Mechanical characterization and comparison of additive manufactured ABS, Polyflex™ and ABS/Polyflex™ blended functional prototypes

2020 ◽  
Vol 26 (2) ◽  
pp. 225-237
Author(s):  
Sunpreet Singh ◽  
Rupinder Singh
Keyword(s):  
Fused Deposition Modeling ◽  
Mechanical Characterization ◽  
Low Cost ◽  
Shape Memory Polymer ◽  
Acrylonitrile Butadiene Styrene ◽  
Fracture Mechanisms ◽  
Standard Samples ◽  
Content Type ◽  
Fused Deposition ◽  
Wide Range

Purpose Additive manufacturing (AM) is one of the latest and most advanced technologies that are continuously expanding into various field applications. Undoubtedly, fused deposition modeling (FDM) is one of the oldest and extensively used AM technologies not only because of the advantage of low cost, comparatively moderate production speed and negligible wastage but also due to acceptance of a wide range of thermoplastics, reinforced and blended feedstock for making the end product suitable for service. The purpose of this work to perform mechanical characterization of standard samples printed on FDM with acrylonitrile butadiene styrene (ABS), shape memory polymer (SMP; make PolyflexTM) and ABS/PolyflexTM blend and a comparative study from AM view point. Design/methodology/approach A low-cost desktop-based FDM setup was used for the fabrication of the test specimens under different processing conditions. Experiments were conducted as per obtained control log, and statistical analysis was conducted to understand the effect of selected variables in response of measured properties. Further, scanning electron microscopy-based micrographs were analyzed to understand the fracture mechanisms. Findings The obtained results highlighted that the mechanical properties of FDM parts are strongly influenced by the selected process variables. However, in case of most of the measured properties, selection of suitable feedstock has dominated the other input variables. Further, the results of test parts made with in-house developed ABS/SMP blend have showed the attainment of remarkable values of both strength and elasticity. Originality/value This work is held to empower the use of FDM technology to fabricate advanced and robust components for serving highly demanding applications.

Dimensional accuracy of FDM-printed polymer parts

2019 ◽  
Vol 26 (2) ◽  
pp. 288-298 ◽  
Author(s):  
Oğuzhan Emre Akbaş ◽  
Onur Hıra ◽  
Sahar Zhiani Hervan ◽  
Shahrad Samankan ◽  
Atakan Altınkaynak
Keyword(s):  
Experimental Data ◽  
Numerical Model ◽  
Feed Rate ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Acrylonitrile Butadiene Styrene ◽  
Strip Width ◽  
Content Type ◽  
Fused Deposition ◽  
Nozzle Temperature

Purpose This paper aims to analyze experimentally and numerically the effect of the nozzle temperature and feed rates on the dimensions of the fused deposition modeling (FDM) polymer parts. Design/methodology/approach In total, 30 strips per sample were printed with the same width as the nozzle diameter. The strips were printed with one vertical movement of the nozzle head. The width of the strips was measured with a caliper at five locations. A linear regression model was created based on the experimental data to understand the correlation between the strip width deviation and the parameters of interest. Numerical simulations were performed to predict the swell of the polymer exiting the nozzle using finite element method combined with level set method. The experimental results were then used to validate the models. Findings The average accuracy of polylactic acid (PLA) samples was better than that of acrylonitrile butadiene styrene (ABS) samples. The average strip width had a tendency to increase with increasing temperature for PLA samples, whereas ABS samples showed mixed behavior. The strip width decreased with increasing feed rate for most cases. The measurement positions had a major effect on strip width when compared to nozzle temperature and feed rate. The numerical model predictions were in good agreement with the experimental data. A few discrepancies were observed at high feed rates and nozzle temperatures. Originality/value This study will contribute to gaps in knowledge regarding the effect of processing conditions on dimensional accuracy of FDM-printed parts. The developed numerical model can be efficiently used to predict the dimensional accuracy of FDM-printed parts.

