Effect of fused deposition modelling process parameters on mechanical properties of 3D printed parts

2019 ◽  
Vol 16 (4) ◽  
pp. 550-559 ◽  
Author(s):  
Abhinav Chadha ◽  
Mir Irfan Ul Haq ◽  
Ankush Raina ◽  
Rana Ratna Singh ◽  
Narendra Babu Penumarti ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Flexural Strength ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Fused Deposition ◽  
Primary Layer ◽  
Bed Temperature ◽  
3D Printed

Purpose This paper aims to explore the effect of bed temperature, primary layer thickness and infill pattern (rectilinear, honeycomb, triangular) on the mechanical properties of tensile strength and bending strength of 3D printed parts. Design/methodology/approach Samples in accordance to various ASTM standards were printed by fused deposition modelling (FDM) method by varying the various input paramaters such as bed temperature, primary layer thickness and infill pattern (rectilinear, honeycomb, triangular). Tensile and bending testing was carried out on the printed parts, and post to the testing, fractography has been carried out using scanning electron microscope. Findings With increase in bed temperature tensile strength and flexural strength first increases then decreases. With the increase in primary layer thickness, tensile strength and flexural strength increase. With regard to infill patterns, triangular and honeycomb exhibit better tensile strength and better flexural strength. Practical implications The 3D printing is increasingly becoming important for manufacturing of engineering parts, determining the process parameters which could result in better mechanical and physical properties shall certainly help designers and manufacturers globally. Originality/value This work elucidates the effect of various process parameters of FDM on tensile and flexural properties of the samples.

Open hole tensile testing of 3D printed parts using in-house fabricated PLA filament

2020 ◽  
Vol 26 (1) ◽  
pp. 21-31 ◽  
Author(s):  
Harshit K. Dave ◽  
Ashish R. Prajapati ◽  
Shilpesh R. Rajpurohit ◽  
Naushil H. Patadiya ◽  
Harit K. Raval
Keyword(s):  
Tensile Strength ◽  
Layer Thickness ◽  
Process Parameters ◽  
Geometrical Shape ◽  
Content Type ◽  
Fused Deposition ◽  
Open Hole ◽  
Raster Angle ◽  
3D Printed ◽  
The Impact

Purpose Fused deposition modeling (FDM) is being increasingly used in automotive and aerospace industries because of its ability to produce specimens having difficult geometrical shape. However, owing to lack of critical information regarding the reliability and mechanical properties of FDM-printed parts at various designs, the use of 3D printed parts in these industries is limited. Therefore, the purpose of this paper is to investigate the impact of process parameters of FDM on the tensile strength of open-hole specimen printed using in-house-fabricated polylactic acid (PLA). Design/methodology/approach In the present study, three process parameters, namely, raster angle, layer thickness and raster width, are selected for investigation of tensile strength. To produce the tensile specimens in the FDM machine, the PLA filament is used which is fabricated from PLA granules using a single-screw extruder. Further, the experimental values are measured and critically analysed. Failure modes under tests are studied using scanning electron microscopy (SEM). Findings Results indicate that the raster angle has a significant effect on the tensile strength of open-hole tensile specimen. Specimens built with 0° raster angle, 200-µm layer thickness and 500-µm raster width obtained maximum tensile strength. Originality/value In this work, a new concept of testing a plate that has a rectangular shape and a circular hole at the centre is tested. Open-hole tensile test standard ASTM D5766 has been implemented for the first time for the FDM process.

Influence of ABS print parameters on a 3D open-source, self-replicable printer

2020 ◽  
Vol 26 (10) ◽  
pp. 1733-1738
Author(s):  
André Luiz Alves Guimarães ◽  
Vicente Gerlin Neto ◽  
Cesar Renato Foschini ◽  
Maximiliano dos Anjos Azambuja ◽  
Luiz Antonio Vasques Hellmeister
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Open Source ◽  
Layer Thickness ◽  
Acrylonitrile Butadiene Styrene ◽  
Influential Factor ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Fused Deposition ◽  
Printing Parameters

