Design for Fused Filament Fabrication Additive Manufacturing

2015 ◽  
Author(s):  
John Steuben ◽  
Douglas L. Van Bossuyt ◽  
Cameron Turner
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Low Cost ◽  
Industrial Applications ◽  
Manufacturing Technology ◽  
Fused Filament Fabrication ◽  
High Quality ◽  
Additive Manufacturing Technology ◽  
Mechanical Assemblies ◽  
3D Printers

In this paper, we explore the topic of Fused Filament Fabrication (FFF) 3D-printing. This is a low-cost additive manufacturing technology which is typically embodied in consumer-grade desktop 3D printers capable of producing useful parts, structures, and mechanical assemblies. The primary goal of our investigation is to produce an understanding of this process which can be employed to produce high-quality, functional engineered parts and prototypes. By developing this understanding, we create a resource which may be turned to by both researchers in the field of manufacturing science, and industrial professionals who are either considering the use of FFF-enabled technologies such as 3D printing, or those who have already entered production and are optimizing their fabrication process. In order to paint a cohesive picture for these readers, we examine several topic areas. We begin with an overview of the FFF process, its key hardware and software components, and the interrelationships between these components and the designer. With this basis, we then proceed to outline a set of design principles which facilitate the production of high quality printed parts, and discuss the selection of appropriate materials. Following naturally from this, we turn to the question of feedstock materials for FFF, and give advice for their selection and use. We then turn to the subject of the as-printed properties of FFF parts and the strong non-isotropic response that they exhibit. We discuss the root causes of this behavior and means by which its deleterious effects may be mitigated. We conclude by discussing a mixed numerical/experimental technique which we believe will enable the accurate characterization of FFF parts and structures, and greatly enhance the utility of this additive manufacturing technology. By formalizing and discussing these topics, we hope to motivate and enable the serious use of low-cost FFF 3D printing for both research and industrial applications.

Manufacture of Lenses and Diffraction Gratings Using DLP As an Additive Manufacturing Technology

2018 ◽  
Author(s):  
Laura Daniela Vallejo Melgarejo ◽  
Jose García ◽  
Ronald G. Reifenberger ◽  
Brittany Newell
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Diffraction Grating ◽  
Diffraction Gratings ◽  
Optical Microscope ◽  
Manufacturing Technology ◽  
Manufacturing Processes ◽  
Digital Light Processing ◽  
Additive Manufacturing Technology ◽  
Potential Use

This document condenses the results obtained when 3D printing lenses and their potential use as diffraction gratings using Digital Light Processing (DLP), as an additive manufacturing technique. This project investigated the feasibility of using DLP additive manufacturing for producing custom designed lenses and gratings. DLP was identified as the preferred manufacturing technology for gratings fabrication. Diffraction gratings take advantage of the anisotropy, inherent in additive manufacturing processes, to produce a collated pattern of multiple fringes on a substrate with completely smooth surfaces. The gratings are transmissive and were manufactured with slit separations of 10, 25 and 50 μm. More than 50 samples were printed at various build angles and mechanically treated for maximum optical transparency. The variables of the irradiance equation were obtained from photographs taken with an optical microscope. These values were used to estimate theoretical irradiance patterns of a diffraction grating and compared against the experimental 3-D printed grating. The resulting patterns were found to be remarkably similar in amplitude and distance between peaks when compared to theoretical values.

scholarly journals Additive Manufacturing in Vascular Stent Fabrication

2019 ◽  
Vol 253 ◽  
pp. 03003
Author(s):  
Lei Yang ◽  
Xin Chen ◽  
Lei Zhang ◽  
Lei Li ◽  
Shuangzhu Kang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Personalized Medicine ◽  
High Efficiency ◽  
Structural Characteristics ◽  
Manufacturing Technology ◽  
Vascular Stent ◽  
Additive Manufacturing Technology ◽  
Vascular Scaffolds ◽  
And Personalized Medicine

High-efficiency formation of personalized stent by additive manufacturing (3D printing) has gained deal of attention and research in interventional and personalized medicine. In this article, the structural characteristics of vascular scaffolds and the application and innovation of additive manufacturing technology in the process of angioplasty are reviewed. In the future, with the continuous maturity of additive manufacturing technology, it is expected to be an important part of interventional precision medicine to manufacture personalized vascular stent.

