Filament Rheological Characterization for Fused Filament Fabrication Additive Manufacturing: A Low-Cost Approach

2021 ◽  
pp. 102208
Author(s):  
Jingdong Chen ◽  
Douglas E. Smith
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Fused Filament Fabrication ◽  
Rheological Characterization ◽  
Cost Approach

scholarly journals Multiscale additive manufacturing of polymers using 3D photo-printable self-assembling ionic liquid monomers

2019 ◽  
Vol 4 (3) ◽  
pp. 580-585 ◽  
Author(s):  
Bineh G. Ndefru ◽  
Bryan S. Ringstrand ◽  
Sokhna I.-Y. Diouf ◽  
Sönke Seifert ◽  
Juan H. Leal ◽  
...  
Keyword(s):  
Ionic Liquid ◽  
Additive Manufacturing ◽  
Self Assembly ◽  
Low Cost ◽  
Low Resolution ◽  
Top Down ◽  
Bottom Up ◽  
Cost Approach ◽  
Self Assembling ◽  
Nanoscale Features

Combining bottom-up self-assembly with top-down 3D photoprinting affords a low cost approach for the introduction of nanoscale features into a build with low resolution features.

Design and Analysis of Hybrid Fused Filament Fabrication Apparatus for Fabrication of Composites

2021 ◽  
Vol 14 ◽  
Author(s):  
Aniket Yadav ◽  
Piyush Chohan ◽  
Ranvijay Kumar ◽  
Jasgurpreet Singh Chohan ◽  
Raman Kumar
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Design Process ◽  
Low Cost ◽  
Matrix Material ◽  
Fabrication Process ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Composite Manufacturing ◽  
Tool Paths

Background: Additive manufacturing is the most famous technology which requires materials or composites to be fabricated with layer by layer deposition strategy. Due to its lower cost, higher accuracy and less material wastage; this technology is used in almost every sector. But in many applications there is a need to alter the properties of a product in a certain direction with the help of some reinforcements. With the use of reinforcements, composite layers can be fabricated using additive manufacturing technique which will enhance the directional properties. A novel apparatus is designed to spray the reinforcement material into the printed structures in a very neat and precise manner. This spray nozzle is fully automated, which works according to tool-paths generated by slicing software. The alternate deposition of layers of reinforcement and build materials helped to fabricate customized composite products. Objective: The objective of present study is to design and analyze the working principle of novel technique which has been developed to fabricate composite materials using additive manufacturing. The apparatus is numerically controlled by computer according to CAD data which facilitates the deposition of alternate layers of reinforcement and matrix material. The major challenges during the design process and function of each component has been explored. Methods: The design process is initiated after comprehensive literature review performed to study previous composite manufacturing processes. The recent patents published by different patent offices of the world are studied in detail and analysis has been used to design a low cost composite fabrication apparatus. A liquid dispensing device comprises a storage tank attached with a pump and microprocessor. The microprocessor receives the signal from the computer as per tool paths generated by slicing software which decides the spray of reinforcements on polymer layers. The spraying apparatus moves in coordination with the primary nozzle of the Fused Filament Fabrication process. Results: The hybridization of Fused Filament Fabrication [process with metal spray process has been successfully performed. The apparatus facilitates the fabrication of low cost composite materials along with flexibility of complete customization of composite manufacturing process. The anisotropic behaviour of products can be easily controlled and managed during fabrication which can be used for different applications.

scholarly journals Processing of Sr2+ Containing Poly L-Lactic Acid-Based Hybrid Composites for Additive Manufacturing of Bone Scaffolds

2020 ◽  
Vol 7 ◽  
Author(s):  
Priscila Melo ◽  
Raasti Naseem ◽  
Ilaria Corvaglia ◽  
Giorgia Montalbano ◽  
Carlotta Pontremoli ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Lactic Acid ◽  
Additive Manufacturing ◽  
Hybrid Composites ◽  
Homogeneous Distribution ◽  
Fused Filament Fabrication ◽  
Rheological Characterization ◽  
Biodegradable Composite ◽  
Manufacturing Technologies

