Impact of 3D-printing structure on the tribological properties of polymers

2020 ◽  
Vol 72 (6) ◽  
pp. 811-818 ◽  
Author(s):  
Muammel M. Hanon ◽  
Róbert Marczis ◽  
László Zsidai
Keyword(s):  
3D Printing ◽  
Tribological Properties ◽  
Future Research ◽  
Fused Deposition Modelling ◽  
Wear Depth ◽  
Printing Process ◽  
Content Type ◽  
Fused Deposition ◽  
Polylactide Acid ◽  
The Impact

Purpose The purpose of this paper is to examine the impact of three-dimensional (3D)-printing process settings (particularly print orientation) on the tribological properties of different polymers. Design/methodology/approach In this study, fused deposition modelling 3D-printing technology was used for fabricating the specimens. To evaluate the influence of print orientation, the test pieces were manufactured horizontally (X) and vertically (Z). The tribological properties of various printed polymers, which are polylactide acid, high tensile/high temperature-polylactide acid and polyethylene terephthalate-glycol have been studied. The tribological tests have been carried out under reciprocating sliding and dry condition. Findings The results show that the presence of various orientations during the 3D-printing process makes a difference in the coefficient of friction and the wear depth values. Findings suggest that printing structure in the horizontal orientation (X) assists in reducing friction and wear. Originality/value To date, there has been very limited research on the tribology of objects produced by 3D printing. This work was made as an attempt to pave the way for future research on the science of tribology of 3D-printed polymers.

An overview of fused deposition modelling (FDM): research, development and process optimisation

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mohammadreza Lalegani Dezaki ◽  
Mohd Khairol Anuar Mohd Ariffin ◽  
Saghi Hatami
Keyword(s):  
Metal Alloys ◽  
Future Research ◽  
Fused Deposition Modelling ◽  
Process Optimisation ◽  
Content Type ◽  
Novel Materials ◽  
Fused Deposition ◽  
Bed Temperature ◽  
Vast Range ◽  
Research Studies

Purpose The purpose of this paper is to review research studies on process optimisation and machine development that lead to the enhancement of final products in various aspects of the fused deposition modelling (FDM) process. Design/methodology/approach An overview of the literature, focussing on process parameters, machine developments and material characterisations. This study investigates recent research studies that studied FDM capabilities in printing a vast range of materials from thermoplastics to metal alloys. Findings FDM is one of the most common techniques in additive manufacturing (AM) processes. Many parameters in this technology have effects on three-dimensional printed products. Therefore, it is necessary to obtain the optimum elements, for example, build orientation, layer thickness, nozzle diameter, infill pattern and bed temperature. By selecting a proper variable range of parameters, the layers adhere strongly and building end-use products of high quality are achievable. A vast range of materials and their properties from polymers to composite-based polymers are presented. Novel techniques to print metal alloys and composites are examined to increase the productivity of the FDM process. Additionally, defects such as shrinkage and warpage are discussed to eliminate the system’s limitations and improve the quality of final products. Multi-axis and mobile machines brought enhancements throughout the process to eliminate obstacles such as staircase defects in the conventional FDM process. In brief, recent developments were identified and a summary of major improvements was discussed in this study for future research. Originality/value This paper is an overview that provides information about research and developments in FDM. This review focusses on process optimisation and obstacles in printing polymers, composites, geopolymers and novel materials. Therefore, machine characteristics were examined to find out the accessibility of printing novel materials for different applications.

Use of polymer concrete for large-scale 3D printing

2021 ◽  
Vol 27 (3) ◽  
pp. 465-474
Author(s):  
Martin Krčma ◽  
David Škaroupka ◽  
Petr Vosynek ◽  
Tomáš Zikmund ◽  
Jozef Kaiser ◽  
...  
Keyword(s):  
3D Printing ◽  
Large Scale ◽  
Mechanical Performance ◽  
Construction Material ◽  
Polymer Concrete ◽  
Fused Deposition Modelling ◽  
Cast State ◽  
Content Type ◽  
Fused Deposition ◽  
3D Printed

