scholarly journals Increasing strength of FFF three-dimensional printed parts by influencing on temperature-related parameters of the process

2020 ◽  
Vol 26 (1) ◽  
pp. 107-121 ◽  
Author(s):  
Vladimir E. Kuznetsov ◽  
Alexey N. Solonin ◽  
Azamat Tavitov ◽  
Oleg Urzhumtsev ◽  
Anna Vakulik
Keyword(s):  
Bulk Material ◽  
Three Dimensional ◽  
Fracture Load ◽  
Bending Test ◽  
Material Strength ◽  
Thermal Imager ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Temperature Conditions ◽  
Two Factors

Purpose This paper aims to investigate how the user-controlled parameters of the fused filament fabrication three-dimensional 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 polylactic acid part. Design/methodology/approach Fracture load in a three-point bending test and calculated related stress were used as a measure. The samples were printed with the long side along the z-axis, thus, in the bend tests, the maximum stress occurred orthogonally to the layers. Temperature distribution on the sample surface during printing was monitored with a thermal imager. Sample mesostructure was analyzed using scanning electron microscopy. The influence of the extrusion temperature, the intensity of part cooling, the printing speed and the time between printing individual layers were considered. Findings 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. Originality/value The novelty of the study consists in the generalization of the outcomes. All the parameters varied can be expressed through two factors, namely, the temperature of the previous layer and the extrusion 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).

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.

Fused filament printing of specialized biomedical devices: a state-of-the art review of technological feasibilities with PEEK

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Erfan Rezvani Ghomi ◽  
Saeideh Kholghi Eshkalak ◽  
Sunpreet Singh ◽  
Amutha Chinnappan ◽  
Seeram Ramakrishna ◽  
...  
Keyword(s):  
High Performance ◽  
State Of The Art ◽  
Three Dimensional ◽  
Patient Specific ◽  
Biomedical Devices ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Patient Specific Implants ◽  
Complex Design ◽  
Wide Range

Purpose The potential implications of the three-dimensional printing (3DP) technology are growing enormously in the various health-care sectors, including surgical planning, manufacturing of patient-specific implants and developing anatomical models. Although a wide range of thermoplastic polymers are available as 3DP feedstock, yet obtaining biocompatible and structurally integrated biomedical devices is still challenging owing to various technical issues. Design/methodology/approach Polyether ether ketone (PEEK) is an organic and biocompatible compound material that is recently being used to fabricate complex design geometries and patient-specific implants through 3DP. However, the thermal and rheological features of PEEK make it difficult to process through the 3DP technologies, for instance, fused filament fabrication. The present review paper presents a state-of-the-art literature review of the 3DP of PEEK for potential biomedical applications. In particular, a special emphasis has been given on the existing technical hurdles and possible technological and processing solutions for improving the printability of PEEK. Findings The reviewed literature highlighted that there exist numerous scientific and technical means which can be adopted for improving the quality features of the 3D-printed PEEK-based biomedical structures. The discussed technological innovations will help the 3DP system to enhance the layer adhesion strength, structural stability, as well as enable the printing of high-performance thermoplastics. Originality/value The content of the present manuscript will motivate young scholars and senior scientists to work in exploring high-performance thermoplastics for 3DP applications.

Effect of system compliance on weld power in ultrasonic additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Gowtham Venkatraman ◽  
Adam Hehr ◽  
Leon M. Headings ◽  
Marcelo J. Dapino
Keyword(s):  
Additive Manufacturing ◽  
Electrical Power ◽  
Three Dimensional ◽  
Power Input ◽  
Material Strength ◽  
Content Type ◽  
Ultrasonic Additive Manufacturing ◽  
Linear Elastic ◽  
Mechanical Compliance ◽  
The Relationship

Purpose Ultrasonic additive manufacturing (UAM) is a solid-state joining technology used for three-dimensional printing of metal foilstock. The electrical power input to the ultrasonic welder is a key driver of part quality in UAM, but under the same process parameters, it can vary widely for different build geometries and material combinations because of mechanical compliance in the system. This study aims to model the relationship between UAM weld power and system compliance considering the workpiece (geometry and materials) and the fixture on which the build is fabricated. Design/methodology/approach Linear elastic finite element modeling and experimental modal analysis are used to characterize the system’s mechanical compliance, and linear system dynamics theory is used to understand the relationship between weld power and compliance. In-situ measurements of the weld power are presented for various build stiffnesses to compare model predictions with experiments. Findings Weld power in UAM is found to be largely determined by the mechanical compliance of the build and insensitive to foil material strength. Originality/value This is the first research paper to develop a predictive model relating UAM weld power and the mechanical compliance of the build over a range of foil combinations. This model is used to develop a tool to determine the process settings required to achieve a consistent weld power in builds with different stiffnesses.

