Three-dimensional printing of dual thermoplastic materials with different layer combinations: Tensile, flexural, and fractured surface investigations

2020 ◽  
pp. 089270572092512 ◽  
Author(s):  
Sudhir Kumar ◽  
Rupinder Singh ◽  
TP Singh ◽  
Ajay Batish ◽  
Akshay Kumar
Keyword(s):  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Thermoplastic Material ◽  
Fused Deposition ◽  
Multiple Materials ◽  
Dual Material ◽  
Single Material ◽  
Fractured Surface

The three-dimensional (3-D) printing with deposition of dual/multiple materials on alternative layers has been explored by some researchers for various engineering applications. But, hitherto, little has been reported on failure mechanism of dual/multiple materials 3-D printed parts in tensile and flexural testing. In this work, investigations were made to explore the tensile, flexural, morphological, and thermal properties of dual thermoplastic material (acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA))-based 3-D printing of functional prototypes with low-cost fused deposition modeling process. The results of the study suggest that for mechanical properties of 3-D printed parts, the number of conversions, the number of negative conversions for selecting particular layer of thermoplastic material, and the number of layers (while selecting the alternative layer’s material) have significant effect. The maximum peak strength of 55.98 MPa (while tensile testing) was observed for combination of four consecutive layers of PLA and two layers of ABS, which is 15.81% higher than the ABS (48.34 MPa) and at par with the PLA-based 3-D printed functional prototype. Also, it has been ascertained that the deposition of ABS on PLA has better compatibility than PLA deposition on ABS platform. In case of flexural strength, single material-based 3-D printed parts have better properties. From fractured surface analysis, it has been observed that dual material-based 3-D printed prototypes have relatively large number of voids/porosity holes in comparison to single material-based 3-D printed prototypes, thus ultimately resulting in poor mechanical performance.

scholarly journals On the Post-Processing of 3D-Printed ABS Parts

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1559
Author(s):  
Mohammad Reza Khosravani ◽  
Jonas Schüürmann ◽  
Filippo Berto ◽  
Tamara Reinicke
Keyword(s):  
Surface Treatment ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Tests ◽  
Fracture Load ◽  
Post Processing ◽  
Fused Deposition ◽  
Dog Bone ◽  
3D Printed

Application of Additive Manufacturing (AM) has significantly increased in the past few years. AM also known as three-dimensional (3D) printing has been currently used in fabrication of prototypes and end-use products. Considering the new applications of additively manufactured components, it is necessary to study structural details of these parts. In the current study, influence of a post-processing on the mechanical properties of 3D-printed parts has been investigated. To this aim, Acrylonitrile Butadiene Styrene (ABS) material was used to produce test coupons based on the Fused Deposition Modeling (FDM) process. More in deep, a device was designed and fabricated to fix imperfection and provide smooth surfaces on the 3D-printed ABS specimens. Later, original and treated specimens were subjected to a series of tensile loads, three-point bending tests, and water absorption tests. The experimental tests indicated fracture load in untreated dog-bone shaped specimen was 2026.1 N which was decreased to 1951.7 N after surface treatment. Moreover, the performed surface treatment was lead and decrease in tensile strength from 29.37 MPa to 26.25 MPa. Comparison of the results confirmed effects of the surface modification on the fracture toughness of the examined semi-circular bending components. Moreover, a 3D laser microscope was used for visual investigation of the specimens. The documented results are beneficial for next designs and optimization of finishing processes.

scholarly journals Novel Method for the Manufacture of Complex CFRP Parts Using FDM-based Molds

Polymers ◽  
2020 ◽  
Vol 12 (10) ◽  
pp. 2220
Author(s):  
Paul Bere ◽  
Calin Neamtu ◽  
Razvan Udroiu
Keyword(s):  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
The Novel ◽  
Reinforced Polymers ◽  
Fused Deposition ◽  
Molded Parts ◽  
Deposition Modeling ◽  
Composite Tooling ◽  
Novel Method

