Skip to main content

Advertisement

SpringerLink
Log in

Identification of a Suitable 3D Printing Material for Mimicking Brittle and Hard Rocks and Its Brittleness Enhancements

  • Original Paper
  • Published:
Rock Mechanics and Rock Engineering Aims and scope Submit manuscript

Abstract

Three-dimensional printing (3DP) is a computer-controlled additive manufacturing technique which is able to repeatedly and accurately fabricate objects with complicated geometry and internal structures. After 30 years of fast development, 3DP has become a mainstream manufacturing process in various fields. This study focuses on identifying the most suitable 3DP material from five targeted available 3DP materials, i.e. ceramics, gypsum, PMMA (poly(methyl methacrylate)), SR20 (acrylic copolymer) and resin (Accura® 60), to simulate brittle and hard rocks. Firstly, uniaxial compression tests were performed to determine the mechanical properties and failure patterns of the 3DP samples fabricated by those five materials. Experimental results indicate that among current 3DP techniques, the resin produced via stereolithography (SLA) is the most suitable 3DP material for mimicking brittle and hard rocks, although its brittleness needs to be improved. Subsequently, three methods including freezing, incorporation of internal macro-crack and addition of micro-defects were adopted to enhance the brittleness of the 3DP resin, followed by uniaxial compression tests on the treated samples. Experimental results reveal that 3DP resin samples with the suggested treatments exhibited brittle properties and behaved similarly to natural rocks. Finally, some prospective improvements which can be used to facilitate the application of 3DP techniques to rock mechanics were also discussed. The findings of this paper could contribute to promoting the application of 3DP technique in rock mechanics.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  • Alber M, Fritschen R, Bischoff M, Meier T (2009) Rock mechanical investigations of seismic events in a deep longwall coal mine. Int J Rock Mech Min Sci 46(2):408–420

    Article  Google Scholar 

  • Anthony S (2014) SpaceX rocket carries the first ever zero-g 3D printer to the space station. http://www.extremetech.com/extreme/190629-spacex-rocket-launches-to-the-space-station-carrying-the-first-ever-zero-g-3d-printer. Accessed 26 Apr 2015

  • ASTM D638 (2010) Standard test method for tensile properties of plastics. ASTM International, West Conshohocken, p 2010

    Google Scholar 

  • Belter JT, Dollar AM (2015) Strengthening of 3D printed fused deposition manufactured parts using the fill compositing technique. PLoS ONE 10(4):e0122915

    Article  Google Scholar 

  • Cai M (2010) Practical estimates of tensile strength and Hoek–Brown strength parameter mi of brittle rocks. Rock Mech Rock Eng 43(2):167–184

    Article  Google Scholar 

  • Capel AJ, Edmondson S, Christie SD, Goodridge RD, Bibb RJ, Thurstans M (2013) Design and additive manufacture for flow chemistry. Lab Chip 13(23):4583–4590

    Article  Google Scholar 

  • Chia HN, Wu BM (2015) Recent advances in 3D printing of biomaterials. J Biol Eng 9(1):4

    Article  Google Scholar 

  • Dal Ferro N, Morari F (2015) From real soils to 3D-printed soils: reproduction of complex pore network at the real size in a silty-loam soil. Soil Sci Soc Am J 79(4):1008–1017

    Article  Google Scholar 

  • Eberhardt E, Stead D, Stimpson B (1999) Quantifying progressive pre-peak brittle fracture damage in rock during uniaxial compression. Int J Rock Mech Min Sci 36(3):361–380

    Article  Google Scholar 

  • Feng P, Meng X, Chen JF, Ye L (2015) Mechanical properties of structures 3D printed with cementitious powders. Constr Build Mater 93:486–497

    Article  Google Scholar 

  • Fereshtenejad S, Song JJ (2016) Fundamental study on applicability of powder-based 3D printer for physical modeling in rock mechanics. Rock Mech Rock Eng 49(6):2065–2074

    Article  Google Scholar 

  • Fredrich JT, Evans B, Wong TF (1990) Effect of grain size on brittle and semibrittle strength: implications for micromechanical modelling of failure in compression. J Geophys Res 95(B7):10907–10920

    Article  Google Scholar 

  • Ganter M, Storti D, Utela B (2009) The printed pot. Ceram Mon 56:36–39

    Google Scholar 

  • Griffith WA, Rosakis A, Pollard DD, Ko CW (2009) Dynamic rupture experiments elucidate tensile crack development during propagating earthquake ruptures. Geology 37:795–798

    Article  Google Scholar 

  • Hart KR, Wetzel ED (2017) Fracture behaviors of additively manufactured acrylonitrile butadiene styrene (ABS) materials. Eng Fract Mech. https://doi.org/10.1016/j.engfracmech.2017.03.028