Purpose This paper aims to focus on the evaluation of a polymer concrete as a three-dimensional (3D) printing material. An associated company has developed plastic concrete made from reused unrecyclable plastic waste. Its intended use is as a construction material. Design/methodology/approach The concrete mix, called PolyBet, composed of polypropylene and glass sand, is printed by the fused deposition modelling process. The process of material and parameter selection is described. The mechanical properties of the filled material were compared to its cast state. Samples were made from castings and two different orientations of 3D-printed parts. Three-point flex tests were carried out, and the area of the break was examined. Computed tomography of the samples was carried out. Findings The influence of the 3D printing process on the material was evaluated. The mechanical performance of the longitudinal samples was close to the cast state. There was a difference in the failure mode between the states, with cast parts exhibiting a tougher behaviour, with fractures propagating in a stair-like manner. The 3D-printed samples exhibited high degrees of porosity. Originality/value The results suggest that the novel material is a good fit for 3D printing, with little to no degradation caused by the process. Layer adhesion was shown to be excellent, with negligible effect on the finished part for the longitudinal orientation. That means, if large-scale testing of buildability is successful, the material is a good fit for additive manufacturing of building components and other large-scale structures.

A review on advancements in applications of fused deposition modelling process

2020 ◽  
Vol 26 (4) ◽  
pp. 669-687 ◽  
Author(s):  
Sathies T. ◽  
Senthil P. ◽  
Anoop M.S.
Keyword(s):  
Additive Manufacturing ◽  
Research Work ◽  
Rapid Tooling ◽  
Future Research ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Fused Deposition ◽  
Low Volume ◽  
Customized Products

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.

scholarly journals Parameters Affecting the Mechanical Properties of Three-Dimensional (3D) Printed Carbon Fiber-Reinforced Polylactide Composites

Polymers ◽  
2020 ◽  
Vol 12 (11) ◽  
pp. 2456
Author(s):  
Demei Lee ◽  
Guan-Yu Wu
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
3D Printing ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Bed Temperature ◽  
3D Printed ◽  
The Impact

Three-dimensional (3D) printing is a manufacturing technology which creates three-dimensional objects layer-by-layer or drop-by-drop with minimal material waste. Despite the fact that 3D printing is a versatile and adaptable process and has advantages in establishing complex and net-shaped structures over conventional manufacturing methods, the challenge remains in identifying the optimal parameters for the 3D printing process. This study investigated the influence of processing parameters on the mechanical properties of Fused Deposition Modelling (FDM)-printed carbon fiber-filled polylactide (CFR-PLA) composites by employing an orthogonal array model. After printing, the tensile and impact strengths of the printed composites were measured, and the effects of different parameters on these strengths were examined. The experimental results indicate that 3D-printed CFR-PLA showed a rougher surface morphology than virgin PLA. For the variables selected in this analysis, bed temperature was identified as the most influential parameter on the tensile strength of CFR-PLA-printed parts, while bed temperature and print orientation were the key parameters affecting the impact strengths of printed composites. The 45° orientation printed parts also showed superior mechanical strengths than the 90° printed parts.

An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Vivek Kumar Tiwary ◽  
Arunkumar P. ◽  
Vinayak R. Malik
Keyword(s):  
3D Printing ◽  
Literature Review ◽  
Adhesive Bonding ◽  
Business Leaders ◽  
Future Research ◽  
3D Printer ◽  
Content Type ◽  
Friction Stir ◽  
Fused Deposition ◽  
3D Printed

Purpose Three-dimensional (3D) printing, one of the important technological pillars of Industry 4.0, is changing the landscape of future manufacturing. However, the limited build volume of a commercially available 3D printer is one inherent constraint, which holds its acceptability by the manufacturing business leaders. This paper aims to address the issue by presenting a novel classification of the possible ways by which 3D-printed parts can be joined or welded to achieve a bigger-sized component. Design/methodology/approach A two-step literature review is performed. The first section deals with the past and present research studies related to adhesive bonding, mechanical interlocking, fastening and big area additive manufacturing of 3D printed thermoplastics. In the second section, the literature searches were focused on retrieving details related to the welding of 3D printed parts, specifically related to friction stir welding, friction (spin) welding, microwave and ultrasonic welding. Findings The key findings of this review study comprise the present up-to-date research developments, pros, cons, critical challenges and the future research directions related to each of the joining/welding techniques. After reading this study, a better understanding of how and which joining/welding technique to be applied to obtain a bigger volume 3D printed component will be acquired. Practical implications The study provides a realistic approach for the joining of 3D printed parts made by the fused deposition modeling (FDM) technique. Originality/value This is the first literature review related to joining or welding of FDM-3D printed parts helping the 3D printing fraternity and researchers, thus increasing the acceptability of low-cost FDM printers by the manufacturing business leaders.

