Bonding quality and fracture analysis of polyamide 12 parts fabricated by fused deposition modeling

2017 ◽  
Vol 23 (6) ◽  
pp. 973-982 ◽  
Author(s):  
Hao Li ◽  
Shuai Zhang ◽  
Zhiran Yi ◽  
Jie Li ◽  
Aihua Sun ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Rheological Properties ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Melt Viscosity ◽  
Bonding Quality ◽  
Content Type ◽  
Polyamide 12 ◽  
Fused Deposition ◽  
Deposition Modeling

Purpose This work aims to evaluate the influence of rheological properties of building materials on the bonding quality and ultimate tensile strength in the fused deposition modeling (FDM) process, through the investigation of parts printed by semi-crystalline and amorphous resins. Little information is currently available about the influence of the crystalline nature on FDM-printed part quality. Design/methodology/approach Semi-crystalline polyamide 12 and amorphous acrylonitrile butadiene styrene (ABS) were used to assess the influence of rheological properties on bonding quality and the tensile strength, by varying three important process parameters: materials, liquefier temperature and raster orientation. A fractography of both tensile and freeze-fractured samples was also investigated. Findings The rheological properties, mainly the melt viscosity, were found to have a significant influence on the bonding quality of fused filaments. Better bonding quality and higher tensile strength of FDM parts printed with semi-crystalline PA12, as compared with amorphous ABS, are suggested to be a result of higher initial sintering rates owing to the lower melt viscosity of PA12 at low shear rates. Near-full dense PA12 parts were obtained by FDM. Originality/value This project provides a variety of data and insight regarding the effect of materials properties on the mechanical performance of FDM-printed parts. The results showed that FDM technique allows the production of PA12 parts with adequate mechanical performance, overcoming the greatest limitation of a dependence on amorphous thermoplastics as a feedstock for the production of prototypes.

The influence of load direction, microstructure, raster orientation on the quasi-static response of fused deposition modeling ABS

2019 ◽  
Vol 25 (3) ◽  
pp. 462-472 ◽  
Author(s):  
Oluwakayode Bamiduro ◽  
Gbadebo Owolabi ◽  
Mulugeta A. Haile ◽  
Jaret C. Riddick
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Mechanical Response ◽  
Mechanical Performance ◽  
Bead Geometry ◽  
Static Response ◽  
Load Direction ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling

Purpose The continual growth of additive manufacturing has increased tremendously because of its versatility, flexibility and high customization of geometric structures. However, design hurdles are presented in understanding the relationship between the fabrication process and materials microstructure as it relates to the mechanical performance. The purpose of this paper is to investigate the role of build architecture and microstructure and the effects of load direction on the static response and mechanical properties of acrylonitrile butadiene styrene (ABS) specimens obtained via the fused deposition modeling (FDM) processing technique. Design/methodology/approach Among additive manufacturing processes, FDM is a prolific technology for manufacturing ABS. The blend of ABS combines strength, rigidity and toughness, all of which are desirable for the production of structural materials in rapid manufacturing applications. However, reported literature has varied widely on the mechanical performance due to the proprietary nature of the ABS material ratio, ultimately creating a design hurdle. While prior experimental studies have studied the mechanical response via uniaxial tension testing, this study has aimed to understand the mechanical response of ABS from the materials’ microstructural point of view. First, ABS specimen was fabricated via FDM using a defined build architecture. Next, the specimens were mechanically tested until failure. Then finally, the failure structures were microstructurally investigated. In this paper, the effects of microstructural evolution on the static mechanical response of various build architecture of ABS aimed at FDM manufacturing technique was analyzed. Findings The results show that the rastering orientation of 0/90 exhibited the highest tensile strength followed by fracture at its maximum load. However, the “45” bead direction of the ABS fibers displayed a cold-drawing behavior before rupture. The morphology analyses before and after tensile failure were characterized by a scanning electron microscopy (SEM) which highlighted the effects of bead geometry (layers) and areas of stress concentration such as interstitial voids in the material during build, ultimately compromising the structural integrity of the specimens. Research limitations/implications The ability to control the constituents and microstructure of a material during fabrication is significant to improving and predicting the mechanical performance of structural additive manufacturing components. In this report, the effects of microstructure on the mechanical performance of FDM-fabricated ABS materials was discussed. Further investigations are planned in understanding the effects of ambient environmental conditions (such as moisture) on the ABS material pre- and post-fabrication. Originality/value The study provides valuable experimental data for the purpose of understanding the inter-dependency between build parameters and microstructure as it relates to the specimens exemplified strength. The results highlighted in this study are fundamental to the development of optimal design of strength and complex ultra-lightweight structure efficiency.

