Single and Multi-objective Optimization of Processing Parameters for Fused Deposition Modeling in 3D Printing Technology

2020 ◽  
Vol 17 (1) ◽  
pp. 7542-7551 ◽  
Author(s):  
V. H. Nguyen ◽  
T. N. Huynh ◽  
T. P. Nguyen ◽  
T. T. Tran
Keyword(s):  
Genetic Algorithm ◽  
3D Printing ◽  
Case Studies ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Processing Parameters ◽  
Fused Deposition Modelling ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Fused Deposition

This paper presents practice and application of Design of Experiment techniques and Genetic Algorithm in single and multi-objective optimization with low cost, robustness, and high effectiveness through 3D printing case studies. 3D printing brings many benefits for engineering design, product development, and production process. However, it faces many challenges related to parameters control. The wrong parameter setup can result in excessive time, high production cost, waste material, and low-quality printing. This study is conducted to optimize the parameter sets for 3D Fused Deposition Modelling (FDM) products. The parameter sets, i.e., layer height, infill percentage, printing temperature, printing speed with different levels are experimented and analyzed to build mathematic models. The objectives are to describe the relationship between the inputs (parameter values) and the outputs (printing quality in term of weight, printing time and tensile strength of products). Single-objective and multi-objective models according to user’s desire are constructed and studied to identify the optimal set, optimal trade-off set of parameters. Besides, an integrated method of response surface methodology and Genetic algorithm to deal with multi-objective optimization is discussed in the paper. 3D printer, testing machines, and quality tools are used for doing experiments, measurement and collecting data. Minitab and Matlab software aid for analysis and decision-making. Proposed solutions for handling multi-objective optimization through 3D Fused Deposition Modelling product printing case study are practical and can extend for other case studies.

A hybrid multi-objective optimization of 3D printing process parameters using genetic algorithm

2021 ◽  
Author(s):  
Zahoor Ahmed Shariff ◽  
Lokesh M. ◽  
K. Mayandi ◽  
A. K. Saravanan ◽  
P. Sethu Ramalingam ◽  
...  
Keyword(s):  
Genetic Algorithm ◽  
3D Printing ◽  
Process Parameters ◽  
Multi Objective Optimization ◽  
Printing Process ◽  
Multi Objective

scholarly journals Energy Saving and Low-Cost-Oriented Design Processes of Blank’s Dimensions Based on Multi-Objective Optimization Model

Processes ◽  
2019 ◽  
Vol 7 (11) ◽  
pp. 811 ◽  
Author(s):  
Yongmao Xiao ◽  
Qingshan Gong ◽  
Xiaowu Chen
Keyword(s):  
Energy Consumption ◽  
Energy Saving ◽  
Optimization Model ◽  
Low Cost ◽  
Minimum Cost ◽  
Processing Parameters ◽  
Multi Objective Optimization ◽  
Nsga Ii ◽  
Multi Objective ◽  
Set Up

The blank’s dimensions are an important focus of blank design as they largely determine the energy consumption and cost of manufacturing and further processing the blank. To achieve energy saving and low cost during the optimization of blank dimensions design, we established energy consumption and cost objectives in the manufacturing and further processing of blanks by optimizing the parameters. As objectives, we selected the blank’s production and further processing parameters as optimization variables to minimize energy consumption and cost, then set up a multi-objective optimization model. The optimal blank dimension was back calculated using the parameters of the minimum processing energy consumption and minimum cost state, and the model was optimized using the non-dominated genetic algorithm-II (NSGA-II). The effect of designing blank dimension in saving energy and costs is obvious compared with the existing methods.

scholarly journals An overview on 3D Printed Medicine

2021 ◽  
Vol 18 (1) ◽  
pp. 07-13
Author(s):  
Neha Thakur ◽  
Hari Murthy
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Herbal Medicines ◽  
Fused Deposition ◽  
Digitally Controlled ◽  
3D Printed ◽  
Semi Solid

Three-dimensional printing (3DP) is a digitally-controlled additive manufacturing technique used for fast prototyping. This paper reviews various 3D printing techniques like Selective Laser Sintering (SLS), Fused Deposition Modeling, (FDM), Semi-solid extrusion (SSE), Stereolithography (SLA), Thermal Inkjet (TIJ) Printing, and Binder jetting 3D Printing along with their application in the field of medicine. Normal medicines are based on the principle of “one-size-fits-all”. This is not true always, it is possible medicine used for curing one patient is giving some side effects to another. To overcome this drawback “3D Printed medicines” are developed. In this paper, 3D printed medicines forming different Active Pharmaceutical Ingredients (API) are reviewed. Printed medicines are capable of only curing the diseases, not for the diagnosis. Nanomedicines have “theranostic” ability which combines therapeutic and diagnostic. Nanoparticles are used as the drug delivery system (DDS) to damaged cells’ specific locations. By the use of nanomedicine, the fast recovery of the disease is possible. The plant-based nanoparticles are used with herbal medicines which give low-cost and less toxic medication called nanobiomedicine. 4D and 5D printing technology for the medical field are also enlightened in this paper.