Bond and part strength in fused deposition modeling

2017 ◽  
Vol 23 (2) ◽  
pp. 414-422 ◽  
Author(s):  
Timothy J. Coogan ◽  
David Owen Kazmer
Keyword(s):  
Bond Strength ◽  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Fiber Direction ◽  
Equilibration Time ◽  
Intimate Contact ◽  
Tensile Direction ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling

Purpose The purpose of this paper is to investigate the factors governing bond strength in fused deposition modeling (FDM) compared to strength in the fiber direction. Design/methodology/approach Acrylonitrile butadiene styrene (ABS) boxes with the thickness of a single fiber were made at different platform and nozzle temperatures, print speeds, fiber widths and layer heights to produce multiple specimens for measuring the strength. Findings Specimens produced with the fibers oriented in the tensile direction had 95 per cent of the strength of the constitutive filament. Bond strengths ranged from 40 to 85 per cent of the filament strength dependent on the FDM processing conditions. Diffusion, wetting and intimate contact all separately affect bond strength. Practical implications This study provides processing recommendations for producing the strongest FDM parts. The needs for higher nozzle temperatures and more robust feed motors are described; these recommendations can be useful for companies producing FDM products as well as companies designing FDM printers. Originality/value This is the first study that discusses wetting and intimate contact separately in FDM, and the results suggest that a fundamental, non-empirical model for predicting FDM bond strength can be developed based on healing models. Additionally, the role of equilibration time at the start of extrusion as well as a motor torque limitation while trying to print at high speeds are described.

Investigations for partial denture casting by fused deposition modelling-assisted chemical vapour smoothing

2020 ◽  
Vol 40 (5) ◽  
pp. 745-754
Author(s):  
Gurpartap Singh ◽  
Rupinder Singh ◽  
S.S. Bal
Keyword(s):  
Ph Value ◽  
Low Cost ◽  
Chemical Vapour ◽  
Dimensional Accuracy ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
View Point ◽  
Content Type ◽  
Fused Deposition ◽  
Set Up

Purpose The purpose of this study is to investigate dimensional accuracy (Δd), surface roughness (Ra) and micro hardness (HV) of partial dentures (PD) prepared with synergic combination of fused deposition modelling (FDM) assisted chemical vapour smoothing (CVS) patterns and conventional dental casting (DC) from multi-factor optimization view point. Design/methodology/approach The master pattern for PD was prepared with acrylonitrile butadiene styrene (ABS) thermoplastic on FDM set-up (one of the low cost additive manufacturing process) followed by CVS process. The final PD as functional prototypes was casted with nickel–chromium-based (Ni-Cr) alloy by varying Ni% (Z). The other input parameters were powder to water ratio P/W (X) and pH value (Y) of water used. Findings The results of this study suggest that for controlling the Δd and Ra of the PD, most important factor is X, followed by Z. For hardness of PD, the most important factor is Z. But from overall optimization viewpoint, the best settings are X-100/12, Y-10 and Z-61% (in Ni-Cr alloy). Further, based upon X-bar chart (for HV), the FDM-assisted DC process used for preparation of PD is statistically controlled. Originality/value This study highlights that PD prepared with X-100/12, Y-10 and Z-61% gives overall better results from multi-factor optimization view point. Finally, X-bar chart has been plotted to understand the statistical nature of the synergic combination of FDM, CVS and DC.

scholarly journals 3D-Printed Low-Cost Dielectric-Resonator-Based Ultra-Broadband Microwave Absorber Using Carbon-Loaded Acrylonitrile Butadiene Styrene Polymer

Materials ◽  
2018 ◽  
Vol 11 (7) ◽  
pp. 1249 ◽  
Author(s):  
Jian Ren ◽  
Jia Yin
Keyword(s):  
Dielectric Resonator ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Acrylonitrile Butadiene Styrene ◽  
Microwave Measurement ◽  
Angle Of Incidence ◽  
Wide Angle ◽  
Fused Deposition ◽  
Operating Band ◽  
Butadiene Styrene

