Integrated laser-based powder bed fusion and fused filament fabrication for three-dimensional printing of hybrid metal/polymer objects

Apertures for small-angle neutron scattering prepared from a boron carbide/polymer composite have been made by three-dimensional printing using fused filament fabrication. Use of enriched 10B4C gives higher absorption and much lower parasitic scattering than natural B4C. The simple fabrication, the capability to replace toxic and environmentally hazardous materials such as cadmium, and the possibility to diminish the secondary background of γ-radiation are attractive features of use of these materials. Complex shapes, apart from apertures, can be fabricated readily with this composite, for example, to make shielding for instrument components and masks used to calibrate detectors.

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Three-Dimensional Printing of Stainless Steel Parts

Materials Science Forum ◽

10.4028/www.scientific.net/msf.591-593.374 ◽

2008 ◽

Vol 591-593 ◽

pp. 374-379 ◽

Cited By ~ 2

Author(s):

Efrain Carreño-Morelli ◽

Sebastien Martinerie ◽

Lisa Mucks ◽

B. Cardis

Keyword(s):

Mechanical Properties ◽

Stainless Steel ◽

Three Dimensional ◽

Tensile Tests ◽

Layer By Layer ◽

Metal Powders ◽

Selective Deposition ◽

Three Dimensional Printing ◽

Dimensional Printing ◽

Metal Polymer

Stainless steel parts have been manufactured by two different layer by layer additive processes. The first one is a standard three dimensional process, in which metal powders are bound by selective deposition of binder with a printer head. The second one is a novel process, which is based on the selective deposition of a solvent on metal-polymer granule beds. The microstructures of green and sintered parts are characterized by optical and scanning electron microscopy, and the mechanical properties evaluated by hardness and tensile tests. Solvent on granule printing allows to reach mechanical properties similar to those of metal injection moulding parts.

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Three Dimensional Printing: Surface Finish and Microstructure of Rapid Prototyped Components

MRS Proceedings ◽

10.1557/proc-249-331 ◽

1991 ◽

Vol 249 ◽

Cited By ~ 11

Author(s):

A. Lauder ◽

M.J. Cima ◽

E. Sachs ◽

T. Fan

Keyword(s):

Surface Finish ◽

Three Dimensional ◽

Thin Layers ◽

Powder Bed ◽

Three Dimensional Printing ◽

Powder Density ◽

Jet Printing ◽

Scan Pattern ◽

Functional Components ◽

Dimensional Printing

ABSTRACTThree Dimensional Printing is a process for rapid prototyping of functional components. Thin layers of powder are bound in selected areas by ink-jet printing of a liquid binder. Layers are added sequentially until a three dimensional part is completed. The unbound powder is then removed. The raster scan pattern and layering used in forming has an observable effect on the surface finish and microstructure of the part, as does the chemistry of the particular materials system used. Important phenomena include ballistic interaction of the jet with the powder bed and wicking of the binder. Process parameters such as layer height, flow rate, and powder density were studied. Microstructural examination of the printed components is also reported.

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Microscopic analysis on dimensional capability of fused filament fabrication three-dimensional printing process

Journal of Elastomers & Plastics ◽

10.1177/00952443211047263 ◽

2021 ◽

pp. 009524432110472

Author(s):

Ans Al Rashid ◽

Sikandar Abdul Qadir ◽

Muammer Koç

Keyword(s):

Three Dimensional ◽

Dimensional Accuracy ◽

Process Conditions ◽

Fused Filament Fabrication ◽

Three Dimensional Printing ◽

Dimensional Measurement ◽

Taguchi’S Design Of Experiments ◽

Functional Components ◽

Accuracy And Repeatability ◽

Dimensional Printing

Fused Filament Fabrication (FFF) has been the most widely used three-dimensional printing (3DP) technology due to its cost-effectiveness, easy application, and material readiness. FFF, to date, has been used to fabricate polymer components for rapid prototyping and increasingly for some end-user applications. Thus, there is a pressing need to optimize 3DP process parameters for FFF materials to achieve higher dimensional accuracy, especially in functional components for final use applications. Therefore, to ensure desired geometries with reasonable accuracy, precise measurements are required to validate the FFF process’s dimensional capability under different process conditions. This study presents the dimensional measurement and statistical analysis to evaluate the effect of printing materials, speed, and layer heights on dimensional accuracy and repeatability of the commercial FFF process. A benchmark part model was designed with different external and internal features commonly used in manufacturing processes. Taguchi’s design of experiments (DOE) was employed to obtain the experiments scheme, followed by the 3DP, dimensional measurement, and analysis of 3DP samples. Results revealed polylactic acid (PLA) material provided better dimensional control in most of the features. Higher printing speeds and layer heights were found optimum for external features/protrusions, whereas lower-to-medium speeds and layer heights were more appropriate for the fabrication of internal features.

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New Process and Materials Developments in 3-Dimensional Printing, 3DP™

MRS Proceedings ◽

10.1557/proc-542-153 ◽

1998 ◽

Vol 542 ◽

Cited By ~ 21

Author(s):

S. A. Uhland ◽

R. K. Holman ◽

M. J. Cima ◽

E. Sachs ◽

Y. Enokido

Keyword(s):

Three Dimensional ◽

Rf Filters ◽

Powder Bed ◽

Three Dimensional Printing ◽

3 Dimensional ◽

System A ◽

Ink Jet ◽

Jet Printing ◽

Major Factors ◽

Dimensional Printing

AbstractThe Three-Dimensional Printing (3DP™) process has been modified to incorporate colloidal science for the fabrication of fine ceramic parts. Complex shaped alumina and silicon nitride components have been formed directly from 3-dimensional CAD files using submicron powders. Parts were built using a sequential layering process of the ceramic slurry followed by ink jet printing of a binder system. A well dispersed slurry and optimized printing parameters are required to form a uniform powder bed with a high green density. Liquid-powder bed interactions affect the geometry and internal structure of the component. The redispersion of the unprinted powder bed is critical in order to retrieve the printed components. The slurry and powder bed chemistry are the major factors controlling powder bed redispersion. The process is generic and can be readily adapted for new materials systems. Our research is currently focused on the fabrication of dielectric RF filters. Preliminary results have demonstrated the ability to successfully fabricate cylindrical RF resonators.

