Geometrical analysis and tensile behaviour of parts manufactured with flame retardant polymers by additive manufacturing

2017 ◽  
Vol 23 (1) ◽  
pp. 169-180 ◽  
Author(s):  
Anderson Vicente Borille ◽  
Jefferson de Oliveira Gomes ◽  
Daniel Lopes
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Flame Retardant ◽  
Dimensional Accuracy ◽  
Tensile Behaviour ◽  
Geometrical Analysis ◽  
Flame Resistance ◽  
Content Type ◽  
Fused Deposition ◽  
Measuring Machine

Purpose Flame-retardant plastics are used in critical applications, such as aircraft interior parts, when the occurrence of fire can lead to serious injury to people. However, there is a lack of related publications. The purpose of this study is to present experimental data regarding geometrical analysis, such as dimensional accuracy and surface roughness, tensile strength and elongation of parts manufactured with flame-retardant materials by additive manufacturing. Design/methodology/approach Two additive manufacturing processes, selective laser sintering (SLS) and fused deposition modeling (FDM), were selected to manufacture the parts to be evaluated. Each process used its respective polymer, that is polyamide with flame-retardant additive (PA) for SLS and polyphenylsulfone (PPSF) for FDM. The samples consist of tensile specimens and representative parts of different products. Tensile tests were performed using standard tensile test machines, and geometrical analyses were performed using coordinate measuring machine as well as surface roughness tester. Findings As each material can be, in commercial machines, produced by only one process, the material selection for final products has to consider the manufacturing process as well. In general, although the FDM/PPSF process provided specimens with the highest ultimate strength, because of its strong influence by the building direction, FDM/PPSF also provided the lowest strength. SLS/PA was able to provide average strength with less dependency on the build-up direction. The geometrical analysis showed that SLS/PA presents a much smoother surface, but FDM/PPSF presented slightly better dimensional accuracy. Originality/value There is still lack of publications on polymers with flame resistance or flame-retardant polymers. Thus, this paper brings new technical information about processing such materials.

A review of melt extrusion additive manufacturing processes: II. Materials, dimensional accuracy, and surface roughness

2015 ◽  
Vol 21 (3) ◽  
pp. 250-261 ◽  
Author(s):  
Brian N. Turner ◽  
Scott A Gold
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Product Design ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Design Parameters ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Am Processes

Purpose – The purpose of this paper is to critically review the literature related to dimensional accuracy and surface roughness for fused deposition modeling and similar extrusion-based additive manufacturing or rapid prototyping processes. Design/methodology/approach – A systematic review of the literature was carried out by focusing on the relationship between process and product design parameters and the dimensional and surface properties of finished parts. Methods for evaluating these performance parameters are also reviewed. Findings – Fused deposition modeling® and related processes are the most widely used polymer rapid prototyping processes. For many applications, resolution, dimensional accuracy and surface roughness are among the most important properties in final parts. The influence of feedstock properties and system design on dimensional accuracy and resolution is reviewed. Thermal warping and shrinkage are often major sources of dimensional error in finished parts. This phenomenon is explored along with various approaches for evaluating dimensional accuracy. Product design parameters, in particular, slice height, strongly impact surface roughness. A geometric model for surface roughness is also reviewed. Originality/value – This represents the first review of extrusion AM processes focusing on dimensional accuracy and surface roughness. Understanding and improving relationships between materials, design parameters and the ultimate properties of finished parts will be key to improving extrusion AM processes and expanding their applications.

Additive manufacturing using fine wire-based laser metal deposition

2019 ◽  
Vol 26 (3) ◽  
pp. 473-483
Author(s):  
Muhammad Omar Shaikh ◽  
Ching-Chia Chen ◽  
Hua-Cheng Chiang ◽  
Ji-Rong Chen ◽  
Yi-Chin Chou ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
High Precision ◽  
Surface Finish ◽  
Dimensional Accuracy ◽  
Laser Metal Deposition ◽  
Cross Sectional ◽  
Content Type ◽  
Fine Wire