In this study, an ultra-broadband dielectric-resonator-based absorber for microwave absorption is numerically and experimentally investigated. The designed absorber is made of the carbon-loaded Acrylonitrile Butadiene Styrene (ABS) polymer and fabricated using the 3D printing technology based on fused deposition modeling with a quite low cost. Profiting from the fundamental dielectric resonator (DR) mode, the higher order DR mode and the grating mode of the dielectric resonator, the absorber shows an absorptivity higher than 90% over the whole ultra-broad operating band from 3.9 to 12 GHz. The relative bandwidth can reach over 100% and cover the whole C-band (4–8 GHz) and X-band (8–12 GHz). Utilizing the numerical simulation, we have discussed the working principle of the absorber in detail. What is more, the absorption performance under different incident angles is also simulated, and the results indicate that the absorber exhibits a high absorptivity at a wide angle of incidence. The advantages of low cost, ultra-broad operating band and a wide-angle feature make the absorber promising in the areas of microwave measurement, stealth technology and energy harvesting.

scholarly journals Stress-limiting test structures for rapid low-cost strength and stiffness assessment

2015 ◽  
Vol 21 (2) ◽  
pp. 144-151 ◽  
Author(s):  
Andrew Katz ◽  
Justin Nussbaum ◽  
Craig P Lusk ◽  
Nathan B Crane
Keyword(s):  
Fused Deposition Modeling ◽  
Low Cost ◽  
Test Methods ◽  
Measurement Sensitivity ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Strength And Stiffness ◽  
Accuracy And Repeatability ◽  
Printing Parameters

Purpose – The purpose of this paper is to evaluate the use of a simple printed geometry to estimate mechanical properties (elastic modulus, yield strength) with inexpensive test equipment. Design/methodology/approach – Test geometry is presented that enables controlled strains with manual deformation and repeatable measurement of vibrational frequencies. This is tested with multiple fused deposition modeling (FDM) machines to assess measurement accuracy and repeatability. Printing orientation and some printing parameters are varied to assess the measurement sensitivity. Findings – The test methods show good correlation with manufacturer material specifications in the X-Y plane and reported elastic strain limits. It is also sensitive to printing orientation and printing parameters. Research limitations/implications – Further work is needed to assess the sensitivity of the method to particular defects and parameter errors expected in particular applications. Originality/value – This method supports process monitoring in production environments and inexpensive assessments of material properties for hobbyist and do-i- yourself users. While it is tested with FDM, it should be applicable to other additive manufacturing processes.

Mechanical characterization of 3D printed, non-planar lattice structures under quasi-static cyclic loading

2020 ◽  
Vol 26 (4) ◽  
pp. 707-717 ◽  
Author(s):  
John C.S. McCaw ◽  
Enrique Cuan-Urquizo
Keyword(s):  
Additive Manufacturing ◽  
Cyclic Loading ◽  
Fused Deposition Modeling ◽  
Mechanical Characterization ◽  
Complex Geometries ◽  
Lattice Structures ◽  
Planar Lattice ◽  
Content Type ◽  
Fused Deposition