scholarly journals Effects of Filament Diameter Tolerances in Fused Filament Fabrication

2016 ◽  
Vol 2 (1) ◽  
pp. 44-47 ◽  
Author(s):  
Carolina Cardona ◽  
Abigail H Curdes ◽  
Aaron J Isaacs
Keyword(s):  
3D Printing ◽  
Low Cost ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Filament Fabrication ◽  
Important Indicator ◽  
Extrusion Rate ◽  
Filament Diameter ◽  
Printing Quality ◽  
3D Printers ◽  
And Control

Fused filament fabrication (FFF) is one of the most popular additive manufacturing (3D printing) technologies due to the growing availability of low-cost desktop 3D printers and the relatively low cost of the thermoplastic filament used in the 3D printing process. Commercial filament suppliers, 3D printer manufacturers, and end-users regard filament diameter tolerance as an important indicator of the 3D printing quality. Irregular filament diameter affects the flow rate during the filament extrusion, which causes poor surface quality, extruder jams, irregular gaps in-between individual extrusions, and/or excessive overlap, which eventually results in failed 3D prints. Despite the important role of the diameter consistency in the FFF process, few studies have addressed the required tolerance level to achieve highest 3D printing quality. The objective of this work is to develop the testing methods to measure the filament tolerance and control the filament fabrication process. A pellet-based extruder is utilized to fabricate acrylonitrile butadiene styrene (ABS) filament using a nozzle of 1.75 mm in diameter. Temperature and extrusion rate are controlled parameters. An optical comparator and an array of digital calipers are used to measure the filament diameter. The results demonstrate that it is possible to achieve high diameter consistency and low tolerances (0.01mm) at low extrusion temperature (180 °C) and low extrusion rate (10 in/min). 

What Is Next?

2017 ◽  
pp. 78-92
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Chemical Reactions ◽  
Digital Control ◽  
Industrial Revolution ◽  
Low Cost ◽  
Science And Technology ◽  
Fourth Industrial Revolution ◽  
3D Printers ◽  
Design Construction

Fourth Industrial Revolution gave birth to few different technologies, not known until now. One of them is 3D printing. If subtracting manufacturing is part of Industrial Revolution 3, Additive manufacturing is for sure part of Industrial Revolution 4.0. 3D printing has the potential to transform science and technology by creating bespoke, low-cost appliances that previously required dedicated facilities to make. 3D printers are used to initiate chemical reactions by printing the reagents directly into a 3D reactionware matrix, and so put reactionware design, construction and operation under digital control. Some models of 3D Printers can print uniquely shaped sugar confections in flavors such as chocolate, vanilla, mint, cherry, sour apple and watermelon. They can also print custom cake toppers–presumably in the likeness of the guest of honor.

The Trends and Challenges of 3D Printing

2019 ◽  
pp. 415-423
Author(s):  
Edna Ho Chu Fang ◽  
Sameer Kumar
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Rapid Prototyping ◽  
Industrial Design ◽  
Consumer Products ◽  
Manufacturing Technology ◽  
3D Object ◽  
Additive Manufacturing Technology ◽  
Human Organs ◽  
Traditional Manufacturing

3D printing is a type of additive manufacturing technology where a 3D object is created by laying down subsequent layers of material at the mm scale. It is also known as rapid prototyping. 3D printing is now applied in various industries such as footwear, jewelry, architecture, engineering and construction, aerospace, dental and medical industries, education, consumer products, automotive, and industrial design. Some claim that 3D printing will put an end to traditional manufacturing, primarily since 3D printing imposes a tool-less process. Though 3D printing technology is used in weapon manufacturing, it is also being used to improve the lives of mankind. In the future, 3D printing will most probably be used to print human organs. The chapter discusses the trends and challenges faced by this exciting technology.

scholarly journals ADDITIVE MANUFACTURING OF FUNCTIONAL PARTS BASED ON MATERIAL EXTRUSION TECHNOLOGY

2016 ◽  
Vol 7 (2) ◽  
Author(s):  
Milan Šljivić ◽  
Cristiano Fragassa ◽  
Ana Pavlović ◽  
Milija Kraišnik ◽  
Jovica Ilić ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
High Accuracy ◽  
Manufacturing Technology ◽  
Material Extrusion ◽  
Additive Manufacturing Technology ◽  
Software Packages ◽  
Design And Manufacturing ◽  
3D Printers ◽  
Banja Luka ◽  
Extrusion Technology

