Nicolas Tardif

Nowadays, Fused Filament Fabrication (FFF) 3D printing offers promising opportunities for the customized manufacturing of ankle–foot orthoses (AFOs) targeted towards rehabilitation purposes. Polypropylene (PP) represents an ideal candidate in orthotic applications due to its light weight and superior mechanical properties, offering an excellent balance between flexibility, chemical resistance, biocompatibility, and long-term durability. However, Additive Manufacturing (AM) of AFOs based on PP remains a major challenge due to its limited bed adhesion and high shrinkage, especially for making large parts such as AFOs. The primary innovation of the present study lies in the optimization of FFF 3D printing parameters for the fabrication of functional, patient-specific orthoses using PP, a material still underutilized in the AM of medical devices. Firstly, a thorough thermomechanical characterization was conducted, allowing the implementation of a (thermo-)elastic material model for the used PP filament. Thereafter, a Taguchi design of experiments (DOE) was established to study the influence of several printing parameters (extrusion temperature, printing speed, layer thickness, infill density, infill pattern, and part orientation) on the mechanical properties of 3D-printed specimens. Three-point bending tests were conducted to evaluate the strength and stiffness of the samples, while additional tensile tests were performed on the 3D-printed orthoses using a home-made innovative device to validate the optimal configurations. The results showed that the maximum flexural modulus of 3D-printed specimens was achieved when the printing speed was around 50 mm/s. The most significant parameter for mechanical performance and reduction in printing time was shown to be infill density, contributing 73.2% to maximum stress and 75.2% to Interlaminar Shear Strength (ILSS). Finally, the applicability of the finite element method (FEM) to simulate the FFF process-induced deflections, part distortion (warpage), and residual stresses in 3D-printed orthoses was investigated using a numerical simulation tool (Digimat-AM^®). The combination of Taguchi DOE with Digimat-AM for polypropylene AFOs highlighted that the 90° orientation appeared to be the most suitable configuration, as it minimizes deformation and von Mises stress, ensuring improved quality and robustness of the printed orthoses. The findings from this study contribute by providing a reliable method for printing PP parts with improved mechanical performance, thereby opening new opportunities for its use in medical-grade additive manufacturing.

This work is focused on elasto-visco-plastic (EVP) buckling of thick shell structures. In particular we are interested in predicting accurately the buckling risk of stainless steel components of nuclear fast sodium reactor working under high pressure and at high temperature (around 500°C). We follow a modelling/experimental approach to solve such problem. The set-up of relevant

Bending moment–curvature relations (M-χ) are useful in many beam modelling approaches. It allows describing in a simple way the mechanical behaviour at the cross-section scale and can be used to model continuous beams as single degree of freedom systems dedicated to perform stochastic analysis. This paper focused on tree mechanical charaterisation and presents an identification method for obtaining bending moment–curvature relationships up to failure from Digital Image Correlation (DIC) and experimental three points bending tests. Due to wood intrinsic variability, the proposed identification method has been validated from a Finite Element (FE) model which aims at simulating precisely the bending response of a cylindrical stem. The refined FE model has been developed based on the geometry and the boundary conditions of the experimentally tested stems. M-χ curves are derived from the FE model and used within a Single Degree Of Freedom (SDOF) approach. At the stem scale, the prediction of the SDOF model (Force-Displacement) is compared to the FE model and lead to a good agreement. Then the approach is used to characterise fresh European beech samples allowing deriving their mechanical properties (longitudinal Young modulus, modulus of elasticity and modulus of rupture).

In a previous paper, Campello et al. presented a combined experimental/numerical approach to identify the creep behaviour of as‐fabricated Zircaloy‐4 claddings under simulated LOCA conditions. The current paper deals with the uncertainties and errors estimation of the two key methods used to measure the thermal and kinematic full fields during the creep tests: near infrared thermography (NIRT) and two‐dimensional digital image correlation (2D‐DIC).The NIRT uncertainties are evaluated as 0.7% of the actual temperature. They are mainly due to the thermocouple measurements used to calibrate the radiometric model of the NIRT.A combined 2D‐DIC/edge detection approach is proposed to quantify the error related to 2D‐DIC when measuring the ballooning of the tubular specimen. The 2D‐DIC error is evaluated as 0.1% of the actual equivalent strain even for ballooning inducing a radius increase of 20%.