scholarly journals Hardware Factors Influencing Interlayer Bonding Strength of Parts Obtained by Fused Filament Fabrication

2019 ◽  
Author(s):  
Vladimir E. Kuznetsov ◽  
Azamat G. Tavitov ◽  
Oleg D. Urzhumtcev
Keyword(s):  
3D Printing ◽  
Flexural Strength ◽  
Layer Thickness ◽  
Bonding Strength ◽  
Cad Model ◽  
Fused Filament Fabrication ◽  
Three Point Bending ◽  
Factors Influencing ◽  
3D Printers ◽  
Interlayer Bonding

Current paper investigates the influence of hardware setup and parameters of a 3D printing process based on fused filament fabrication (FFF) technology on resulting sample strength. Three-point bending of samples printed with long side oriented along Z axis was used as a measure of the interlayer bonding strength. The same CAD model was converted into NC-programs through same slicing software to be run on four different desktop FFF 3D printers, out of filament of same brand and color. Within all the printers same ranges of layer thickness values from 0.1 to 0.3 mm and feed rates from 25 to 75 mm/s were planned to be varied. All the machines demonstrated statistically almost identical values of maximum flexural strength, however the different machines exhibited maximum sample strength with different combinations of varied parameters. Among all the hardware factors observed, the most important was proved to be extruder type, direct or Bowden. This feature fundamentally changes the nature of studied parameters influence onto the resulting strength of the FFF process. For the extruders of Bowden type the length of flexible guiding tube is of great importance.All the machines demonstrated statistically almost identical values of maximum flexural strength, however the different machines exhibited maximum sample strength with different combinations of varied parameters. Among all the hardware factors observed, the most important was proved to be extruder type, direct or Bowden. This feature fundamentally changes the nature of studied parameters influence onto the resulting strength of the FFF process. For the extruders of Bowden type the length of flexible guiding tube is of great importance.

scholarly journals Hardware Factors Influencing Strength of Parts Obtained by Fused Filament Fabrication

Polymers ◽  
2019 ◽  
Vol 11 (11) ◽  
pp. 1870 ◽  
Author(s):  
Vladimir E. Kuznetsov ◽  
Azamat G. Tavitov ◽  
Oleg D. Urzhumtsev ◽  
Mikhail V. Mikhalin ◽  
Alexander I. Moiseev
Keyword(s):  
Layer Thickness ◽  
Mechanical Performance ◽  
Machine Design ◽  
3D Printer ◽  
Technological Parameters ◽  
Fused Filament Fabrication ◽  
Three Point Bending ◽  
3D Printers ◽  
Pros And Cons ◽  
Interlayer Bonding

The current paper investigates the influence of the hardware setup and parameters of a 3D printing process on the resulting sample strength obtained through fused filament fabrication (FFF) technology. Three-point bending was chosen as the strength measure for samples printed with the long side oriented along the Z-axis. A single CAD model was converted into NC-programs through the same slicing software to be run on five different desktop FFF 3D printers with filament of the same brand and color. For all the printers, the same ranges of layer thickness values from 0.1 to 0.3 mm and feed rates from 25 to 75 mm/s were planned to be varied. The first four machines considered in the study were off the shelf devices available on the market, and the fifth was a quick prototype of a desktop machine design based on the analysis of pros and cons of the four machines considered. The results of the study show that the hardware setup of a desktop 3D printer can drastically change the influence of basic technological parameters such as feed rate and layer thickness on the interlayer bonding. This means that many of the conclusions drawn from previous studies connecting the technological parameters of the FFF process with the mechanical performance of parts and samples may only be correct for specific hardware setups.

scholarly journals Optimization of the 3D Printing Parameters for Tensile Properties of Specimens Produced by Fused Filament Fabrication of 17-4PH Stainless Steel

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 774 ◽  
Author(s):  
Damir Godec ◽  
Santiago Cano ◽  
Clemens Holzer ◽  
Joamin Gonzalez-Gutierrez
Keyword(s):  
Stainless Steel ◽  
3D Printing ◽  
Tensile Properties ◽  
Layer Thickness ◽  
Flow Rate ◽  
Three Dimensional ◽  
Steel Powder ◽  
Extrusion Temperature ◽  
Fused Filament Fabrication ◽  
Printing Parameters

