Investigating impact of five build parameters on the maximum flexural force in FDM specimens – a definitive screening design approach

Purpose The purpose of this study was to examine the impact of five key build parameters – layer thickness, deposition angle, infill, extrusion speed and extrusion temperature, and their interactions – on the maximum flexural force in specimens which are made of polylactic acid (PLA). Design/methodology/approach Through a previous study on the flexural properties of PLA specimens, a statistically significant effect of layer thickness was indicated, requiring further experimentation to establish the values of quadratic term in the model, as well as to perform optimization. Instead of performing a conventional Central Composite Design, a novel, definitive screening design (DSD) was used as statistical method. DSD allowed the reduction of the number of runs required for optimization while minimizing aliasing. Findings Significance of deposition angle and infill as main effects was established. Moreover, significant two-way interactions between infill/layer thickness and infill/extrusion speed were detected and discussed. The optimization procedure showed that minimum level of deposition angle, maximum levels of extrusion speed and infill and near mid-level of layer thickness yield maximum flexural force. Research limitations/implications In this study, the three levels of infill were 0.1, 0.2 and 0.3, which corresponds to 10, 20 and 30 per cent of infill, respectively. In everyday practice, infill is usually kept within this range since it allows time-efficiency, i.e. significant reduction of build time. Though, unsurprisingly, higher infill is positively correlated with flexural strength, this study provides practical directions for optimal selection of other key parameters when working with low infill values. Social implications Optimal 3D printing with low infill can contribute to lower material waste and pollution, while PLA plastic’s biodegradability remains high on the environment protection agenda. Originality/value According to available literature, no previous studies have investigated the FDM extrusion of PLA material using a combination of low infill, deposition angle, layer thickness, extrusion speed and extrusion temperature.

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Influence of processing parameters on creep and recovery behavior of FDM manufactured part using definitive screening design and ANN

Rapid Prototyping Journal ◽

10.1108/rpj-12-2015-0198 ◽

2017 ◽

Vol 23 (6) ◽

pp. 998-1010 ◽

Cited By ~ 10

Author(s):

Omar Ahmed Mohamed ◽

Syed Hasan Masood ◽

Jahar Lal Bhowmik

Keyword(s):

Layer Thickness ◽

Process Parameters ◽

Air Gap ◽

Content Type ◽

Screening Design ◽

Definitive Screening ◽

Raster Angle ◽

Road Width ◽

Recoverable Compliance ◽

The Relationship

Purpose The purpose of this paper is to investigate the effect of process parameters of fused deposition modelling (FDM) 3D printing process on viscoelastic responses (creep compliance and recoverable compliance) of FDM built parts using a novel experimental design technique. Design/methodology/approach As part of the process characterization, a recently developed class of three-level design methodology – definitive screening design (DSD) – was used in this study to fit a second-order polynomial regression model. Artificial neural network (ANN) was also used to determine the optimal process parameters to improve creep compliance and recoverable compliance. The relationship between layer thickness, air gap, raster angle, build orientation, road width, number of contours and creep performance of FDM fabricated part was thereafter established empirically. Scanning electron microscope (SEM) is used to examine and characterize the morphology of the structures for some samples. Findings This study found that the creep resistance of FDM-manufactured part is significantly influenced by layer thickness, air gap, raster angle and number of contours and it can be improved by optimizing the settings of the selected parameters. The relationship between FDM process parameters and creep properties was determined, with the best creep performance observed by using 0.127 mm of layer thickness, zero air gap, zero raster angle, build orientation of 17.188°, road width of 0.4572 mm and 10 contours. Finally, the result is verified by confirmation experiments. The results prove that a DSD is a very effective design in characterizing the influence of process parameters on creep properties of FDM-built part at the lowest cost. Originality/value The originality of this paper lies in characterizing and optimizing the effect of process parameters on creep performance of FDM manufactured part that has not been studied in all previous studies. The paper highlights, for the first time, how the application of DSD can overcome most of the limitations encountered in the conventional techniques. This study can be used as a guide to the different additive manufacturing users of various industries and the results provide a good technical database on how FDM process parameters influence the creep performance of manufactured parts.

