scholarly journals 3D printing with moondust

2016 ◽  
Vol 22 (6) ◽  
pp. 864-870 ◽  
Author(s):  
Athanasios Goulas ◽  
Ross J. Friel
Keyword(s):  
Process Parameters ◽  
Lunar Regolith ◽  
Dimensional Accuracy ◽  
Main Process ◽  
Material Particle ◽  
Content Type ◽  
Material Hardness ◽  
Lunar Regolith Simulant ◽  
Potential Applicability ◽  
Relative Porosity

Purpose The purpose of this paper is to investigate the effect of the main process parameters of laser melting (LM) type additive manufacturing (AM) on multi-layered structures manufactured from JSC-1A Lunar regolith (Moondust) simulant powder. Design/methodology/approach Laser diffraction technology was used to analyse and confirm the simulant powder material particle sizes and distribution. Geometrical shapes were then manufactured on a Realizer SLM™ 100 using the simulant powder. The laser-processed samples were analysed via scanning electron microscopy to evaluate surface and internal morphologies, X-ray fluorescence spectroscopy to analyse the chemical composition after processing, and the samples were mechanically investigated via Vickers micro-hardness testing. Findings A combination of process parameters resulting in an energy density value of 1.011 J/mm2 allowed the successful production of components directly from Lunar regolith simulant. An internal relative porosity of 40.8 per cent, material hardness of 670 ± 11 HV and a dimensional accuracy of 99.8 per cent were observed in the fabricated samples. Originality/value This research paper is investigating the novel application of a powder bed fusion AM process category as a potential on-site manufacturing approach for manufacturing structures/components out of Lunar regolith (Moondust). It was shown that this AM process category has the capability to directly manufacture multi-layered parts out of Lunar regolith, which has potential applicability to future moon colonization.

Large-Diameter Line Pipe Expanding Process

2012 ◽  
Vol 192 ◽  
pp. 180-184 ◽  
Author(s):  
Ai Xia He ◽  
Rong Chang Li
Keyword(s):  
Process Parameters ◽  
Large Diameter ◽  
Dimensional Accuracy ◽  
Optimization Method ◽  
Main Process ◽  
Shape Accuracy ◽  
Line Pipe ◽  
Factors Affecting ◽  
Array Optimization

Mechanical expanding process for large diameter line pipe, a detailed analysis of factors affecting the quality of the final products of the mechanical expansion and proposed optimization using orthogonal array optimization method, as an indicator of dimensional accuracy and shape accuracy of the products, combination of a variety of specifications of mechanical expanding products, the main process parameters to be optimized. Analysis and discussion of results, revealing the degree of influence of various factors on the quality of the final product, and gives the optimum combination of the results. Experiments show that the combination of optimized process parameters, and more help to improve the accuracy of the size and shape of products.

Experimental Investigation of Microfluidic Feature Manufacturing by Digital Light Processing Stereolithography

2020 ◽  
Author(s):  
Lara Rebaioli ◽  
Irene Fassi
Keyword(s):  
Process Parameters ◽  
Low Cost ◽  
Dimensional Accuracy ◽  
Machine Building ◽  
Single Step ◽  
Main Process ◽  
Single Chip ◽  
Digital Light Processing ◽  
And Performance ◽  
User Friendly

Abstract Lab on Chips (LOCs) are devices, mostly based on microfluidics, that allow to perform one or several chemical, biochemical or biological analysis in a miniaturized format on a single chip. The Additive Manufacturing processes, and in particular the Digital Light Processing stereolithography (DLP-SLA), could quickly produce a complete LOC with high resolution 3D features in a single step, i.e. without the need for assembly processes, and using low cost and user-friendly desktop machines. However, the potential of DLP-SLA to produce non-planar channels or channels with complex sections has not been fully investigated yet. This study proposes a benchmark artifact (including also some channels with their axis lying in a plane parallel to the machine building platform) aiming at assessing the capability and performance of DLP-SLA for manufacturing microfeatures for microfluidic devices. A proper experimental campaign was performed to evaluate the effect of the main process parameters (namely, layer thickness and exposure time) on the process performance. The results pointed out that both the process parameters influence the quality and dimensional accuracy of the analyzed features.

scholarly journals The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer

2015 ◽  
Vol 21 (5) ◽  
pp. 604-617 ◽  
Author(s):  
Antonio Lanzotti ◽  
Marzio Grasso ◽  
Gabriele Staiano ◽  
Massimo Martorelli
Keyword(s):  
Mechanical Properties ◽  
Open Source ◽  
Process Parameters ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Testing Machine ◽  
Main Process ◽  
Content Type ◽  
Fused Deposition ◽  
The Impact