Fused filament fabrication (FFF) combined with debinding and sintering could be an economical process for three-dimensional (3D) printing of metal parts. In this paper, compounding, filament making, and FFF processing of feedstock material with 55% vol. of 17-4PH stainless steel powder in a multicomponent binder system are presented. The experimental part of the paper encompasses central composite design for optimization of the most significant 3D printing parameters (extrusion temperature, flow rate multiplier, and layer thickness) to obtain maximum tensile strength of the 3D-printed specimens. Here, only green specimens were examined in order to be able to determine the optimal parameters for 3D printing. The results show that the factor with the biggest influence on the tensile properties was flow rate multiplier, followed by the layer thickness and finally the extrusion temperature. Maximizing all three parameters led to the highest tensile properties of the green parts.

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). 

scholarly journals Strength of PLA Components Fabricated with Fused Deposition Technology Using a Desktop 3D Printer as a Function of Geometrical Parameters of the Process

2018 ◽  
Author(s):  
Vladimir Kuznetsov ◽  
Alexey Solonin ◽  
Oleg Urzhumtcev ◽  
Azamat Tavitov ◽  
Richard Schilling
Keyword(s):  
3D Printing ◽  
Significant Influence ◽  
Assessment Method ◽  
Geometrical Parameters ◽  
3D Printer ◽  
Three Point Bending ◽  
Geometric Process ◽  
Fused Deposition ◽  
3D Printers ◽  
Deposition Technology

The current paper is studying the influence of geometrical parameters of the FDM (FFF) 3D printing process on printed part strength for open source desktop 3D printers and the most popular material used for that purpose, i.e. PLA (polylactic acid). The study was conducted using a set of different nozzles (0.4, 0.6 and 0.8 mm) and a range of layer heights from the minimum to maximum physical limits of the machine. To assess print strength, a novel assessment method is proposed. A tubular sample is loaded in the weakest direction (across layers) in a three-point bending fixture. To explain the results obtained, a mesostructure evaluation through SEM scans of the samples were used. A significant influence of geometric process parameters was detected on sample mesostructure and, consequently, on sample strength.

scholarly journals Consumer vs. High-End 3D Printers for Guided Implant Surgery—An In Vitro Accuracy Assessment Study of Different 3D Printing Technologies

2021 ◽  
Vol 10 (21) ◽  
pp. 4894
Author(s):  
Lukas Wegmüller ◽  
Florian Halbeisen ◽  
Neha Sharma ◽  
Sebastian Kühl ◽  
Florian M. Thieringer
Keyword(s):  
3D Printing ◽  
Accuracy Assessment ◽  
Subjective Assessment ◽  
Fused Filament Fabrication ◽  
Digital Light Processing ◽  
Implant Surgery ◽  
Surgical Guides ◽  
3D Printers ◽  
3D Printed

This study evaluates the accuracy of drill guides fabricated in medical-grade, biocompatible materials for static, computer-aided implant surgery (sCAIS). The virtually planned drill guides of ten completed patient cases were printed (n = 40) using professional (Material Jetting (MJ)) and consumer-level three-dimensional (3D) printing technologies, namely, Stereolithography (SLA), Fused Filament Fabrication (FFF), and Digital Light Processing (DLP). After printing and post-processing, the drill guides were digitized using an optical scanner. Subsequently, the drill guide’s original (reference) data and the surface scans of the digitized 3D-printed drill guide were superimposed to evaluate their incongruencies. The accuracy of the 3D-printed drill guides was calculated by determining the root mean square (RMS) values. Additionally, cast models of the planned cases were used to check that the drill guides fitted manually. The RMS (mean ± SD) values for the accuracy of 3D-printed drill guides were—MJ (0.09 ± 0.01 mm), SLA (0.12 ± 0.02 mm), FFF (0.18 ± 0.04 mm), and DLP (0.25 ± 0.05 mm). Upon a subjective assessment, all drill guides could be mounted on the cast models without hindrance. The results revealed statistically significant differences (p < 0.01) in all except the MJ- and SLA-printed drill guides. Although the measured differences in accuracy were statistically significant, the deviations were negligible from a clinical point of view. Within the limits of this study, we conclude that consumer-level 3D printers can produce surgical guides with a similar accuracy to a high-end, professional 3D printer with reduced costs.