Purpose Using wire as feedstock has several advantages for additive manufacturing (AM) of metal components, which include high deposition rates, efficient material use and low material costs. While the feasibility of wire-feed AM has been demonstrated, the accuracy and surface finish of the produced parts is generally lower than those obtained using powder-bed/-feed AM. The purpose of this study was to develop and investigate the feasibility of a fine wire-based laser metal deposition (FW-LMD) process for producing high-precision metal components with improved resolution, dimensional accuracy and surface finish. Design/methodology/approach The proposed FW-LMD AM process uses a fine stainless steel wire with a diameter of 100 µm as the additive material and a pulsed Nd:YAG laser as the heat source. The pulsed laser beam generates a melt pool on the substrate into which the fine wire is fed, and upon moving the X–Y stage, a single-pass weld bead is created during solidification that can be laterally and vertically stacked to create a 3D metal component. Process parameters including laser power, pulse duration and stage speed were optimized for the single-pass weld bead. The effect of lateral overlap was studied to ensure low surface roughness of the first layer onto which subsequent layers can be deposited. Multi-layer deposition was also performed and the resulting cross-sectional morphology, microhardness, phase formation, grain growth and tensile strength have been investigated. Findings An optimized lateral overlap of about 60-70% results in an average surface roughness of 8-16 µm along all printed directions of the X–Y stage. The single-layer thickness and dimensional accuracy of the proposed FW-LMD process was about 40-80 µm and ±30 µm, respectively. A dense cross-sectional morphology was observed for the multilayer stacking without any visible voids, pores or defects present between the layers. X-ray diffraction confirmed a majority austenite phase with small ferrite phase formation that occurs at the junction of the vertically stacked beads, as confirmed by the electron backscatter diffraction (EBSD) analysis. Tensile tests were performed and an ultimate tensile strength of about 700-750 MPa was observed for all samples. Furthermore, multilayer printing of different shapes with improved surface finish and thin-walled and inclined metal structures with a minimum achievable resolution of about 500 µm was presented. Originality/value To the best of the authors’ knowledge, this is the first study to report a directed energy deposition process using a fine metal wire with a diameter of 100 µm and can be a possible solution to improving surface finish and reducing the “stair-stepping” effect that is generally observed for wires with a larger diameter. The AM process proposed in this study can be an attractive alternative for 3D printing of high-precision metal components and can find application for rapid prototyping in a range of industries such as medical and automotive, among others.

Investigations for statistically controlled investment casting solution of FDM-based ABS replicas

2014 ◽  
Vol 20 (3) ◽  
pp. 215-220 ◽  
Author(s):  
Rupinder Singh ◽  
Gurwinder Singh
Keyword(s):  
Investment Casting ◽  
Fused Deposition Modeling ◽  
Plastic Material ◽  
Dimensional Accuracy ◽  
International Standard Organization ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Standard Organization ◽  
Measuring Machine

Purpose – The purpose of the present study is to investigate statistically controlled investment casting (IC) solution of fused deposition modeling (FDM)-based ABS replicas. Design/methodology/approach – The work started with the identification of the benchmark/component. Prototypes (to be used as pattern) were built on FDM with ABS plastic material, followed by IC. The measurements on final casting prepared were made on the co-ordinate measuring machine (CMM) from which international tolerance (IT) grades were calculated to establish the dimensional accuracy of the components. Findings – This study further highlighted the cast component properties (like hardness and surface finish) for suitability of this process. Final castings produced are acceptable as per international standard organization (ISO) standard UNI EN 20286-I (1995). Originality/value – This process ensures development of statistically controlled IC solution as technological prototypes and proof of concept at less production cost and time.

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.

Process capability analysis of fused deposition modelling for plastic components

2014 ◽  
Vol 20 (1) ◽  
pp. 69-76 ◽  
Author(s):  
Rupinder Singh
Keyword(s):  
Process Capability ◽  
Dimensional Accuracy ◽  
Fused Deposition Modelling ◽  
Economic Point ◽  
Content Type ◽  
Process Capability Analysis ◽  
Fused Deposition ◽  
Capability Analysis ◽  
Measuring Machine ◽  
Plastic Components

