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3D printing reinvent foam, and it’s better

by • April 26, 2016 • No Comments

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Foam is a part of day to day life and has remained largely unchanged for a long time. Now a study by the Lawrence Livermore National Laboratory () has announced which a new, 3D printed design is only advantageous than the foam we understand and love.

Traditional production methods mean which the foam is in fact highly irregular and the structure shows a huge variance in the dimensions, shape and thickness of each cell. Scientists at the LLNL have now created a 3D printed alternative which they claim is excellent in approximately each way. It lasts longer, offers excellent impact protection and can be tailored to each specific use.

Equite foam is different types of

Of course a few foam is thrown away approximately immediately, while the cushions of a sofa take a beating each and each day for the lifespan of the furniture. Foam has been with us for so long which we take it for granted, actually yet we have the likes of memory foam which offers a advantageous night’s sleep. To come up with a consume replacement is no tiny feat and LLNL has had to embark on a huge programme of research and development.

This involved accelerated aging, via elevated temperatures and the same constant compression. Traditional foam was utilized as a benchmark and the different types of solutions were tested for their response to stress, their mechanical response and the amount of permanent deformation over the course of a one-year period. The results were and so extrapolated via time-temperature superposition techniques which showed how the cushions may fare in the real world over a much longer period.

3D printed foam is only advantageous

LLNL announced which the 3D printed foam retained its shape, as well as its internal structure and mechanical properties, far advantageous than the traditional alternative. In case you are considering this was one long love letter to the 3D printing industry, the lab announced simultaneously which 3D printed rubber in the foam fared far worse than the old-school version.

The team carried out a series of Computed Tomography (CT) scans to analyse the stress distribution in each structure. It discovered the lack of uniformity in the traditional stochastic foam intended which the forces weren’t distributed actuallyly. The foam yet did its job, for the many part, but the forces were concentrated at weak points in the foam’s structure. This led to long-term injure.

In contrast, the 3D printed form was totally uniform, the forces were spread actuallyly and mechanically this is a much sounder solution which should last longer and perform advantageous.

“3D printing of foams offers immense flexibility in creating programmable architectures, customizable shapes and tunable mechanical response,” said the lead author of the study, Amitesh Maiti. “Now which our work strongly indicates excellent long-term stability and performance of the printed material, there is no reason not to consider replacing traditional foam with appropriately created 3D-printed foam in specific next applications.”

Foams, in addition understandn as cellular solids, are significant to a vast number of industries and figure in all of our lives on a continuous basis. The car, aerospace, marine, biomedical, defence and electronics industry all rely on foam. Equite industry uses it, at a few point, so an improved design can touch all of our lives.

Mass production may be a problem

There is only one issue which the study does not address and which is how 3D printing can effectively store up with the demand for foam at an effective price-point. Mass making on this level is only beyond the industry right now and foam’s quite ubiquity is what can manufacture it an almighty challenge to take on.

We may see 3D printed foam surface in high-end furniture, mattresses and other specialist functions which demand the absolute most materials. Beyond which, we may have to wait for the weight production capabilities of 3D printing to catch up with this particular curve.

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