Estimating Powder-Polymer Material Properties Used in Design for Metal Fused Filament Fabrication (DfMF3)

JOM ◽  
2019 ◽  
Vol 72 (1) ◽  
pp. 485-495 ◽  
Author(s):  
Paramjot Singh ◽  
Qasim Shaikh ◽  
Vamsi K. Balla ◽  
Sundar V. Atre ◽  
Kunal H. Kate
Keyword(s):  
Polymer Material ◽  
Material Properties ◽  
Fused Filament Fabrication

Effects of infill patterns on the strength and stiffness of 3D printed topologically optimized geometries

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nadim S. Hmeidat ◽  
Bailey Brown ◽  
Xiu Jia ◽  
Natasha Vermaak ◽  
Brett Compton
Keyword(s):  
Material Properties ◽  
Failure Modes ◽  
Mechanical Anisotropy ◽  
Failure Behavior ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Orthotropic Composite ◽  
Material Extrusion ◽  
Specific Material ◽  
Strength And Stiffness

Purpose Mechanical anisotropy associated with material extrusion additive manufacturing (AM) complicates the design of complex structures. This study aims to focus on investigating the effects of design choices offered by material extrusion AM – namely, the choice of infill pattern – on the structural performance and optimality of a given optimized topology. Elucidation of these effects provides evidence that using design tools that incorporate anisotropic behavior is necessary for designing truly optimal structures for manufacturing via AM. Design/methodology/approach A benchmark topology optimization (TO) problem was solved for compliance minimization of a thick beam in three-point bending and the resulting geometry was printed using fused filament fabrication. The optimized geometry was printed using a variety of infill patterns and the strength, stiffness and failure behavior were analyzed and compared. The bending tests were accompanied by corresponding elastic finite element analyzes (FEA) in ABAQUS. The FEA used the material properties obtained during tensile and shear testing to define orthotropic composite plies and simulate individual printed layers in the physical specimens. Findings Experiments showed that stiffness varied by as much as 22% and failure load varied by as much as 426% between structures printed with different infill patterns. The observed failure modes were also highly dependent on infill patterns with failure propagating along with printed interfaces for all infill patterns that were consistent between layers. Elastic FEA using orthotropic composite plies was found to accurately predict the stiffness of printed structures, but a simple maximum stress failure criterion was not sufficient to predict strength. Despite this, FE stress contours proved beneficial in identifying the locations of failure in printed structures. Originality/value This study quantifies the effects of infill patterns in printed structures using a classic TO geometry. The results presented to establish a benchmark that can be used to guide the development of emerging manufacturing-oriented TO protocols that incorporate directionally-dependent, process-specific material properties.

Additive manufacturing of 316L stainless-steel structures using fused filament fabrication technology: mechanical and geometric properties

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Miguel Ángel Caminero ◽  
Ana Romero ◽  
Jesús Miguel Chacón ◽  
Pedro José Núñez ◽  
Eustaquio García-Plaza ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Austenitic Stainless Steel ◽  
Material Properties ◽  
Steel Structures ◽  
Fused Filament Fabrication ◽  
Geometric Properties ◽  
Content Type ◽  
Build Orientation ◽  
Manufacturing Alternatives

Purpose Fused filament fabrication (FFF) technique using metal filled filaments in combination with debinding and sintering steps can be a cost-effective alternative for laser-based powder bed fusion processes. The mechanical behaviour of FFF-metal materials is highly dependent on the processing parameters, filament quality and adjusted post-processing steps. In addition, the microstructural material properties and geometric characteristics are inherent to the manufacturing process. The purpose of this study is to characterize the mechanical and geometric performance of three-dimensional (3-D) printed FFF 316 L metal components manufactured by a low-cost desktop 3-D printer. The debinding and sintering processes are carried out using the BASF catalytic debinding process in combination with the BASF 316LX Ultrafuse filament. Special attention is paid on the effects of build orientation and printing strategy of the FFF-based technology on the tensile and geometric performance of the 3-D printed 316 L metal specimens. Design/methodology/approach This study uses a toolset of experimental analysis techniques [metallography and scanning electron microcope (SEM)] to characterize the effect of microstructure and defects on the material properties under tensile testing. Shrinkage and the resulting porosity of the 3-D printed 316 L stainless steel sintered samples are also analysed. The deformation behaviour is investigated for three different build orientations. The tensile test curves are further correlated with the damage surface using SEM images and metallographic sections to present grain deformation during the loading progress. Mechanical properties are directly compared to other works in the field and similar additive manufacturing (AM) and Metal Injection Moulding (MIM) manufacturing alternatives from the literature. Findings It has been shown that the effect of build orientation was of particular significance on the mechanical and geometric performance of FFF-metal 3-D printed samples. In particular, Flat and On-edge samples showed an average increase in tensile performance of 21.7% for the tensile strength, 65.1% for the tensile stiffness and 118.3% for maximum elongation at fracture compared to the Upright samples. Furthermore, it has been able to manufacture near-dense 316 L austenitic stainless steel components using FFF. These properties are comparable to those obtained by other metal conventional processes such as MIM process. Originality/value 316L austenitic stainless steel components using FFF technology with a porosity lower than 2% were successfully manufactured. The presented study provides more information regarding the dependence of the mechanical, microstructural and geometric properties of FFF 316 L components on the build orientation and printing strategy.