Purpose – The purpose of the present study is process capability analysis of fused deposition modelling (FDM) process as rapid pattern making (RDPM) solutions for plastic components. Design/methodology/approach – Starting from the identification of component, prototypes with ABS plastic material were produced and dimensional measurements were made with coordinate measuring machine (CMM). Some important mechanical properties were also compared to verify the suitability of the components. Findings – The study highlighted the best settings of orientation, support material quantity for the selected component as a case study on FDM machine from dimensional accuracy and economic point of view as RDPM solution for plastic components. Practical implications – This process ensures rapid production of statistically controlled pre-series technological prototypes and proof of concept at less production cost and time. Final components produced are acceptable as per ISO standard UNI EN 20286-I and DIN16901. Originality/value – The results of the study suggest that FDM process lies in ±4.5 sigma (σ) limit in regard to dimensional accuracy of plastic component is concerned and may be gainfully employed as RDPM solution for bio-medical applications.

scholarly journals Dimensional capability of selected 3DP technologies

2019 ◽  
Vol 25 (5) ◽  
pp. 915-924 ◽  
Author(s):  
Younss Ait Mou ◽  
Muammer Koc
Keyword(s):  
Surface Roughness ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Digital Measurement ◽  
Content Type ◽  
Micro Scale ◽  
Fused Deposition ◽  
Manufacturing Technologies ◽  
The Right

Purpose This paper aims to report on the findings of an investigation to compare three different three-dimensional printing (3DP) or additive manufacturing technologies [i.e. fused deposition modeling (FDM), stereolithography (SLA) and material jetting (MJ)] and four different equipment (FDM, SLA, MJP 2600 and Object 260) in terms of their dimensional process capability (dimensional accuracy and surface roughness). It provides a comprehensive and comparative understanding about the level of attainable dimensional accuracy, repeatability and surface roughness of commonly used 3DP technologies. It is expected that these findings will help other researchers and industrialists in choosing the right technology and equipment for a given 3DP application. Design/methodology/approach A benchmark model of 5 × 5 cm with several common and challenging features, such as around protrusion and hole, flat surface, micro-scale ribs and micro-scale long channels was designed and printed repeatedly using four different equipment of three different 3DP technologies. The dimensional accuracy of the printed models was measured using non-contact digital measurement methods. The surface roughness was evaluated using a digital profilometer. Finally, the surface quality and edge sharpness were evaluated under a reflected light ZEISS microscope with a 50× magnification objective. Findings The results show that FDM technology with the used equipment results in a rough surface and loose dimensional accuracy. The SLA printer produced a smoother surface, but resulted in the distortion of thin features (<1 mm). MJ printers, on the other hand, produced comparable surface roughness and dimensional accuracy. However, ProJet MJP 3600 produced sharper edges when compared to the Objet 260 that produced round edges. Originality/value This paper, for the first time, provides a comprehensive comparison of three different commonly used 3DP technologies in terms of their dimensional capability and surface roughness without farther post-processing. Thus, it offers a reliable guideline for design consideration and printer selection based on the target application.

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.

scholarly journals Geometrical deviation identification and prediction method for additive manufacturing

2018 ◽  
Vol 24 (9) ◽  
pp. 1524-1538 ◽  
Author(s):  
Zhicheng Huang ◽  
Jean-Yves Dantan ◽  
Alain Etienne ◽  
Mickaël Rivette ◽  
Nicolas Bonnet
Keyword(s):  
Additive Manufacturing ◽  
Prediction Method ◽  
Defect Modes ◽  
Content Type ◽  
Fused Deposition ◽  
Geometrical Quality ◽  
Study Results ◽  
Measuring Machine ◽  
Geometrical Defects

Purpose One major problem preventing further application and benefits from additive manufacturing (AM) nowadays is that AM build parts always end up with poor geometrical quality. To help improving geometrical quality for AM, this study aims to propose geometrical deviation identification and prediction method for AM, which could be used for identifying the factors, forms and values of geometrical deviation of AM parts. Design/methodology/approach This paper applied the skin model-based modal decomposition approach to describe the geometrical deviations of AM and decompose them into different defect modes. On that basis, the approach to propose and extend defect modes was developed. Identification and prediction of the geometrical deviations were then carried out with this method. Finally, a case study with cylinders manufactured by fused deposition modeling was introduced. Two coordinate measuring machine (CMM) machines with different measure methods were used to verify the effectiveness of the methods and modes proposed. Findings The case study results with two different CMM machines are very close, which shows that the method and modes proposed by this paper are very effective. Also, the results indicate that the main geometrical defects are caused by the shrinkage and machine inaccuracy-induced errors which have not been studied enough. Originality/value This work could be used for identifying and predicting the forms and values of AM geometrical deviation, which could help realize the improvement of AM part geometrical quality in design phase more purposefully.

