Fused filament fabrication printing process of polymers highly filled with metallic powder: a significant influence of the nozzle radiation on the substrate temperature

2021 ◽  
Author(s):  
A. Thézé ◽  
G. Régnier ◽  
A. Guinault ◽  
S. Richard ◽  
B. Macquaire
Keyword(s):  
Substrate Temperature ◽  
Significant Influence ◽  
Metallic Powder ◽  
Fused Filament Fabrication ◽  
Printing Process

Temperature-compensated constitutive model of fused filament fabrication 3D printed PLA materials with full extrusion temperatures

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Kaiyang Zhu ◽  
Zichen Deng ◽  
Shi Dai ◽  
Yajun Yu
Keyword(s):  
Mechanical Properties ◽  
Thermal Decomposition ◽  
Constitutive Model ◽  
Polylactic Acid ◽  
Extrusion Temperature ◽  
Fused Filament Fabrication ◽  
Printing Process ◽  
Content Type ◽  
3D Printed ◽  
Interlayer Bonding

Purpose This study aims to focus on the effect of interlayer bonding and thermal decomposition on the mechanical properties of fused filament fabrication-printed polylactic acid specimens at high extrusion temperatures. Design/methodology/approach A printing process, that is simultaneous manufacturing of contour and specimen, is used to improve the printing accuracy at high extrusion temperatures. The effects of the extrusion temperature on the mechanical properties of the interlayer and intra-layer are evaluated via tensile experiments. In addition, the microstructure evolution affected by the extrusion temperature is observed using scanning electron microscopy. Findings The results show that the extrusion temperature can effectively improve the interlayer bonding property; however, the mechanical properties of the specimen for extrusion temperatures higher than 270°C may worsen owing to the thermal decomposition of the polylactic acid (PLA) material. The optimum extrusion temperature of PLA material in the three-dimensional (3D) printing process is recommended to be 250–270°C. Originality/value A temperature-compensated constitutive model for 3D printed PLA material under different extrusion temperatures is proposed. The present work facilitates the prediction of the mechanical properties of specimens at an extrusion temperature for different printing temperatures and different layers.

Problems of Producing Thin-Walled and Elastic Elements by Selective Laser Sintering

2014 ◽  
Vol 223 ◽  
pp. 191-198 ◽  
Author(s):  
Tomasz Kozior
Keyword(s):  
Process Parameters ◽  
Significant Influence ◽  
Selective Laser Sintering ◽  
Additive Technology ◽  
Printing Process ◽  
Strength Tests ◽  
Thin Walled ◽  
Polyamide Powder ◽  
Printing Processes ◽  
Elastic Elements

The article describes the technology of making thin-walled components and elastic by additive technology SLS using a polyamide powder PA 2200. The characteristics of the selected elements and the results of their strength tests are presented. The research focuses on the anisotropy of the materials in the various models. Printing processes were investigated on surfaces perpendicular and parallel to the axis of the model. Based on measurements of deformation, coefficients of elasticity, and the influence of selected parameters of the printing process, the accuracy of tested elements were determined. Comparing results of the research indicated that there is a significant influence of direction and printing process parameters on elastic properties. Research can be helpful in the future in the design process of elastic and thin-walled components such as springs and bellows.

Health Monitoring Using Acoustic Emission Technique During Fused Filament Fabrication Printing Process

2021 ◽  
Author(s):  
Ke Xu ◽  
Souran Manoochehri
Keyword(s):  
Acoustic Emission ◽  
Real Time ◽  
In Situ Monitoring ◽  
Fused Filament Fabrication ◽  
Printing Process ◽  
Process Reliability ◽  
Ae Signal ◽  
The Time Domain ◽  
Manufacturing Technologies ◽  
Key Indicators