Biodegradable composite materials represent one of the major areas of investigation for bone tissue engineering due to their tuneable compositional and mechanical properties, which can potentially mimic those of bone and potentially avoid the removal of implants, mitigating the risks for the patient and reducing the overall clinical costs. In addition, the introduction of additive manufacturing technologies enables a strict control over the final morphological features of the scaffolds. In this scenario, the optimisation of 3D printable resorbable composites, made of biocompatible polymers and osteoinductive inorganic phases, offers the potential to produce a chemically and structurally biomimetic implant, which will resorb over time. The present work focuses on the development and process optimisation of two hybrid composite filaments, to be used as feedstock for the fused filament fabrication 3D printing process. A Poly L-lactic acid matrix was blended with either rod-like nano-hydroxyapatite (nano-HA) or nanoparticles of mesoporous bioactive glasses, both partially substituted with strontium (Sr2+), due to the well-known pro-osteogenic effect of this ion. Both inorganic phases were incorporated into Poly L-lactic acid using an innovative combination of processes, obtaining a homogeneous distribution throughout the polymer whilst preserving their ability to release Sr2+. The filament mechanical properties were not hindered after the incorporation of the inorganic phases, resulting in tensile strengths and moduli within the range of cancellous bone, 50 ± 10 MPa and 3 ± 1 GPa. Finally, the rheological characterization of the hybrid composites indicated a shear thinning behaviour, ideal for the processing with fused filament fabrication, proving the potential of these materials to be processed into 3D structures aiming bone regeneration.

Fused filament fabrication, debinding and sintering as a low cost additive manufacturing method of 316L stainless steel

2019 ◽  
Vol 30 ◽  
pp. 100861 ◽  
Author(s):  
Yvonne Thompson ◽  
Joamin Gonzalez-Gutierrez ◽  
Christian Kukla ◽  
Peter Felfer
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
316L Stainless Steel ◽  
Low Cost ◽  
Fused Filament Fabrication ◽  
Manufacturing Method

scholarly journals Dimensional Accuracy and Mechanical Properties of Chopped Carbon Reinforced Polymers Produced by Material Extrusion Additive Manufacturing

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3885 ◽  
Author(s):  
Evren Yasa ◽  
Kıvılcım Ersoy
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Modulus Of Elasticity ◽  
High Speed ◽  
Polymer Matrix Composites ◽  
Low Cost ◽  
Dimensional Accuracy ◽  
Fused Filament Fabrication ◽  
Material Extrusion ◽  
Pull Out

Fused Filament Fabrication (FFF), classified under material extrusion additive manufacturing technologies, is a widely used method for fabricating thermoplastic parts with high geometrical complexity. To improve the mechanical properties of pure thermoplastic materials, the polymeric matrix may be reinforced by different materials such as carbon fibers. FFF is an advantageous process for producing polymer matrix composites because of its low cost of investment, high speed and simplicity as well as the possibility to use multiple nozzles with different materials. In this study, the aim was to investigate the dimensional accuracy and mechanical properties of chopped carbon-fiber-reinforced tough nylon produced by the FFF process. The dimensional accuracy and manufacturability limits of the process are evaluated using benchmark geometries as well as process-inherent effects like stair-stepping effect. The hardness and tensile properties of produced specimens in comparison to tough nylon without any reinforcement, as well as continuous carbon-reinforced specimens, were presented by taking different build directions and various infill ratios. The fracture surfaces of tensile specimens were observed using a Scanning Electron Microscope (SEM). The test results showed that there was a severe level of anisotropy in the mechanical properties, especially the modulus of elasticity, due to the insufficient fusion between deposited layers in the build direction. Moreover, continuous carbon-reinforced specimens exhibited very high levels of tensile strength and modulus of elasticity whereas the highest elongation was achieved by tough nylon without reinforcement. The failure mechanisms were found to be inter-layer porosity between successive tracks, as well as fiber pull out.

Design for Fused Filament Fabrication Additive Manufacturing

2015 ◽  
Author(s):  
John Steuben ◽  
Douglas L. Van Bossuyt ◽  
Cameron Turner
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Low Cost ◽  
Industrial Applications ◽  
Manufacturing Technology ◽  
Fused Filament Fabrication ◽  
High Quality ◽  
Additive Manufacturing Technology ◽  
Mechanical Assemblies ◽  
3D Printers

In this paper, we explore the topic of Fused Filament Fabrication (FFF) 3D-printing. This is a low-cost additive manufacturing technology which is typically embodied in consumer-grade desktop 3D printers capable of producing useful parts, structures, and mechanical assemblies. The primary goal of our investigation is to produce an understanding of this process which can be employed to produce high-quality, functional engineered parts and prototypes. By developing this understanding, we create a resource which may be turned to by both researchers in the field of manufacturing science, and industrial professionals who are either considering the use of FFF-enabled technologies such as 3D printing, or those who have already entered production and are optimizing their fabrication process. In order to paint a cohesive picture for these readers, we examine several topic areas. We begin with an overview of the FFF process, its key hardware and software components, and the interrelationships between these components and the designer. With this basis, we then proceed to outline a set of design principles which facilitate the production of high quality printed parts, and discuss the selection of appropriate materials. Following naturally from this, we turn to the question of feedstock materials for FFF, and give advice for their selection and use. We then turn to the subject of the as-printed properties of FFF parts and the strong non-isotropic response that they exhibit. We discuss the root causes of this behavior and means by which its deleterious effects may be mitigated. We conclude by discussing a mixed numerical/experimental technique which we believe will enable the accurate characterization of FFF parts and structures, and greatly enhance the utility of this additive manufacturing technology. By formalizing and discussing these topics, we hope to motivate and enable the serious use of low-cost FFF 3D printing for both research and industrial applications.