Purpose While additive manufacturing via melt-extrusion of plastics has been around for more than several decades, its application to complex geometries has been hampered by the discretization of parts into planar layers. This requires wasted support material and introduces anisotropic weaknesses due to poor layer-to-layer adhesion. Curved-layer manufacturing has been gaining attention recently, with increasing potential to fabricate complex, low-weight structures, such as mechanical metamaterials. This paper aims to study the fabrication and mechanical characterization of non-planar lattice structures under cyclic loading. Design/methodology/approach A mathematical approach to parametrize lattices onto Bèzier surfaces is validated and applied here to fabricate non-planar lattice samples via curved-layer fused deposition modeling. The lattice chirality, amplitude and unit cell size were varied, and the properties of the samples under cyclic-loading were studied experimentally. Findings Overall, lattices with higher auxeticity showed less energy dissipation, attributed to their bending-deformation mechanism. Additionally, bistability was eliminated with increasing auxeticity, reinforcing the conclusion of bending-dominated behavior. The analysis presented here demonstrates that mechanical metamaterial lattices such as auxetics can be explored experimentally for complex geometries where traditional methods of comparing simple geometry to end-use designs are not applicable. Research limitations/implications The mechanics of non-planar lattice structures fabricated using curved-layer additive manufacturing have not been studied thoroughly. Furthermore, traditional approaches do not apply due to parameterization deformations, requiring novel approaches to their study. Here the properties of such structures under cyclic-loading are studied experimentally for the first time. Applications for this type of structures can be found in areas like biomedical scaffolds and stents, sandwich-panel packaging, aerospace structures and architecture of lattice domes. Originality/value This work presents an experimental approach to study the mechanical properties of non-planar lattice structures via quasi-static cyclic loading, comparing variations across several lattice patterns including auxetic sinusoids, disrupted sinusoids and their equivalent-density quadratic patterns.

Comparative evaluation of an open-source FDM system

2014 ◽  
Vol 20 (3) ◽  
pp. 205-214 ◽  
Author(s):  
Wayne M. Johnson ◽  
Matthew Rowell ◽  
Bill Deason ◽  
Malik Eubanks
Keyword(s):  
Open Source ◽  
Computer Aided Design ◽  
Laser Scanning ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Dimensional Accuracy ◽  
Scanning System ◽  
Content Type ◽  
Geometric Dimensioning And Tolerancing ◽  
Fused Deposition

Purpose – The purpose of this paper is to present a qualitative and quantitative comparison and evaluation of an open-source fused deposition modeling (FDM) additive manufacturing (AM) system with a proprietary FDM AM system based on the fabrication of a custom benchmarking model. Design/methodology/approach – A custom benchmarking model was fabricated using the two AM systems and evaluated qualitatively and quantitatively. The fabricated models were visually inspected and scanned using a 3D laser scanning system to examine their dimensional accuracy and geometric dimensioning and tolerancing (GD&T) performance with respect to the computer-aided design (CAD) model geometry. Findings – The open-source FDM AM system (CupCake CNC) successfully fabricated most of the features on the benchmark, but the model did suffer from greater thermal warping and surface roughness, and limitations in the fabrication of overhang structures compared to the model fabricated by the proprietary AM system. Overall, the CupCake CNC provides a relatively accurate, low-cost alternative to more expensive proprietary FDM AM systems. Research limitations/implications – This work is limited in the sample size used for the evaluation. Practical implications – This work will provide the public and research AM communities with an improved understanding of the performance and capabilities of an open-source AM system. It may also lead to increased use of open-source systems as research testbeds for the continued improvement of current AM processes, and the development of new AM system designs and processes. Originality/value – This study is one of the first comparative evaluations of an open-source AM with a proprietary AM system.

Rapid tooling using 3D printing system for manufacturing of customized tracheal stent

2014 ◽  
Vol 20 (1) ◽  
pp. 2-12 ◽  
Author(s):  
Evila L. Melgoza ◽  
Guillem Vallicrosa ◽  
Lidia Serenó ◽  
Joaquim Ciurana ◽  
Ciro A. Rodríguez
Keyword(s):  
Open Source ◽  
Fused Deposition Modeling ◽  
Tool Path ◽  
Low Cost ◽  
Integrated System ◽  
Medical Doctors ◽  
Content Type ◽  
Tracheal Stent ◽  
Fused Deposition ◽  
Medical Grade