Abstract Fused Filament Fabrication (FFF) is one of the most popular additive manufacturing technologies for manufacturing prototypes with various complex geometries. However, current commercial FFF machines have limitations in terms of process reliability and product quality. In order to overcome these limitations and improve the accuracy and reliability of these machines, a real-time monitoring system is needed to make sure that any part defects can be detected during the printing process and printing parameters can be identified that can be modified to resolve the printing anomalies resulting in minimization of waste and improvement of efficiency. In this study, a method for in-situ monitoring of FFF machine conditions is proposed utilizing an acoustic emission (AE) technology. The AE sensor is used to monitor the vibration signals generated during the whole printing process in real-time. The AE signal is then analyzed and processed, and categorized according to the selected objective characteristics. The proposed method can be utilized to identify the abnormal states of machine conditions. The time-domain features of AE hits after post-processing are used as key indicators. Experimental results show that this method has the potential to be used as a non-invasive diagnostic and prognostic tool for FFF machine maintenance and process control.

scholarly journals Increasing of Strength of FDM (FFF) 3D Printed Parts by Influencing on Temperature-Related Parameters of the Process

2018 ◽  
Author(s):  
Vladimir E. Kuznetsov ◽  
Alexey N. Solonin ◽  
Azamat G. Tavitov ◽  
Oleg D. Urzhumtsev ◽  
Anna H. Vakulik
Keyword(s):  
Bulk Material ◽  
Fracture Load ◽  
Material Strength ◽  
Thermal Imager ◽  
Fused Filament Fabrication ◽  
Printing Process ◽  
Temperature Conditions ◽  
Two Factors ◽  
Related Stress ◽  
Point Bend

Current work investigates how user-controlled parameters of 3D printing process define temperature conditions on the boundary between layers of the part being fabricated and how these conditions influence structure and strength of the part. The process studied is fused filament fabrication with a desktop 3D printer and the material utilized is PLA (polylactic acid). As a characteristic of the part strength the fracture load in the case of a three-point bend and calculated related stress were used. During the printing process parts were oriented the long side along the Z axis, thus, in the bend tests, the maximum stress occurred orthogonally to the layers. During the fabrication process temperature distribution on the samples surface was monitored with thermal imager. Sample mesostructure was analyzed using SEM. The influence of the extrusion temperature, the intensity of part cooling, the printing speed and the time between printing individual layers were considered. The influence of all the parameters can be expressed through two generalizing factors: the temperature of the previous layer and the flow efficiency, determining the ratio of the amount of extruded plastic to the calculated. A regression model was proposed that describes the effect of the two factors on the printed part strength. Along with interlayer bonding strength, these two factors determine the formation of the part mesostructure (the geometry of the boundaries between individual threads). It is shown that the optimization of the process parameters responsible for temperature conditions makes it possible to approximate the strength of the interlayer cohesion to the bulk material strength.

scholarly journals Increasing of Strength of FDM (FFF) 3D Printed Parts by Influencing on Temperature-Related Parameters of the Process

2018 ◽  
Author(s):  
Vladimir E. Kuznetsov ◽  
Alexey N. Solonin ◽  
Azamat G. Tavitov ◽  
Oleg D. Urzhumtsev ◽  
Anna H. Vakulik
Keyword(s):  
Bulk Material ◽  
Sample Surface ◽  
Fracture Load ◽  
Material Strength ◽  
Thermal Imager ◽  
Fused Filament Fabrication ◽  
Printing Process ◽  
Temperature Conditions ◽  
Two Factors ◽  
Related Stress

This work investigates how the user-controlled parameters of the 3D printing process define temperature conditions on the boundary between layers of the part being fabricated and how these conditions influence the structure and strength of the part. The process studied is fused filament fabrication with a desktop 3D printer and the material utilized is PLA (polylactic acid). As a characteristic of the part strength the fracture load in the case of a three-point bend and calculated related stress were used. During the printing process parts were oriented with the long side along the Z axis, thus, in the bend tests, the maximum stress occurred orthogonally to the layers. During the fabrication process, temperature distribution on the sample surface was monitored with thermal imager. Sample mesostructure was analyzed using SEM. The influence of the extrusion temperature, the intensity of part cooling, the printing speed and the time between printing individual layers were considered. The influence of all the parameters can be expressed through two generalizing factors: the temperature of the previous layer and the flow efficiency, determining the ratio of the amount of extruded plastic to the calculated. A regression model was proposed that describes the effect of the two factors on the printed part strength. Along with interlayer bonding strength, these two factors determine the formation of the part mesostructure (the geometry of the boundaries between individual threads). It is shown that the optimization of the process parameters responsible for temperature conditions makes it possible to approximate the strength of the interlayer cohesion to the bulk material strength.

