Design and verification of enhanced CFRTPCs fabrication technique using fused deposition modeling

2020 ◽  
pp. 089270572094191
Author(s):  
Ali Bin Naveed ◽  
Shahid Ikramullah Butt ◽  
Aamir Mubashar ◽  
Fausz Naeem Chaudhry ◽  
Najam ul Qadir ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Control Method ◽  
Volume Fraction ◽  
Research Work ◽  
High Strength ◽  
Thermoplastic Composites ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Industrial Level

Research shows that mechanical properties of parts produced using fused deposition modeling (FDM) are inferior when compared to parts produced using conventional techniques such as injection molding. Efforts have been made in recent years to improve mechanical properties by reinforcing the parts with high strength fibers. This has been achieved by either modifying FDM setups to extrude fibers with thermoplastics and fabricate continuous fiber reinforced thermoplastic composites (CFRTPCs) or employing manual techniques subsequent to part production. Existing CFRTPCs fabrication procedures have limitations of fiber exposure to environment, no direct control method for volume fraction, and poor surface finish. This research work is focused on improving the process of producing CFRTPCs by addressing these limitations using a dual extruder FDM setup. The process developed was tested for its feasibility using Kevlar fiber as reinforcement for commercially available ABS, PLA, PLA-C, and PLA-Cu thermoplastic fibers. Taguchi L16 orthogonal array was used to design experiments, while tensile and flexural testing was performed to determine mechanical properties achieved. Tensile strength was improved up to 3 times the baseline value of thermoplastics, while flexural strength was improved up to 1.6 times. This technique can further the goal of developing CFRTPCs, on industrial level, using FDM with better control over volume fraction and fiber layup.

Improving mechanical properties of continuous fiber-reinforced thermoplastic composites produced by FDM 3D printer

2018 ◽  
Vol 38 (3) ◽  
pp. 99-116 ◽  
Author(s):  
Behnam Akhoundi ◽  
Amir Hossein Behravesh ◽  
Arvin Bagheri Saed
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Thermoplastic Composites ◽  
3D Printer ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fiber Volume ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Consistent Method

The main purpose of this research is to bolster mechanical properties of the parts, produced by an extrusion-based 3D printer, or fused deposition modeling machine, via increasing the content of continuous fiber yarn to its practical limit. In-melt continuous glass fiber yarn embedding was applied as a reliable and consistent method for simultaneous impregnation to produce continuous fiber-reinforced thermoplastic composites in the fused deposition modeling process. It is well known that the main weakness in the fused deposition modeling 3D printed products is their low strength compared to the manufactured ones by conventional methods such as injection molding and machining processes. This characteristic can be related to both inherent weakness of thermoplastic materials and poor adhesion between the deposited rasters and the layers. Although various attempts have been performed to tackle this issue, it is widely believed that using continuous fibers is the most effective method to serve this purpose if a reliable and consistent method is implemented. Since the mechanical properties of continuous fiber-reinforced composites directly depend on the content of fiber volume, maximizing the fiber content as well as producing an integrated part was assumed as the main objective. In this work, an analysis of various patterns of raster deposition was conducted, followed by the experiments and verification. The effective parameters on the fiber yarn volume, such as fiber yarn diameter, fiber yarn laying pattern, extrusion width, layer height, and flow percentage, were investigated and their optimal values were reported. The attained experimental results showed that, for polylactic acid-glass fiber yarn reinforced composite, with the extrusion width of 0.3 mm, the layer heights of 0.22 mm, flow percentage of 0.43, and the rectangular laying pattern, approximately 50% fiber-volume content can be achieved which resulted in tensile yield strength and modulus of 478 MPa and 29.4 GPa, respectively. There was an excellent agreement between these experimental results and predicted theoretically values by rule of mixture.