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Eco-Structured Biosorptive Removal of Basic Fuchsin Using Pistachio Nutshells: A Definitive Screening Design—Based Approach

Applied Sciences ◽

10.3390/app9224855 ◽

2019 ◽

Vol 9 (22) ◽

pp. 4855 ◽

Cited By ~ 7

Author(s):

Marwa El-Azazy ◽

Ahmed S. El-Shafie ◽

Aya Ashraf ◽

Ahmed A. Issa

Keyword(s):

Adsorption Capacity ◽

Textural Properties ◽

Basic Fuchsin ◽

Equilibrium Studies ◽

Screening Design ◽

Bet Analysis ◽

Definitive Screening ◽

Wastewater Samples ◽

The Impact ◽

Definitive Screening Design

Biosorptive removal of basic fuchsin (BF) from wastewater samples was achieved using the recycled agro-wastes of pistachio nut shells (PNS). Seven adsorbents were developed; raw shells (RPNS) and the thermally activated biomasses at six different temperatures (250–500 °C). Two measures were implemented to assess the performance of utilized adsorbents; %removal (%R) and adsorption capacity (qe). RPNS proved to be the best among the tested adsorbents. A smart approach, definitive-screening design (DSD) was operated to test the impact of independent variables on the adsorption capacity of RPNS. pH, adsorbent dose (AD), dye concentration (DC), and stirring time (ST), were the tested variables. Analysis of variance (ANOVA), control, and quality charts helped establishing regression model. Characterization was performed using Fourier- transform infrared (FT-IR)/Raman spectroscopies together with thermogravimetric analysis (TGA) and scanning electron microscopy (SEM)/energy-dispersive X-ray spectroscopy (EDX) analyses. The surface area and other textural properties were determined using the Brunauer Emmett-Teller (BET) analysis. Removal of 99.71% of BF with an adsorption capacity of 118.2 mg/g could be achieved using a factorial blend of pH 12, 100 mg/50 mL of RPNS, and 250 ppm BF for 20 min. Equilibrium studies reveal that the adsorption is physisorption with adsorption energy of 7.45 kJ/mol as indicated by Dubinin-Radushkevich (DR) and Langmuir isotherms. Moreover, adsorption follows pseudo-second-order kinetics with respect to BF and is controlled by the adsorption rate.

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Impact of processing parameters on tensile strength, in-process crystallinity and mesostructure in FDM-fabricated PLA specimens

Rapid Prototyping Journal ◽

10.1108/rpj-12-2018-0316 ◽

2019 ◽

Vol 25 (8) ◽

pp. 1398-1410 ◽

Cited By ~ 4

Author(s):

Ognjan Luzanin ◽

Dejan Movrin ◽

Vassilis Stathopoulos ◽

Pavlos Pandis ◽

Tanja Radusin ◽

...

Keyword(s):

