On improving the surface finish of 3D printing polylactic acid parts by corundum blasting

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ana Pilar Valerga Puerta ◽  
J.D. Lopez-Castro ◽  
Adrián Ojeda López ◽  
Severo Raúl Fernández Vidal
Keyword(s):  
Layer Thickness ◽  
Polylactic Acid ◽  
Surface Quality ◽  
Fused Deposition Modeling ◽  
Fused Filament Fabrication ◽  
High Exposure ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling

Purpose Fused filament fabrication or fused deposition modeling (FFF/FDM) has as one of its main restrictions the surface quality intrinsic to the process, especially linked to the layer thickness used during manufacture. The purpose of this paper is to study the possibility of improving the surface quality of polylactic acid (PLA) parts manufactured by FFF using the shot blasting technique. Design/methodology/approach The influence of corundum blasting on 0.2 mm layer thickness FDM PLA parts treated with two sizes of abrasive, different exposure times and different incidence pressures. Findings As a result, improvements of almost 80% were obtained in the surface roughness of the pieces with high exposure times, and more than 50% in just 20 s. Originality/value This technique is cheap, versatile and adaptable to different part sizes and geometries. Furthermore, it is a fast and environmentally friendly technique compared to conventional machining or vapor smoothing. Despite this, no previous studies have been carried out to improve the quality of this technology.

scholarly journals Analysis of the surface quality of polycaprolactam 3D prints enriched with carbon and glass fiber

2021 ◽  
Vol 338 ◽  
pp. 01005
Author(s):  
Damian Dzienniak ◽  
Jan Pawlik
Keyword(s):  
Glass Fiber ◽  
Surface Quality ◽  
Fused Deposition Modeling ◽  
Polyamide 6 ◽  
Fiber Glass ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
The Impact ◽  
The Relationship

Additive manufacturing has been gaining popularity and availability year by year, which has resulted in its dynamic development. The most common 3D printing method as of today, FDM (Fused Deposition Modeling), owing to its peculiarity, does not always guarantee producing objects with low surface roughness. The authors of the present article have taken on the analysis of the impact of FDM printing on the roughness of the filament thus processed. They also investigate the relationship between the roughness of the unprocessed filament (made of polycaprolactam, that is, polyamide 6 or PA6) with admixtures of other materials (carbon fiber, glass fiber) and the surface quality of the manufactured object. The main subject of the analysis is the side surfaces of 3D prints, as it is their quality that is usually directly dependent on many factors connected with the process of the laying of the consecutive layers. The authors check step by step whether there exists a pronounced relationship between the roughness of the original filament material and the roughness of the obtained surface.

Experimental study on the accuracy and surface quality of printed versus machined holes in PEI Ultem 9085 FDM specimens

2021 ◽  
Vol 27 (11) ◽  
pp. 1-12
Author(s):  
Giovanni Gómez-Gras ◽  
Marco A. Pérez ◽  
Jorge Fábregas-Moreno ◽  
Guillermo Reyes-Pozo
Keyword(s):  
Surface Quality ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Technological Parameters ◽  
Content Type ◽  
Fused Deposition ◽  
Comparison Of The Results ◽  
Through Hole

Purpose This paper aims to investigate the quality of printed surfaces and manufacturing tolerances by comparing the cylindrical cavities machined in parts obtained by fused deposition modeling (FDM) with the holes manufactured during the printing process itself. The comparison focuses on the results of roughness and tolerances, intending to obtain practical references when making assemblies. Design/methodology/approach The experimental approach focuses on the comparison of the results of roughness and tolerances of two manufacturing strategies: geometric volumes with a through-hole and the through-hole machined in volumes that were initially printed without the hole. Throughout the study, both alternates are explained to make appropriate recommendations. Findings The study shows the best combinations of technological parameters, both machining and three-dimensional printing, which have been decisive for obtaining successful results. These conclusive results allow enunciating recommendations for use in the industrial environment. Originality/value This paper fulfills an identified need to study the dimensional accuracy of the geometries obtained by additive manufacturing, as no experimental evidence has been found of studies that directly address the problem of the FDM-printed part with geometric and dimensional tolerances and desirable surface quality for assembly.

