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Stefano Rosso
University of Padova

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Conference paper
Published: 22 April 2021 in Recent Advances in Computational Mechanics and Simulations
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Thanks to the great diffusion of additive manufacturing technologies, the interest in lattice structures is growing. Among them, minimal surfaces are characterized by zero mean curvature, allowing enhanced properties such as mechanical response and fluidynamic behavior. Recent works showed a method for geometric modeling triply periodic minimal surfaces (TPMS) based on subdivision surface. In this paper, the deviation between the subdivided TPMS and the implicit defined ones is investigated together with mechanical properties computed by numerical methods. As a result, a model of mechanical properties as a function of the TPMS thickness and relative density is proposed.

ACS Style

Stefano Rosso; Andrea Curtarello; Federico Basana; Luca Grigolato; Roberto Meneghello; Gianmaria Concheri; Gianpaolo Savio. Modeling Symmetric Minimal Surfaces by Mesh Subdivision. Recent Advances in Computational Mechanics and Simulations 2021, 249 -254.

AMA Style

Stefano Rosso, Andrea Curtarello, Federico Basana, Luca Grigolato, Roberto Meneghello, Gianmaria Concheri, Gianpaolo Savio. Modeling Symmetric Minimal Surfaces by Mesh Subdivision. Recent Advances in Computational Mechanics and Simulations. 2021; ():249-254.

Chicago/Turabian Style

Stefano Rosso; Andrea Curtarello; Federico Basana; Luca Grigolato; Roberto Meneghello; Gianmaria Concheri; Gianpaolo Savio. 2021. "Modeling Symmetric Minimal Surfaces by Mesh Subdivision." Recent Advances in Computational Mechanics and Simulations , no. : 249-254.

Journal article
Published: 13 March 2021 in Applied Sciences
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Additive Manufacturing (AM) brought a revolution in parts design and production. It enables the possibility to obtain objects with complex geometries and to exploit structural optimization algorithms. Nevertheless, AM is far from being a mature technology and advances are still needed from different perspectives. Among these, the literature highlights the need of improving the frameworks that describe the design process and taking full advantage of the possibilities offered by AM. This work aims to propose a workflow for AM guiding the designer during the embodiment design phase, from the engineering requirements to the production of the final part. The main aspects are the optimization of the dimensions and the topology of the parts, to take into consideration functional and manufacturing requirements, and to validate the geometric model by computer-aided engineering software. Moreover, a case study dealing with the redesign of a piston rod is presented, in which the proposed workflow is adopted. Results show the effectiveness of the workflow when applied to cases in which structural optimization could bring an advantage in the design of a part and the pros and cons of the choices made during the design phases were highlighted.

ACS Style

Stefano Rosso; Federico Uriati; Luca Grigolato; Roberto Meneghello; Gianmaria Concheri; Gianpaolo Savio. An Optimization Workflow in Design for Additive Manufacturing. Applied Sciences 2021, 11, 2572 .

AMA Style

Stefano Rosso, Federico Uriati, Luca Grigolato, Roberto Meneghello, Gianmaria Concheri, Gianpaolo Savio. An Optimization Workflow in Design for Additive Manufacturing. Applied Sciences. 2021; 11 (6):2572.

Chicago/Turabian Style

Stefano Rosso; Federico Uriati; Luca Grigolato; Roberto Meneghello; Gianmaria Concheri; Gianpaolo Savio. 2021. "An Optimization Workflow in Design for Additive Manufacturing." Applied Sciences 11, no. 6: 2572.

Journal article
Published: 14 November 2020 in Additive Manufacturing
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Recently, the possibility of producing medium-to-large batches has increased the interest in polymer powder bed fusion technologies such as selective laser sintering (SLS) and multi jet fusion (MJF). Only scant data about the characterization of parts produced by MJF can be found in the literature, and fatigue behavior studies are absent. This study analyzes the material properties of Polyamide 12 (PA12) powders and printed specimens using both SLS and MJF technologies. The morphology, crystalline phases, density, porosity, dimensional accuracy, and roughness are measured and compared; tensile and fatigue tests are performed to assess the effect of the technologies on the mechanical behavior of the produced structures. In addition, lattice structure specimens obtained by different geometric modeling approaches are tested to understand the influence of modeling methods on the fatigue life. The PA12 powders printed by both SLS and MJF mainly show by X-Ray Diffraction γ-phase and a small shoulder of α-phase. The crystallinity decreases after printing the powders both in SLS and MJF technology. The printed parts fabricated using the two technologies present a total porosity of 7.95% for SLS and 6.75% for MJF. The roughness values are similar, Ra ≈ 11 µm along the building direction. During tensile tests, SLS samples appear to be stiffer, with a lower plastic deformation than MJF samples, that are tougher than SLS ones. Fatigue tests demonstrate higher dispersion for MJF specimens and an enhancement of fatigue life for both SLS and MJF printed lattice structures modeled with a novel geometric modeling approach that allows the creation of smoother surfaces at nodal points. Scanning electron microscopy on fracture surfaces shows a brittle failure for the SLS tensile specimens, a more ductile failure for the MJF tensile specimens, a crazing failure mechanism for the SLS fatigue tested samples, and a crack initiation and slow growth and propagation for the MJF fatigue tested samples.

