The influence of support base on FDM accuracy in Z

2014 ◽  
Vol 20 (3) ◽  
pp. 182-191 ◽  
Author(s):  
Neri Volpato ◽  
José Aguiomar Foggiatto ◽  
Daniel Coradini Schwarz
Keyword(s):  
Fused Deposition Modeling ◽  
Surface Profile ◽  
Dimensional Accuracy ◽  
Contact Method ◽  
Content Type ◽  
Fused Deposition ◽  
Support Strategy ◽  
Deposition Modeling ◽  
Quality Surface

Purpose – The aim of this work is to study the influence of the quality (surface profile) of the support base on dimensional accuracy in the Z-axis in fused deposition modeling (FDM). Design/methodology/approach – The surface profile of a support base produced using a standard (default) FDM configuration is analyzed experimentally, and two new deposition configurations are proposed. Some parts are built using these approaches, and the influence of the profile on Z accuracy is investigated. The parts are examined using a contact method and measured using a caliper. Findings – The surface profile of the support base has a direct influence on FDM part accuracy in Z. The results show that the accuracy in the Z dimension of an FDM prototype can be increased by improving the surface quality of the support base. In cases where accuracy is paramount, this can be achieved by better planning (tuning) of the support strategy. Originality/value – A significant component of the Z error in FDM has been identified and studied.

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.

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.

Parameters Optimization of FDM for the Quality of Prototypes Using an Integrated MCDM Approach

2019 ◽  
pp. 199-220
Author(s):  
Jagadish ◽  
Sumit Bhowmik
Keyword(s):  
Process Parameters ◽  
Shell Thickness ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Parameters Optimization ◽  
Layer Height ◽  
Fused Deposition ◽  
Optimal Setting ◽  
Deposition Modeling

Fused deposition modeling (FDM) is one of the emerging rapid prototyping (RP) processes in additive manufacturing. FDM fabricates the quality prototype directly from the CAD data and is dependent on the various process parameters, hence optimization is essential. In the present chapter, process parameters of FDM process are analyzed using an integrated MCDM approach. The integrated MCDM approach consists of modified fuzzy with ANP methods. Experimentation is performed considering three process parameters, namely layer height, shell thickness, and fill density, and corresponding response parameters, namely ultimate tensile strength, dimensional accuracy, and manufacturing time are determined. Thereafter, optimization of FDM process parameters is done using proposed method. The result shows that exp.no-4 yields the optimal process parameters for FDM and provides optimal parameters as layer height of 0.08 mm, shell thickness of 2.0 mm and fill density of 100%. Also, optimal setting provides higher ultimate TS, good DA, and lesser MT as well as improving the performance and efficiency of FDM.

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.

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 Automated Testing and Characterization of Additive Manufacturing (ATCAM)

2021 ◽  
Author(s):  
Arash Alex Mazhari ◽  
Randall Ticknor ◽  
Sean Swei ◽  
Stanley Krzesniak ◽  
Mircea Teodorescu
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Cell System ◽  
Automated Testing ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Machine Calibration

AbstractThe sensitivity of additive manufacturing (AM) to the variability of feedstock quality, machine calibration, and accuracy drives the need for frequent characterization of fabricated objects for a robust material process. The constant testing is fiscally and logistically intensive, often requiring coupons that are manufactured and tested in independent facilities. As a step toward integrating testing and characterization into the AM process while reducing cost, we propose the automated testing and characterization of AM (ATCAM). ATCAM is configured for fused deposition modeling (FDM) and introduces the concept of dynamic coupons to generate large quantities of basic AM samples. An in situ actuator is printed on the build surface to deploy coupons through impact, which is sensed by a load cell system utilizing machine learning (ML) to correlate AM data. We test ATCAM’s ability to distinguish the quality of three PLA feedstock at differing price points by generating and comparing 3000 dynamic coupons in 10 repetitions of 100 coupon cycles per material. ATCAM correlated the quality of each feedstock and visualized fatigue of in situ actuators over each testing cycle. Three ML algorithms were then compared, with Gradient Boost regression demonstrating a 71% correlation of dynamic coupons to their parent feedstock and provided confidence for the quality of AM data ATCAM generates.

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.

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