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.

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 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.

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.

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.

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.

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.

Exposures during industrial 3-D printing and post-processing tasks

2018 ◽  
Vol 24 (5) ◽  
pp. 865-871 ◽  
Author(s):  
Sonette Du Preez ◽  
Alyson Johnson ◽  
Ryan F. LeBouf ◽  
Stephanus J.L. Linde ◽  
Aleksandr B. Stefaniak ◽  
...  
Keyword(s):  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Personal Exposure ◽  
Breathing Zone ◽  
Post Processing ◽  
Organic Vapors ◽  
Content Type ◽  
Fused Deposition ◽  
Personal Exposures ◽  
Control Technologies

Purpose This paper aims to measure exposures to airborne contaminants during three-dimensional (3-D) printing and post-processing tasks in an industrial workplace. Design/methodology/approach Contaminant concentrations were assessed using real-time particle number (0.007 to 1 µm) and total volatile organic compound (TVOC) monitors and thermal desorption tubes during various tasks at a manufacturing facility using fused deposition modeling (FDMTM) 3-D printers. Personal exposures were measured for two workers using nanoparticle respiratory deposition samplers for metals and passive badges for specific VOCs. Findings Opening industrial-scale FDMTM 3-D printer doors after printing, removing desktop FDMTM 3-D printer covers during printing, acetone vapor polishing (AVP) and chloroform vapor polishing (CVP) tasks all resulted in transient increases in levels of submicrometer-scale particles and/or organic vapors, a portion of which enter the workers’ breathing zone, resulting in exposure. Personal exposure to quantifiable levels of metals in particles <300 nm were 0.02 mg/m3 for aluminum, chromium, copper, iron and titanium during FDMTM printing. Personal exposures were 0.38 to 6.47 mg/m3 for acetone during AVP and 0.18 mg/m3 for chloroform during CVP. Originality/value Characterization of tasks provided insights on factors that influenced contaminant levels, and in turn exposures to various particles, metals < 300 nm and organic vapors. These concentration and exposure factors data are useful for identifying tasks and work processes to consider for implementation of new or improved control technologies to mitigate exposures in manufacturing facilities using FDMTM 3-D printers.

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.

Parallel non-dominated sorting genetic algorithm-II for optimal part deposition orientation in additive manufacturing based on functional features

2017 ◽  
Vol 232 (19) ◽  
pp. 3384-3395 ◽  
Author(s):  
Renkai Huang ◽  
Ning Dai ◽  
Dawei Li ◽  
Xiaosheng Cheng ◽  
Hao Liu ◽  
...  
Keyword(s):  
Genetic Algorithm ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Fused Deposition ◽  
Industrial Grade ◽  
Build Time ◽  
Functional Features

Surface finish, especially the surface finish of functional features, and build time are two important concerns in additive manufacturing. A suitable part deposition orientation can enhance the surface quality of functional features and reduce the build time. This article proposes a novel method to obtain an optimum part deposition orientation for industrial-grade 3D printing based on fused deposition modeling process by considering two objective functions at a time, namely adaptive feature roughness (the weighted sum of all feature roughnesses) and build time. First, mesh segmentation and level classification of features are carried out. Then, models for evaluation of adaptive feature roughness and build time are established. Finally, a non-dominated sorting genetic algorithm-II based on Compute Unified Device Architecture is used to obtain the Pareto-optimal set. The feasible of the algorithm is evaluated on several examples. Results demonstrate that the proposed parallel algorithm obtains a limiting solution that enhances the surface quality of functional features significantly and reduces average running time by 94.8% compared with the traditional genetic algorithm.

Investigations for Wax Coated 3D Printed Hybrid Patterns for Partial Dentures

2019 ◽  
Author(s):  
Kamaljit Singh Boparai ◽  
Gurpartap Singh ◽  
Rupinder Singh ◽  
Sarabjit Singh
Keyword(s):  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Surface Hardness ◽  
Dimensional Accuracy ◽  
Acrylonitrile Butadiene Styrene ◽  
Processing Technique ◽  
Patient Specific ◽  
Fused Deposition ◽  
3D Printed

Abstract In this work, 3D printed master patterns of acrylonitrile butadiene styrene (ABS) thermoplastic material have been used for the preparation of Ni-Cr based functional prototypes as partial dentures (PD). The study started with patient specific three dimensional (3D), CAD data (fetched through scanning). This data was used for preparation of .STL file for printing of master patterns on fused deposition modeling (FDM) setup. The 3D printed master patterns were further wax coated to reduce the surface irregularities (as cost effective post processing technique). The hybrid patterns were subjected to investment casting for the preparation of Ni-Cr based PD. The finally prepared functional prototypes as PD were optimized for dimensional accuracy, surface finish and surface hardness as responses. The results are visualized and supported by photomicrographs and in-vitro analysis.

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