Purpose – This work aims to present the design of a new continuous tool-path strategy for open-source low-cost fused deposition modeling (FDM) machines, such as Fab@Home or RepRap; and the development of an innovative integrated tool to design and fabricate customized tracheal stents with any FDM machine and six patient parameters. Both contributions were validated and implemented by obtaining a customized medical-grade silicone tracheal stent. Design/methodology/approach – For the design of the new deposition strategy, a Python programming language was used. The new tool-path strategy was proposed as a continuous path to avoid drops and gaps and to improve the accuracy of the final model. Meanwhile, patient parameters were obtained by medical doctors and introduced into the innovative integrated system. On the one hand, one mold generated automatically, and viewed with Matlab® software, was fabricated with a Fab@Home machine, optimized with the continuous tool-path strategy. On the other hand, the same generated mold was viewed in SolidWorks/Excel software and was fabricated using a commercial FDM machine. Finally, the mold was filled with medical grade silicone, and a silicone tracheal stent was obtained. Findings – Path planning for extrusion technologies is still a major concern, especially for open-source FDM machines. The results obtained in this work show the benefits of applying the newly developed continuous tool-path strategy to optimize the performance and efficiency of these machines. In addition, the proposed innovative integrated system allows the fabrication of customized tracheal stents rapidly and affordably. Practical implications – The possibility of obtaining customized tracheal stents is a worthy challenge. Medical doctors could play a more active role and interact during the design process, helping to obtain more suitable stents. The method proposed herein would provide the opportunity to obtain real values from the trachea of a patient in the operating room and quickly fabricate a customized stent that would fit the patient's trachea perfectly. Originality/value – The results obtained in this work are relevant and have future applications in both the medical and the additive manufacturing fields. The optimized tool-path strategy can help to improve and enhance the use of low-cost FDM machines. Moreover, the innovative automatic design approach to fabricate tracheal stents may open new market opportunities in the medical device field.

scholarly journals Additive Technology Parts and their Material Properties

2019 ◽  
Vol 16 (1) ◽  
pp. 58-61
Author(s):  
Juraj Beniak ◽  
Miloš Matúš ◽  
Peter Križan ◽  
Michal Holdy
Keyword(s):  
Fused Deposition Modeling ◽  
Plastic Material ◽  
Acrylonitrile Butadiene Styrene ◽  
Additive Technology ◽  
Modeling Technology ◽  
Fused Deposition ◽  
Steel Material ◽  
Plastic Materials ◽  
Wide Range ◽  
Plastic Parts

Abstract Additive technology uses a wide range of materials. Beginning from plastic material, different types of resin but also steel material. Presented paper deals with Fused Deposition Modeling technology which is focused to processing of plastic materials based on polymers. Mostly used are ABS plastic (Acrylonitrile Butadiene Styrene), Nylon, Polycarbonate (PC), or composites based on different polymers. New devices designed for the production of plastic parts are able to work also with environmentally friendly and biodegradable materials as Polylactic acid (PLA). The aim of this paper is to show the possibility of using materials based on organic polymers whose properties are comparable to conventionally used polymers. Presented are measured and statistically evaluated data related to basic properties of PLA material.

Biodegradable Polymers for the Production of Prototypes

2016 ◽  
Vol 832 ◽  
pp. 152-158
Author(s):  
Juraj Beniak ◽  
Miloš Matúš ◽  
Peter Križan
Keyword(s):  
Rapid Prototyping ◽  
Biodegradable Polymers ◽  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Biodegradable Materials ◽  
Fused Deposition ◽  
Plastic Materials ◽  
Wide Range ◽  
Deposition Modeling ◽  
Butadiene Styrene

Technologies dedicated to the rapid prototyping uses a wide range of materials. The mostly used plastic materials are based on polymers. It is for example an Acrylonitrile Butadiene Styrene (ABS), Nylon, Polycarbonate (PC), or composites based on different polymers. New devices designed for the production of a prototype models, based on Fused Deposition Modeling (FDM) are able to work with environmentally friendly and biodegradable materials as Polylactic acid (PLA). The aim of this paper is to show the possibility of using materials based on organic polymers whose properties are comparable to conventionally used polymers. Presented are measured and statistically evaluated data related to basic properties of PLA material.

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