Additive manufacturing of an automotive brake pedal by metal fused deposition modelling

Author(s):  
M.I.M. Sargini ◽  
S.H. Masood ◽  
Suresh Palanisamy ◽  
Elammaran Jayamani ◽  
Ajay Kapoor
2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Wiktoria Maria Wojnarowska ◽  
Jakub Najowicz ◽  
Tomasz Piecuch ◽  
Michał Sochacki ◽  
Dawid Pijanka ◽  
...  

Purpose Chicken orthoses that cover the ankle joint area are not commercially available. Therefore, the main purpose of this study is to fabricate a customised temporary Ankle–Foot Orthosis (AFO) for a chicken with a twisted ankle using computer-aided design (CAD) and three-dimensional (3D) printing. The secondary objective of the paper is to present the specific application of Additive Manufacturing (AM) in veterinary medicine. Design/methodology/approach The design process was based on multiple sketches, photos and measurements that were provided by the owner of the animal. The 3D model of the orthosis was made with Autodesk Fusion 360, while the prototype was fabricated using fused deposition modelling (FDM). Evaluation of the AFO was performed using the finite element method. Findings The work resulted in a functional 3D printed AFO for chicken. It was found that the orthosis made with AM provides satisfactory stiffen and a good fit. It was concluded that AM is suitable for custom bird AFO fabrication and, in some respects, is superior to traditional manufacturing methods. It was also concluded that the presented procedure can be applied in other veterinary cases and to other animal species and other parts of their body. AM provides veterinary with a powerful tool for the production of well-fitted and durable orthoses for animals. Research limitations/implications The study does not include the chicken's opinion on the comfort or fit of the manufactured AFO due to communication issues. Evaluation of the final prototype was done by the researchers and the animal owner. Originality/value No evidence was found in the literature on the use of AM for chicken orthosis, so this study is the first to describe such an application of AM. In addition, the study demonstrates the value of AM in veterinary medicine, especially in the production of devices such as orthoses.


TEM Journal ◽  
2020 ◽  
pp. 966-970
Author(s):  
Damir Hodžić ◽  
Adi Pandžić ◽  
Ismar Hajro ◽  
Petar Tasić

Widely used additive manufacturing technique for plastic materials is Fused Deposition Modelling (FDM). The FDM technology has gained interest in industry for a wide range of applications, especially today when large number of different materials on the market are available. There are many different manufacturers for the same FDM material where the difference in price goes up to 50%. This experimental study investigates possible difference in strength of the 3D printed PLA material of five different manufacturers. All specimens are 3D printed on Ultimaker S5 printer with the same printing parameters, and they are all the same colour.


2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mattia Mele ◽  
Michele Ricciarelli ◽  
Giampaolo Campana

Purpose Powder bed additive manufacturing processes are widespread due to their many technical and economic advantages. Nevertheless, the disposal of leftover powder poses a problem in terms of process sustainability. The purpose of this paper is to provide an alternative solution to recycle waste PA12 powder from HP multi jet fusion. In particular, the opportunity to use this material as a dispersion in three-dimensional (3D) printed clay is investigated. Design/methodology/approach A commercial fused deposition modelling printer was re-adapted to extrude a viscous paste composed of clay, PA12 and water. Once printed, parts were dried and then put in an oven to melt the polymer fraction. Four compositions with different PA12 concentration were studied. First, the extrudability of the paste was observed by testing different extrusion lengths. Then, the surface porosities were evaluated through microscopical observations of the manufactured parts. Finally, benchmarks with different geometries were digitalised via 3D scanning to analyse the dimensional alterations arising at each stage of the process. Findings Overall, the feasibility of the process is demonstrated. Extrusion tests revealed that the composition of the paste has a minor influence on the volumetric flow rate, exhibiting a better consistency in the case of long extrusions. The percentage of surface cavities was proportional to the polymer fraction contained in the mix. From dimensional analyses, it was possible to conclude that PA12 reduced the degree of shrinkage during the drying phase, while it increased dimensional alterations occurring in the melting phase. The results showed that the dimensional error measured on the z-axis was always higher than that of the XY plane. Practical implications The method proposed in this paper provides an alternative approach to reuse leftover powders from powder bed fusion processes via another additive manufacturing process. This offers an affordable and open-source solution to companies dealing with polymer powder bed fusion, allowing them to reduce their environmental impacts while expanding their production. Originality/value The paper presents an innovative additive manufacturing solution for powder reuse. Unlike the recycling methods in the body of literature, this solution does not require any intermediate transformation process, such as filament fabrication. Also, the cold material deposition enables the adoption of very inexpensive extrusion equipment. This preliminary study demonstrates the feasibility and the benefits of this process, paving the way for numerous future studies.


2020 ◽  
Vol 26 (4) ◽  
pp. 669-687 ◽  
Author(s):  
Sathies T. ◽  
Senthil P. ◽  
Anoop M.S.

