#foam materials

New Post has been published on https://www.aneddoticamagazine.com/fabricating-objects-expanding-and-changing-shape-with-heat/

Fabricating Objects Expanding and Changing Shape with Heat

ExpandFab is a fabrication method for creating expanding objects using foam materials. The printed objects change their shape and volume, which is advantageous for reducing the printing time and transportation costs.

For the fabrication of expanding objects, we investigated a basic principle of the expansion rate and developed materials by mixing a foam powder and elastic adhesive. Furthermore, we developed a fabrication method using the foam materials. A user can design expanded objects using our design software and sets the expansion areas on the surface. The software simulates and exports the 3d model into a three-dimensional (3D) printer. The 3D printer prints the expandable object by curing with ultraviolet light. Finally, the user heats the printed objects, and the objects expand to maximum approximately 2.7 times of their original size. ExpandFab allows users to prototype products that expand and morph into various shapes, such as objects changing from one shape to various shapes, and functional prototype with electronic components.

In this paper, we describe the basic principle of this technique, implementation of the software and hardware, application examples, limitations and discussions, and future works.

New Post has been published on https://www.aneddoticamagazine.com/fabricating-objects-expanding-and-changing-shape-with-heat/

Fabricating Objects Expanding and Changing Shape with Heat

ExpandFab is a fabrication method for creating expanding objects using foam materials. The printed objects change their shape and volume, which is advantageous for reducing the printing time and transportation costs.

For the fabrication of expanding objects, we investigated a basic principle of the expansion rate and developed materials by mixing a foam powder and elastic adhesive. Furthermore, we developed a fabrication method using the foam materials. A user can design expanded objects using our design software and sets the expansion areas on the surface. The software simulates and exports the 3d model into a three-dimensional (3D) printer. The 3D printer prints the expandable object by curing with ultraviolet light. Finally, the user heats the printed objects, and the objects expand to maximum approximately 2.7 times of their original size. ExpandFab allows users to prototype products that expand and morph into various shapes, such as objects changing from one shape to various shapes, and functional prototype with electronic components.

In this paper, we describe the basic principle of this technique, implementation of the software and hardware, application examples, limitations and discussions, and future works.

New Post has been published on https://www.aneddoticamagazine.com/fabricating-objects-expanding-and-changing-shape-with-heat/

Fabricating Objects Expanding and Changing Shape with Heat

ExpandFab is a fabrication method for creating expanding objects using foam materials. The printed objects change their shape and volume, which is advantageous for reducing the printing time and transportation costs.

For the fabrication of expanding objects, we investigated a basic principle of the expansion rate and developed materials by mixing a foam powder and elastic adhesive. Furthermore, we developed a fabrication method using the foam materials. A user can design expanded objects using our design software and sets the expansion areas on the surface. The software simulates and exports the 3d model into a three-dimensional (3D) printer. The 3D printer prints the expandable object by curing with ultraviolet light. Finally, the user heats the printed objects, and the objects expand to maximum approximately 2.7 times of their original size. ExpandFab allows users to prototype products that expand and morph into various shapes, such as objects changing from one shape to various shapes, and functional prototype with electronic components.

In this paper, we describe the basic principle of this technique, implementation of the software and hardware, application examples, limitations and discussions, and future works.

3D-printed foam outperforms traditional cellular materials

Image: Microstructures of two different foam materials. Left, a traditional open-cell stochastic foam, and right, a 3D-printed foam with a face-centered tetragonal lattice structure.

Material scientists from Lawrence Livermore National Laboratory (LLNL), USA, have discovered that 3D-printed foam works better than standard cellular materials, outperforming them in durability and long-term mechanical performance.

Traditionally standard cellular foams are created in a process that creates highly non-uniform structure with significant dispersion in size, shape, thickness and organisation. To improve on current methods, the scientists from LLNL demonstrated the feasibility of 3D printing of uniform foam structures through a direct-ink-write process. However, they believed it was important to understand the long-term mechanical stability of such printed materials before they can be commercialised, especially in applications such as support cushions, where the foam material is subject to long-term mechanical stresses. 

To test this, the scientists put a series of foams through an advanced ageing process subjecting them to a series of stress tests to replicate the stress condition, mechanical response and permanent structural deformation each sample would experience for a year or longer. They used a method called time-temperature-superposition to quantitatively model the evolution of such properties under ambient conditions. The results demonstrated that 3D-printed materials age better and retain their mechanical and structural characteristics compared to their traditional counterparts.

The team then imaged the 3D micro-structure of each foam sample with X-ray computed tomography, and performed finite-element analysis of the stress distribution within each micro-structure. They found that there is a much wider variation in local stresses within the stochastic foam, with points of extreme stress significantly higher than the maximum stress points within the 3D-printed foam.

Amitesh Maiti, lead author commented, ‘3D printing of foams offers tremendous flexibility in creating programmable architectures, customisable shapes and tunable mechanical response. Our work strongly indicates superior long-term stability and performance of the printed material, there is no reason not to consider replacing traditional foam with appropriately designed 3D-printed foam in specific future applications.’

The research appears in the April edition of Scientific Reports. To read the full study, visit bit.ly/21gxZT5

In other news:

·      Volvo to test self-drive cars in UK

·      Nanowire battery shows potential for lifelong use

·      Glass packaging industry calls for mandatory separate collections

·      Car makers prepare #steel back-up plans amid Tata fear

To find out more on materials science, packaging and engineering news, visit our website IOM3 or follow us on Twitter @MaterialsWorld for regular news updates. You can also now get access to our content any time, anywhere via our app. For more information, visit app.materialsworld.org

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