Purpose – This study aims to quantify the ultimate tensile strength and the nominal strain at break (ɛf) of printed parts made from polylactic acid (PLA) with a Replicating Rapid prototyper (Rep-Rap) 3D printer, by varying three important process parameters: layer thickness, infill orientation and the number of shell perimeters. Little information is currently available about mechanical properties of parts printed using open-source, low-cost 3D printers. Design/methodology/approach – A computer-aided design model of a tensile test specimen was created, conforming to the ASTM:D638. Experiments were designed, based on a central composite design. A set of 60 specimens, obtained from combinations of selected parameters, was printed on a Rep-Rap Prusa I3 in PLA. Testing was performed using a JJ Instruments – T5002-type tensile testing machine and the load was measured using a load cell of 1,100 N. Findings – This study investigated the main impact of each process parameter on mechanical properties and the effects of interactions. The use of a response surface methodology allowed the proposition of an empirical model which connects process parameters and mechanical properties. Even though results showed a high variability, additional ideas on how to understand the impact of process parameters are suggested in this paper. Originality/value – On the basis of experimental results, it is possible to obtain practical suggestions to set common process parameters in relation to mechanical properties. Experiments discussed in the present paper provide a variety of data and insight regarding the relationship among the main process parameters and the stiffness and strength of fused deposition modeling-printed parts made from PLA. In particular, this paper underlines the shortage in existing literature concerning the impact of process parameters on the elastic modulus and the strain to failure for the PLA. The experimental data produced show a good degree of compliance with analytical formulations and other data found in literature.

Effects of process parameters on compressive property of FDM with ABS

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Supphachai Nathaphan ◽  
Worrasid Trutassanawin
Keyword(s):  
Yield Stress ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Optimum Process ◽  
Content Type ◽  
Layer Height ◽  
Compressive Yield Stress ◽  
Bed Temperature ◽  
Nozzle Temperature ◽  
Printing Speed

Purpose This work aims to investigate the interaction effects of printing process parameters of acrylonitrile butadiene styrene (ABS) parts fabricated by fused deposition modeling (FDM) technology on both the dimensional accuracy and the compressive yield stress. Another purpose is to determine the optimum process parameters to achieve the maximum compressive yield stress and dimensional accuracy at the same time. Design/methodology/approach The standard cylindrical specimens which produced from ABS by using an FDM 3D printer were measured dimensions and tested compressive yield stresses. The effects of six process parameters on the dimensional accuracy and compressive yield stress were investigated by separating the printing orientations into horizontal and vertical orientations before controlling five factors: nozzle temperature, bed temperature, number of shells, layer height and printing speed. After that, the optimum process parameters were determined to accomplish the maximum compressive yield stress and dimensional accuracy simultaneously. Findings The maximum compressive properties were achieved when layer height, printing speed and number of shells were maintained at the lowest possible values. The bed temperature should be maintained 109°C and 120°C above the glass transition temperature for horizontal and vertical orientations, respectively. Practical implications The optimum process parameters should result in better FDM parts with the higher dimensional accuracy and compressive yield stress, as well as minimal post-processing and finishing techniques. Originality/value The important process parameters were prioritized as follows: printing orientation, layer height, printing speed, nozzle temperature and bed temperature. However, the number of shells was insignificant to the compressive property and dimensional accuracy. Nozzle temperature, bed temperature and number of shells were three significant process parameters effects on the dimensional accuracy, while layer height, printing speed and nozzle temperature were three important process parameters influencing compressive yield stress. The specimen fabricated in horizontal orientation supported higher compressive yield stress with wide processing ranges of nozzle and bed temperatures comparing to the vertical orientation with limited ranges.

On Technologies of Electrochemical Finishing with Pulsed Current

2012 ◽  
Vol 522 ◽  
pp. 41-46
Author(s):  
Adayi Xieeryazidan ◽  
Muhetar Wumerhali ◽  
Gui Bing Pang
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Experimental Results ◽  
Main Process ◽  
Pulsed Current ◽  
Electrode Gap ◽  
Electric Parameter ◽  
Machining Quality ◽  
Electrochemical Finishing

Electrochemical finishing with pulsed current (ECFP) is introduced in this paper. The main process parameters, such as electric parameter and inter-electrode gap, etc., were investigated. The results show that the ECFP is an effective finishing method for improving the machining quality as the result of the machining mechanism. The related experimental results show that the obtained surface quality and dimensional accuracy are improved significantly as the result of the application of the pulsed current. Moreover, machining quality is increased with shorter pulses.