Effect of layer thickness on irreversible thermal expansion and interlayer strength in fused deposition modeling

2017 ◽  
Vol 23 (5) ◽  
pp. 943-953 ◽  
Author(s):  
Anthony A. D’Amico ◽  
Analise Debaie ◽  
Amy M. Peterson
Keyword(s):  
Mechanical Properties ◽  
Thermal Expansion ◽  
Flexural Strength ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Thermal Strain ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
The Impact

Purpose The aim of this paper is to examine the impact of layer thickness on irreversible thermal expansion, residual stress and mechanical properties of additively manufactured parts. Design/methodology/approach Samples were printed at several layer thicknesses, and their irreversible thermal expansion, tensile strength and flexural strength were determined. Findings Irreversible thermal strain increases with decreasing layer thickness, up to 22 per cent strain. Tensile and flexural strengths exhibited a peak at a layer thickness of 200 μm although the maximum was not statistically significant at a 95 per cent confidence interval. Tensile strength was 54 to 97 per cent of reported values for injection molded acrylonitrile butadiene styrene (ABS) and 29 to 73 per cent of those reported for bulk ABS. Flexural strength was 18 to 41 per cent of reported flexural strength for bulk ABS. Practical implications The large irreversible thermal strain exhibited that corresponding residual stresses could lead to failure of additively manufactured parts over time. Additionally, the observed irreversible thermal strains could enable thermally responsive shape in additively manufactured parts. Variation in mechanical properties with layer thickness will also affect manufactured parts. Originality/value Tailorable irreversible thermal strain of this magnitude has not been previously reported for additively manufactured parts. This strain occurs in parts made with both high-end and consumer grade fused deposition modeling machines. Additionally, the impact of layer thickness on tensile and flexural properties of additively manufactured parts has received limited attention in the literature.

scholarly journals A Theoretical and Experimental Research on the Influence of FDM Parameters on Tensile Strength and Hardness of Parts Made of Polylactic Acid

2021 ◽  
Vol 11 (4) ◽  
pp. 7458-7463
Author(s):  
D. G. Zisopol ◽  
I. Nae ◽  
A. I. Portoaca ◽  
I. Ramadan
Keyword(s):  
Tensile Strength ◽  
Rapid Prototyping ◽  
Polylactic Acid ◽  
Experimental Research ◽  
Fused Deposition Modeling ◽  
Plastic Material ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Plastic Parts

Fused Deposition Modeling (FDM) is a rapid prototyping method, widely used in the manufacture of plastic parts with complex geometric shapes. The quality of the parts manufactured by this process depends on the plastic material used and the FDM parameters. In this context, this paper will present the results of a theoretical and experimental research on how FDM parameters influence the tensile strength and hardness of samples made of PLA (Polylactic Acid).

scholarly journals Influence of Process Parameters on Tensile Strength of Additive Manufactured PLA Parts using Taguchi Method

2019 ◽  
Vol 8 (3) ◽  
pp. 7635-7639
Keyword(s):  
Tensile Strength ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Optimal Parameter ◽  
Fused Filament Fabrication ◽  
Influence Of Process Parameters ◽  
Layer Height ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Nozzle Temperature

Influence of layer thickness nozzle temperature and angle on tensile strength of PLA fabricated with FDM (FFF) was experimentally investigated. Polylactic Acid (PLA) is a semi-crystalline and bio-friendly thermoplastic polymer has identified as important material in different applications due to its mechanical characteristics. Fused Deposition Modeling (FDM) is a one of the proved technology in Fused Filament Fabrication (FFF) technique in additive manufacturing process. In present investigation different specimens were fabricated using FDM technique with different layer height and different layer angles for finding influence of these manufacturing parameters on tensile strength of the specimen. Specimens were fabricated and tested as per ASTM D638 standard. It is clearly observed that tensile strength is more for +450 /-450 layer angle than the +00 /-0 0 layer angle for a given layer height(h=0.10 mm, h=0.15mm and h=0.20mm).The TAGUCHI analysis is carried with nozzle temperature, layer thickness and angle finding optimal values. It has been observed that, the optimal parameter is angle, which is equal to 30 0 .the ANOVA variation of angle layer with tensile strength has been observed that 18.10-31.90.

scholarly journals Effect of the filling percentage on tensile strength in 3D desktop printing for different printing patterns, using a randomized design of experiments

Enfoque UTE ◽  
2019 ◽  
Vol 10 (4) ◽  
pp. 13-27
Author(s):  
Juan Carlos Parra Mena ◽  
Erling Ricardo Gallardo Vizuete ◽  
Erick Damian Torres Peñaloza
Keyword(s):  
Tensile Strength ◽  
Design Of Experiments ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Single Factor ◽  
Fused Filament Fabrication ◽  
Fused Deposition ◽  
Randomized Design ◽  
Filling Pattern ◽  
Deposition Modeling

The evaluation of the tensile strength of printed parts by means of fused deposition modeling (FDM) or fused filament fabrication (FFF) is essential, since parts whose resistance does not differ significantly depending on the percentage of filling used can be obtained, optimizing the use of the material. The present work details the analysis of polylactic acid (PLA) specimens manufactured according to ASTM D 638 with different percentages for the most commonly used filling patterns (Honeycomb, Octagram, Stars, Archimedean, Hilbert and Triangles). With the help of an analysis of variance and a design of experiments with a single factor, the appropriate percentages for printing parts according to the desired filling pattern are obtained.

