Reconstruction of Broken Parts Utilizing 3D Printing

Muntaka Musa; Ahmad Baharuddin Abdullah

doi:10.58915/aset.v5i1.3210

Authors

Muntaka Musa Universiti Sains Malaysia
Ahmad Baharuddin Abdullah Universiti Sains Malaysia

DOI:

https://doi.org/10.58915/aset.v5i1.3210

Keywords:

Extend part life cycle, Digital model, Reconstruction, Dimensional accuracy

Abstract

One of the applications of 3D printing, like fused deposition modelling (FDM), is for the reconstruction of broken parts or features. The reconstruction of a part or feature proceeds mainly to extend its life cycle. The most common challenges in the reconstruction include achieving acceptable dimensional accuracy and good surface roughness. In this project, the focus is to observe the effect of process parameters, like layer heights to the dimensional accuracy and surface finish. Four layer heights (0.1, 0.2, 0.3, and 0.4 mm) are used, and other parameters such as wall thickness, printing temperature, hot-bed temperature, print speed, and infill density are set to 0.8 mm, 2200C, 50.0 0C, 80.0 mm/s, and 20%, respectively. This study begins by generating a digital model of the broken features, followed by modification of the G-code program, and ends with a repair operation by printing the broken features on the real part. A plastic gear was used as a case study. These results showed high dimensional accuracy, with deviations of 10 to 1 microns at a layer height of 0.2 mm. Similarly, acceptable surface roughness was observed at a layer height of 0.2 mm, with an average and root-mean-square roughness of Ra-21.2392µm and Rq-25.6308µm, respectively. The developed method shows a very promising approach to be applied in various applications.

References

[1] Chadha, C., Patterson, A. E., Allison, J. T., James, K. A., Jasiuk, I. M. Repair of high-value plastic components using fused deposition modeling. Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium – An Additive Manufacturing Conference (2019) pp.1732–1755.

[2] Alhafeiti, H., Ziout, A., Alsaadiya, A., Alhebsi, A. Re-designing a gear using reverse engineering. Proceedings of the International Conference on Industrial Engineering and Operations Management, vol 2019 (2019) pp.1883–1892.

[3] Zong, Y., et al. A high-efficiency and high-precision automatic 3d scanning system for industrial parts based on a scanning path planning algorithm. Optics and Lasers in Engineering, vol 158 (2022) pp.107176.

[4] Song, L., Jiang, Q., Zhong, Z., Dai, F., Wang, G., Wang, X. Technical path of model reconstruction and shear wear analysis for natural joint based on 3d scanning technology. vol 188 (2022) pp.110584.

[5] Karganroudi, S. S., Aminzadeh, A., Ibrahim, H., Rahmatabadi, D., Francois, V., Cuillière, J. C. A novel automated approach for geometric reconstruction and flexible remanufacturing of spur gears using point cloud mapping analysis. Comput Aided Des Appl, vol 20, issue 1 (2023) pp.92–108.

[6] Parry, E. J., Best, J. M., Banks, C. E. Three-dimensional (3D) scanning and additive manufacturing (am) allows the fabrication of customized crutch grips. Mater Today Commun, vol 25 (2020) pp.2352-4928.

[7] Guo, X., Shi, Z., Yu, B., Zhao, B., Li, K., Sun, Y. 3d measurement of gears based on a line structured light sensor. Precis Eng, vol 61 (2020) pp.160–169.

[8] Rajaguru, K., Karthikeyan, T., Vijayan, V. Additive manufacturing-state of art. Mater Today Proc, vol 21 (2020) pp.628–633.

[9] Rabiu, A., Bawa, K. 3d printing technology as a means of self-reliance for technical education graduates in Kaduna, Nigeria. Northwest Journal of Educational Studies, vol 5, issue 1 (2022) pp.371304745.

[10] Mahamood, R. M., Jen, T. C., Akinlabi, S. A., Hassan, S., Akinlabi, E. T. Introduction to additive manufacturing technologies. Advances in Additive Manufacturing: Artificial Intelligence, Nature-Inspired, and Biomanufacturing (2023) pp.3-13.

[11] Shinde, A. A., Patil, R. D., Dandekar, A. R., Dhawale, N. M. 3d printing technology, material used for printing and its applications. International Journal of Scientific & Engineering Research, vol 11, issue 7 (2020) pp.105-108.

[12] Gojzewski, H., et al. Layer-by-layer printing of photopolymers in 3d: How weak is the interface? ACS Applied Materials & Interfaces, vol 12, issue 7 (2020) pp.8908-8914.

[13] Chadha, C., James, K., Jasiuk, I. M., Patterson, A. E. Extending the operating life of thermoplastic components via on-demand patching and repair using fused filament fabrication. Journal of Manufacturing and Materials Processing (JMPP), vol 6, issue 5 (2022) pp.103.

[14] Lakkala, P., Munnangi, S. R., Bandari, S., Repka, M. Additive manufacturing technologies with emphasis on stereolithography 3d printing in pharmaceutical and medical applications: A review. International Journal of Pharmaceutics: X, vol 5 (2023) pp.100159.

[15] Aprilia, A., Wu, N., Zhou, W. Repair and restoration of engineering components by laser directed energy deposition. Materials Today: Proceedings, vol 70 (2022) pp.206-211.

[16] Joo, H., Cho, S. Comparative studies on polyurethane composites filled with polyaniline and graphene for dlp-type 3d printing. Polymers (Basel), vol 12, issue 1 (2020) pp.67.

[17] Qian, J., et al. High-resolution real-time 360° 3d model reconstruction of a handheld object with fringe projection profilometry. Optics Letters, vol 44, issue 23 (2019) pp.5751-5754.