scholarly journals Comparing additive manufacturing technologies for customised wrist splints

2015 ◽  
Vol 21 (3) ◽  
pp. 230-243 ◽  
Author(s):  
Abby Megan Paterson ◽  
Richard Bibb ◽  
R. Ian Campbell ◽  
Guy Bingham
Keyword(s):  
Additive Manufacturing ◽  
Upper Extremity ◽  
Digital Design ◽  
Future Research ◽  
Fused Deposition Modelling ◽  
Full Potential ◽  
Content Type ◽  
Fused Deposition ◽  
Am Processes ◽  
Design For Am

Purpose – The purpose of this paper is to compare four different additive manufacturing (AM) processes to assess their suitability in the context of upper extremity splinting. Design/methodology/approach – This paper describes the design characteristics and subsequent fabrication of six different wrist splints using four different AM processes: laser sintering (LS), fused deposition modelling (FDM), stereolithography (SLA) and polyjet material jetting via Objet Connex. The suitability of each process was then compared against competing designs and processes from traditional splinting. The splints were created using a digital design workflow that combined recognised clinical best practice with design for AM principles. Findings – Research concluded that, based on currently available technology, FDM was considered the least suitable AM process for upper extremity splinting. LS, SLA and material jetting show promise for future applications, but further research and development into AM processes, materials and splint design optimisation is required if the full potential is to be realised. Originality/value – Unlike previous work that has applied AM processes to replicate traditional splint designs, the splints described are based on a digital design for AM workflow, incorporating novel features and physical properties not previously possible in clinical splinting. The benefits of AM for customised splint fabrication have been summarised. A range of AM processes have also been evaluated for splinting, exposing the limitations of existing technology, demonstrating novel and advantageous design features and opportunities for future research.

Organizational adoption of 3D printing technology: a semisystematic literature review

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Desiree Valeria Ukobitz
Keyword(s):  
Decision Making ◽  
3D Printing ◽  
Literature Review ◽  
Strategic Decision ◽  
Future Research ◽  
Managerial Decision ◽  
Organizational Adoption ◽  
Content Type ◽  
Theoretical Concepts ◽  
The Impact

PurposeThree-dimensional (3D) printing (3DP) offers a promising value proposition across multiple manufacturing industries. Despite the variety of production benefits the technology entails, its rate of adoption is still low compared to industry forecasts. In face of this challenge, industry as well as academia requires more information and guidance. This review aims to examine the characteristics of the existing body of research on the organizational adoption of 3DP as well as its underlying theoretical concepts. The most common criteria driving adoption will be derived, such as to facilitate the managerial decision-making process. Pathways for future research will be presented.Design/methodology/approachThis study underlies a bibliometric literature review and additionally applies content analysis to systematically investigate the existing body of research and group decision criteria along the four major pillars of strategic decision-making.FindingsThe contributions of this paper are threefold. First, the bibliometric analysis reveals interesting aspects of the existing body of research. The most prominent characteristics of the contemporary literature are reflected along descriptive indicators, such as industry, method, model, origin, research outlet or adoption drivers, thus granting relevant insights into academia and practice. Second, the most notable adoption models are carefully analyzed on their inherent attributes and their application fit for the context of organizational 3DP adoption. Findings, for instance, revealed the dominance of diffusion of innovation (DOI) across the existing body of research and divulge that this construct is generally applied in combination with user-centered decision frameworks to yield more precise results. Third, an ample range of opportunities for future research are detected and thoroughly explained. Among others, the authors identified a clear lack of information on the impact environmental variables and contingency factors exerted on the organizational adoption of 3DP. Guidance in relation to the sourcing of industry data, usage of adoption frameworks and avenues for future scientific projects is supplied.Originality/valueThis study represents the first semi-systematic literature review on the organizational adoption of 3DP. Thus, it not only offers a valuable evaluation guide for potential adopters but also determines a future research agenda.