Purpose Fabrication of customized products in low volume through conventional manufacturing incurs a high cost, longer processing time and huge material waste. Hence, the concept of additive manufacturing (AM) comes into existence and fused deposition modelling (FDM), is at the forefront of researches related to polymer-based additive manufacturing. The purpose of this paper is to summarize the research works carried on the applications of FDM. Design/methodology/approach In the present paper, an extensive review has been performed related to major application areas (such as a sensor, shielding, scaffolding, drug delivery devices, microfluidic devices, rapid tooling, four-dimensional printing, automotive and aerospace, prosthetics and orthosis, fashion and architecture) where FDM has been tested. Finally, a roadmap for future research work in the FDM application has been discussed. As an example for future research scope, a case study on the usage of FDM printed ABS-carbon black composite for solvent sensing is demonstrated. Findings The printability of composite filament through FDM enhanced its application range. Sensors developed using FDM incurs a low cost and produces a result comparable to those conventional techniques. EMI shielding manufactured by FDM is light and non-oxidative. Biodegradable and biocompatible scaffolds of complex shapes are possible to manufacture by FDM. Further, FDM enables the fabrication of on-demand and customized prosthetics and orthosis. Tooling time and cost involved in the manufacturing of low volume customized products are reduced by FDM based rapid tooling technique. Results of the solvent sensing case study indicate that three-dimensional printed conductive polymer composites can sense different solvents. The sensors with a lower thickness (0.6 mm) exhibit better sensitivity. Originality/value This paper outlines the capabilities of FDM and provides information to the user about the different applications possible with FDM.


Coatings ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 457 ◽  
Author(s):  
Philipp Sauerbier ◽  
James Anderson ◽  
Douglas Gardner

Recent advances in large-scale thermoplastic additive manufacturing (AM), using fused deposition modelling (FDM), have shown that the technology can effectively produce large aerospace tools with common feed stocks, costing 2.3 $/kg, such as a 20% carbon-filled acrylonitrile butadiene styrene (ABS). Large-scale additive manufacturing machines have build-volumes in the range of cubic meters and use commercially available pellet feedstock thermoplastics, which are significantly cheaper (5–10 $/kg) than the filament feedstocks for desktop 3D printers (20–50 $/kg). Additionally, large-scale AM machines have a higher material throughput on the order of 50 kg/h. This enables the cost-efficient tool production for several industries. Large-scale 3D-printed tooling will be computerized numerical control (CNC)-machined and -coated, to provide a surface suitable for demolding the composite parts. This paper outlines research undertaken to review and improve the adhesion of the coating systems to large, low-cost AM composite tooling, for marine or infrastructure composite applications. Lower cost tooling systems typically have a lower dimensional accuracy and thermal operating requirements than might be required for aerospace tooling. As such, they can use lower cost commodity grade thermoplastics. The polymer systems explored in the study included polypropylene (PP), styrene-maleic anhydride (SMA), and polylactic acid (PLA). Bio-based filler materials were used to reduce cost and increase the strength and stiffness of the material. Fillers used in the study included wood flour, at 30% by weight and spray-dried cellulose nano-fibrils, at 20% by weight. Applicable adhesion of the coating was achieved with PP, after surface treatment, and untreated SMA and PLA showed desirable coating adhesion results. PLA wood-filled composites offered the best properties for the desired application and, furthermore, they have environment-friendly advantages.


Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 672 ◽  
Author(s):  
Elena Verdejo de Toro ◽  
Juana Coello Sobrino ◽  
Alberto Martínez Martínez ◽  
Valentín Miguel Eguía ◽  
Jorge Ayllón Pérez

New technologies are offering progressively more effective alternatives to traditional ones. Additive Manufacturing (AM) is gaining importance in fields related to design, manufacturing, engineering and medicine, especially in applications which require complex geometries. Fused Deposition Modelling (FDM) is framed within AM as a technology in which, due to their layer-by-layer deposition, thermoplastic polymers are used for manufacturing parts with a high degree of accuracy and minimum material waste during the process. The traditional technology corresponding to FDM is Polymer Injection Moulding, in which polymeric pellets are injected by pressure into a mould using the required geometry. The increasing use of PA6 in Additive Manufacturing makes it necessary to study the possibility of replacing certain parts manufactured by injection moulding with those created using FDM. In this work, PA6 was selected due to its higher mechanical properties in comparison with PA12. Moreover, its higher melting point has been a limitation for 3D printing technology, and a further study of composites made of PA6 using 3D printing processes is needed. Nevertheless, analysis of the mechanical response of standardised samples and the influence of the manufacturing process on the polyamide’s mechanical properties needs to be carried out. In this work, a comparative study between the two processes was conducted, and conclusions were drawn from an engineering perspective.


2019 ◽  
Vol 821 ◽  
pp. 137-143 ◽  
Author(s):  
Pavan Kumar Gurrala ◽  
Brijesh Tripathi

In the current technological evolution, additive manufacturing is taking a lead role in manufacturing of components for both prototyping as well as finished products. Metallization of the polymer parts has high potential to add value in-terms of metallic luster, improved strength, long shelf-life and better radiation resistance. Standard acid copper plating process has been adopted for deposition of copper on polymer parts manufactured by fused deposition modelling (FDM) technique. The parameters namely the etching time, voltage and the surface finish of the manufactured FDM parts are studied for their influence on the surface quality. Experiments have been designed using design of experiments strategy. Experiments have been conducted and surface roughness has been measured. Influence of each of the three parameters has been discussed in detail. For the reported process the optimal value of etching time of Acrylonitrile Butadiene Styrene (ABS) has been found in the range of 30 to 60 minutes along with applied voltage in the range of 1.5 to 2.5 Volts for copper electroplating.


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