scholarly journals Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing Technology

Polymers ◽  
2021 ◽  
Vol 13 (21) ◽  
pp. 3700
Author(s):  
Patrich Ferretti ◽  
Gian Maria Santi ◽  
Christian Leon-Cardenas ◽  
Marco Freddi ◽  
Giampiero Donnici ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Deposition Process ◽  
Advanced Materials ◽  
Fused Deposition ◽  
Good Surface ◽  
Fiber Manufacturing

Fused Deposition Modeling (FDM) 3D printing is the most widespread technology in additive manufacturing worldwide that thanks to its low costs, finished component applications, and the production process of other parts. The need for lighter and higher-performance components has led to an increased usage of polymeric matrix composites in many fields ranging from automotive to aerospace. The molds used to manufacture these components are made with different technologies, depending on the number of pieces to be made. Usually, they are fiberglass molds with a thin layer of gelcoat to lower the surface roughness and obtain a smooth final surface of the component. Alternatively, they are made from metal, thus making a single carbon fiber prototype very expensive due to the mold build. Making the mold using FDM technology can be a smart solution to reduce costs, but due to the layer deposition process, the roughness is quite high. The surface can be improved by reducing the layer height, but it is still not possible to reach the same degree of surface finish of metallic or gelcoat molds without the use of fillers. Thermoplastic polymers, also used in the FDM process, are generally soluble in specific solvents. This aspect can be exploited to perform chemical smoothing of the external surface of a component. The combination of FDM and chemical smoothing can be a solution to produce low-cost molds with a very good surface finish.

A Low-Cost Method to Prepare Biocompatible Filaments with Enhanced Physico-mechanical Properties for FDM 3D Printing

2020 ◽  
Vol 18 ◽  
Author(s):  
Deck Khong Tan ◽  
Niko Münzenrieder ◽  
Mohammed Maniruzzaman ◽  
Ali Nokhodchi
Keyword(s):  
3D Printing ◽  
Low Cost ◽  
Fused Deposition Modelling ◽  
Processing Temperature ◽  
Melt Extrusion ◽  
Screw Extruder ◽  
Fused Deposition ◽  
Single Screw ◽  
Pharmaceutical Applications ◽  
Twin Screw

Background: Fused Deposition Modelling (FDM) 3D printing has received much interest as a fabrication method in the medical and pharmaceutical industry due to its accessibility and cost-effectiveness. A low-cost method to produce biocompatible and biodegradable filaments can improve the usability of FDM 3D printing for biomedical applications. Objectives: The feasibility of producing low-cost filaments suitable for FDM 3D printing via single screw and twin-screw hot melt extrusion was explored. Methods: A single-screw extruder and a twin-screw extruder were used to produce biocompatible filaments composed of varying concentrations of polyethylene glycol (PEG) at 10%, 20%, 30% w/w and polylactic acid (PLA) 90%, 80% and 70% w/w, respectively. DSC, TGA and FTIR were employed to investigate the effect of PEG on the PLA filaments. Results: The presence of PEG lowered the processing temperature of the formulation compositions via melt-extrusion, making it suitable for pharmaceutical applications. The use of PEG can lower the melting point of the PLA polymer to 170 °C, hence lowering the printing temperature. PEG can also improve the plasticity of the filaments, as the rupture strain of twinscrew extruded filaments increased up to 10-fold as compared to the commercial filaments. Advanced application of FTIR analysis confirmed the compatibility and miscibility of PEG with PLA. Conclusion: Twin-screw extrusion is more effective in producing a polymeric mixture of filaments as the mixing is more homogenous. The PEG/PLA filament is suitable to be used in 3D printing of medical or pharmaceutical applications such as medical implants, drug delivery systems, or personalised tablets.