FDM 3D printing method utility assessment in small RC aircraft design

2019 ◽  
Vol 91 (6) ◽  
pp. 865-872 ◽  
Author(s):  
Igor Skawiński ◽  
Tomasz Goetzendorf-Grabowski
Keyword(s):  
3D Printing ◽  
Aircraft Design ◽  
Cost Effective ◽  
Fused Deposition Modelling ◽  
Thin Wall ◽  
Good Reliability ◽  
Content Type ◽  
Fused Deposition ◽  
Wall Structures ◽  
3D Printed

Purpose The purpose of this paper is to investigate the possibility of manufacturing fused deposition modelling (FDM) 3D printed structures such as wings or fuselages for small remote control (RC) air craft and mini unmaned aerial vehicles (UAVs). Design/methodology/approach Material tests, design assumptions and calculations were verified by designing and manufacturing a small radio-controlled motor-glider using as many printed parts as possible and performing test flights. Findings It is possible to create an aircraft with good flight characteristics using FDM 3D printed parts. Current level of technology allows for reasonably fast manufacturing of 3D printed aircraft with good reliability and high success ratio of prints; however, only some of the materials are suitable for printing thin wall structures such as wings. Practical implications The paper proves that apart from currently popular small RC aircraft structural materials such as composites, wood and foam, there is also printed plastic. Moreover, 3D printing is highly competitive in some aspects such as first unit production time or production cost. Originality/value The presented manufacturing technique can be useful for quick and cost-effective creating scale prototypes of the aircraft for performing test flights.

scholarly journals Impact of additive manufacturing on engineering education – evidence from Italy

2015 ◽  
Vol 21 (5) ◽  
pp. 535-555 ◽  
Author(s):  
Paolo Minetola ◽  
Luca Iuliano ◽  
Elena Bassoli ◽  
Andrea Gatto
Keyword(s):  
Additive Manufacturing ◽  
Product Design ◽  
Mechanical Engineering ◽  
Additive Technologies ◽  
Direct Access ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Entry Level ◽  
Fused Deposition ◽  
The Impact

Purpose – The purpose of this paper is to evaluate how the direct access to additive manufacturing (AM) systems impacts on education of future mechanical engineers, within a Master’s program at a top Italian University. Design/methodology/approach – A survey is specifically designed to assess the relevance of entry-level AM within the learning environment, as a tool for project development. The survey is distributed anonymously to three consecutive cohorts of students who attended the course of “computer-aided production (CAP)”, within the Master of Science Degree in Mechanical Engineering at Politecnico di Torino. The course includes a practical project, consisting in the design of a polymeric product with multiple components and ending with the production of an assembled prototype. The working assembly is fabricated by the students themselves, who operate a fused deposition modelling (FDM) machine, finish the parts and evaluate assemblability and functionality. The post-course survey covers diverse aspects of the learning process, such as: motivation, knowledge acquisition, new abilities and team-working skills. Responses are analyzed to evaluate students’ perception of the usefulness of additive technologies in learning product design and development. Among the projects, one representative case study is selected and discussed. Findings – Results of the research affirm a positive relationship of access to AM devices to perceived interest, motivation and ease of learning of mechanical engineering. Entry-level additive technologies offer a hands-on experience within academia, fostering the acquisition of technical knowledge. Research limitations/implications – The survey is distributed to more than 200 students to cover the full population of the CAP course over three academic years. The year the students participated in the CAP course is not tracked because the instructor was the same and there were no administrative differences. For this reason, the survey administration might be a limitation of the current study. In addition to this, no gender distinction is made because historically, the percentage of female students in Mechanical Engineering courses is about 10 per cent or lower. Although the answers to the survey are anonymous, only 37 per cent of the students gave a feedback. Thus, on the one hand, impact assessment is limited to a sample of about one-third of the complete population, but, on the other hand, the anonymity ensures randomization in the sample selection. Practical implications – Early exposure of forthcoming designers to AM tools can turn into a “think-additive” approach to product design, that is a groundbreaking conception of geometries and product functionalities, leading to the full exploitation of the possibilities offered by additive technologies. Social implications – Shared knowledge can act as a springboard for mass adoption of AM processes. Originality/value – The advantages of adopting AM technologies at different levels of education, for diverse educational purposes and disciplines, are well assessed in the literature. The innovative aspect of this paper is that the impact of AM is evaluated through a feedback coming directly from mechanical engineering students.

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