Low Volume Plastics Manufacturing Strategies

2005 ◽  
Author(s):  
Ruchi Karania ◽  
David Kazmer
Keyword(s):  
Injection Molding ◽  
Lead Time ◽  
Fused Deposition Modeling ◽  
Selective Laser Sintering ◽  
High Volume ◽  
Cnc Machining ◽  
Process Selection ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Plastic Components

Plastic components are vital components of many engineered products, frequently representing 20–40% of the product value. While injection molding is the most common process for economically producing complex designs in large quantities, a large initial monetary investment is required to develop appropriate tooling. Accordingly, injection molding may not be appropriate for applications that are not guaranteed to recoup the initial costs. This paper extends previous work [1] with component cost and lead-time models developed from extensive industry data. The application is an electrical enclosure consisting of two parts produced by a variety of low to high volume manufacturing processes including CNC machining, fused deposition modeling, selective laser sintering, vacuum casting, direct fabrication, and injection molding with soft prototype and production tooling. The viability of each process is compared for production quantities of one hundred, one thousand, and ten thousand. The results indicate that the average cost per enclosure assembly is highly sensitive to the production quantity, varying in range from US$0.35 per enclosure for ten thousand assemblies produced via injection molding to US$49.30 per enclosure for one hundred assemblies produced via fused deposition modeling. The results indicate the cost and lead time advantages of the alternative processes; a flow chart is provided to assist process selection in engineering design.

An Update on the Use of Alginate in Additive Biofabrication Techniques

2019 ◽  
Vol 25 (11) ◽  
pp. 1249-1264 ◽  
Author(s):  
Amoljit Singh Gill ◽  
Parneet Kaur Deol ◽  
Indu Pal Kaur
Keyword(s):  
Fused Deposition Modeling ◽  
Low Cost ◽  
Selective Laser Sintering ◽  
Layer By Layer ◽  
Three Dimension ◽  
Anionic Polymer ◽  
Fused Deposition ◽  
The Status ◽  
Deposition Modeling ◽  
Extrusion Printing

Background: Solid free forming (SFF) technique also called additive manufacturing process is immensely popular for biofabrication owing to its high accuracy, precision and reproducibility. Method: SFF techniques like stereolithography, selective laser sintering, fused deposition modeling, extrusion printing, and inkjet printing create three dimension (3D) structures by layer by layer processing of the material. To achieve desirable results, selection of the appropriate technique is an important aspect and it is based on the nature of biomaterial or bioink to be processed. Result & Conclusion: Alginate is a commonly employed bioink in biofabrication process, attributable to its nontoxic, biodegradable and biocompatible nature; low cost; and tendency to form hydrogel under mild conditions. Furthermore, control on its rheological properties like viscosity and shear thinning, makes this natural anionic polymer an appropriate candidate for many of the SFF techniques. It is endeavoured in the present review to highlight the status of alginate as bioink in various SFF techniques.

scholarly journals Energy and Eco-Impact Evaluation of Fused Deposition Modeling and Injection Molding of Polylactic Acid

2021 ◽  
Vol 13 (4) ◽  
pp. 1875
Author(s):  
Emmanuel Ugo Enemuoh ◽  
Venkata Gireesh Menta ◽  
Abdulaziz Abutunis ◽  
Sean O’Brien ◽  
Labiba Imtiaz Kaya ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Injection Molding ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Plastic Injection Molding ◽  
Measurement Models ◽  
Fused Deposition ◽  
Dog Bone ◽  
Deposition Modeling ◽  
Plastic Injection

There is limited knowledge about energy and carbon emission performance comparison between additive fused deposition modeling (FDM) and consolidation plastic injection molding (PIM) forming techniques, despite their recent high industrial applications such as tools and fixtures. In this study, developed empirical models focus on the production phase of the polylactic acid (PLA) thermoplastic polyester life cycle while using FDM and PIM processes to produce American Society for Testing and Materials (ASTM) D638 Type IV dog bone samples to compare their energy consumption and eco-impact. It was established that energy consumption by the FDM layer creation phase dominated the filament extrusion and PLA pellet production phases, with, overwhelmingly, 99% of the total energy consumption in the three production phases combined. During FDM PLA production, about 95.5% of energy consumption was seen during actual FDM part building. This means that the FDM process parameters such as infill percentage, layer thickness, and printing speed can be optimized to significantly improve the energy consumption of the FDM process. Furthermore, plastic injection molding consumed about 38.2% less energy and produced less carbon emissions per one kilogram of PLA formed parts compared to the FDM process. The developed functional unit measurement models can be employed in setting sustainable manufacturing goals for PLA production.

scholarly journals USE OF FUSED DEPOSITION MODELING PROCESS IN INVESTMENT PRECISION CASTING AND RISK OF USING SELECTIVE LASER SINTERING PROCESS

2012 ◽  
pp. 226-230
Author(s):  
SIVADASAN M ◽  
N.K SINGH ◽  
ANOOP KUMAR SOOD
Keyword(s):  
Fused Deposition Modeling ◽  
Selective Laser Sintering ◽  
Thermal Response ◽  
Acrylonitrile Butadiene Styrene ◽  
Laser Sintering ◽  
Precision Casting ◽  
Fused Deposition ◽  
Rp Process ◽  
Deposition Modeling ◽  
Metallic Parts