Fibre-reinforced polymers (FRP) have attracted much interest within many industrial fields where the use of 3D printed molds can provide significant cost and time savings in the production of composite tooling. Within this paper, a novel method for the manufacture of complex-shaped FRP parts has been proposed. This paper features a new design of bike saddle, which was manufactured through the use of molds created by fused deposition modeling (FDM), of which two 3D printable materials were selected, polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS), and these molds were then chemically and thermally treated. The novel bike saddles were fabricated using carbon fiber-reinforced polymer (CFRP), by vacuum bag technology and oven curing, utilizing additive manufactured (AM) molds. Following manufacture the molded parts were subjected to a quality inspection, using non-contact three-dimensional (3D) scanning techniques, where the results were then statistically analyzed. The statistically analyzed results state that the main deviations between the CAD model and the manufactured CFRP parts were within the range of ±1 mm. Additionally, the weight of the upper part of the saddles was found to be 42 grams. The novel method is primarily intended to be used for customized products using CFRPs.

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.

Multimaterial printing and characterization for mechanical and surface properties of functionally graded prototype

2019 ◽  
Vol 233 (19-20) ◽  
pp. 6741-6753 ◽  
Author(s):  
Sudhir Kumar ◽  
Rupinder Singh ◽  
TP Singh ◽  
Ajay Batish
Keyword(s):  
Polylactic Acid ◽  
Surface Properties ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Three Dimensional ◽  
Surface Hardness ◽  
Functionally Graded ◽  
Three Dimensional Printing ◽  
Fused Deposition ◽  
Dimensional Printing

In this work, an effort has been made for multimaterial three-dimensional printing of functionally graded prototypes of polylactic acid matrix (tensile specimens as per ASTM D638 type IV) followed by characterization of mechanical and surface properties. The work is an extension of previous reported studies on twin-screw extrusion process for the preparation of multimaterial wires as feedstock filaments in possible three-dimensional printing applications. The results of the study suggest that the highest peak strength (46.28 MPa) and break strength (41.65 MPa) was obtained for multimaterial three-dimensional printed samples at infill density 100%, infill angle 45°, and infill speed of 90 mm/s on commercial open source fused deposition modeling setup. Further surface hardness measurements performed on two extreme surfaces (top surface comprising magnetite (Fe3O4)-reinforced polylactic acid and bottom with polylactic acid without any reinforcement) revealed that the hardness for the bottom layer was more than the hardness for the top layer. From fractured surface analysis (using photomicrographs), it has been observed that the three-dimensional printed samples with low infill density resulted into more void formation due to which the performance while mechanical testing was poor in comparison to samples printed with higher infill density. The results are also supported by rendered images of photomicrographs, which revealed that high roughness value of samples printed with low infill density was also one of the reasons for poor mechanical performance of multimaterial three-dimensional printed functionally graded prototypes.

Mechanical properties of an additive manufactured CF-PLA/ABS hybrid composite sheet

2019 ◽  
pp. 089270571986940
Author(s):  
Syed Waqar Ahmed ◽  
Ghulam Hussain ◽  
Khalid A Al-Ghamdi ◽  
Khurram Altaf
Keyword(s):  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Hybrid Composites ◽  
Desirability Function ◽  
Acrylonitrile Butadiene Styrene ◽  
Composite Sheet ◽  
Layer Height ◽  
Fused Deposition ◽  
Laminar Composites ◽  
Printing Speed

Laminar composites have widespread applications in the automotive and aircraft industry. This research was aimed to investigate the suitability of fused deposition modeling to produce multi-material laminar composites. Composites comprising of two dissimilar laminates, named as hybrid composites, were printed from acrylonitrile butadiene styrene filament and carbon fiber-reinforced polylactic acid filament (a composite filament) by varying different printing parameters. Tensile tests were conducted to examine the mechanical performance of the produced composite sheet. A detailed analysis of the results revealed that a high ultimate tensile strength is primarily achieved by setting low values of printing speed, layer height, and clad ratio while high elongation is obtained by employing low printing speed, medium layer height, and high clad ratio. The optimum printing conditions were sought out through desirability function with an objective to simultaneously enhance all the considered properties. Further, the composite sheet exhibited a reasonably good combination of tensile properties as compared to its monolithic constituent sheets. Based on the results, it is concluded that the bi-material laminating approach employed herein can produce printed structures with desired properties.