ACS Style

Stefano Rosso; Roberto Meneghello; Lisa Biasetto; Luca Grigolato; Gianmaria Concheri; Gianpaolo Savio. In-depth comparison of polyamide 12 parts manufactured by Multi Jet Fusion and Selective Laser Sintering. Additive Manufacturing 2020, 36, 101713 .

AMA Style

Stefano Rosso, Roberto Meneghello, Lisa Biasetto, Luca Grigolato, Gianmaria Concheri, Gianpaolo Savio. In-depth comparison of polyamide 12 parts manufactured by Multi Jet Fusion and Selective Laser Sintering. Additive Manufacturing. 2020; 36 ():101713.

Chicago/Turabian Style

Stefano Rosso; Roberto Meneghello; Lisa Biasetto; Luca Grigolato; Gianmaria Concheri; Gianpaolo Savio. 2020. "In-depth comparison of polyamide 12 parts manufactured by Multi Jet Fusion and Selective Laser Sintering." Additive Manufacturing 36, no. : 101713.

Short original paper
Published: 22 October 2020 in International Journal on Interactive Design and Manufacturing (IJIDeM)
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Demand for innovation represents a driver not only in the industrial field but also in niche markets such as orthodontics. Among different type of orthodontic devices, functional appliances are used for the correction of class II skeletal malocclusion, mostly in young patients. In a previous study based on a systematic design approach, several concepts were generated for this device. This work shortly introduces the concept selection and the interactive design process of the device. The concept consisting of two-side guiding surfaces, obtained by TRIZ inventive principles, has been selected by the decision matrix. This concept consists in guiding the jaw movements without any connections between the parts of the device. Operating on patient morphometrics parameters, the proposed approach allows to establish a virtual interaction during the design of the device by facilitating the collaboration between orthodontist, dental technician, designer and the software, through a dedicated user interface. Dedicated algorithms were also developed to simulate the occlusion correction and the mandible path, and to support the geometric modelling in a virtual environment. As a result, the proposed approach allows manufacturing patient-customized devices using a digital interactive workflow in an innovative way.

ACS Style

Luca Grigolato; Stefano Filippi; Daniele Cantarella; Roberta Lione; Won Moon; Stefano Rosso; Roberto Meneghello; Gianmaria Concheri; Gianpaolo Savio. Concept selection and interactive design of an orthodontic functional appliance. International Journal on Interactive Design and Manufacturing (IJIDeM) 2020, 15, 137 -142.

AMA Style

Luca Grigolato, Stefano Filippi, Daniele Cantarella, Roberta Lione, Won Moon, Stefano Rosso, Roberto Meneghello, Gianmaria Concheri, Gianpaolo Savio. Concept selection and interactive design of an orthodontic functional appliance. International Journal on Interactive Design and Manufacturing (IJIDeM). 2020; 15 (1):137-142.

Chicago/Turabian Style

Luca Grigolato; Stefano Filippi; Daniele Cantarella; Roberta Lione; Won Moon; Stefano Rosso; Roberto Meneghello; Gianmaria Concheri; Gianpaolo Savio. 2020. "Concept selection and interactive design of an orthodontic functional appliance." International Journal on Interactive Design and Manufacturing (IJIDeM) 15, no. 1: 137-142.