Investment Castings (IC) is one of the most economical ways to produce intricate metallic parts when forging, forming and other casting processes tend to fail. However, high tooling cost and long lead time associated with the fabrication of metal moulds for producing IC wax (sacrificial) patterns result in cost justification problems for customized single casting or small-lot production. Generating pattern using rapid prototyping (RP) process may be one of the feasible alternatives. For this purpose present study assessed the suitability of the fused deposition modeling (FDM) process for creating sacrificial IC patterns by studying FDM fabricated part thermal response at various temperatures. A series of experiments with RP patterns are conducted and a set of test castings are also made in steel for establishing feasibility. The build material used is acrylonitrile butadiene styrene (ABS). As an annexe to this work a concurrent attempt is also made to quantify the risk in using Selective Laser Sintering patterns for Investment Castings. Authors hope this work might establish applicability of ABS in IC and also lead the investigations to theoretically tone down the shell cracking tendency with Selective Laser Sintering patterns when Proprietary Duraform is used as the build material.

Comparison of FDM-printed and compression molded tensile samples

2020 ◽  
Vol 62 (10) ◽  
pp. 985-992
Author(s):  
Robin Roj ◽  
Jessica Nürnberg ◽  
Ralf Theiß ◽  
Peter Dültgen
Keyword(s):  
Mechanical Properties ◽  
Private Consumption ◽  
Fused Deposition Modeling ◽  
Time Cost ◽  
Quality Factors ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Manufacturing Techniques ◽  
Plastic Components ◽  
Plastic Parts

Abstract Since the processing of plastics by additive manufacturing techniques, for example, fused deposition modeling, has become quite common, it is mainly used for the production of unique pieces for private consumption as well as for prototyping in industry. In order to professionally manufacture plastic components in large amounts, due to time, cost, and quality factors, injection molding is more suitable. Nevertheless, it is of great interest to print plastic parts in small batch series for technical tasks. In this paper, FDM-produced tensile samples, made from 16 materials, printed in three orientations, are compared to compression molded components. In addition to ordinary filaments, composite materials with metal-, carbon-, wood-, and stone-additives are also examined. While some cavities emerged in both printed and molded samples, the results support the hypothesis that the mechanical properties depend on the components’ densities.

scholarly journals Z-axis limit switch 3D printer

2020 ◽  
pp. 22-27
Author(s):  
Vadym Shalenko ◽  
Boris Korniychuk ◽  
Andriі Masluyk
Keyword(s):  
3D Printing ◽  
Large Scale ◽  
Fused Deposition Modeling ◽  
Selective Laser Sintering ◽  
3D Printer ◽  
Fused Deposition ◽  
Laminated Object Manufacturing ◽  
The Future ◽  
Deposition Modeling ◽  
Additive Methods

Not much time has passed since the appearance of the first 3D printer. Today there are many different printers. They differ in various 3D printing technologies, namely: Stereolithography – SL, Selective Laser Sintering, Fused Deposition Modeling – FDM, Laminated Object Manufacturing – LOM, Polyjet and Ployjet Matrix. In recent years, the spread of 3D printing technology has become and continues to be used more and more today. Of course, in the future we will see a large-scale spread of additive methods, but the practical application of 3D printing today is available to everyone. Melting deposition modeling technologies have become widespread and available. The authors in this article consider possible options for upgrading the mounting of the end sensor of the Z Axis and automating the process of calibration of the zero gap of the extruder nozzle relative to the working surface of the printer. This calibration is important. This affects the accuracy and printing process of the future plastic model. During the operation of the 3D printer, it is often necessary to service the extruder, which forces the process of calibrating the zero gap of the printer nozzle. Optimally correct selected nozzle clearance affects the accuracy, geometry of the model and printing as a whole. It also allows you to get rid of peeling off the model from the desktop surface and the destruction of the model during printing.

scholarly journals Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

2011 ◽  
Vol 199-200 ◽  
pp. 1984-1987 ◽  
Author(s):  
Olaf Diegel ◽  
Sarat Singamneni ◽  
Ben Huang ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Conductive Polymer ◽  
Fused Deposition ◽  
National University ◽  
Deposition Modeling ◽  
Plastic Components ◽  
Manufacturing Technologies ◽  
Plastic Parts

This paper describes a curved-layer additive manufacturing technology that has the potential to print plastic components with integral conductive polymer electronic circuits. Researchers at AUT University in New Zealand and the National University of Singapore have developed a novel Fused Deposition Modeling (FDM) process in which the layers of material that make up the part are deposited as curved layers instead of the conventional flat layers. This technology opens up possibilities of building curved plastic parts that have conductive electronic tracks and components printed as an integral part of the plastic component, thereby eliminating printed circuit boards and wiring. It is not possible to do this with existing flat-layer additive manufacturing technologies as the continuity of a circuit could be interrupted between the layers. With curved-layer fused deposition modeling (CLFDM) this problem is removed as continuous filaments in 3 dimensions can be produced, allowing for continuous conductive circuits.

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