In this thesis work, the design of a 3D printer for the production of denture frameworks using an innovative composite printing technology called Continuous Fiber Manufacturing is considered as a case study. Continuous Fiber Manufacturing (CFM) is an additive manufacturing technology developed by Italian startup Moi Composites that is based on the deposition and subsequent polymerization of a long fiber (glass, carbon, Kevlar, basalt...) impregnated with a thermosetting resin following smart trajectories calculated through FEA to achieve the highest strength-to-weight ratio. Since 2014, CFM is used to conduct experimental research and 3D print parts for testing in various fields (marine, automotive, prosthetic, hydraulic...). In 2020, Moi Composites has identified the dental sector as a new business opportunity, developing a system for 3D printing frameworks to reinforce dental prosthesis and launching the Hi-Fiber project. After a couple of years of development and with a view to rapid expansion, the design of a new 3D printer optimized for the production of Hi-Fiber structures has been considered. My thesis work takes this brief, deepens and develops it starting from a research on the state-of-the-art of computer-aided manufacturing technologies for the dental sector and an analysis of current Hi-Fiber 3D printers to understand their most relevant limits and potentials. Different concepts are developed trying to follow a Design Engineering approach, so to create a design conscious of the mechanical, electronic and control systems required by such a machine, the different interfaces with the users, and finally aesthetics, to represent the Hi-Fiber brand and its values in the market. I entirely developed the mechanical layout of this 3D printer, proposed a possible electronic design, and left the code writing to control the actuations of the various sub-systems to the Moi Composites Software team. To test the validity of the solutions addressed in this thesis, my journey ended with the creation of a prototype, identifying limits and problems to be solved in future developments.
In questa tesi viene affrontata la progettazione di una stampante 3D per la produzione di strutture di rinforzo per protesi dentali che impiega un’innovativa tecnologia di stampa di materiali compositi brevettata come Continuous Fiber Manufacturing. Continuous Fiber Manufacturing (CFM) è una tecnologia di fabbricazione additiva sviluppata dalla startup italiana Moi Composites che si basa sulla deposizione e successiva polimerizzazione di un materiale composito a fibra lunga (vetro, carbonio, kevlar, basalto...) seguendo traiettorie smart calcolate tramite analisi FEM per ottenere il massimo rapporto resistenza-peso del pezzo prodotto. Dal 2014, la tecnologia CFM viene impiegata da Moi Composites per condurre progetti di Ricerca & Sviluppo e stampare in 3D parti per svariati settori (nautico, automobilistico, protesico, idraulico...). Nel 2020, Moi Composites ha individuato nel settore dentale una nuova opportunità di business, sviluppando un sistema per la stampa 3D di strutture per protesi dentali e lanciando il progetto Hi-Fiber. Dopo un paio di anni di sviluppo e in vista di una rapida espansione, è stato preso in considerazione lo sviluppo di una nuova stampante 3D ottimizzata per la produzione di strutture Hi-Fiber. Il mio lavoro di tesi parte da questo brief e lo approfondisce attraverso una ricerca sullo stato dell'arte delle tecnologie di digital manufacturing per il settore dentale e da un'analisi delle stampanti 3D di Hi-Fiber, per comprenderne principali limiti e potenzialità. Sono stati quindi sviluppati diversi concept seguendo un approccio di Design Engineering, cercando di sviluppare una macchina funzionale dal punto di vista meccanico, elettronico, di controllo e di interazione con gli operatori senza trascurare la forma, che rappresenta il marchio Hi-Fiber e i suoi valori sul mercato. Ho quindi interamente sviluppato il layout meccanico di questa macchina, proposto un possibile schema di cablaggio e lasciato la scrittura del codice per controllare le attuazioni dei vari sottosistemi al team Software di Moi Composites. Per testare la validità delle soluzioni descritte in questa tesi, il mio percorso progettuale si è concluso con la realizzazione di un prototipo, del quale sono state individuate potenzialità e limiti.
hi-print design and engineering of a dual extruder 3d printer for dental frameworks in continuous glass fiber composites
Ferrari, Davide
2021/2022
Abstract
In this thesis work, the design of a 3D printer for the production of denture frameworks using an innovative composite printing technology called Continuous Fiber Manufacturing is considered as a case study. Continuous Fiber Manufacturing (CFM) is an additive manufacturing technology developed by Italian startup Moi Composites that is based on the deposition and subsequent polymerization of a long fiber (glass, carbon, Kevlar, basalt...) impregnated with a thermosetting resin following smart trajectories calculated through FEA to achieve the highest strength-to-weight ratio. Since 2014, CFM is used to conduct experimental research and 3D print parts for testing in various fields (marine, automotive, prosthetic, hydraulic...). In 2020, Moi Composites has identified the dental sector as a new business opportunity, developing a system for 3D printing frameworks to reinforce dental prosthesis and launching the Hi-Fiber project. After a couple of years of development and with a view to rapid expansion, the design of a new 3D printer optimized for the production of Hi-Fiber structures has been considered. My thesis work takes this brief, deepens and develops it starting from a research on the state-of-the-art of computer-aided manufacturing technologies for the dental sector and an analysis of current Hi-Fiber 3D printers to understand their most relevant limits and potentials. Different concepts are developed trying to follow a Design Engineering approach, so to create a design conscious of the mechanical, electronic and control systems required by such a machine, the different interfaces with the users, and finally aesthetics, to represent the Hi-Fiber brand and its values in the market. I entirely developed the mechanical layout of this 3D printer, proposed a possible electronic design, and left the code writing to control the actuations of the various sub-systems to the Moi Composites Software team. To test the validity of the solutions addressed in this thesis, my journey ended with the creation of a prototype, identifying limits and problems to be solved in future developments.File | Dimensione | Formato | |
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2023_05_Ferrari_01.pdf
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Descrizione: Testo della tesi
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45.59 MB
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2023_05_Ferrari_02.pdf
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Descrizione: Tavole tecniche
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17.37 MB
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17.37 MB | Adobe PDF | Visualizza/Apri |
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https://hdl.handle.net/10589/206975