    Google Scholar 

  • Hiller J, Lipson H (2009) Design and analysis of digital materials for physical 3D voxel printing. Rapid Prototyp J 15(2):137–149

    Article  Google Scholar 

  • Huang SH, Liu P, Mokasdar A, Hou L (2013a) Additive manufacturing and its societal impact: a literature review. Int J Adv Manuf Technol 67(5):1191–1203

    Article  Google Scholar 

  • Huang S, Xia K, Zheng H (2013b) Observation of microscopic damage accumulation in brittle solids subjected to dynamic compressive loading. Rev Sci Instrum 84(9):093903

    Article  Google Scholar 

  • Huang L, Stewart RR, Dyaur N, Baez-Franceschi J (2016) 3D-printed rock models: elastic properties and the effects of penny-shaped inclusions with fluid substitution. Geophysics 81(6):669–677

    Article  Google Scholar 

  • Ishutov S, Hasiuk FJ, Harding C, Gray JN (2015) 3D printing sandstone porosity models. Interpretation 3(3):SX49–SX61

    Article  Google Scholar 

  • Jiang C, Zhao GF (2015) A preliminary study of 3D printing on rock mechanics. Rock Mech Rock Eng 48(3):1041–1050

    Article  Google Scholar 

  • Jiang Q, Feng XT, Gong YH, Song LB, Ran SG, Cui J (2016) Reverse modelling of natural rock joints using 3D scanning and 3D printing. Comput Geotech 73:210–220

    Article  Google Scholar 

  • Ju Y, Xie H, Zheng Z, Lu J, Mao L, Gao F et al (2014) Visualization of the complex structure and stress field inside rock by means of 3D printing technology. Chin Sci Bull 59(36):5354–5365

    Article  Google Scholar 

  • Ju Y, Wang L, Xie H, Ma G, Zheng Z, Mao L (2017) Visualization and transparentization of the structure and stress field of aggregated geomaterials through 3D printing and photoelastic techniques. Rock Mech Rock Eng 50(6):1383–1407

    Article  Google Scholar 

  • Karaca M, Egger P (1993) Failure phenomena around shallow tunnels in jointed rock. In: Proceedings of the International Symposium on Assessment and Prevention of Failure Phenomena in Rock Engineering, Istanbul, Turkey, pp 381–388

  • Kawakata H, Cho A, Kiyama T, Yanagidani T, Kusunose K, Shimada M (1999) Three-dimensional observations of faulting process in Westerly granite under uniaxial and triaxial conditions by X-ray CT scan. Tectonophysics 313(3):293–305

    Article  Google Scholar 

  • Kokkinis D, Schaffner M, Studart AR (2015) Multimaterial magnetically assisted 3D printing of composite materials. Nat Commun 6:8643

    Article  Google Scholar 

  • Liu J, Liu FH, Kong XJ, Yu L (2014) Large-scale shaking table model tests of aseismic measures for concrete faced rock-fill dams. Soil Dyn Earthq Eng 61–62(3):152–163

    Article  Google Scholar 

  • Lockner D, Byerlee J, Kuksenko V, Ponomarev A, Sidorin A (1991) Quasi-static fault growth and shear fracture energy in granite. Nature 350(6313):39–42

    Article  Google Scholar 

  • Marks P (2011) 3D printing takes off with the world’s first printed plane. New Sci 211(2823):17–18

    Article  Google Scholar 

  • Michna S, Wu W, Lewis JA (2005) Concentrated hydroxyapatite inks for direct-write assembly of 3-D periodic scaffolds. Biomaterials 26(28):5632–5639

    Article  Google Scholar 

  • Mitchell MG (2016) Cell biology: translational impact in cancer biology and bioinformatics. Elsevier, Cambridge, p 122

    Google Scholar 

  • Munz D, Fett T (1999) Ceramics: mechanical properties, failure behaviour, materials selection. Springer, NewYork, p 1

    Google Scholar 

  • NASA (2014) Space station 3-D printer builds ratchet wrench to complete first phase of operations. http://www.nasa.gov/mission_pages/station/research/news/3Dratchet_wrench. Accessed 26 Apr 2015

  • Otten W, Pajor R, Schmidt S, Baveye PC, Hague R, Falconer RE (2012) Combining X-ray CT and 3D printing technology to produce microcosms with replicable, complex pore geometries. Soil Biol Biochem 51:53–55

    Article  Google Scholar 

  • Richeton J, Ahzi S, Vecchio KS, Jiang FC, Adharapurapu RR (2006) Influence of temperature and strain rate on the mechanical behavior of three amorphous polymers: characterization and modeling of the compressive yield stress. Int J Solids Struct 43(7):2318–2335