Finite Element Simulation of Temperature Field in Fused Deposition Modeling

2010 ◽  
Vol 97-101 ◽  
pp. 2585-2588 ◽  
Author(s):  
Liang Bo Ji ◽  
Tian Rui Zhou
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Fused Deposition Modeling ◽  
Parametric Design ◽  
Three Dimensional ◽  
Physical Property ◽  
Acrylonitrile Butadiene Styrene ◽  
Element Model ◽  
Fused Deposition ◽  
Deposition Modeling

Taking into account temperature-dependent thermal conduction and heat capacity, based in the research on the physical property of the material of Acrylonitrile Butadiene Styrene (ABS), a three-dimensional transient thermal finite element model has been developed in Fused Deposition Modeling (FDM). The moving material of ABS by the sprayer on the mold equipment is simulated with the employment of ANSYS parametric design language (APDL) and latent heat is considered by using enthalpy. By the technique of element live and die on ANSYS software and using the nonlinear finite element method, several conclusions according to the simulation results were produced, first of all, the simulation result shows that the temperature field distribution likes an ellipse; secondly, comparing with the previous track, the latter one has larger heat affected region and larger inhomogeneous temperature distribution; the greatest temperature gradient takes place near the edges of deposited part where the sprayer scanning direction changes.

An experimental study of FDM parameters effects on tensile strength, density, and production time of ABS/Cu composites

2020 ◽  
pp. 009524432091683 ◽  
Author(s):  
Mojtaba Nabipour ◽  
Behnam Akhoundi
Keyword(s):  
Tensile Strength ◽  
Taguchi Method ◽  
Fused Deposition Modeling ◽  
Signal To Noise Ratio ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Production Time ◽  
Fused Deposition ◽  
Raster Angle ◽  
Nozzle Temperature

Recently, applications of three-dimensional (3-D) printers have extensively been increased in various industries. Fused deposition modeling process is one of the most widely used 3-D printing methods in this area due to its simplicity, reliability, and the ability to produce complex parts made of thermoplastic materials. In this research, composite sample parts consisted of copper particles with a constant 25 wt% of metallic powder as a filler and acrylonitrile butadiene styrene granules as a polymeric matrix. A filament production line to acquire printable filaments was applied and its optimum parameters were reported. Four printing parameters involved nozzle diameter, layer height, raster angle, and nozzle temperature were chosen in three levels for investigation of composite samples’ tensile strength, density, and production time as a new study. The Taguchi method, a well-known design of experiment tool, was employed to find the effect of each parameter and optimum levels with including the main effect, signal-to-noise ratio, and analysis of variance. Finally, optimum composite specimens manufactured by 3-D printer verified Taguchi method analysis and results.

Mechanical and morphological investigations of 3D printed recycled ABS reinforced with bakelite–SiC–Al2O3

2019 ◽  
Vol 233 (17) ◽  
pp. 5933-5944 ◽  
Author(s):  
Rupinder Singh ◽  
Inderpreet Singh ◽  
Ranvijay Kumar
Keyword(s):  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Morphological Properties ◽  
Fused Deposition ◽  
Software Configuration ◽  
Twin Screw ◽  
Deposition Modeling ◽  
3D Printed ◽  
Commercial Applications

The utilization of thermosetting waste is a serious issue as it is not recycled commercially due to inherent molecular properties and high technology cost. This research details the study of the mechanical behavior and surface analysis with energy-dispersive X-ray spectroscopy and scanning electron microscope of three-dimensional printed parts of the waste thermosetting polymer, bakelite (BAK) as the reinforcement along with ceramic particles (SiC and Al2O3) in recycled thermoplastic acrylonitrile butadiene styrene matrix for sustainability. The process involves twin-screw extrusion for the preparation of filament, followed by 3D printing of functional prototypes on fused deposition modeling setup. The 3D printed parts prepared with fused deposition modeling were used for the testing of mechanical, thermal, and morphological properties. The results of the present study suggests that for commercial applications recycling of thermoplastic up to 10 wt% can be easily performed without a change in any hardware/ software configuration of the fused deposition modeling setup and the ceramic concentration in thermoplastic-thermosetting blends further led to better mechanical and surface properties.