Purpose The purpose of this paper is to investigate and discuss the influence of printing parameters on the mechanical properties of acrylonitrile butadiene styrene (ABS) print by fused deposition modelling (FDM). The mechanical properties of ABS are highly influenced by printing parameters, and they determine the final product quality of printed pieces. Design/methodology/approach For the paper’s purpose, five main parameters (extrusion temperature, infill pattern, air gap, printing speed and layer thickness) were selected and varied during ABS printing on an open-source and self-replicable FDM printer. Three different colors of commercially available ABS were also used to investigate color and printing parameter’s influence on the tensile strength. Findings The research results suggest that two parameters (infill pattern and layer thickness) were most influential on the mechanical properties of print ABS, being able to enhance its tensile strength. Another key influential factor was material color selected prior to printing, which influenced the tensile strength of the print specimen. Originality/value This study provides information on print parameters’ influence on the tensile strength of ABS print on replicable open-source three-dimensional (3D) printers. It also suggests the influence of materials’ color on print pieces’ tensile strength, indicating a new parameter for materials selection for 3D printing.

Linear model analysis of fused deposition modeling process parameters for obtaining the maximum tensile strength in acrylonitrile butadiene styrene (ABS) and carbon fiber polylactic acid (PLA) materials

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Debashis Mishra ◽  
Anil Kumar Das
Keyword(s):  
Tensile Strength ◽  
Carbon Fiber ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Thermoplastic Material ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Printing Speed

PurposeThe purpose of the experimental investigation was to optimize the process parameters of the fused deposition modeling (FDM) technique. The optimization of the process was performed to identify the relationship between the chosen factors and the tensile strength of acrylonitrile butadiene styrene (ABS) and carbon fiber polylactic acid (PLA) thermoplastic material, FDM printed specimens. The relationship was demonstrated by using the linear experimental model analysis, and a prediction expression was established. The developed prediction expression can be used for the prediction of tensile strength of selected thermoplastic materials at a 95% confidence level.Design/methodology/approachThe Taguchi L9 experimental methodology was used to plan the total number of experiments to be performed. The process parameters were chosen as three at three working levels. The working range of chosen factors was the printing speed (60, 80 and 100mm/min), 40%, 60% and 80% as the infill density and 0.1mm, 0.2mm and 0.3mm as the layer thickness. The fused deposition modeling process parameters were optimized to get the maximum tensile strength in FDM printed ABS and carbon fiber PLA thermoplastic material specimens.FindingsThe optimum condition was achieved by the process optimization, and the desired results were obtained. The maximum desirability was achieved as 0.98 (98%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.3mm. The strength of the ABS specimen was predicted to be 23.83MPa. The observed strength value was 23.66MPa. The maximum desirability was obtained as 1 (100%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.2mm. The strength of the carbon fiber PLA specimen was predicted to be 26.23MPa, and the obtained value was 26.49MPa.Research limitations/implicationsThe research shows the useful process parameters and their suitable working conditions to print the tensile specimens of the ABS and carbon fiber PLA thermoplastics by using the fused deposition modeling technique. The process was optimized to identify the most influential factor, and the desired optimum condition was achieved at which the maximum tensile strength was reported. The produced prediction expression can be used to predict the tensile strength of ABS and carbon fiber PLA filaments.Practical implicationsThe results obtained from the experimental investigation are useful to get an insight into the FDM process and working limits to print the parts by using the ABS and carbon fiber PLA material for various industrial and structural applications.Social implicationsThe results will be useful in choosing the suitable thermoplastic filament for the various prototyping and structural applications. The products that require freedom in design and are difficult to produce by most of the conventional techniques can be produced at low cost and in less time by the fused deposition modeling technique.Originality/valueThe process optimization shows the practical exposures to state an optimum working condition to print the ABS and carbon fiber PLA tensile specimens by using the FDM technique. The carbon fiber PLA shows better strength than ABS thermoplastic material.

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.

Experimental study on tensile strength of copper microparticles filled polymer composites printed by fused deposition modelling process

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Hamed Adibi ◽  
Mohammad Reza Hashemi
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Layer Thickness ◽  
Noise Analysis ◽  
Acrylonitrile Butadiene Styrene ◽  
Process Parameter ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Fused Deposition ◽  
Filling Pattern