Enhancing the mechanical properties of SCF/PEEK composites in FDM via process-parameter optimization

2021 ◽  
pp. 095400832110036
Author(s):  
Bin Hu ◽  
Zehua Xing ◽  
Weidong Wu ◽  
Xiaojun Zhang ◽  
Huamin Zhou ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Weight Ratio ◽  
High Strength ◽  
Processing Parameters ◽  
High Viscosity ◽  
Polymer Composite Material ◽  
Fused Deposition ◽  
Deposition Modeling

Short-carbon-fiber (SCF)–reinforced poly-ether-ether-ketone (PEEK) is a promising polymer composite material with good biocompatibility, a high strength-to-weight ratio, and low friction properties. In artificial-bone fabrication and other applications with more flexible fabrication demands, fused-deposition modeling (FDM) technology enables the rapid and low-cost fabrication of SCF/PEEK parts with sophisticated structures. Owing to the high viscosity of melting PEEK composites, great challenges, associated with the poor internal interface, need to be overcome before enhanced mechanical properties can be obtained. In this study, key processing parameters and various SCF amounts were studied to investigate their effects on the mechanical properties of PEEK composites. It was revealed that the existence of voids and gaps between the SCF and PEEK led to a decrease in the strength of the composite systems. The FDM processing parameters were tuned to eliminate these defects in the PEEK composites. The tensile strength of the 2% SCF/PEEK sample reached 96.4 MPa, which is comparable to that of PEEK parts prepared by injection molding. Meanwhile, its elastic modulus reached 2.6 GPa, which is 169% higher than that of the bare PEEK sample.

An innovative design approach in three-dimensional printing of continuous fiber–reinforced thermoplastic composites via fused deposition modeling process: In-melt simultaneous impregnation

2019 ◽  
Vol 234 (1-2) ◽  
pp. 243-259 ◽  
Author(s):  
Behnam Akhoundi ◽  
Amir Hossein Behravesh ◽  
Arvin Bagheri Saed
Keyword(s):  
Mechanical Properties ◽  
Glass Fiber ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fiber Volume ◽  
Fused Deposition ◽  
Deposition Modeling

In this study, an innovative method was devised and implemented to produce continuous glass fiber–reinforced thermoplastic composites via a fused deposition modeling three-dimensional printer to enhance the mechanical properties of the printed products. In the extrusion-based, or filament-based, additive manufacturing process, namely, fused deposition modeling, the parts are basically formed via deposition of the material in the molten state, and thus embedding continuous fiber, in a solid form, is highly challenging. Hence, a nozzle system was designed and manufactured to feed the continuous fiber into the molten polymer simultaneously, which is called, here, in-melt simultaneous impregnation. With the presence of continuous fibers in the nozzle outlet, the feed of filament was calculatedly adjusted in the G-codes depending on the fiber volume percentage, to produce sound flow, and consistent deposition. Composite products were produced with various geometrical shapes. Via analysis and close control of the filament feeding, as a critical requirement to produce a sound printed product, composites with various fiber volume percentages were printed. Also, the mechanical properties of the printed parts with 30% by volume of glass fiber were measured. The results of the tensile test indicated that the continuous fibers were appropriately and effectively embedded that could result in remarkable increases in tensile strength and modulus of the samples, higher than 700%. The resulted values of tensile modulus were consistent with the values calculated via the rule of mixture. In addition, scanning electron microscopic images of the fracture sections suggest a sound adhesion between fibers and the matrix.

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.

Assessing the effect of FDM processing parameters on mechanical properties of PLA parts using Taguchi method

2021 ◽  
pp. 089270572110530
Author(s):  
Nagarjuna Maguluri ◽  
Gamini Suresh ◽  
K Venkata Rao
Keyword(s):  
Mechanical Properties ◽  
Tensile Properties ◽  
Fused Deposition Modeling ◽  
Fracture Strain ◽  
Processing Parameters ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Nozzle Temperature ◽  
Experimental Runs ◽  
Printing Speed

Fused deposition modeling (FDM) is a fast-expanding additive manufacturing technique for fabricating various polymer components in engineering and medical applications. The mechanical properties of components printed with the FDM method are influenced by several process parameters. In the current work, the influence of nozzle temperature, infill density, and printing speed on the tensile properties of specimens printed using polylactic acid (PLA) filament was investigated. With an objective to achieve better tensile properties including elastic modulus, tensile strength, and fracture strain; Taguchi L8 array has been used for framing experimental runs, and eight experiments were conducted. The results demonstrate that the nozzle temperature significantly influences the tensile properties of the FDM printed PLA products followed by infill density. The optimum processing parameters were determined for the FDM printed PLA material at a nozzle temperature of 220°C, infill density of 100%, and printing speed of 20 mm/s.

scholarly journals Hedysarum coronarium-Based Green Composites Prepared by Compression Molding and Fused Deposition Modeling