Realization of Modified Elliptical Shaped Dielectric Lens Antenna for X Band Applications with 3D Printing Technology

2020 ◽  
Vol 35 (8) ◽  
pp. 916-921
Author(s):  
Aysu Belen ◽  
Evrim Tetik
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
High Gain ◽  
Printing Technology ◽  
Lens Antenna ◽  
3D Printing Technology ◽  
Fused Deposition ◽  
Dielectric Lens ◽  
3D Em

Placing dielectric lens structures into an antenna's aperture has proven to be one of the most reliable methods of enhancing its gain. However, the selected material and the prototyping method usually limit their fabrication process. With the advances in 3D printing technology and their applications, the microwave designs that were either impractical or impossible in the past to manufacture using traditional methods, are now feasible. Herein, a novel prototyping method by using 3D-printer technology for low-cost, broadband, and high gain dielectric lens designs has been presented. Firstly, the elliptical lens design has been modeled in the 3D EM simulation environment. Then fused deposition modeling based 3D-printing method has been used for the fabrication of the dielectric lens. The measured results of the 3D printed antenna show that the lens antenna has a realized gain of 17 to 20.5 dBi over 8-12 GHz. Moreover, the comparison of the prototyped antenna with its counterpart dielectric lens antenna in the literature has indicated that the proposed method is more efficient, more beneficial, and has a lower cost.

Multi material 3D printing of PLA-PA6/TiO2 polymeric matrix: Flexural, wear and morphological properties

2020 ◽  
pp. 089270572095319 ◽  
Author(s):  
Sudhir Kumar ◽  
Rupinder Singh ◽  
Mohit Singh ◽  
TP Singh ◽  
Ajay Batish
Keyword(s):  
3D Printing ◽  
Wear Rate ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Polymeric Composite ◽  
Wear Testing ◽  
Morphological Properties ◽  
Poly Lactic Acid ◽  
Fused Deposition ◽  
Fractured Surface

The poly-lactic acid (PLA), bio compatible polyamide (PA6) and TiO2 has established bio-medical applications especially in 3D printing of scaffolds. But hitherto little has been reported on improving the performance of multi-material matrix for PLA-PA6/TiO2 especially in 3D printing application of biomedical scaffolds. The anti-bacterial properties of PA6/TiO2 make it worthy to be explored with PLA matrix in multi layered fashion on the platform of fused deposition modeling (FDM) being low cost 3D printing technology for in house development of scaffolds. In this work an effort has been made for in-house development of feedstock filaments of PLA and PA6/TiO2 based polymeric composite matrix on twin screw extrusion (TSE) machine. Further the feedstock filament wires were used on FDM to establish the flexural, wear and morphological properties of multi-material 3D printed functional prototype. The results of the study suggest that for flexural strength, infill speed: 90mm/s; infill pattern: triangular and layer combination as 5 consecutive layers of PLA and 5 consecutive layers of PA6/TiO2 are the optimized conditions for FDM printing. The wear testing results suggest that the composite of PA6/TiO2 held low wear rate (823 µm) in comparison to PLA (wear rate: 1092 µm). Further porosity testing (based upon optical photomicrographs) at ×100 and fractured surface analysis at ×30 supported the observed trends for flexural and wear testing. The photomicrographs of fractured surface were 3D rendered to predict the role of surface roughness (Ra) profile for flexural properties. The mechanical and morphological observations are also supported with scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) analysis.

scholarly journals Biodegradable Poly(Lactic Acid) Nanocomposites for Fused Deposition Modeling 3D Printing

Nanomaterials ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 2567
Author(s):  
Madison Bardot ◽  
Michael D. Schulz
Keyword(s):  
Mechanical Properties ◽  
Lactic Acid ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Ecological Crisis ◽  
Poly Lactic Acid ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Biodegradable Poly ◽  
Deposition Modeling

3D printing by fused deposition modelling (FDM) enables rapid prototyping and fabrication of parts with complex geometries. Unfortunately, most materials suitable for FDM 3D printing are non-degradable, petroleum-based polymers. The current ecological crisis caused by plastic waste has produced great interest in biodegradable materials for many applications, including 3D printing. Poly(lactic acid) (PLA), in particular, has been extensively investigated for FDM applications. However, most biodegradable polymers, including PLA, have insufficient mechanical properties for many applications. One approach to overcoming this challenge is to introduce additives that enhance the mechanical properties of PLA while maintaining FDM 3D printability. This review focuses on PLA-based nanocomposites with cellulose, metal-based nanoparticles, continuous fibers, carbon-based nanoparticles, or other additives. These additives impact both the physical properties and printability of the resulting nanocomposites. We also detail the optimal conditions for using these materials in FDM 3D printing. These approaches demonstrate the promise of developing nanocomposites that are both biodegradable and mechanically robust.

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