scholarly journals Real-Time 3D Printing Remote Defect Detection (Stringing) with Computer Vision and Artificial Intelligence

Processes ◽  
2020 ◽  
Vol 8 (11) ◽  
pp. 1464
Author(s):  
Konstantinos Paraskevoudis ◽  
Panagiotis Karayannis ◽  
Elias P. Koumoulos
Keyword(s):  
Neural Networks ◽  
Computer Vision ◽  
3D Printing ◽  
Large Scale ◽  
Video Camera ◽  
Fused Filament Fabrication ◽  
Printing Process ◽  
3D Printed ◽  
Live Environment ◽  
Printing Parameters

This work describes a novel methodology for the quality assessment of a Fused Filament Fabrication (FFF) 3D printing object during the printing process through AI-based Computer Vision. Specifically, Neural Networks are developed for identifying 3D printing defects during the printing process by analyzing video captured from the process. Defects are likely to occur in 3D printed objects during the printing process, with one of them being stringing; they are mostly correlated to one of the printing parameters or the object’s geometries. The defect stringing can be on a large scale and is usually located in visible parts of the object by a capturing camera. In this case, an AI model (Deep Convolutional Neural Network) was trained on images where the stringing issue is clearly displayed and deployed in a live environment to make detections and predictions on a video camera feed. In this work, we present a methodology for developing and deploying deep neural networks for the recognition of stringing. The trained model can be successfully deployed (with appropriate assembly of required hardware such as microprocessors and a camera) on a live environment. Stringing can be then recognized in line with fast speed and classification accuracy. Furthermore, this approach can be further developed in order to make adjustments to the printing process. Via this, the proposed approach can either terminate the printing process or correct parameters which are related to the identified defect.

scholarly journals Quality Characteristics and Clinical Relevance of In-House 3D-Printed Customized Polyetheretherketone (PEEK) Implants for Craniofacial Reconstruction

2020 ◽  
Vol 9 (9) ◽  
pp. 2818
Author(s):  
Neha Sharma ◽  
Soheila Aghlmandi ◽  
Shuaishuai Cao ◽  
Christoph Kunz ◽  
Philipp Honigmann ◽  
...  
Keyword(s):  
Dimensional Accuracy ◽  
Quality Characteristics ◽  
Patient Specific ◽  
Class Iii ◽  
Fused Filament Fabrication ◽  
Craniofacial Reconstruction ◽  
Printing Process ◽  
Alloplastic Materials ◽  
Group 2 ◽  
Group 1

Additive manufacturing (AM) of patient-specific implants (PSIs) is gradually moving towards in-house or point-of-care (POC) manufacturing. Polyetheretherketone (PEEK) has been used in cranioplasty cases as a reliable alternative to other alloplastic materials. As only a few fused filament fabrication (FFF) printers are suitable for in-house manufacturing, the quality characteristics of the implants fabricated by FFF technology are still under investigated. This paper aimed to investigate PEEK PSIs fabricated in-house for craniofacial reconstruction, discussing the key challenges during the FFF printing process. Two exemplary cases of class III (Group 1) and class IV (Group 2) craniofacial defects were selected for the fabrication of PEEK PSIs. Taguchi’s L9 orthogonal array was selected for the following nonthermal printing process parameters, i.e., layer thickness, infill rate, number of shells, and infill pattern, and an assessment of the dimensional accuracy of the fabricated implants was made. The root mean square (RMS) values revealed higher deviations in Group 1 PSIs (0.790 mm) compared to Group 2 PSIs (0.241 mm). Horizontal lines, or the characteristic FFF stair-stepping effect, were more perceptible across the surface of Group 1 PSIs. Although Group 2 PSIs revealed no discoloration, Group 1 PSIs displayed different zones of crystallinity. These results suggest that the dimensional accuracy of PSIs were within the clinically acceptable range; however, attention must be paid towards a requirement of optimum thermal management during the printing process to fabricate implants of uniform crystallinity.

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