A Benchmark Artifact to Evaluate the Manufacturing of Microfeatures by Digital Light Processing Stereolithography

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Lara Rebaioli ◽  
Irene Fassi
Keyword(s):  
Layer Thickness ◽  
Exposure Time ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Main Process ◽  
Process Performance ◽  
Digital Light Processing ◽  
Specific Process ◽  
Experimental Campaign ◽  
Increasing Demand

Abstract Suitable benchmark artifacts are needed for assessing the technological capabilities and limitations of a specific process or for comparing the performances of different processes. Only a few benchmark artifacts have been specifically designed for features with microscale dimensions, even if their manufacturing is becoming very common due to the increasing demand for miniaturized parts or objects with microscale features. In this study, a suitable benchmark part is designed to evaluate the geometrical performance of a digital light processing (DLP) stereolithography (SLA) system for manufacturing microfeatures. The effect of the main process parameters (i.e., layer thickness and exposure time) and the feature position within the building platform on the process performance was assessed by a specifically studied experimental campaign. The results show that both the analyzed process parameters influence the minimum feasible size of protruding features and that the feature position influences the dimensional accuracy.

Multi-objective optimization of dimensional accuracy, surface roughness and hardness of hybrid investment cast components

2017 ◽  
Vol 23 (5) ◽  
pp. 845-857 ◽  
Author(s):  
Parlad Kumar Garg ◽  
Rupinder Singh ◽  
IPS Ahuja
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Surface Finish ◽  
Dimensional Accuracy ◽  
Multi Objective Optimization ◽  
Content Type ◽  
Multi Objective ◽  
Fused Deposition ◽  
Taguchi Design Of Experiments ◽  
Investment Cast

Purpose The purpose of this paper is to optimize the process parameters to obtain the best dimensional accuracy, surface finish and hardness of the castings produced by using fused deposition modeling (FDM)-based patterns in investment casting (IC). Design/methodology/approach In this paper, hip implants have been prepared by using plastic patterns in IC process. Taguchi design of experiments has been used to study the effect of six different input process parameters on the dimensional deviation, surface roughness and hardness of the implants. Analysis of variance has been used to find the effect of each input factor on the output. Multi-objective optimization has been done to find the combined best values of output. Findings The results proved that the FDM patterns can be used successfully in IC. A wax coating on the FDM patterns improves the surface finish and dimensional accuracy. The improved dimensional accuracy, surface finish and hardness have been achieved simultaneously through multi-objective optimization. Research limitations/implications A thin layer of wax is used on the plastic patterns. The effect of thickness of the layer has not been considered. Further research is needed to study the effect of the thickness of the wax layer. Practical implications The results obtained by the study would be helpful in making decisions regarding machining and/or coating on the parts produced by this process. Originality/value In this paper, multi-objective optimization of dimensional accuracy, surface roughness and hardness of hybrid investment cast components has been performed.

Rheological and printable behavior of resin – class materials for 3D printing applications

2019 ◽  
Vol 25 (5) ◽  
pp. 801-808
Author(s):  
Jianzhong Shang ◽  
Xin Li ◽  
Zhuo Wang ◽  
Rong Wang ◽  
Hong Zhu
Keyword(s):  
Process Parameters ◽  
Cross Sections ◽  
Rheological Behavior ◽  
Dimensional Accuracy ◽  
Cross Sectional ◽  
Content Type ◽  
Nozzle Height ◽  
Uniform Wall ◽  
The Cross ◽  
Printing Parameters

Purpose This study aims to investigate rheological and extrusion behavior of thermosetting epoxy resins, which to find the universal property and printing parameters for extrusion-based rapid prototyping applications. Design/methodology/approach The thickener proportion greatly influences its viscosity and rheological behavior and therefore plays an important role in the shape of the cross-section of the extrudate. Findings A pseudoplastic (shear-thinning) is a basic requirement for obtaining extruded lines with plump cross-sections. In addition to the effects of the rheological behavior of the composite, shape maintenance and its wettability on the substrate, the cross-sectional geometry of the extrudate is also strongly affected by printing process parameters including the extrusion nozzle height, nozzle moving speed, extrusion rate and critical nozzle height. Proper combinations of these process parameters are necessary to obtain single-line extrudates with plump cross-sections and 3-D objects with dimensional accuracy, uniform wall thickness, good wall uprightness and no wall slumping. Formulas and procedures for determining these extrusion parameters are proposed and demonstrated in experiments. Originality/value The results obtained have been explained in terms of the interactions among the rheological properties of the composite, the shear rate imposed on the composite during extrusion, the wettability of the composite on the substrate and the shape maintenance of the composite during extrusion.