scholarly journals Development of Antimicrobial PLA Composites for Fused Filament Fabrication

Polymers ◽  
2021 ◽  
Vol 13 (4) ◽  
pp. 580
Author(s):  
Zachary Brounstein ◽  
Chris M. Yeager ◽  
Andrea Labouriau
Keyword(s):  
3D Printing ◽  
Renewable Resources ◽  
Material Properties ◽  
Poly Lactic Acid ◽  
Poly Ethylene Glycol ◽  
Fused Filament Fabrication ◽  
Potential Growth ◽  
Thermal Phase ◽  
Poly Ethylene ◽  
Phase Behaviors

In addition to possessing the desirable properties of being a biodegradable and biocompatible polymer fabricated from renewable resources, poly (lactic acid) (PLA) has useful mechanical and thermal attributes that has enabled it to be one of the most widely-used plastics for medicine, manufacturing, and agriculture. Yet, PLA composites have not been heavily explored for use in 3D-printing applications, and the range of feasible materials for the technology is limited, which inhibits its potential growth and industry adoption. In this study, tunable, multifunctional antimicrobial PLA composite filaments for 3D-printing have been fabricated and tested via chemical, thermal, mechanical, and antimicrobial experiments. Thermally stable antimicrobial ceramics, ZnO and TiO2, were used as fillers up to 30 wt%, and poly (ethylene glycol) (PEG) was used as a plasticizer to tune the physical material properties. Results demonstrate that the PLA composite filaments exhibit the thermal phase behaviors and thermal stability suitable for 3D-printing. Additionally, PEG can be used to tune the mechanical properties while not affecting the antimicrobial efficacy that ZnO and TiO2 imbue.

scholarly journals Experimental and Theoretical Analysis on the Dynamic Characteristics of Fused Filament Fabrication Plates

2019 ◽  
Vol 2019 ◽  
pp. 1-9
Author(s):  
Shijie Jiang ◽  
Ming Zhan ◽  
Mingyu Sun ◽  
Weibing Dai ◽  
Chunyu Zhao
Keyword(s):  
Dynamic Characteristics ◽  
Material Properties ◽  
Theoretical Basis ◽  
Mechanical Performance ◽  
Dynamic Performance ◽  
Sem Analysis ◽  
Measured Data ◽  
Fused Filament Fabrication ◽  
Dynamic Mechanical

With the increasingly wide application of fused filament fabrication (FFF) technique, the built products are inevitably exposed to dynamic mechanical loading and vibration. However, there has been no systematic study in the literature on understanding and characterization of dynamic mechanical performance for FFF products. In this paper, the dynamic characteristics of FFF plates are quantified, with the effect of different extrusion width taken into account. A dynamic model of the built plate with cantilever boundary conditions is established, and the inherent characteristics are predicted. Modal tests are then performed on these samples to obtain the measured data. Through the comparison between predictions and measurements, the theoretical model is validated. Different extrusion width makes the material properties of the plates different, resulting in different dynamic characteristics. The scanning electron microscopy (SEM) analysis on the samples confirms that the dynamic characteristic is deteriorated as the extrusion width decreases. This present work provides theoretical basis and technical support for further research in improving the dynamic performance of FFF products and helps extend the applications of this technique.

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