Journal article
Published: 17 June 2020 in Applied Sciences
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Background: resin-bonded fixed dental prosthesis (RBFDP) represents a highly aesthetic and conservative treatment option to replace a single tooth in a younger patient. The purpose of this in vitro study was to compare the fracture strength and the different types of failure on anterior cantilever RBFDPs fabricated using zirconia (ZR), lithium disilicate (LD), and PMMA-based material with ceramic fillers (PM) by the same standard tessellation language (STL) file. Methods: sixty extracted bovine mandibular incisives were embedded resin block; scanned to design one master model of RBFDP with a cantilevered single-retainer. Twenty cantilevered single-retainer RBFDPs were fabricated using ZR; LD; and PM. Static loading was performed using a universal testing machine. Results: the mean fracture strength for the RBFDPs was: 292.5 Newton (Standard Deviation (SD) 36.6) for ZR; 210 N (SD 37.6) for LD; and 133 N (SD 16.3) for PM. All the failures of RBFDPs in ZR were a fracture of the abutment tooth; instead; the 80% of failures of RBFDPs in LD and PM were a fracture of the connector. Conclusion: within the limitations of this in vitro study, we can conclude that the zirconia RBFDPs presented load resistance higher than the maximum anterior bite force reported in literature (270 N) and failure type analysis showed some trends among the groups

ACS Style

Adolfo Di Fiore; Edoardo Stellini; Gianpaolo Savio; Stefano Rosso; Lorenzo Graiff; Stefano Granata; Carlo Monaco; Roberto Meneghello. Assessment of the Different Types of Failure on Anterior Cantilever Resin-Bonded Fixed Dental Prostheses Fabricated with Three Different Materials: An In Vitro Study. Applied Sciences 2020, 10, 4151 .

AMA Style

Adolfo Di Fiore, Edoardo Stellini, Gianpaolo Savio, Stefano Rosso, Lorenzo Graiff, Stefano Granata, Carlo Monaco, Roberto Meneghello. Assessment of the Different Types of Failure on Anterior Cantilever Resin-Bonded Fixed Dental Prostheses Fabricated with Three Different Materials: An In Vitro Study. Applied Sciences. 2020; 10 (12):4151.

Chicago/Turabian Style

Adolfo Di Fiore; Edoardo Stellini; Gianpaolo Savio; Stefano Rosso; Lorenzo Graiff; Stefano Granata; Carlo Monaco; Roberto Meneghello. 2020. "Assessment of the Different Types of Failure on Anterior Cantilever Resin-Bonded Fixed Dental Prostheses Fabricated with Three Different Materials: An In Vitro Study." Applied Sciences 10, no. 12: 4151.

Conference paper
Published: 20 September 2019 in Recent Advances in Computational Mechanics and Simulations
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The freedom in geometry given by additive manufacturing allows to produce cellular materials, also called lattice structures, with unit cells and mesoscale features that are impossible to obtain with traditional manufacturing techniques. The geometric modeling of lattice structures still presents issues such as robustness and automation, but, with a novel modeling approach based on subdivision surface algorithm, these troubles were limited. Furthermore, the subdivision method smooths surfaces, avoiding sharp edges at nodal points and increasing performances in fatigue properties. The aim of this work is twofold; a. The subdivision surface method is validated through fatigue tests on specimen additively manufactured by selective laser melting technology in SS316L stainless steel; dynamic tests were carried out on two types of lattice structures based on cubic cell: one obtained with a traditional modeling method, one obtained with a subdivision surface approach. b. Additional tests on bulk cylindrical samples, allowed to propose a preliminary model that describes the fatigue behaviour of additively manufactured lattices as a function of the bulk material properties, considering the shape and scale effects coming from stress concentration factor, increased area, surface roughness and porosity of the part. Results show that the subdivision surface approach improves the fatigue life of lattice structures, as expected. More, the lattices have a worse fatigue life compared to the bulk samples due to the scale and shape effects, that results in a higher sensibility to surface and internal defects related to the manufacturing process.

ACS Style

Stefano Rosso; Roberto Meneghello; Gianmaria Concheri; Gianpaolo Savio. Scale and Shape Effects on the Fatigue Behaviour of Additively Manufactured SS316L Structures: A Preliminary Study. Recent Advances in Computational Mechanics and Simulations 2019, 879 -890.

AMA Style

Stefano Rosso, Roberto Meneghello, Gianmaria Concheri, Gianpaolo Savio. Scale and Shape Effects on the Fatigue Behaviour of Additively Manufactured SS316L Structures: A Preliminary Study. Recent Advances in Computational Mechanics and Simulations. 2019; ():879-890.

