, according to him, cells were grown in the laboratory and a vagina was created for a girl who was born several years ago with a congenital deformity of the genital organs - several years have passed since the transplant.
Image caption,Bioprinted polycaprolactam ear implant base
Atala smiles and adds that his team is also working on a working penis. This research has been going on for several years, and the most troublesome for scientists is the complex structure of tissues and the specific sensitivity of the organ itself.
Among others, Igor Vasyutin, a Russian post-graduate student of the First Moscow State Medical University (MGMU) named after Sechenov, is working on this under laboratory conditions. He is a cell biologist, Atala's right hand.
Vasyutin has been in the USA for about a year - he came on an exchange. He is ready to talk about the behavior of stem cells for hours, but becomes less verbose when it comes to Russian science.
Vasyutin's alma mater has not reached mass regeneration of human organs and is still training on animals: local scientists "printed" a mouse thyroid gland on a 3D printer.
However, they are also involved in the study of human organs. According to the head of the Institute of Regenerative Medicine at MSMU Denis Butnar, several years ago the Institute recreated a special engineering design of the buccal mucosa. She functioned perfectly for the first six months, but subsequently had to undergo a second operation.
Image caption,Ultraviolet test sample of an ear implant
In Russia, however, over the past few years, the Italian surgeon-transplantologist Paolo Macchiarini, the man who was the first in history to perform a synthetic organ transplantation operation - a plastic tube that replaced the patient trachea.
- Paolo Macchiarini: the rise and fall of the famous surgeon
However, seven of his nine patients died, and the breathing tubes implanted in the remaining two subsequently had to be replaced with donor ones.
Several criminal cases were brought against him, including on charges of pressure on patients and fraud, and the leading doctors of the world called Macchiarini's operations "ethical Chernobyl."
Will printed organs replace donors?
At the zenith of his career, Macchiarini argued that a new perspective is opening up for humanity: you can "print" any human organ on a printer, create an engineering structure from it, enriched with the patient's stem cells, and get the perfect prosthesis.
Be that as it may, complex human organs - the liver, kidneys, heart, lungs - have not yet been able to grow any regenerative surgeon.
Bioprinting of the so-called simple organs, however, is already available in the USA, Sweden, Spain and Israel - at the level of clinical trials and special programs.
The American government is actively investing in such programs - in addition to Wake Forest, cooperating with the Pentagon, the Massachusetts Institute of Technology also receives significant amounts to recreate the work of the liver, heart and lungs.
Image caption,Skin application test on a burnt wound
According to Professor Jorge Raquela, a gastroenterologist at the Mayo Clinic Research Center, "Bioprinting is one of the most exciting branches of modern medicine, it has huge potential, and the turning point of the most important discoveries is already close."
Meanwhile, Pete Basillier, head of R&D at analytics firm Gartner, insists technology is advancing much faster than understanding the implications of 3D printing.
Such developments, according to Basilière, even created with the best of intentions, give rise to a set of questions: what will happen when "improved" organs are created, the basis of which will not only be human cells - will they have "superpowers"? Will a regulatory body be created to monitor their production? Who will check the quality of these organs?
More than 150,000 Americans are on the waiting list for organ transplants every year, according to a report from the US National Library of Medicine.
Donor organs will receive only 18% of them; every day in the United States, without waiting for a transplant, 25 people die. Organ transplants and subsequent rehabilitation cost insurance companies and patients $300 billion in 2012 alone.
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Most Americans are potential donors: upon obtaining a driver's license, they voluntarily answer the question of whether they agree to donate their organs in the event of a car accident or other dangerous incident . In case of consent, a small "heart" and the word "donor" appear in the corner of the document.
Professor Atala's driver's license is like that - despite all his achievements and faith in the press, he is ready to share his with others.