Linear model analysis of fused deposition modeling process parameters for obtaining the maximum tensile strength in acrylonitrile butadiene styrene (ABS) and carbon fiber polylactic acid (PLA) materials

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Debashis Mishra ◽  
Anil Kumar Das
Keyword(s):  
Tensile Strength ◽  
Carbon Fiber ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Thermoplastic Material ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Printing Speed

PurposeThe purpose of the experimental investigation was to optimize the process parameters of the fused deposition modeling (FDM) technique. The optimization of the process was performed to identify the relationship between the chosen factors and the tensile strength of acrylonitrile butadiene styrene (ABS) and carbon fiber polylactic acid (PLA) thermoplastic material, FDM printed specimens. The relationship was demonstrated by using the linear experimental model analysis, and a prediction expression was established. The developed prediction expression can be used for the prediction of tensile strength of selected thermoplastic materials at a 95% confidence level.Design/methodology/approachThe Taguchi L9 experimental methodology was used to plan the total number of experiments to be performed. The process parameters were chosen as three at three working levels. The working range of chosen factors was the printing speed (60, 80 and 100mm/min), 40%, 60% and 80% as the infill density and 0.1mm, 0.2mm and 0.3mm as the layer thickness. The fused deposition modeling process parameters were optimized to get the maximum tensile strength in FDM printed ABS and carbon fiber PLA thermoplastic material specimens.FindingsThe optimum condition was achieved by the process optimization, and the desired results were obtained. The maximum desirability was achieved as 0.98 (98%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.3mm. The strength of the ABS specimen was predicted to be 23.83MPa. The observed strength value was 23.66MPa. The maximum desirability was obtained as 1 (100%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.2mm. The strength of the carbon fiber PLA specimen was predicted to be 26.23MPa, and the obtained value was 26.49MPa.Research limitations/implicationsThe research shows the useful process parameters and their suitable working conditions to print the tensile specimens of the ABS and carbon fiber PLA thermoplastics by using the fused deposition modeling technique. The process was optimized to identify the most influential factor, and the desired optimum condition was achieved at which the maximum tensile strength was reported. The produced prediction expression can be used to predict the tensile strength of ABS and carbon fiber PLA filaments.Practical implicationsThe results obtained from the experimental investigation are useful to get an insight into the FDM process and working limits to print the parts by using the ABS and carbon fiber PLA material for various industrial and structural applications.Social implicationsThe results will be useful in choosing the suitable thermoplastic filament for the various prototyping and structural applications. The products that require freedom in design and are difficult to produce by most of the conventional techniques can be produced at low cost and in less time by the fused deposition modeling technique.Originality/valueThe process optimization shows the practical exposures to state an optimum working condition to print the ABS and carbon fiber PLA tensile specimens by using the FDM technique. The carbon fiber PLA shows better strength than ABS thermoplastic material.

Fused deposition modeling with polyamide 1012

2019 ◽  
Vol 25 (7) ◽  
pp. 1145-1154 ◽  
Author(s):  
Xia Gao ◽  
Daijun Zhang ◽  
Xiangning Wen ◽  
Shunxin Qi ◽  
Yunlan Su ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Content Type ◽  
Good Ductility ◽  
Fused Deposition ◽  
Bed Temperature ◽  
Deposition Modeling ◽  
Nozzle Temperature ◽  
Printing Parameters