Chicago/Turabian Style

Stefano Rosso; Roberto Meneghello; Gianmaria Concheri; Gianpaolo Savio. 2019. "Scale and Shape Effects on the Fatigue Behaviour of Additively Manufactured SS316L Structures: A Preliminary Study." Recent Advances in Computational Mechanics and Simulations , no. : 879-890.

Conference paper
Published: 20 September 2019 in Lecture Notes in Mechanical Engineering
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Additive manufacturing technology offers new design possibilities compared to traditional casting processes applied to metallic materials. Not only there are no limits in shape, but a higher microstructure control is allowed compared to traditional processes. Irrespective of the sample dimensions, the solidification defects induced by SLM process depend only on process parameters and do not vary from zone to zone of the component like in a casting component: the higher the casting dimensions and thickness variations, the lower the microstructure homogeneity resulting from different cooling conditions inside the casting itself. The effect of process parameters on porosity, in selective laser melted AlSi10Mg aluminium alloy, is carefully analysed with the aim to find optimal conditions that guarantee the maximum material density and the best mechanical properties.

ACS Style

Federico Uriati; Filippo Da Rin Betta; Paolo Ferro; Stefano Rosso; Gianpaolo Savio; Gianmaria Concheri; Roberto Meneghello. High Density AlSi10Mg Aluminium Alloy Specimens Obtained by Selective Laser Melting. Lecture Notes in Mechanical Engineering 2019, 871 -878.

AMA Style

Federico Uriati, Filippo Da Rin Betta, Paolo Ferro, Stefano Rosso, Gianpaolo Savio, Gianmaria Concheri, Roberto Meneghello. High Density AlSi10Mg Aluminium Alloy Specimens Obtained by Selective Laser Melting. Lecture Notes in Mechanical Engineering. 2019; ():871-878.

Chicago/Turabian Style

Federico Uriati; Filippo Da Rin Betta; Paolo Ferro; Stefano Rosso; Gianpaolo Savio; Gianmaria Concheri; Roberto Meneghello. 2019. "High Density AlSi10Mg Aluminium Alloy Specimens Obtained by Selective Laser Melting." Lecture Notes in Mechanical Engineering , no. : 871-878.

Conference paper
Published: 28 April 2019 in Proceedings of the 2nd Annual International Conference on Material, Machines and Methods for Sustainable Development (MMMS2020)
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The unique capabilities of additive manufacturing (AM) technologies highlight limits in commercial CAD tools. In this manuscript, after a synthetic description of the main AM technologies based on international standards classification, geometric modeling methods and data exchange file formats available in the literature are presented. Twelve geometric models have been studied to evaluate the effectiveness of the file format, noting the file dimension and the time to open and close the file. As a result, a roadmap in the development of new tools for design in AM is drawn, taking into account the new possibilities offered by AM technologies.

ACS Style

G. Savio; Roberto Meneghello; S. Rosso; G. Concheri. 3D Model Representation and Data Exchange for Additive Manufacturing. Proceedings of the 2nd Annual International Conference on Material, Machines and Methods for Sustainable Development (MMMS2020) 2019, 412 -421.

AMA Style

G. Savio, Roberto Meneghello, S. Rosso, G. Concheri. 3D Model Representation and Data Exchange for Additive Manufacturing. Proceedings of the 2nd Annual International Conference on Material, Machines and Methods for Sustainable Development (MMMS2020). 2019; ():412-421.

Chicago/Turabian Style

G. Savio; Roberto Meneghello; S. Rosso; G. Concheri. 2019. "3D Model Representation and Data Exchange for Additive Manufacturing." Proceedings of the 2nd Annual International Conference on Material, Machines and Methods for Sustainable Development (MMMS2020) , no. : 412-421.

Original paper
Published: 16 January 2019 in International Journal on Interactive Design and Manufacturing (IJIDeM)
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The diffusion of design tools suitable for regular lattice structures was recently stimulated by the spread of additive manufacturing technologies that enable the fabrication of complex geometries, exceeding the limits of traditional manufacturing methods. Fillet radii play a fundamental role in the design of lattice materials, reducing the stress concentration and improving fatigue life. However, only simplified beam and 2D models are available in the literature, which are unable to capture the actual stiffness and stress concentrations in the cell nodes of the 3-D beam based lattice structures with fillets. In this paper, four types of polyamide 12 cells, fabricated by selective laser sintering technology, based on cylindrical elements, are studied by finite element (FE) analysis, evaluating the influence of struts and fillet radii on the mechanical properties. In order to study a single cell, specific boundary conditions, simulating the presence of adjacent cells, were adopted in FE analysis. As a result, a model describing mechanical properties as a function of geometrical characteristics is obtained. By this model, it is possible to replace the complex shape of a lattice structure with its boundary, simplifying numerical analyses. This approach, called homogenization, is very useful in the design process of lightweight structures and can be adopted in optimization strategies. Numerical outcomes show that the effect of fillet radius is not negligible, especially in cells having a large number of struts. Moreover, experimental tests were also carried out showing a good agreement with the numerical analysis. Finally, an interactive design process for lattice structures based on experimental and numerical outcomes is proposed.