Fused filament fabrication of continuous optic fiber reinforced polylactic acid composites

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Rui Yan ◽  
Yuye Wang ◽  
Pengjun Luo ◽  
Yangbo Li ◽  
Xiaochun Lu
Keyword(s):  
Polylactic Acid ◽  
Three Dimensional ◽  
Underlying Mechanism ◽  
Uniaxial Tensile ◽  
Optic Fiber ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication ◽  
Engineering Applications ◽  
Content Type ◽  
Axial Tensile

Purpose The limited strength of polylactic acid (PLA) hinders its extensive engineering applications. This paper aims to enhance its strength and realize diverse applications. Design/methodology/approach Here, the continuous fiber reinforced PLA composites are fabricated by a customized fused filament fabrication three-dimensional printer. Uniaxial tensile and three-point flexural tests have been conducted to analyze the reinforcement effect of the proposed composites. To unveil the adhering mechanism of optic fiber (OF) and PLA, post failure analysis including the micro imaging and morphology have been performed. The underlying mechanism is that the axial tensile strength of the OF and the interfacial adhesion between PLA and OF compete to enhance the mechanical properties of the composite. Findings It is found that 10%–20% enhancement of strength, ductility and toughness due to the incorporation of the continuous OF. Originality/value The continuous OFs are put into PLA first time to improve the strength. The fabrication method and process reported here are potentially applied in such engineering applications as aerospace, defense, auto, medicine, etc.

scholarly journals Comparative study of the flexural properties of ABS, PLA and a PLA–wood composite manufactured through fused filament fabrication

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
J.A. Travieso-Rodriguez ◽  
R. Jerez-Mesa ◽  
Jordi Llumà ◽  
Giovanni Gomez-Gras ◽  
Oriol Casadesus
Keyword(s):  
Additive Manufacturing ◽  
Acrylonitrile Butadiene Styrene ◽  
Nozzle Diameter ◽  
Bending Test ◽  
Mechanical Resistance ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Layer Height ◽  
Maximum Deformation ◽  
Materials Used

Purpose The aim of this paper is to analyze the mechanical properties of acrylonitrile-butadiene-styrene (ABS) parts manufactured through fused filament fabrication and compare these results to analogous ones obtained on polylactic acid (PLA) and PLA–wood specimens to contribute for a wider understanding of the different materials used for additive manufacturing. Design/methodology/approach With that aim, an experimental based on an L27 Taguchi array was used to combine the specific parameters taken into account in the study, namely, layer height, nozzle diameter, infill density, orientation and printing velocity. All samples were subjected to a four-point bending test performed according to the ASTM D6272 standard. Findings Young’s modulus, elastic limit, maximum stress and maximum deformation of every sample were computed and subjected to an analysis of variance. Results prove that layer height and nozzle diameter are the most significant factors that affect the mechanical resistance in pieces generated through additive manufacturing and subjected to bending loads, regardless of the material. Practical implications The best results were obtained by combining a layer height of 0.1 mm and a nozzle diameter of 0.6 mm. The comparison of materials evidenced that PLA and its composite version reinforced with wood particles present more rigidity than ABS, whereas the latter can experience further deflection before break. Originality/value This study is of interest for manufacturers that want to decide which is the best material to be applied for their application, as it derives in a practical technical recommendation of the best parameters that should be selected to treat the material during the fused filament fabrication process.

Mechanical feasibility of ABS/HIPS-based multi-material structures primed by low-cost polymer printer

2019 ◽  
Vol 25 (1) ◽  
pp. 152-161 ◽  
Author(s):  
Sunpreet Singh ◽  
Narinder Singh ◽  
Munish Gupta ◽  
Chander Prakash ◽  
Rupinder Singh
Keyword(s):  
Low Cost ◽  
Acrylonitrile Butadiene Styrene ◽  
Sem Analysis ◽  
Bending Test ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Multiple Parameters ◽  
Mechanical Responses ◽  
Bending Load ◽  
Input Variables

Purpose The purpose of this paper is to fabricate acrylonitrile-butadiene-styrene (ABS)/high impact polystyrene (HIPS) based multi-material geometries using a low cost polymer printer. At the same time, efforts have been made to investigate the mechanical characteristics of the obtained prints and to perform the optimization using the Taguchi-Grey (TGRA) method. Design/methodology/approach Initially, the feedstock materials were in-house fabricated in the form of filament wires, workable with fused filament fabrication (FFF) technique, of 1.75 ± 0.1 mm diameter by using a single screw extruder. Multi-material structures were fabricated using variable parameters (such as: raster angles, layer height, fill density and solid layers) and the experimentation was conducted as per Taguchi L18 array. Mechanical responses obtained by performing tensile, impact and bending test were studied in response to input variables and ultimately optimized settings were obtained, for individual as well as multiple parameters). Scanning electron microscopy (SEM) analysis was performed to analyze the fractured surfaces. Findings The Signal/Noise (S/N) plots for the quality characteristics highlighted that selected input parameters significantly influenced the obtained values for tensile strength, impact strength and flexural strength. Micrographs of the fractured specimens showed the occurrence of brittle fracture with higher levels of perimeter, infill density and solid layers. The extent of delamination was also increased under the bending load and further increased by increasing solid layers. Practical implications The results of the study strongly advocated the utility of fabricated multi-materials structures in automotive, aerospace and other manufacturing industries. Originality/value This work represents the fabrication, testing and analysis of polymer-based multi-material structures for engineering applications.

