Effects of material properties on warpage in fused deposition modeling parts

Polyamide 66 (PA66) is a material with high wear resistance, toughness, and heat resistance. However, low stiffness and thermal deformation during thermal processes define applications in many conditions. Carbon powder efficiently enhances stiffness and reduces thermal deformation, which makes up defects of plastic materials. However, forming a composite with fused deposition modeling (FDM) that accumulates material to a specified location by melting plastic filaments is limited, including fluidity and viscosity to form normally. In this paper, filaments of polyamide 66 (PA66) reinforced with carbon powder were produced. Digimat was used to analyze the composite material properties of different carbon contents and predict the proper carbon content. Then, the material properties were imported to ANSYS software to simulate the thermal deformation of the workpieces during processing. It was verified that adding carbon powder is helpful in decreasing thermal deformation. Comparing experiments and simulations, we found that 20% carbon mass fraction was best, and that thermal deformation was minimal at 240 °C nozzle temperature while hot bed temperature was 90 °C. The optimal ratio of extrusion speed to filling speed was 0.87, and the best aspect ratio was 0.25.

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Melt Flow Index of Recycle ABS for Fused Deposition Modeling (FDM) Filament

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.773-774.3 ◽

2015 ◽

Vol 773-774 ◽

pp. 3-7 ◽

Cited By ~ 2

Author(s):

Nasuha Sa'ude ◽

Khairu Kamarudin ◽

Mustaffa Ibrahim ◽

Mohd Halim Irwan Ibrahim

Keyword(s):

Material Properties ◽

Fused Deposition Modeling ◽

Acrylonitrile Butadiene Styrene ◽

Melt Flow Index ◽

Flow Index ◽

Melt Flow ◽

Fused Deposition ◽

Deposition Modeling ◽

Higher Temperature ◽

Butadiene Styrene

This paper presents the melt flow index (MFI) of acrylonitrile butadiene styrene (ABS) and recycle ABS filament wire for Fused Deposition Modeling (FDM) machine. In this study, the effect of MFI on recycle ABS material was investigated experimentally based on the melting temperature, density, screw speed and material properties. The MFI result on ABS recycle in wire filament was investigated using Melt Indexer Machine (MIM). Based on the result obtained, it was found that, ABS recycle was increase the density and MFI results. It can be observed that, the higher temperature was melt the recycle ABS material through the MIM and extruder machine.

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Topology Optimization for FDM Parts Considering the Hybrid Deposition Path Pattern

Micromachines ◽

10.3390/mi11080709 ◽

2020 ◽

Vol 11 (8) ◽

pp. 709

Author(s):

Shuzhi Xu ◽

Jiaqi Huang ◽

Jikai Liu ◽

Yongsheng Ma

Keyword(s):

Boundary Layer ◽

Material Properties ◽

Orthotropic Material ◽

Fused Deposition Modeling ◽

Structure Design ◽

Numerical Examples ◽

Fused Deposition ◽

Final Design ◽

Deposition Modeling ◽

Double Smoothing

Based on a solid orthotropic material with penalization (SOMP) and a double smoothing and projection (DSP) approach, this work proposes a methodology to find an optimal structure design which takes the hybrid deposition path (HDP) pattern and the anisotropic material properties into consideration. The optimized structure consists of a boundary layer and a substrate. The substrate domain is assumed to be filled with unidirectional zig-zag deposition paths and customized infill patterns, while the boundary is made by the contour offset deposition paths. This HDP is the most commonly employed path pattern for the fused deposition modeling (FDM) process. A critical derivative of the sensitivity analysis is presented in this paper, which ensures the optimality of the final design solutions. The effectiveness of the proposed method is validated through several 2D numerical examples.

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Comparison of As-Built FEA Simulations and Experimental Results for Additively Manufactured Dogbone Geometries

Volume 1: 37th Computers and Information in Engineering Conference ◽

10.1115/detc2017-67538 ◽

2017 ◽

Cited By ~ 3

Author(s):

Prathamesh J. Baikerikar ◽

Cameron J. Turner

Keyword(s):

Material Properties ◽

Fused Deposition Modeling ◽

Experimental Tests ◽

Tensile Loading ◽

3D Models ◽

Element Analysis ◽

Fused Deposition ◽

Deposition Modeling ◽

End Use ◽

Strength And Stiffness

Fused Deposition Modeling (FDM - a technology of additive manufacturing) parts entail a certain amount of ambiguity in terms of its material properties and microstructure due to its manufacturing technique. Therefore, an FDM part differs from its design model in terms of strength and stiffness. With an increasing amount of FDM parts being used as end use products, it is necessary to simulate and analyze them. Due to the differences in microstructure and material properties of FDM parts, it is necessary to determine the accuracy of analysis methods like Finite Element Analysis (FEA) while analyzing the non-continuous, non-linear FDM parts. The goal of this study is to compare FEA simulations of the as-built geometries with the experimental tests of actual FDM parts. A dogbone geometry with different infill patterns is tested under tensile loading. Further, as-built 3D models are simulated using FEA and the stress results are compared with experimental data. This study found that FEA results are not always an accurate or reliable means of predicting FDM part behaviors.

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Two-Compartment Capsular Devices for Oral Pulsatile Delivery 3D-Printed by Fused Deposition Modeling

10.26226/morressier.57d6b2b6d462b8028d88d9d6 ◽

2016 ◽

Author(s):

Federica Casati

Keyword(s):

Fused Deposition Modeling ◽

Fused Deposition ◽

Deposition Modeling ◽

3D Printed ◽

Pulsatile Delivery

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Biodegradable 3D Printed Polymer Microneedles for Transdermal Drug Delivery

10.26434/chemrxiv.5851950.v1 ◽

2018 ◽

Cited By ~ 1

Author(s):

Michael A. Luzuriaga ◽

Danielle R. Berry ◽

John C. Reagan ◽

Ronald A. Smaldone ◽

Jeremiah J. Gassensmith

Keyword(s):

Drug Delivery ◽

3D Printing ◽

Transdermal Drug Delivery ◽

Fused Deposition Modeling ◽

Fused Deposition ◽

Modeling Software ◽

Deposition Modeling ◽

3D Printed ◽

Microfabrication Technique ◽

Mechanical Strengths

Biodegradable polymer microneedle (MN) arrays are an emerging class of transdermal drug delivery devices that promise a painless and sanitary alternative to syringes; however, prototyping bespoke needle architectures is expensive and requires production of new master templates. Here, we present a new microfabrication technique for MNs using fused deposition modeling (FDM) 3D printing using polylactic acid, an FDA approved, renewable, biodegradable, thermoplastic material. We show how this natural degradability can be exploited to overcome a key challenge of FDM 3D printing, in particular the low resolution of these printers. We improved the feature size of the printed parts significantly by developing a post fabrication chemical etching protocol, which allowed us to access tip sizes as small as 1 μm. With 3D modeling software, various MN shapes were designed and printed rapidly with custom needle density, length, and shape. Scanning electron microscopy confirmed that our method resulted in needle tip sizes in the range of 1 – 55 µm, which could successfully penetrate and break off into porcine skin. We have also shown that these MNs have comparable mechanical strengths to currently fabricated MNs and we further demonstrated how the swellability of PLA can be exploited to load small molecule drugs and how its degradability in skin can release those small molecules over time.

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