ACS Style

Gianpaolo Savio; Andrea Curtarello; Stefano Rosso; Roberto Meneghello; Gianmaria Concheri. Homogenization driven design of lightweight structures for additive manufacturing. International Journal on Interactive Design and Manufacturing (IJIDeM) 2019, 13, 263 -276.

AMA Style

Gianpaolo Savio, Andrea Curtarello, Stefano Rosso, Roberto Meneghello, Gianmaria Concheri. Homogenization driven design of lightweight structures for additive manufacturing. International Journal on Interactive Design and Manufacturing (IJIDeM). 2019; 13 (1):263-276.

Chicago/Turabian Style

Gianpaolo Savio; Andrea Curtarello; Stefano Rosso; Roberto Meneghello; Gianmaria Concheri. 2019. "Homogenization driven design of lightweight structures for additive manufacturing." International Journal on Interactive Design and Manufacturing (IJIDeM) 13, no. 1: 263-276.

Journal article
Published: 02 November 2018 in Additive Manufacturing
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According to recent studies, a new paradigm in the geometric modeling of lattice structures based on subdivision surfaces for additive manufacturing overcomes the critical issues on CAD modeling highlighted in the literature, such as scalability, robustness, and automation. In this work, the mechanical behavior of the subdivided lattice structures was investigated and compared with the standard lattices. Five types of cellular structures based on cubic cell were modeled: struts based on squared or circular section, with or without fillets and cell based on the subdivision approach. Sixty-five specimens were manufactured by selective laser sintering technology in polyamide 12 and tensile and fatigue tests were performed. Furthermore, numerical analyses were carried out in order to establish the stress concentration factors. Results show that subdivided lattice structures, at the same resistant area, improve stiffness and fatigue life and reduce stress concentration while opening new perspectives in the development of lattice structures for additive manufacturing technologies and applications.

ACS Style

Gianpaolo Savio; Stefano Rosso; Andrea Curtarello; Roberto Meneghello; Gianmaria Concheri. Implications of modeling approaches on the fatigue behavior of cellular solids. Additive Manufacturing 2018, 25, 50 -58.

AMA Style

Gianpaolo Savio, Stefano Rosso, Andrea Curtarello, Roberto Meneghello, Gianmaria Concheri. Implications of modeling approaches on the fatigue behavior of cellular solids. Additive Manufacturing. 2018; 25 ():50-58.

Chicago/Turabian Style

Gianpaolo Savio; Stefano Rosso; Andrea Curtarello; Roberto Meneghello; Gianmaria Concheri. 2018. "Implications of modeling approaches on the fatigue behavior of cellular solids." Additive Manufacturing 25, no. : 50-58.

Review
Published: 01 February 2018 in Applied Bionics and Biomechanics
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Advances in additive manufacturing technologies facilitate the fabrication of cellular materials that have tailored functional characteristics. The application of solid freeform fabrication techniques is especially exploited in designing scaffolds for tissue engineering. In this review, firstly, a classification of cellular materials from a geometric point of view is proposed; then, the main approaches on geometric modeling of cellular materials are discussed. Finally, an investigation on porous scaffolds fabricated by additive manufacturing technologies is pointed out. Perspectives in geometric modeling of scaffolds for tissue engineering are also proposed.

ACS Style

Gianpaolo Savio; Stefano Rosso; Roberto Meneghello; Gianmaria Concheri. Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review. Applied Bionics and Biomechanics 2018, 2018, 1 -14.

AMA Style

Gianpaolo Savio, Stefano Rosso, Roberto Meneghello, Gianmaria Concheri. Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review. Applied Bionics and Biomechanics. 2018; 2018 ():1-14.

Chicago/Turabian Style

Gianpaolo Savio; Stefano Rosso; Roberto Meneghello; Gianmaria Concheri. 2018. "Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review." Applied Bionics and Biomechanics 2018, no. : 1-14.