Experimental study of surface roughness, dimensional accuracy and time of fabrication of parts produced by fused deposition modelling

2020 ◽  
Vol 26 (9) ◽  
pp. 1535-1554
Author(s):  
Swapnil Vyavahare ◽  
Shailendra Kumar ◽  
Deepak Panghal
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Layer Thickness ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Build Orientation ◽  
Fused Deposition ◽  
Significant Process

Purpose This paper aims to focus on an experimental study of surface roughness, dimensional accuracy and time of fabrication of parts produced by fused deposition modelling (FDM) technique of additive manufacturing. The fabricated parts of acrylonitrile butadiene styrene (ABS) material have pyramidal and conical features. Influence of five process parameters of FDM, namely, layer thickness, wall print speed, build orientation, wall thickness and extrusion temperature is studied on response characteristics. Furthermore, regression models for responses are developed and significant process parameters are optimized. Design/methodology/approach Comprehensive experimental study is performed using response surface methodology. Analysis of variance is used to investigate the influence of process parameters on surface roughness, dimensional accuracy and time of fabrication in both outer pyramidal and inner conical regions of part. Furthermore, a multi-response optimization using desirability function is performed to minimize surface roughness, improve dimensional accuracy and minimize time of fabrication of parts. Findings It is found that layer thickness and build orientation are significant process parameters for surface roughness of parts. Surface roughness increases with increase in layer thickness, while it decreases initially and then increases with increase in build orientation. Layer thickness, wall print speed and build orientation are significant process parameters for dimensional accuracy of FDM parts. For the time of fabrication, layer thickness and build orientation are found as significant process parameters. Based on the analysis, statistical non-linear quadratic models are developed to predict surface roughness, dimensional accuracy and time of fabrication. Optimization of process parameters is also performed using desirability function. Research limitations/implications The present study is restricted to the parts of ABS material with pyramidal and conical features only fabricated on FDM machine with delta configuration. Originality/value From the critical review of literature it is found that some researchers have made to study the influence of few process parameters on surface roughness, dimensional accuracy and time of fabrication of simple geometrical parts. Also, regression models and optimization of process parameters has been performed for simple parts. The present work is focussed on studying all these aspects in complicated geometrical parts with pyramidal and conical features.

Investigation of effect of process variable on dimensional accuracy of FDM component using response surface methodology

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nagendra Kumar Maurya ◽  
Manish Maurya ◽  
Shashi Prakash Dwivedi ◽  
Ashish Kumar Srivastava ◽  
Ambuj Saxena ◽  
...  
Keyword(s):  
Response Surface Methodology ◽  
Layer Thickness ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Percentage Error ◽  
Content Type ◽  
Average Percentage ◽  
Raster Angle ◽  
Radial Dimension ◽  
Average Percentage Error

Purpose Nowadays, rapid prototyping is emerging as end use product in low volume. The accuracy of the fabricated components depends on various process parameters. Process parameters used in this investigation are layer thickness (150, 200 and 250 µm), infill pattern (linear, hexagonal and star fill), raster angle (0°, 45° and 90°) and infill density (40, 60 and 80%). Linear and radial dimension of knuckle joint are selected for the response factor. Design/methodology/approach The experiments are design by using response surface methodology (RSM). Four design variables at three levels are used to examine their influence on percentage error in linear dimension and radial dimension of the component. A prototype Knuckle joint is selected as component. Minitab-14 software is used for the design of experiments. Findings Experimental measure data is analyzed by using “smaller is better” quality characteristics. A regression model for the forecasting of percentage error in linear and radial dimension is developed. The developed model is within precision range. The optimum level of process for linear and radial dimensions are obtained: layer thickness of 150 µm, Infill pattern of linear, Raster angle of 90° and infill density of 40%. Research limitations/implications It proves that both the mathematical model is significant and can be able to approximate the desired output value close to the accurate dimensions. While comparing the calculated F-values for both linear and radial dimension with the standard table (F-table, 0.05), it is found that at the given set of degree of freedom the standard F-values (6.61) is lower for that regression, linear, square and interaction source of the predicted model, for which p-values have already less than 0.05. It is desirable for significant process parameters. Practical implications The dimensional accuracy with respect to average percentage error of FDM produced knuckle joint is successfully examined. The effect of process parameters, namely, layer thickness, infill pattern, raster angle and infill density on average percentage error was investigated by RSM and analysis of variance table. Social implications The novelty of this work lies in the fact that only few studies are available in archival literature related to influence of these process parameters on percentage error in linear and radial dimension for Polycarbonate (PC) material. Originality/value The novelty of this work lies in the fact only few studies are available in archival literature related to influence of these process parameters on percentage error in linear and radial dimension for Polycarbonate (PC) material.

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