Purpose This work aims to develop a new kind of semicrystalline polymer filament and optimize its printing parameters in the fused deposition modeling process. The purpose of this work also includes producing FDM parts with good ductility. Design/methodology/approach A new kind of semicrystalline filaments composed of long-chain polyamide (PA)1012 was prepared by controlling screw speed and pulling speed carefully. The optimal printing parameters for PA1012 filaments were explored through investigating dimensional accuracy and bonding strength of FDM parts. Furthermore, the mechanical properties of PA1012 specimens were also evaluated by varying nozzle temperatures and raster angles. Findings It is found that PA1012 filaments can accommodate for FDM process under suitable printing parameters. The print quality and mechanical properties of FDM parts highly depend on nozzle temperature and bed temperature. Even though higher temperatures facilitate stronger interlayer bonding, FDM parts with excellent tensile strength were obtained at a moderate nozzle temperature. Moreover, a bed temperature well above the glass transition temperature of PA1012 can eliminate shrinkage and distortion of FDM parts. As expected, FDM parts prepared with PA1012 filaments exhibit good ductility. Originality/value Results in this work demonstrate that the PA1012 filament allows the production of FDM parts with desired mechanical performance. This indicates the potential for overcoming the dependence on amorphous thermoplastics as a feedstock in the FDM technique. This work also provides insight into the effect of materials properties on the mechanical performance of FDM-printed parts.

The effects of moisture and temperature on the mechanical properties of additive manufacturing components: fused deposition modeling

2016 ◽  
Vol 22 (6) ◽  
pp. 887-894 ◽  
Author(s):  
Eunseob Kim ◽  
Yong-Jun Shin ◽  
Sung-Hoon Ahn
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Water Absorption ◽  
Fused Deposition Modeling ◽  
Content Type ◽  
Fused Deposition ◽  
Temperature Conditions ◽  
Molded Parts ◽  
Deposition Modeling ◽  
Injection Molded

Purpose This paper aims to investigate the water absorption behaviors and mechanical properties, according to water absorption and temperature, of components fabricated by fused deposition modeling (FDM) and injection molding. The mechanical properties of FDM and injection molded parts were studied under several environmental conditions. Design/methodology/approach FDM components can be used as load-carrying elements under a range of moisture and temperature conditions. FDM parts show anisotropic mechanical properties according to build orientation. Components were fabricated from acrylonitrile-butadiene-styrene in three different orientations. The mechanical properties of parts fabricated by FDM were compared to injection molded components made from the same material. Water absorption tests were conducted in distilled water between 20 and 60°C to identify the maximum water absorption rate. Both moisture and temperature were considered as environmental variables in the tensile tests, which were conducted under various conditions to measure the effects on mechanical properties. Findings The water absorption behavior of FDM components obeyed Fickian diffusion theory, irrespective of the temperature. High temperatures accelerated the diffusion rate, although the maximum water absorption rate was not affected. The tensile strength of FDM parts under dry, room temperature conditions, was approximately 26-56 per cent that of injection molded parts, depending on build orientation. Increased temperature and water absorption had a more significant effect on FDM parts than injection molded components. The tensile strength was decreased by 67-71 per cent in hot, wet environments compared with dry, room temperature conditions. Originality/value The water absorption behavior of FDM components was investigated. The quantitative effects of temperature and moisture on tensile strength, modulus and strain were also measured. These results will contribute to the design of FDM parts for use under various environmental conditions.

Synthesis and properties of modified PBT for FDM

2017 ◽  
Vol 23 (4) ◽  
pp. 804-810 ◽  
Author(s):  
Shiqing Cao ◽  
Dandan Yu ◽  
Weilan Xue ◽  
Zuoxiang Zeng ◽  
Wanyu Zhu
Keyword(s):  
Mechanical Properties ◽  
Impact Strength ◽  
Fused Deposition Modeling ◽  
Complex Structure ◽  
Three Dimensional ◽  
Sebacic Acid ◽  
Wire Drawing ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling

Purpose The purpose of this paper is to prepare a new modified polybutylene terephalate (MPBT) for fused deposition modeling (FDM) to increase the variety of materials compatible with printing. And the printing materials can be used to print components with a complex structure and functional mechanical parts. Design/methodology/approach The MPBT, poly(butylene terephalate-co-isophthalate-co-sebacate) (PBTIS), was prepared for FDM by direct esterification and subsequent polycondensation using terephthalic acid (PTA), isophthalic acid (PIA), sebacic acid (SA) and 1,4-butanediol (BDO). The effects of the content of PIA (20-40 mol%) on the mechanical properties of PBTIS were investigated when the mole per cent of SA (αSA) is zero. The effects of αSA (0-7mol%) on the thermal, rheological and mechanical properties of PBTIS were investigated at nPTA/nPIA = 7/3. A desktop wire drawing and extruding machine was used to fabricate the filaments, whose printability and anisotropy were tested by three-dimensional (3D) printing experiments. Findings A candidate content of PIA introducing into PBT was obtained to be about 30 per cent, and the Izod notched impact strength of PBTIS increased with the increase of αSA. The results showed that the PBTIS (nPTA/nPIA = 7/3, αSA = 3-5mol%) is suitable for FDM. Originality/value New printing materials with good Izod notched impact strength were obtained by introducing PIA and SA (nPTA/nPIA = 7/3, αSA = 3-5 mol%) into PBT and their anisotropy are better than that of ABS.