scholarly journals Design of Shape Memory Thermoplastic Material Systems for FDM-Type Additive Manufacturing

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4254
Author(s):  
Paulina A. Quiñonez ◽  
Leticia Ugarte-Sanchez ◽  
Diego Bermudez ◽  
Paulina Chinolla ◽  
Rhyan Dueck ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Shape Memory ◽  
Thermomechanical Processing ◽  
Material Selection ◽  
Shape Memory Polymer ◽  
Fused Filament Fabrication ◽  
Materials Development ◽  
Thermoplastic Material ◽  
Polymer Systems ◽  
Injection Molded

The work presented here describes a paradigm for the design of materials for additive manufacturing platforms based on taking advantage of unique physical properties imparted upon the material by the fabrication process. We sought to further investigate past work with binary shape memory polymer blends, which indicated that phase texturization caused by the fused filament fabrication (FFF) process enhanced shape memory properties. In this work, two multi-constituent shape memory polymer systems were developed where the miscibility parameter was the guide in material selection. A comparison with injection molded specimens was also carried out to further investigate the ability of the FFF process to enable enhanced shape memory characteristics as compared to other manufacturing methods. It was found that blend combinations with more closely matching miscibility parameters were more apt at yielding reliable shape memory polymer systems. However, when miscibility parameters differed, a pathway towards the creation of shape memory polymer systems capable of maintaining more than one temporary shape at a time was potentially realized. Additional aspects related to impact modifying of rigid thermoplastics as well as thermomechanical processing on induced crystallinity are also explored. Overall, this work serves as another example in the advancement of additive manufacturing via materials development.

Fused Filament Fabrication 3D Printed Polylactic Acid Electroosmotic Pumps

Lab on a Chip ◽  
2021 ◽  
Author(s):  
Liang Wu ◽  
Stephen Beirne ◽  
Joan-Marc Cabot Canyelles ◽  
Brett Paull ◽  
Gordon G. Wallace ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Polylactic Acid ◽  
Fused Filament Fabrication ◽  
Flexible Approach ◽  
Electroosmotic Pump ◽  
3D Printed ◽  
Electroosmotic Pumps

Additive manufacturing (3D printing) offers a flexible approach for the production of bespoke microfluidic structures such as the electroosmotic pump. Here a readily accessible fused filament fabrication (FFF) 3D printing...

The influence of infill density gradient on the mechanical properties of PLA optimized structures by additive manufacturing

2021 ◽  
pp. 146442072110071
Author(s):  
AIL Pais ◽  
C Silva ◽  
MC Marques ◽  
JL Alves ◽  
J Belinha
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Additive Manufacturing ◽  
Structural Optimization ◽  
Meshless Method ◽  
Load Case ◽  
Fused Filament Fabrication ◽  
Ductile Metals ◽  
Four Point Bending ◽  
Bending Load

The aim of this work is the development of a novel framework for structural optimization using bio-inspired remodelling algorithm adapted to additive manufacturing. The fact that polylactic acid (PLA, E = 3145 MPa (Young’s modulus) according to the supplier for parts obtained by injection) shows a similar parameterized behavior with ductile metals, in the sense that both materials are characterized by a bi-linear elastic-plastic law, allows to simulate and prototype parts to be further constructed in ductile metals at a lower cost and then be produced with more expensive fabrication processes. Moreover, cellular materials allow for a significant weight reduction and therefore reduction of production costs. Structural optimization algorithms based on biological phenomena were used to determine the density distribution of the infill density of the specimens. Several simple structures were submitted to distinct complex load cases and analyzed using the mentioned optimization algorithms combined with the finite element method and a meshless method. The surface was divided according to similar density and then converted to stereolitography files and infilled with the gyroid structure at the desired density determined before, using open-source slicing software. Smoothing functions were used to smooth the density field obtained with the remodeling algorithms. The samples were printed with fused filament fabrication technology and submitted to mechanical flexural tests similar to the ones analyzed analytically, namely three- and four-point bending tests. Thus, the factors of analysis were the smoothing parameter and the remodeling method, and the responses evaluated were stiffness, specific stiffness, maximum force, and mass. The experimental results correlated (obtaining accuracy of 35% for the three-point bending load case and 5% for the four-point bending load case) to the numerical results in terms of flexural stiffness and it was found that the complexity of the load case is relevant for the efficiency of the functional gradient. The fused filament fabrication process is still not accurate enough to be able to experimentally compare the results based of finite element method and meshless method analyses.

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