This paper presents the advantages and the process of making of complex functional parts using additive manufacturing technology. Design and manufacturing of components were performed at the Laboratory for Technology of Plasticity and Processing Systems at the Faculty of Mechanical Engineering in Banja Luka. The parts were designed using SolidWorks and Catia software packages. Then, CatalystEX and Simplify3D software packages were used to process the CAD model and to prepare it for 3D printing, which included defining of the process parameters, generating layers and support. Functional parts were produced on 3D printers based on the principle of material extrusion. The results of this study show that additive manufacturing technology, specifically technology based on material extrusion, enables very fast production of complex functional parts, with high accuracy and much lower costs and development time compared to conventional technologies.

Foam additive manufacturing technology: main characteristics and experiments for hull mold manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Elodie Paquet ◽  
Alain Bernard ◽  
Benoit Furet ◽  
Sébastien Garnier ◽  
Sébastien Le Loch
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Process ◽  
Manufacturing Industry ◽  
Pressure Head ◽  
Manufacturing Technology ◽  
Cnc Machining ◽  
Numerical Control ◽  
Content Type ◽  
Additive Manufacturing Technology

Purpose The purpose of this paper is to present a novel methodology to produce a large boat hull with a foam additive manufacturing (FAM) process. To respond to shipping market needs, this new process is being developed. FAM technology is a conventional three-dimensional (3D) printing process whereby layers are deposited onto a high-pressure head mounted on a six-axis robotic arm. Traditionally, molds and masters are made with computer numerical control (CNC) machining or finished by hand. Handcrafting the molds is obviously time-consuming and labor-intensive, but even CNC machining can be challenging for parts with complex geometries and tight deadlines. Design/methodology/approach The proposed FAM technology focuses on the masters and molds, that are directly produced by 3D printing. This paper describes an additive manufacturing technology through which the operator can create a large part and its tools using the capacities of this new FAM technology. Findings The study shows a comparison carried out between the traditional manufacturing process and the additive manufacturing process, which is illustrated through an industrial case of application in the manufacturing industry. This work details the application of FAM technology to fabricate a 2.5 m boat hull mold and the results show the time and cost savings of FAM in the fabrication of large molds. Originality/value Finally, the advantages and drawbacks of the FAM technology are then discussed and novel features such as monitoring system and control to improve the accuracy of partly printed are highlighted.

The Trends and Challenges of 3D Printing

2018 ◽  
pp. 4382-4389
Author(s):  
Edna Ho Chu Fang ◽  
Sameer Kumar
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Rapid Prototyping ◽  
Industrial Design ◽  
Consumer Products ◽  
Manufacturing Technology ◽  
3D Object ◽  
Additive Manufacturing Technology ◽  
Human Organs ◽  
Traditional Manufacturing

3D printing is a type of additive manufacturing technology where a 3D object is created by laying down subsequent layers of material at the mm scale. It is also known as rapid prototyping. 3D printing is now applied in various industries such as footwear, jewelry, architecture, engineering and construction, aerospace, dental and medical industries, education, consumer products, automotive and industrial design. Some claim that 3D printing will put an end to traditional manufacturing primarily since 3D printing imposes a tool-less process. Though 3D printing technology is used in weapon manufacturing, it is also being used to improve the lives of mankind. In the future, 3D printing will most probably be used to print human organs. The article discusses the trends and challenges faced by this exciting technology.

Research  status and  Application Analysis  of 3D Printing Technology

2014 ◽  
Vol 529 ◽  
pp. 697-700
Author(s):  
Wan Li Ma ◽  
Feng He Tao ◽  
Chang Zhi Jia ◽  
Jian Chun Yang
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Technology ◽  
Printing Technology ◽  
Research Status ◽  
3D Printing Technology ◽  
Additive Manufacturing Technology ◽  
Application Analysis

3D printing technology is one additive manufacturing technology based on the principle of material accumulation. The domestic and foreign research status is specially introduced. The main principles and features of 3D printing technology are summarized. The applications in the civilian aspect is analyzed

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