Tensile Strength ◽

Layer Thickness ◽

Process Model ◽

Processing Parameters ◽

Poly Lactic Acid ◽

Extrusion Speed ◽

Plate Temperature ◽

Content Type ◽

Designed Experiment ◽

The Impact

Purpose This study aims to investigate the impact of layer thickness, extrusion temperature, extrusion speed and build plate temperature on the tensile strength, crystallinity achieved during fabrication (herein, in-process crystallinity) and mesostructure of Poly(lactic acid) specimens. Both tensile strength and in-process crystallinity were optimized and verified as the function of processing parameters, and their relationship was thoroughly examined. Design/methodology/approach The four key technological parameters were systematically varied as factors on three levels, using the statistically designed experiment. Surface response methodology was used to optimize tensile strength and crystallinity for the given ranges of input factors. Optimized factor settings were used in a set of confirmation runs, where the result of optimization was experimentally confirmed. Material characterization was performed using differential scanning calorimetry and X-ray diffraction analysis, while the effect of processing parameters on mesostructure was examined by scanning electron microscopy. Findings Layer thickness and its quadratic effect are dominant contributors to tensile strength. Significant interaction between layer thickness and extrusion speed implies that these parameters should always be varied simultaneously within designed experiment to obtain adequate process model. As regards, the in-process crystallinity, extrusion speed is part of two significant interactions with plate temperature and layer thickness, respectively. Quality of mesostructure is vital contributor to tensile strength during FDM process, while the in-process crystallinity exhibited no impact, remaining below the 20 per cent margin regardless of process parameter settings. Originality/value According to available literature, there have been no previously published investigations which studied the effect of process parameters on tensile strength, mesostructure and in-process crystallinity through systematic variation of four critical processing parameters.

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Experimental Study of the Wear Performance of Fused Deposition Modeling Printed Polycarbonate-Acrylonitrile Butadiene Styrene Parts Using Definitive Screening Design and Machine Learning-Genetic Algorithm

Journal of Materials Engineering and Performance ◽

10.1007/s11665-021-06408-6 ◽

2021 ◽

Author(s):

Omar Ahmed Mohamed ◽

Syed Hasan Masood ◽

Jahar Lal Bhowmik

Keyword(s):

Genetic Algorithm ◽

Fused Deposition Modeling ◽

Acrylonitrile Butadiene Styrene ◽

Wear Performance ◽

Fused Deposition ◽

Screening Design ◽

Definitive Screening ◽

Deposition Modeling ◽

Definitive Screening Design ◽

Butadiene Styrene

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Optimization of biodiesel production from waste frying palm oil using definitive screening design

International Journal of Engineering Science and Technology ◽

10.4314/ijest.v11i2.4 ◽

2019 ◽

Vol 11 (2) ◽

pp. 48 ◽

Cited By ~ 4

Author(s):

Y Rajesh ◽

Aditya Kolakoti ◽

B.G. Chandra Sheakar ◽

J Bhargavi

Keyword(s):

Palm Oil ◽

Biodiesel Production ◽

Screening Design ◽

Definitive Screening ◽

Definitive Screening Design

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Erratum to: Investigation on the Flexural Creep Stiffness Behavior of PC–ABS Material Processed by Fused Deposition Modeling Using Response Surface Definitive Screening Design

JOM ◽

10.1007/s11837-017-2254-5 ◽

2017 ◽

Vol 69 (3) ◽

pp. 612-612

Author(s):

Omar Ahmed Mohamed ◽

Syed Hasan Masood ◽

Jahar Lal Bhowmik

Keyword(s):

Response Surface ◽

Fused Deposition Modeling ◽

Fused Deposition ◽

Screening Design ◽

Flexural Creep ◽

Definitive Screening ◽

Creep Stiffness ◽

Deposition Modeling ◽

Definitive Screening Design

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Application of a definitive screening design for the synthesis of a charge-transfer complex of sparfloxacin with tetracyanoethylene: spectroscopic, thermodynamic, kinetics, and DFT computational studies

RSC Advances ◽

10.1039/c9ra03141c ◽

2019 ◽

Vol 9 (43) ◽

pp. 24722-24732 ◽

Cited By ~ 1

Author(s):

Ahmed S. El-Shafie ◽

Areej W. Khashan ◽

Yasser H. A. Hussein ◽

Marwa El-Azazy

Keyword(s):

Charge Transfer ◽

Charge Transfer Complex ◽

Computational Studies ◽

Screening Design ◽

Definitive Screening ◽

A Charge ◽

Definitive Screening Design

A spectrochemical approach was adopted to study the charge-transfer (CT) complexation of sparfloxacin (SFX) with tetracyanoethylene (TCNE). Definitive screening design (DSD) was used to investigate the reaction variables.

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

Rapid Prototyping Journal ◽

10.1108/rpj-05-2016-0077 ◽

2017 ◽

Vol 23 (5) ◽

pp. 943-953 ◽

Cited By ~ 25

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.

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