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.

An approach for mechanical property optimization of fused deposition modeling with polylactic acid via design of experiments

2016 ◽  
Vol 22 (2) ◽  
pp. 387-404 ◽  
Author(s):  
Jonathan Torres ◽  
Matthew Cole ◽  
Allen Owji ◽  
Zachary DeMastry ◽  
Ali P. Gordon
Keyword(s):  
Mechanical Properties ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Mechanical Tests ◽  
Content Type ◽  
Fused Deposition ◽  
Structural Applications ◽  
3D Printers ◽  
Deposition Modeling

Purpose This paper aims to present the influences of several production variables on the mechanical properties of specimens manufactured using fused deposition modeling (FDM) with polylactic acid (PLA) as a media and relate the practical and experimental implications of these as related to stiffness, strength, ductility and generalized loading. Design/methodology/approach A two-factor-level Taguchi test matrix was defined to allow streamlined mechanical testing of several different fabrication settings using a reduced array of experiments. Specimens were manufactured and tested according to ASTM E8/D638 and E399/D5045 standards for tensile and fracture testing. After initial analysis of mechanical properties derived from mechanical tests, analysis of variance was used to infer optimized production variables for general use and for application/load-specific instances. Findings Production variables are determined to yield optimized mechanical properties under tensile and fracture-type loading as related to orientation of loading and fabrication. Practical implications The relation of production variables and their interactions and the manner in which they influence mechanical properties provide insight to the feasibility of using FDM for rapid manufacturing of components for experimental, commercial or consumer-level use. Originality/value This paper is the first report of research on the characterization of the mechanical properties of PLA coupons manufactured using FDM by the Taguchi method. The investigation is relevant both in commercial and consumer-level aspects, given both the currently increasing utilization of 3D printers for component production and the viability of PLA as a renewable, biocompatible material for use in structural applications.

scholarly journals A Comparative Analysis of Selected Methods for Determining Young’s Modulus in Polylactic Acid Samples Manufactured with the FDM Method

Materials ◽  
2021 ◽  
Vol 15 (1) ◽  
pp. 149
Author(s):  
Bartosz Pszczółkowski ◽  
Konrad W. Nowak ◽  
Wojciech Rejmer ◽  
Mirosław Bramowicz ◽  
Łukasz Dzadz ◽  
...  
Keyword(s):  
Young’S Modulus ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Young's Modulus ◽  
Acrylonitrile Butadiene Styrene ◽  
Tensile Tests ◽  
Fused Filament Fabrication ◽  
Fused Deposition ◽  
Static Tensile ◽  
Deposition Modeling

The objective of this study was to compare three methods for determining the Young’s modulus of polylactic acid (PLA) and acrylonitrile-butadiene-styrene (ABS) samples. The samples were manufactured viathe fused filament fabrication/fused deposition modeling (FFF/FDM) 3D printing technique. Samples for analysis were obtained at processing temperatures of 180 °C to 230 °C. Measurements were performed with the use of two nondestructive techniques: the impulse excitation technique (IET) and the ultrasonic (US) method. The results were compared with values obtained in static tensile tests (STT), which ranged from 2.06 ± 0.03 to 2.15 ± 0.05 GPa. Similar changes in Young’s modulus were observed in response to the processing temperatures of the compared methods. The values generated by the US method were closer to the results of the STT, but still diverged considerably, and the error exceeded 10% in all cases. Based on the present findings, it might be concluded that the results of destructive and nondestructive tests differ by approximately 1 GPa.

Experiment Study on Effects of Critical Factors on Quality of Prototypes in Fused Deposition Modeling

2012 ◽  
Vol 535-537 ◽  
pp. 73-76
Author(s):  
An Hua Peng
Keyword(s):  
Surface Quality ◽  
Line Width ◽  
Fused Deposition Modeling ◽  
Critical Factors ◽  
Experiment Study ◽  
Fused Deposition ◽  
Processing Program ◽  
Deposition Modeling ◽  
Filling Line

This paper presents an experiment investigation on the effects on the surface quality and strength of a model in FDM, of critical factors including stratification parameters, build orientation, brace structure, auxiliary brace, and defects in STL files. With experiments using MEM-300, the conclusions can be drawn that, no matter what the number of interval is, greater filling line width always easily lead to poor surface quality, and that when the demands on surface quality and strength conflict one another, the demands on the both must first be balanced to obtain the better economical processing program.

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