Fracture assessment of polycarbonate parts produced by fused deposition modeling in the out-of-plane printing direction – effect of raster angle

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Iman Sedighi ◽  
Majid R. Ayatollahi ◽  
Bahador Bahrami ◽  
Marco A. Pérez-Martínez ◽  
Andrés A. Garcia-Granada
Keyword(s):  
Fracture Toughness ◽  
Finite Element ◽  
Fracture Behavior ◽  
Fused Deposition Modeling ◽  
Mode I ◽  
Content Type ◽  
Fused Deposition ◽  
Out Of Plane ◽  
Deposition Modeling ◽  
Fracture Tests

Purpose The purpose of this paper is to study the Mode I fracture behavior of polycarbonate (PC) parts produced using fused deposition modeling (FDM). The focus of this study is on samples printed along the out-of-plane direction with different raster angles. Design/methodology/approach Tensile and Mode I fracture tests were conducted. Semi-circular bend specimens were used for the fracture tests, which were printed in four different raster patterns of (0/90), (15/−75) (30/−60) and (45/−45). Moreover, the finite element method (FEM) was used to determine the applicability of linear elastic fracture mechanics (LEFM) for the printed PC parts. The fracture toughness results, as well as the fracture path and the fracture surfaces, were studied to describe the fracture behavior of the samples. Findings Finite element results confirm that the use of LEFM is allowed for the tested PC samples. The fracture toughness results show that changing the direction of the printed rasters can have an effect of up to 50% on the fracture toughness of the printed parts, with the (+45/−45) and (0/90) orientations having the highest and lowest resistance to crack propagation, respectively. Moreover, except for the (0/90) orientation, the other samples have higher crack resistance compared to the bulk material. The fracture toughness of the tested PC depends more on the toughness of the printed sample, rather than its tensile strength. Originality/value The toughness and the energy absorption capability of the printed samples (with different raster patterns) were identified as the main properties affecting the fracture toughness of the AM PC parts. Because the fracture resistance of almost all the samples was higher than that of the base material, it is evident that by choosing the right raster patterns for 3D-printed parts, very high resistance to crack growth may be obtained. Also, using FEM and comparing the size of the plastic zones, it was concluded that, although the tensile curves show nonlinearity, LEFM is still applicable for the printed parts.

Multi-objective optimization approach in design for additive manufacturing for fused deposition modeling

2019 ◽  
Vol 25 (5) ◽  
pp. 875-887
Author(s):  
Elnaz Asadollahi-Yazdi ◽  
Julien Gardan ◽  
Pascal Lafon
Keyword(s):  
Optimization Problem ◽  
Fused Deposition Modeling ◽  
Topological Optimization ◽  
Design For Additive Manufacturing ◽  
Multi Objective Optimization ◽  
Content Type ◽  
Fused Deposition ◽  
Design And Manufacturing ◽  
Deposition Modeling ◽  
Manufacturing Parameters