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Evaluating the Electrical Conductivity and Resistivity of Carbon Nanostructures Embedded in the PLA Matrix

Letters in Applied NanoBioScience ◽

10.33263/lianbs93.11411146 ◽

2020 ◽

Vol 9 (3) ◽

pp. 1141-1146

Keyword(s):

Polymer Nanocomposites ◽

Electrical Resistance ◽

Carbon Nanostructures ◽

Three Dimensional ◽

Xrd Analysis ◽

Resin Matrix ◽

Electronic Circuits ◽

Fused Filament Fabrication ◽

Three Dimensional Printing ◽

Dimensional Printing

In this work, we evaluated the fabrication and three-dimensional printing (3DP) of conductive filaments intended for designing electronic circuits using fused filament fabrication (FFF). For this 15 wt. % of graphene (GR), carbon black (CB) and carbon nanotubes (CNTs) were embedded into thermoplastic polylactic acid (PLA) resin matrix. Measurements of electrical resistance and conductivity, SEM, DSC, and XRD analysis were used to characterize the materials. The resistivity of the polymer nanocomposites was found to be between 0,7 and 1,4 Ω/cm and conductivity ranging between 0,71 and 1,42 S/cm, respectively.

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Mechanical and thermal performance of additively manufactured copper, silver and copper–silver alloys

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/14644207211040929 ◽

2021 ◽

pp. 146442072110409

Author(s):

John Robinson ◽

Arun Arjunan ◽

Ahmad Baroutaji ◽

Mark Stanford

Keyword(s):

Tensile Strength ◽

Ultimate Tensile Strength ◽

Thermal Performance ◽

Mechanical Performance ◽

Three Dimensional ◽

Powder Bed Fusion ◽

Laser Powder Bed Fusion ◽

Powder Bed ◽

Three Dimensional Printing ◽

Industry Standard

On-demand additive manufacturing (three-dimensional printing) offers great potential for the development of functional materials for the next generation of energy-efficient devices. In particular, novel materials suitable for efficient dissipation of localised heat fluxes and non-uniform thermal loads with superior mechanical performance are critical for the accelerated development of future automotive, aerospace and renewable energy technologies. In this regard, this study reports the laser powder bed fusion processing of high purity (>99%) copper (Cu), silver (Ag) and novel copper–silver (CuAg) alloys ready for on-demand additive manufacturing. The processed materials were experimentally analysed for their relative density, mechanical and thermal performance using X-ray computed tomography, destructive tensile testing and laser flash apparatus, respectively. It was found that while Ag featured higher failure strains, Cu in comparison showed a 109%, 17% and 59% improvement in yield strength ([Formula: see text]), Young’s modulus ( E) and ultimate tensile strength, respectively. As such the [Formula: see text], E and ultimate tensile strength for laser powder bed fusion Cu is comparable to commercially available laser powder bed fusion Cu materials. CuAg alloys, however, significantly outperformed Ag, Cu and all commercial Cu materials when it came to mechanical performance offering significantly superior performance. The [Formula: see text], E and ultimate tensile strength for the novel CuAg composition were 105%, 33% and 94% higher in comparison to Cu. Although slightly different, the trend continued with a 106% and 91% rise for [Formula: see text] and ultimate tensile strength, respectively, for CuAg in comparison to industry-standard Cu. Unfortunately, E values for industry-standard Cu alloys were not available. When it came to thermal performance, laser powder bed fusion Ag was found to offer a 70% higher thermal diffusivity in comparison to Cu despite the variation in density and porosity. CuAg alloys however only showed a 0.8% variation in thermal performance despite a 10–30% increase in Ag. Overall, the study presents a new understanding regarding the three-dimensional printing and performance of Cu, Ag and CuAg alloys.

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Thermal Deformations of Thermoplast during 3D Printing: Warping in the Case of ABS

Materials ◽

10.3390/ma14227070 ◽

2021 ◽

Vol 14 (22) ◽

pp. 7070

Author(s):

Jakub Ramian ◽

Jan Ramian ◽

Daniel Dziob

Keyword(s):

Three Dimensional ◽

Acrylonitrile Butadiene Styrene ◽

Fused Filament Fabrication ◽

Three Dimensional Printing ◽

Thermal Deformations ◽

Whole Process ◽

Bed Temperature ◽

Nozzle Temperature ◽

Dimensional Printing ◽

Butadiene Styrene

This research focuses on thermal deformations of thermoplast during three-dimensional printing. A filament acrylonitrile butadiene styrene was used, and the main focus was put on warping. Twenty-seven cuboids divided in six categories by their length, height, surface area, color, nozzle temperature and bed temperature were printed by Fused Filament Fabrication 3D printer. The whole process was captured by a thermal camera and the movies were used to analyze the temperature distribution during printing. All printouts were measured and scanned with a 3D scanner in order to highlight any abbreviations from the original digital models. The obtained results were used to formulate some general conclusions on the influence of selected parameters on the warping process. Based on the outcomes of the study, a set of guidelines on how to minimalize warping was proposed.

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