scholarly journals Biodegradable PGA/PBAT Blends for 3D Printing: Material Performance and Periodic Minimal Surface Structures

Polymers ◽  
2021 ◽  
Vol 13 (21) ◽  
pp. 3757
Author(s):  
Zihui Zhang ◽  
Fengtai He ◽  
Bo Wang ◽  
Yiping Zhao ◽  
Zhiyong Wei ◽  
...  
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Three Dimensional ◽  
Weight Ratio ◽  
Polyglycolic Acid ◽  
Green Energy ◽  
Surface Structures ◽  
Good Thermal Stability ◽  
Fused Deposition

Biodegradable polymers have been rapidly developed for alleviating excessive consumption of non-degradable plastics. Additive manufacturing is also a green energy-efficiency and environment-protection technique to fabricate complicated structures. Herein, biodegradable polyesters, polyglycolic acid (PGA) and poly (butyleneadipate-co-terephthalate) (PBAT) were blended and developed into feedstock for 3D printing. Under a set of formulations, PGA/PBAT blends exhibited a tailored stiffness-toughness mechanical performance. Then, PGA/PBAT (85/15 in weight ratio) with good thermal stability and mechanical property were extruded into filaments with a uniform wire diameter. Mechanical testing clearly indicated that FDM 3D-printed exhibited comparable tensile, flexural and impact properties with injection-molded samples of PGA/PBAT (85/15). Furthermore, uniform and graded Diamond-Triply Periodic Minimal Surfaces (D-TPMS) structures were designed and successfully manufactured via the fused deposition modeling (FDM) technique. Computer tomography (CT) was employed to confirm the internal three-dimensional structures. The compressive test results showed that PGA/PBAT (85/15) D-surface structures bear better load-carrying capacity than that of neat PGA, giving an advantage of energy absorption. Additionally, typical industrial parts were manufactured with excellent dimension-stability, no-wrapping and fine quality. Collectively, biodegradable PGA/PBAT material with good printability has great potentials in application requiring stiffer structures.

scholarly journals A path for lignin valorization via additive manufacturing of high-performance sustainable composites with enhanced 3D printability

2018 ◽  
Vol 4 (12) ◽  
pp. eaat4967 ◽  
Author(s):  
Ngoc A. Nguyen ◽  
Sietske H. Barnes ◽  
Christopher C. Bowland ◽  
Kelly M. Meek ◽  
Kenneth C. Littrell ◽  
...  
Keyword(s):  
Carbon Fibers ◽  
High Performance ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
High Volume ◽  
Butadiene Rubber ◽  
Mechanical Stiffness ◽  
Printing Process ◽  
Fused Deposition

We report the manufacture of printable, sustainable polymer systems to address global challenges associated with high-volume utilization of lignin, an industrial waste from biomass feedstock. By analyzing a common three-dimensional printing process—fused-deposition modeling—and correlating the printing-process features to properties of materials such as acrylonitrile-butadiene-styrene (ABS) and nylon, we devised a first-of-its-kind, high-performance class of printable renewable composites containing 40 to 60 weight % (wt %) lignin. An ABS analog made by integrating lignin into nitrile-butadiene rubber needs the presence of a styrenic polymer to avoid filament buckling during printing. However, lignin-modified nylon composites containing 40 to 60 wt % sinapyl alcohol–rich, melt-stable lignin exhibit enhanced stiffness and tensile strength at room temperature, while—unexpectedly—demonstrating a reduced viscosity in the melt. Further, incorporation of 4 to 16 wt % discontinuous carbon fibers enhances mechanical stiffness and printing speed, as the thermal conductivity of the carbon fibers facilitates heat transfer and thinning of the melt. We found that the presence of lignin and carbon fibers retards nylon crystallization, leading to low-melting imperfect crystals that allow good printability at lower temperatures without lignin degradation.

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