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Large Scale Vat-Photopolymerization of Investment Casting Master Patterns: The Total Solution

The material properties and processing of investment casting patterns manufactured using conventional wax injection Molding and those manufactured by vat photopolymerization can be substantially different in terms of thermal expansion and mechanical properties, which can generate problems with dimen...

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Autores principales: Sameni, Farzaneh, Ozkan, Basar, Karmel, Sarah, Engstrøm, Daniel S., Sabet, Ehsan
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9656478/
https://www.ncbi.nlm.nih.gov/pubmed/36365587
http://dx.doi.org/10.3390/polym14214593
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author Sameni, Farzaneh
Ozkan, Basar
Karmel, Sarah
Engstrøm, Daniel S.
Sabet, Ehsan
author_facet Sameni, Farzaneh
Ozkan, Basar
Karmel, Sarah
Engstrøm, Daniel S.
Sabet, Ehsan
author_sort Sameni, Farzaneh
collection PubMed
description The material properties and processing of investment casting patterns manufactured using conventional wax injection Molding and those manufactured by vat photopolymerization can be substantially different in terms of thermal expansion and mechanical properties, which can generate problems with dimensional accuracy and stability before and during ceramic shelling and shell failures during the burn-out of the 3D printed casting patterns. In this paper and for the first time, the monofunctional Acryloyl morpholine monomer was used for 3D printing of casting patterns, due to its thermoplastic-like behavior, e.g., softening by heat. However, the hydrophilic behavior of this polymer led to an incorporation of up to 60 wt% of Hexanediol diacrylate, to control the water absorption of the network, which to some extent, compromised the softening feature of Acryloyl morpholine. Addition of a powdered wax filler resulted in a delayed thermal decomposition of the polymer network, however, it helped to reduce the thermal expansion of the parts. The dimensional accuracy and stability of the wax-filled formulation indicated an excellent dimensional tolerance of less than ±130 µm. Finally, the 3D printed patterns successfully went through a burn out process with no damages to the ceramic shell.
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spelling pubmed-96564782022-11-15 Large Scale Vat-Photopolymerization of Investment Casting Master Patterns: The Total Solution Sameni, Farzaneh Ozkan, Basar Karmel, Sarah Engstrøm, Daniel S. Sabet, Ehsan Polymers (Basel) Article The material properties and processing of investment casting patterns manufactured using conventional wax injection Molding and those manufactured by vat photopolymerization can be substantially different in terms of thermal expansion and mechanical properties, which can generate problems with dimensional accuracy and stability before and during ceramic shelling and shell failures during the burn-out of the 3D printed casting patterns. In this paper and for the first time, the monofunctional Acryloyl morpholine monomer was used for 3D printing of casting patterns, due to its thermoplastic-like behavior, e.g., softening by heat. However, the hydrophilic behavior of this polymer led to an incorporation of up to 60 wt% of Hexanediol diacrylate, to control the water absorption of the network, which to some extent, compromised the softening feature of Acryloyl morpholine. Addition of a powdered wax filler resulted in a delayed thermal decomposition of the polymer network, however, it helped to reduce the thermal expansion of the parts. The dimensional accuracy and stability of the wax-filled formulation indicated an excellent dimensional tolerance of less than ±130 µm. Finally, the 3D printed patterns successfully went through a burn out process with no damages to the ceramic shell. MDPI 2022-10-29 /pmc/articles/PMC9656478/ /pubmed/36365587 http://dx.doi.org/10.3390/polym14214593 Text en © 2022 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Sameni, Farzaneh
Ozkan, Basar
Karmel, Sarah
Engstrøm, Daniel S.
Sabet, Ehsan
Large Scale Vat-Photopolymerization of Investment Casting Master Patterns: The Total Solution
title Large Scale Vat-Photopolymerization of Investment Casting Master Patterns: The Total Solution
title_full Large Scale Vat-Photopolymerization of Investment Casting Master Patterns: The Total Solution
title_fullStr Large Scale Vat-Photopolymerization of Investment Casting Master Patterns: The Total Solution
title_full_unstemmed Large Scale Vat-Photopolymerization of Investment Casting Master Patterns: The Total Solution
title_short Large Scale Vat-Photopolymerization of Investment Casting Master Patterns: The Total Solution
title_sort large scale vat-photopolymerization of investment casting master patterns: the total solution
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9656478/
https://www.ncbi.nlm.nih.gov/pubmed/36365587
http://dx.doi.org/10.3390/polym14214593
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