Purpose The purpose of this paper is to investigate the variables of the fused deposition modelling (FDM) process and improve their effect on the mechanical properties of acrylonitrile butadiene styrene (ABS) components reinforced with copper microparticles. Design/methodology/approach In the experimental approach, after drying the ABS granule, it was mixed with copper microparticles (at concentrations of 5%, 8% and 10%) in a single screw extruder to fabricate pure ABS and composite filaments. Then, by making the components by the FDM process, the tensile strength of the parts was determined through tensile strength tests. Taguchi DOE method was used to design the experiments in which nozzle temperature, filling pattern and layer thickness were the design variables. The analysis of variance (ANOVA) and signal-to-noise analysis were conducted to determine the effectiveness of each FDM process parameter on the ultimate tensile strength of printed samples. Following that, the main effect analysis was used to optimize each process parameter for pure ABS and its composite at different copper contents. Findings The study allows the layer thickness and filling pattern had the highest effects on the ultimate tensile strength of the printed materials (pure and composite) in the FDM process. Moreover, the results show that the ultimate tensile strength of the ABS composite containing 5% copper was nearly 12.3% higher than the pure ABS part. According to validation tests, the maximum error of experiments was about 0.96%. Originality/value In this paper, the effect of copper microparticles (as filling agent) was investigated on the ultimate tensile strength of printed ABS material during the FDM process.

Effect of process parameters on tensile strength of FDM printed PLA part

2018 ◽  
Vol 24 (8) ◽  
pp. 1317-1324 ◽  
Author(s):  
Shilpesh R. Rajpurohit ◽  
Harshit K. Dave
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Process Parameters ◽  
Fused Deposition Modelling ◽  
Type I ◽  
Content Type ◽  
Layer Height ◽  
Fused Deposition ◽  
Anisotropic Mechanical Properties ◽  
Raster Angle

PurposeThe purpose of this paper to study the tensile strength of the fused deposition modelling (FDM) printed PLA part. In recent times, FDM has been evolving from rapid prototyping to rapid manufacturing where parts fabricated by FDM process can be directly used for application. However, application of FDM fabricated part is significantly affected by poor and anisotropic mechanical properties. Mechanical properties of FDM part can be improved by proper selection of process parameters.Design/methodology/approachIn the present study, three process parameter, namely, raster angle, layer height and raster width, have been selected to study their effect on tensile properties. Parts are fabricated as per ASTM D638 Type I standard.FindingsIt has been observed that the highest tensile strength obtained at 0° raster angle. Lower value of layer height is observed to be good for higher tensile strength because of higher bonding area between the layers. At higher value of raster width, tensile strength is improved up to certain extent after which presence of void reduces the tensile strength.Originality/valueIn the present investigation, layer height and raster width have been also varied along with raster angle to study their effect on the tensile strength of FDM printed PLA part.

Investigations of process parameters during dissolution studies of drug loaded 3D printed tablets

2021 ◽  
pp. 095441192199358
Author(s):  
Varun Sharma ◽  
Khaja Moinuddin Shaik ◽  
Archita Choudhury ◽  
Pramod Kumar ◽  
Prateek Kala ◽  
...  
Keyword(s):  
Dissolution Rate ◽  
Process Parameters ◽  
Empirical Relation ◽  
Three Dimensional ◽  
Critical Parameters ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Rate Of Dissolution ◽  
3D Printed ◽  
Percentage Release

The present research paper attempts to study the effect of different process parameters on the dissolution rate during 3D printed tablets. Three-dimensional printing has the potential of serving tailored made tablets to cater personalized drug delivery systems. Fluorescein loaded PVA filaments through impregnation route was used to fabricate tablets based on Taguchi based design of experimentation using Fused Deposition Modelling (FDM). The effect of print speed, infill percentage and layer thickness were analyzed to study the effect on rate of dissolution. Infill percentage followed by print speed were found to be critical parameters affecting dissolution rate. The data analysis provided an insight into the study of interaction among different 3D printing parameters to develop an empirical relation for percentage release of the drug in human body.

Effect of process parameters on flexural strength and surface roughness in fused deposition modeling of PC-ABS material

2021 ◽  
pp. 251659842110311
Author(s):  
Shrikrishna Pawar ◽  
Dhananjay Dolas1
Keyword(s):  
Surface Roughness ◽  
Flexural Strength ◽  
Response Surface ◽  
Layer Thickness ◽  
Process Parameters ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Build Orientation ◽  
Fused Deposition ◽  
Deposition Modeling

Fused deposition modeling (FDM) is one of the most commonly used additive manufacturing (AM) technologies, which has found application in industries to meet the challenges of design modifications without significant cost increase and time delays. Process parameters largely affect the quality characteristics of AM parts, such as mechanical strength and surface finish. This article aims to optimize the parameters for enhancing flexural strength and surface finish of FDM parts. A total of 18 test specimens of polycarbonate (PC)-ABS (acrylonitrile–butadiene–styrene) material are printed to analyze the effect of process parameters, viz. layer thickness, build orientation, and infill density on flexural strength and surface finish. Empirical models relating process parameters with responses have been developed by using response surface regression and further analyzed by analysis of variance. Main effect plots and interaction plots are drawn to study the individual and combined effect of process parameters on output variables. Response surface methodology was employed to predict the results of flexural strength 48.2910 MPa and surface roughness 3.5826 µm with an optimal setting of parameters of 0.14-mm layer thickness and 100% infill density along with horizontal build orientation. Experimental results confirm infill density and build orientation as highly significant parameters for impacting flexural strength and surface roughness, respectively.