    Article  Google Scholar 

  • Roylance D (2001) Introduction to fracture mechanics. Massachusetts Institute of Technology, Cambridge, p 1

    Google Scholar 

  • Saba N, Jawaid M, Alothman OY, Paridah MT (2016) A review on dynamic mechanical properties of natural fibre reinforced polymer composites. Constr Build Mater 106:149–159

    Article  Google Scholar 

  • Sammis CG, Rosakis AJ, Bhat HS (2009) Effects of off-fault damage on earthquake rupture propagation: experimental studies. Pure appl Geophys 166:1629–1648

    Article  Google Scholar 

  • Seweryn A, Poskrobko S, Mróz Z (1997) Brittle fracture in plane elements with sharp notches under mixed-mode loading. J Eng Mech 123(6):535–543

    Article  Google Scholar 

  • Tang CA, Kaiser PK (1998) Numerical simulation of cumulative damage and seismic energy release during brittle rock failure-part I: fundamentals. Int J Rock Mech Min Sci 35(2):113–121

    Article  Google Scholar 

  • Vaitkus A, Gražulyt J, Kleizien R (2014) Influence of static and impact load on pavement performance. In: The 9th international conference on environmental engineering, Vilnius, Lithuania, pp 1–9

  • Wawersik WR, Fairhurst C (1970) A study of brittle rock fracture in laboratory compression experiments. Int J Rock Mech Min Sci 7(5):561–575

    Article  Google Scholar 

  • Wong NY (2008) Crack coalescence in molded gypsum and Carrara marble. Ph.D. thesis, Massachusetts Institute of Technology, Cambridge, MA, p 35

  • Wong TF, David C, Zhu W (1997) The transition from brittle faulting to cataclastic flow in porous sandstones: mechanical deformation. J Geophys Res 102(B2):3009–3025

    Article  Google Scholar 

  • Wu Y, McGarry FJ, Zhu B, Keryk JR, Katsoulis DE (2005) Temperature effect on mechanical properties of toughened silicone resins. Polym Eng Sci 45(11):1522–1531

    Article  Google Scholar 

  • Wu C, Luo Y, Cuniberti G, Xiao Y, Gelinsky M (2011) Three-dimensional printing of hierarchical and tough mesoporous bioactive glass scaffolds with a controllable pore architecture, excellent mechanical strength and mineralization ability. Acta Biomater 7(6):2644–2650

    Article  Google Scholar 

  • Wu C, Fan W, Zhou Y, Luo Y, Gelinsky M, Chang J et al (2012) 3D-printing of highly uniform CaSiO 3 ceramic scaffolds: preparation, characterization and in vivo osteogenesis. J Mater Chem 22(24):12288–12295

    Article  Google Scholar 

  • Zhu JB, Zhou T, Liao ZY, Sun L, Li XB, Chen R (unpublished manuscript) Replication of internal defects and investigation of mechanical and fracture behaviours of rocks using 3D printing and 3D numerical methods with combination of X-ray computerized tomography. Submitted to Geophys J Int

  • Yan X, Gu PENG (1996) A review of rapid prototyping technologies and systems. Comput Aided Des 28(4):307–318

    Article  Google Scholar 

  • Zhou T, Zhu JB (2017) An experimental investigation of tensile fracturing behavior of natural and artificial rocks in static and dynamic Brazilian disc tests. Procedia Eng 191:992–998. The 2017 ISRM European Rock Mechanics Symposium, Ostrava, Czech

Download references

Acknowledgements

We thank W. F. Wong, S. K. Yik and C. M. Wong from Industrial Centre of the Hong Kong Polytechnic University for their support in 3DP sample preparation. We are grateful to K. M. Leung from Rock Mechanics Laboratory of the Hong Kong Polytechnic University and R. Chen at National University of Defense Technology for their support in performing laboratory tests. A portion of this paper was reported in a conference paper (Zhou and Zhu 2017). This research was financially supported by the Hong Kong Research Grant Council (No. 25201814) and the National Natural Science Foundation of China (No. 41402241).

Author information

Authors and Affiliations

  1. State Key Laboratory of Hydraulic Engineering Simulation and Safety, School of Civil Engineering, Tianjin University, Tianjin, China

    T. Zhou & J. B. Zhu

  2. Department of Civil and Environmental Engineering, Hong Kong Polytechnic University, Hong Kong, China

    T. Zhou

Authors
  1. T. Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. B. Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to J. B. Zhu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhou, T., Zhu, J.B. Identification of a Suitable 3D Printing Material for Mimicking Brittle and Hard Rocks and Its Brittleness Enhancements. Rock Mech Rock Eng 51, 765–777 (2018). https://doi.org/10.1007/s00603-017-1335-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00603-017-1335-7

Keywords

Search

Navigation