Materials ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 465
Author(s):  
Roberto Scaffaro ◽  
Maria Clara Citarrella ◽  
Emmanuel Fortunato Gulino ◽  
Marco Morreale
Keyword(s):  
Mechanical Properties ◽  
Young’S Modulus ◽  
Fused Deposition Modeling ◽  
Young's Modulus ◽  
Compression Molding ◽  
Green Composite ◽  
Fused Deposition ◽  
Hedysarum Coronarium ◽  
Deposition Modeling ◽  
Fibers Orientation

In this work, an innovative green composite was produced by adding Hedysarum coronarium (HC) flour to a starch-based biodegradable polymer (Mater-Bi®, MB). The flour was obtained by grinding together stems, leaves and flowers and subsequently sieving it, selecting a fraction from 75 μm to 300 μm. Four formulations have been produced by compression molding (CM) and fused deposition modeling (FDM) by adding 5%, 10%, 15% and 20% of HC to MB. The influence of filler content on the processability was tested, and rheological, morphological and mechanical properties of composites were also assessed. Through CM, it was possible to obtain easily homogeneous samples with all filler amounts. Concerning FDM, 5% and 10% HC-filled composites proved also easily printable. Mechanical results showed filler effectively acted as reinforcement: Young’s modulus and tensile strengths of the composites increased from 74.3 MPa to 236 MPa and from 18.6 MPa to 33.4 MPa, respectively, when 20% of HC was added to the pure matrix. FDM samples, moreover, showed higher mechanical properties if compared with CM ones due to rectilinear infill and fibers orientation. In fact, regarding the 10% HC composites, Young’s modulus of the CM and FDM ones displayed a relative increment of 176% and 224%, respectively.

scholarly journals EFFECT OF EXTRUSION PROCESS PARAMETERS ON MECHANICAL PROPERTIES OF 3D PRINTED PLA PRODUCT

2021 ◽  
Vol 6 (2) ◽  
pp. 119
Author(s):  
Nanang Ali Sutisna ◽  
Rakha Amrillah Fattah
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Extrusion Process ◽  
Experimental Procedure ◽  
Fused Deposition ◽  
Novel Approach ◽  
Deposition Modeling ◽  
3D Printed ◽  
3D Digital Models

The method of producing items through synchronously depositing material level by level, based on 3D digital models, is named Additive Manufacturing (AM) or 3D-printing. Amongs many AM methods, the Fused Deposition Modeling (FDM) technique along with PLA (Polylactic acid) material is commonly used in additive manufacturing. Until now, the mechanical properties of the AM components could not be calculated or estimated until they've been assembled and checked. In this work, a novel approach is suggested as to how the extrusion process affects the mechanical properties of the printed component to obtain how the parts can be manufactured or printed to achieve improved mechanical properties. This methodology is based on an experimental procedure in which the combination of parameters to achieve an optimal from a manufacturing experiment and its value can be determined, the results obtained show the effect of the extrusion process affects the mechanical properties.

scholarly journals Process Parameter Optimization in Fused Deposition Modeling (FDM) Using Response Surface Methodology (RSM)

2020 ◽  
Author(s):  
Muhammad Salman Mustafa ◽  
Muhammad Qasim Zafar ◽  
Muhammad Arslan Muneer ◽  
Muhammad Arif ◽  
Farrukh Arsalan Siddiqui ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Response Surface Methodology ◽  
Impact Strength ◽  
Response Surface ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Experimental Results ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Printing Parameters

Abstract Fused Deposition Modeling (FDM) is a widely adopted additive manufacturing process to produce complex 3D structures and it is typically used in the fabrication of biodegradable materials e.g. PLA/PHA for biomedical applications. However, FDM as a fabrication process for such material needs to be optimized to enhance mechanical properties. In this study, dogbone and notched samples are printed with the FDM process to determine optimum values of printing parameters for superior mechanical properties. The effect of layer thickness, infill density, and print bed temperature on mechanical properties is investigated by applying response surface methodology (RSM). Optimum printing parameters are identified for tensile and impact strength and an empirical relation has been formulated with response surface methodology (RSM). Furthermore, the analysis of variance (ANOVA) was performed on the experimental results to determine the influence of the process parameters and their interactions. ANOVA results demonstrate that 44.7% infill density, 0.44 mm layer thickness, and 20C° printing temperatures are the optimum values of printing parameters owing to improved tensile and impact strength respectively. The experimental results were found in strong agreement with the predicted theoretical results.

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