An overview of fused deposition modelling (FDM): research, development and process optimisation

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mohammadreza Lalegani Dezaki ◽  
Mohd Khairol Anuar Mohd Ariffin ◽  
Saghi Hatami
Keyword(s):  
Metal Alloys ◽  
Future Research ◽  
Fused Deposition Modelling ◽  
Process Optimisation ◽  
Content Type ◽  
Novel Materials ◽  
Fused Deposition ◽  
Bed Temperature ◽  
Vast Range ◽  
Research Studies

Purpose The purpose of this paper is to review research studies on process optimisation and machine development that lead to the enhancement of final products in various aspects of the fused deposition modelling (FDM) process. Design/methodology/approach An overview of the literature, focussing on process parameters, machine developments and material characterisations. This study investigates recent research studies that studied FDM capabilities in printing a vast range of materials from thermoplastics to metal alloys. Findings FDM is one of the most common techniques in additive manufacturing (AM) processes. Many parameters in this technology have effects on three-dimensional printed products. Therefore, it is necessary to obtain the optimum elements, for example, build orientation, layer thickness, nozzle diameter, infill pattern and bed temperature. By selecting a proper variable range of parameters, the layers adhere strongly and building end-use products of high quality are achievable. A vast range of materials and their properties from polymers to composite-based polymers are presented. Novel techniques to print metal alloys and composites are examined to increase the productivity of the FDM process. Additionally, defects such as shrinkage and warpage are discussed to eliminate the system’s limitations and improve the quality of final products. Multi-axis and mobile machines brought enhancements throughout the process to eliminate obstacles such as staircase defects in the conventional FDM process. In brief, recent developments were identified and a summary of major improvements was discussed in this study for future research. Originality/value This paper is an overview that provides information about research and developments in FDM. This review focusses on process optimisation and obstacles in printing polymers, composites, geopolymers and novel materials. Therefore, machine characteristics were examined to find out the accessibility of printing novel materials for different applications.

Use of polymer concrete for large-scale 3D printing

2021 ◽  
Vol 27 (3) ◽  
pp. 465-474
Author(s):  
Martin Krčma ◽  
David Škaroupka ◽  
Petr Vosynek ◽  
Tomáš Zikmund ◽  
Jozef Kaiser ◽  
...  
Keyword(s):  
3D Printing ◽  
Large Scale ◽  
Mechanical Performance ◽  
Construction Material ◽  
Polymer Concrete ◽  
Fused Deposition Modelling ◽  
Cast State ◽  
Content Type ◽  
Fused Deposition ◽  
3D Printed

Purpose This paper aims to focus on the evaluation of a polymer concrete as a three-dimensional (3D) printing material. An associated company has developed plastic concrete made from reused unrecyclable plastic waste. Its intended use is as a construction material. Design/methodology/approach The concrete mix, called PolyBet, composed of polypropylene and glass sand, is printed by the fused deposition modelling process. The process of material and parameter selection is described. The mechanical properties of the filled material were compared to its cast state. Samples were made from castings and two different orientations of 3D-printed parts. Three-point flex tests were carried out, and the area of the break was examined. Computed tomography of the samples was carried out. Findings The influence of the 3D printing process on the material was evaluated. The mechanical performance of the longitudinal samples was close to the cast state. There was a difference in the failure mode between the states, with cast parts exhibiting a tougher behaviour, with fractures propagating in a stair-like manner. The 3D-printed samples exhibited high degrees of porosity. Originality/value The results suggest that the novel material is a good fit for 3D printing, with little to no degradation caused by the process. Layer adhesion was shown to be excellent, with negligible effect on the finished part for the longitudinal orientation. That means, if large-scale testing of buildability is successful, the material is a good fit for additive manufacturing of building components and other large-scale structures.

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