scholarly journals 3D Printed Masks for Powders and Viruses Safety Protection Using Food Grade Polymers: Empirical Tests

Polymers ◽  
2021 ◽  
Vol 13 (4) ◽  
pp. 617
Author(s):  
Ruben Foresti ◽  
Benedetta Ghezzi ◽  
Matteo Vettori ◽  
Lorenzo Bergonzi ◽  
Silvia Attolino ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Material Selection ◽  
Mechanical Resistance ◽  
Biological Safety ◽  
Fused Deposition ◽  
Industrial Grade ◽  
Safety Protection ◽  
3D Printed ◽  
Manufacturing Technologies

The production of 3D printed safety protection devices (SPD) requires particular attention to the material selection and to the evaluation of mechanical resistance, biological safety and surface roughness related to the accumulation of bacteria and viruses. We explored the possibility to adopt additive manufacturing technologies for the production of respirator masks, responding to the sudden demand of SPDs caused by the emergency scenario of the pandemic spread of SARS-COV-2. In this study, we developed different prototypes of masks, exclusively applying basic additive manufacturing technologies like fused deposition modeling (FDM) and droplet-based precision extrusion deposition (db-PED) to common food packaging materials. We analyzed the resulting mechanical characteristics, biological safety (cell adhesion and viability), surface roughness and resistance to dissolution, before and after the cleaning and disinfection phases. We showed that masks 3D printed with home-grade printing equipment have similar performances compared to the industrial-grade ones, and furthermore we obtained a perfect face fit by customizing their shape. Finally, we developed novel approaches to the additive manufacturing post-processing phases essential to assure human safety in the production of 3D printed custom medical devices.

Additive manufacturing to assist prosthetically guided bone regeneration of atrophic maxillary arches

2015 ◽  
Vol 21 (6) ◽  
pp. 705-715 ◽  
Author(s):  
M. Fantini ◽  
F. De Crescenzio ◽  
L. Ciocca ◽  
F. Persiani
Keyword(s):  
Additive Manufacturing ◽  
Bone Regeneration ◽  
Dental Implants ◽  
Surgical Intervention ◽  
Guided Bone Regeneration ◽  
Autogenous Bone ◽  
Bone Augmentation ◽  
Virtual Planning ◽  
Content Type ◽  
Fused Deposition

Purpose – The purpose of this paper is to describe two different approaches for manufacturing pre-formed titanium meshes to assist prosthetically guided bone regeneration of atrophic maxillary arches. Both methods are based on the use of additive manufacturing (AM) technologies and aim to limit at the minimal intervention the bone reconstructive surgery by virtual planning the surgical intervention for dental implants placement. Design/methodology/approach – Two patients with atrophic maxillary arches were scheduled for bone augmentation using pre-formed titanium mesh with particulate autogenous bone graft and alloplastic material. The complete workflow consists of four steps: three-dimensional (3D) acquisition of medical images and virtual planning, 3D modelling and design of the bone augmentation volume, manufacturing of biomodels and pre-formed meshes, clinical procedure and follow up. For what concerns the AM, fused deposition modelling (FDM) and direct metal laser sintering (DMLS) were used. Findings – For both patients, a post-operative control CT examination was scheduled to evaluate the progression of the regenerative process and verify the availability of an adequate amount of bone before the surgical intervention for dental implants placement. In both cases, the regenerated bone was sufficient to fix the implants in the planned position, improving the intervention quality and reducing the intervention time during surgery. Originality/value – A comparison between two novel methods, involving AM technologies are presented as viable and reproducible methods to assist the correct bone augmentation of atrophic patients, prior to implant placement for the final implant supported prosthetic rehabilitation.

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