Improving the forming quality of fused filament fabrication parts by applied vibration

2020 ◽  
Vol 26 (1) ◽  
pp. 202-212 ◽  
Author(s):  
Shijie Jiang ◽  
Yannick Siyajeu ◽  
Yinfang Shi ◽  
Shengbo Zhu ◽  
He Li
Keyword(s):  
Damping Ratio ◽  
Three Dimensional ◽  
Experimental Tests ◽  
Tensile Tests ◽  
Future Research ◽  
Fused Filament Fabrication ◽  
Forming Quality ◽  
Content Type ◽  
Application Range

Purpose The purpose of this study is to investigate the efficiency of applied vibration in improving the forming quality (mechanical property and dynamics characteristics) of fused filament fabrication (FFF) parts. Design/methodology/approach A vibrating FFF three-dimensional printer was set up, with which the samples fabricated in different directions were manufactured separately without and with vibration applied. A series of experimental tests, including tensile tests, dynamics tests and scanning electron microscopy (SEM) tests, were performed on these samples to experimentally quantify the effect of applied vibration on their forming quality. Findings It has been found that the applied vibration can significantly increase the tensile strength and plasticity of the samples built in Z-direction, and obviously decrease the orthogonal anisotropy. It can also significantly change the sample’s natural frequency, decrease the resonant response and increase the modal damping ratio, thus improve the anti-vibration capability of FFF samples. In addition, the SEM analysis confirmed that applying vibration into FFF process could improve the forming quality of the fabricated part. Research limitations/implications Future research may be focused on investigating the efficiency of applied vibration in improving the forming quality of parts fabricated by the other additive manufacturing techniques. Practical implications This study helps to improve the reliability of FFF parts and extend the application range of FFF technology. Originality/value A novel method to improve the forming quality of FFF parts is provided and the available information about the performance of dynamics characteristics.

Additive manufacturing of mechanochromic polycaprolactone on entry-level systems

2015 ◽  
Vol 21 (5) ◽  
pp. 520-527 ◽  
Author(s):  
Gregory I. Peterson ◽  
Mete Yurtoglu ◽  
Michael B Larsen ◽  
Stephen L. Craig ◽  
Mark A. Ganter ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Smart Materials ◽  
Color Change ◽  
Three Dimensional ◽  
Analytical Techniques ◽  
Force Sensor ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Entry Level ◽  
Chemical Response

Purpose – This paper aims to explore and demonstrate the ability to integrate entry-level additive manufacturing (AM) techniques with responsive polymers capable of mechanical to chemical energy transduction. This integration signifies the merger of AM and smart materials. Design/methodology/approach – Custom filaments were synthesized comprising covalently incorporated spiropyran moieties. The mechanical activation and chemical response of the spiropyran-containing filaments were demonstrated in materials that were produced via fused filament fabrication techniques. Findings – Custom filaments were successfully produced and printed with complete preservation of the mechanochemical reactivity of the spiropyran units. These smart materials were demonstrated in two key constructs: a center-cracked test specimen and a mechanochromic force sensor. The mechanochromic nature of the filament enables (semi)quantitative assessment of peak loads based on color change, without requiring any external analytical techniques. Originality/value – This paper describes the first examples of three-dimensional-printed mechanophores, which may be of significant interest to the AM community. The ability to control the chemical response to external mechanical forces, in combination with AM to process the bulk materials, potentiates customizability at the molecular and macroscopic length scales.

An Experimental Evaluation of Laser-Assisted Micromilling of Two Difficult to Machine Alloys

2008 ◽  
Author(s):  
Jonathan A. Shelton ◽  
Yung C. Shin
Keyword(s):  
Material Removal ◽  
Bulk Material ◽  
Three Dimensional ◽  
Acoustic Emissions ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Material Strength ◽  
Machined Surface ◽  
Macro Scale ◽  
Localized Heating

Micro-milling can be difficult to apply to many engineering materials due to a variety of scaling induced factors including: low cutting speeds, high relative tool deflections and runout, and increased material strength at smaller size scales. Additionally, edge burrs which can easily be removed after macro scale milling must be avoided in micro-milling due to the lack of available finishing operations. Laser assisted machining (LAM) involves localized heating of the work material prior to the cutting tool. This localized heating thermally weakens the workpiece resulting in lower cutting forces, improved surface finish, and longer tool life. Applying this concept to micro-milling offers the opportunity for process improvements, especially with materials which are considered difficult to machine. Laser assisted micro-milling (LAMM) was evaluated on Ti-6Al-4V and 316 stainless steel alloys using 100 μm diameter endmills in slotting operations. Micro-scale laser-material interactions were first studied with bulk material absorptivity being determined experimentally through a novel technique utilizing several calibrated melting mediums. A three-dimensional transient finite volume based thermal model was then used to analytically predict appropriate process parameters on the basis of material removal temperatures. A thorough investigation of acoustic emissions (AE) during LAMM was performed. In particular, the effects of depth of cut, tool wear, and material removal temperature on the RMS of AE were studied. Additionally, the effect of LAMM on the machined surface was evaluated quantitatively.

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