[18] NextEngine. Nextengine 3D scanner ultra HD. (2018).

[19] Qian, J., Feng, S., Tao, T., Hu, Y. High-resolution real-time 360∘ 3d surface defect inspection with fringe projection profilometry. Optics and Lasers in Engineering, vol 137 (2021) pp.106382.

[20] Hong, T. C., Ma’aram, A., Boon, O. J. High-accuracy cloud point scanning method based on a dual laser 3d scanner for head profile. Malaysian Journal of Fundamental and Applied Sciences, vol 18, issue 5 (2022) pp.558-569.

[21] Rašovic, N., Obad, M. A framework for optimal quality of parts in reverse engineering. Proceedings of the 27th DAAAM International Symposium, vol 27 (2016) pp.0328-0337.

[22] Autodesk Inc. To convert a mesh object to a 3d solid | Autocad 2016. (2026).

[23] Liu, Y., Zhao, Y., Liu, M., Sun, X. Parameterized high-precision finite element modelling method of 3d helical gears with contact zone refinement. Shock and Vibration, vol 2019, issue 1 (2019) pp.17.

[24] Palka, D. Use of reverse engineering and additive printing in the reconstruction of gears. Multidisciplinary Aspects of Production Engineering. MAPE 2020, vol 3, issue 1 (2020) pp.274–284.

[25] Nyuysoni, S. B., Mutua, J. M., Home, P. Mathematical model development and 3d printing of cylindrically shaped biofilm carrier media from recycled plastic waste for wastewater treatment. Journal of Environmental Protection, vol 13, issue 1 (2022) pp.15-31.

[26] Almudhaf, T. I. Design of automotive engine components by CAD software: Autodesk Inventor and SolidWorks. Journal of Engineering Research and Application, vol 10, issue 1 (2020) pp.25–31.

[27] Abdallah, R., et al. The use of SolidWorks in the evaluation of wind turbines in Palestine. Energy Nexus, vol 7 (2022) pp.100135.

[28] Kulczyk, T., et al. Computed tomography versus optical scanning: A comparison of different methods of 3d data acquisition for tooth replication. Biomed Research International, vol 2019, issue 1 (2019) pp.1-7.

[29] Muhammad, A. R., Sakura, R. R., Dwilaksana, D., Sumarji, Trifiananto, M. Layer height, temperature nozzle, infill geometry and printing speed effect on accuracy 3d printing PETG. R.E.M. (Rekayasa Energi Manufaktur) Jurnal, vol 7, issue 2 (2022) pp.81–88.

[30] Ultimaker. Ultimaker cura. (2023).

[31] Morettini, G., Palmieri, M., Capponi, L., Landi, L. Comprehensive characterization of mechanical and physical properties of PLA structures printed by FFF-3D-printing process in different directions. Progress Additive Manufacturing, vol 7, issue 5 (2022) pp.1111–1122.

[32] Kim, S. 3d model data generation and conversion for 3d printers. Journal of ELECTRONIC MATERIALS, vol 44, issue 3 (2015) pp.815–822.

[33] John, P., Komma, V. R., Bhore, S. P. Development of MATLAB code for tool path data extraction from the G-code of the fused filament fabrication (FFF) parts. Engineering Research Express, vol 5, issue 2 (2023) pp.025018.

[34] Maturkar, P. Design and development of 3d printer. International Journal of Scientific Research in Engineering and Management, vol 7, issue 4 (2023).

[35] Aljazara, A., et al. Quality of 3d printed objects using fused deposition modeling (FDM) technology in terms of dimensional accuracy. International Journal of Online and Biomedical Engineering (iJOE), vol 19, issue 14 (2023) pp.45-62.

[36] Biglete, E. R., et al. Dimensional accuracy evaluation of 3d - printed parts using a 3d scanning surface metrology technique. 2020 11th IEEE Control and System Graduate Research Colloquium ICSGRC (2020) pp.185–190.

[37] Tümer, E. H., Erbil, H. Y. Extrusion-based 3d printing applications of PLA composites: A review. Coatings, vol 11, issue 4 (2021) pp.390.

[38] Suhr, B., Skipper, W. A., Lewis, R., Six, K. Sanded wheel–rail contacts: Experiments on sand crushing behaviour. Lubricants, vol 11, issue 2 (2023) pp.38.

[39] Rezanezhad, S., Azadi, M. Impact of 3D-printed PLA coatings on the mechanical and adhesion properties of AM60 magnesium alloys. Composites Part C: Open Access, vol 12 (2023) pp.100415.

[40] Schneider, L., Gärtner, H. Additive manufacturing for lab applications in environmental sciences: Pushing the boundaries of rapid prototyping. Dendrochronologia (Verona), vol 76 (2022) pp.126015.

[41] Bolat, Ç., Ergene, B. An investigation on dimensional accuracy of 3d printed PLA, PET-G, and ABS samples with different layer heights. Çukurova Üniversitesi Mühendislik Fakültesi Dergisi, vol 37, issue 2 (2022) pp.449–458.

[42] Chiffre, L. D., et al. Accurate measurements in a production environment using dynamic length metrology (DLM). Procedia CIRP, vol 75 (2018) pp.343-348.

[43] Zisopol, D. G., Portoaca, A. I., Tanase, M. Dimensional accuracy of 3d printed dog-bone tensile samples: A case study. Engineering, Technology and Applied Science Research, vol 13, issue 4 (2023) pp.11400-11405.

[44] He, B., Ding, S., Shi, Z. A comparison between profile and areal surface roughness parameters. Metrology and Measurement Systems, vol 28, issue 3 (2021) pp.413–438.