Purpose This paper aims to provide a multi-objective optimization problem in design for manufacturing (DFM) approach for fused deposition modeling (FDM). This method considers the manufacturing criteria and constraints during the design by selecting the best manufacturing parameters to guide the designer and manufacturer in fabrication with FDM. Design/methodology/approach Topological optimization and bi-objective optimization problems are suggested to complete the DFM approach for design for additive manufacturing (DFAM) to define a product. Topological optimization allows the shape improvement of the product through a material distribution for weight gain based on the desired mechanical behavior. The bi-objective optimization problem plays an important role to evaluate the manufacturability by quantification and optimization of the manufacturing criteria and constraint simultaneously. Actually, it optimizes the production time, required material regarding surface quality and mechanical properties of the product because of two significant parameters as layer thickness and part orientation. Findings A comprehensive analysis of the existing DFAM approaches illustrates that these approaches are not developed sufficiently in terms of manufacturability evaluation in quantification and optimization levels. There is no approach that investigates the AM criteria and constraints simultaneously. It is necessary to provide a decision-making tool for the designers and manufacturers to lead to better design and manufacturing regarding the different AM characteristics. Practical implications To assess the efficiency of this approach, a wheel spindle is considered as a case study which shows how this method is capable to find the best design and manufacturing solutions. Originality/value A multi-criteria decision-making approach as the main contribution is developed to analyze FDM technology and its attributes, criteria and drawbacks. It completes the DFAM approach for FDM through a bi-objective optimization problem which deals with finding the best manufacturing parameters by optimizing production time and material mass because of the product mechanical properties and surface roughness.

Simulation of edge quality in fused deposition modeling

2019 ◽  
Vol 25 (3) ◽  
pp. 541-554 ◽  
Author(s):  
Antonio Armillotta
Keyword(s):  
Fused Deposition Modeling ◽  
Experimental Tests ◽  
Geometric Errors ◽  
Content Type ◽  
Fused Deposition ◽  
Graphical Simulation ◽  
Deposition Modeling ◽  
Edge Quality ◽  
Input Variables

Purpose The purpose of this paper is to propose a method for simulating the profile of part edges as a result of the FDM process. Deviations from nominal edge shape are predicted as a function of the layer thickness and three characteristic angles depending on part geometry and build orientation. Design/methodology/approach Typical patterns of edge profiles were observed on sample FDM parts and interpreted as the effects of possible toolpath generation strategies. An algorithm was developed to generate edge profiles consistent with the patterns expected for any combination of input variables. Findings Experimental tests confirmed that the simulation procedure can correctly predict basic geometric properties of edge profiles such as frequency, amplitude and shape of periodic asperities. Research limitations/implications The algorithm takes into account only a subset of the error causes recognized in previous studies. Additional causes could be integrated in the simulation to improve the estimation of geometric errors. Practical implications Edge simulation may help avoid process choices that result in aesthetic and functional defects on FDM parts. Originality/value Compared to the statistical estimation of geometric errors, graphical simulation allows a more detailed characterization of edge quality and a better diagnosis of error causes.

Deposition-induced effects of isotactic polypropylene and polycarbonate composites during fused deposition modeling

2017 ◽  
Vol 23 (5) ◽  
pp. 869-880 ◽  
Author(s):  
Ying-Guo Zhou ◽  
Bei Su ◽  
Lih-sheng Turng
Keyword(s):  
Mechanical Properties ◽  
Design Methodology ◽  
Fused Deposition Modeling ◽  
Content Type ◽  
Fused Deposition ◽  
Close Relationship ◽  
Molded Parts ◽  
Deposition Modeling ◽  
Injection Molded ◽  
First Time

Purpose Although the feasibility and effectiveness of the fused deposition modeling (FDM) method have been proposed and developed, studies of applying this technology to various materials are still needed for researching its applicability, especially with regard to polymer blends and composites. The purpose of this paper is to study the deposition-induced effect and the effect of compatibilizers on the mechanical properties of polypropylene and polycarbonate (PP/PC) composites. Design/methodology/approach For this purpose, three different deposition modes for PP/PC composites with or without compatibilizers were used for the FDM method and tested for tensile properties. Also, parts with the same materials were made by injection molding and used for comparison. In addition, different deposition speeds were used to investigate the different deposition-induced effects. Furthermore, the behavior of the mechanical properties was clarified with scanning electron microscope images of the fracture surfaces. Findings The research results suggest that the deposition orientation has a significant influence on the mechanical behavior of PP/PC composite FDM parts. The results also indicate that there is a close relationship between the mechanical properties and morphological structures which are deeply influenced by compatibilization. Compared with injection molded parts, the ductility of the FDM parts can be dramatically improved due to the formation of fibrils and micro-fibrils by the deposition induced during processing. Originality/value This is the first paper to investigate a PP/PC composite FDM process. The results of this paper verified the applicability of PP/PC composites to FDM technology. It is also the first time that the deposition-induced effect during FDM has been investigated and studied.

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