Influence of Layer Thickness and Continuous Carbon Fiber on the Mechanical Property of 3D Printed Polyamide

2020 ◽  
Vol 861 ◽  
pp. 165-169
Author(s):  
Tian Lan ◽  
Li Chao Dong ◽  
Zhong Yuan Lu ◽  
Shi Feng Guo ◽  
Hao Zhang ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Layer Thickness ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication ◽  
Carbon Fiber Reinforced Composites ◽  
Continuous Carbon Fiber ◽  
3D Printed ◽  
Carbon Fiber Reinforced ◽  
Interface Bonding Strength

3D printed carbon fiber reinforced composites (CFRP) have shown great potential in lightweight application. Here, we report a prepreg carbon fiber reinforced polyamide composite by fused filament fabrication 3D printing process. The influence of layer thickness and carbon fiber layers on mechanical properties of 3D printed parts was well studied. With the incorporation of prepreg carbon fibers, the value of tension and flexural strengths of 3D printed CFRP parts could achieve 2.7 and 13.6 times compared to neat polyamide, respectively. Result illustrates that with the prepreg process the carbon fiber have good interface bonding strength with neat polyimide. This work could also be used for more 3D printing composite systems.

Experimental and simulation studies on flexural strength of laminated glass using ring-on-ring and three-point bending test

2017 ◽  
Vol 232 (21) ◽  
pp. 3930-3941 ◽  
Author(s):  
Ajitanshu Vedrtnam ◽  
SJ Pawar
Keyword(s):  
Flexural Strength ◽  
Layer Thickness ◽  
Vinyl Acetate ◽  
Load Capacity ◽  
Polyvinyl Butyral ◽  
Bending Test ◽  
Laminated Glass ◽  
Element Analysis ◽  
Ethyl Vinyl ◽  
Three Point Bending

Flexural strength of laminated glass is noteworthy in architectural, glazing, automotive safety, photo-voltaic, and decorative applications. The flexural strength of laminated glass samples having polyvinyl butyral/ethyl vinyl acetate interlayer of different critical thickness (0.38/0.76/1.52 mm) was determined by ring-on-ring test following the ASTM C1499-15 and also by three-point bending test (for an interlayer of 0.38 mm thickness) following the ASTM D790-03. The effect of inter-layer type and inter-layer thickness on flexural strength is evidently reported from this brief study. The significance F-statics value during regression analysis shows the strong association of flexural strength with inter-layer types and inter-layer thickness, and P-value shows that the error in the analysis is within considerable limits. It is also concluded that the laminated glass samples with polyvinyl butyral interlayer have comparatively lower load capacity than laminated glass samples with ethyl vinyl acetate interlayer for same interlayer and glass thickness. The inter-layer thickness has more prominent role in the determination of load capacity in case of ethyl vinyl acetate laminated glass samples. There is an increment in average load capacity with an increment in critical inter-layer thickness in laminated glass. A finite element analysis is also carried out for simulating the experimentation and obtaining the variation of displacements in the laminated glass samples at their load capacity. The output of the finite element analysis fairly describes the fracture pattern (based on deformation and stress) of the laminated glass samples. The conclusions may be utilized for the selection of suitable laminated glass and predicting failure of laminated glass while used in various structural, automotive and other applications.

The Influence of an Infill Density, Percent on the Flexural Strength of the 3D

2020 ◽  
Vol 870 ◽  
pp. 73-80
Author(s):  
Nuha Hadi Jasim Al Hasan
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Flexural Strength ◽  
Layer Thickness ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Bending Test ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Deposition Modeling

3D printing innovation, as a quick prototyping, utilize plastic or metal as the crude material to print the genuine parts layer by layer. In this way, it is likewise called added substance producing procedure. Contrasted and conventional assembling innovation, 3D printing innovation has evident points of interest in assembling items with complex shapes and structures. Fused deposition modeling (FDM) is one of the most broadly utilized 3D printing advances. Fibers of thermoplastic materials, for example, polylactic acid is for the most part utilized as crude materials. The present examination will concentrate on the effect of the infill density, percent on the flexural strength of polylactic acid. Bending test was performed on different infill density, percent of specimens. According to ASTM D638.14 standards, samples for testing are made in different infill density, percent (20, 30, 40, 50 and 60 %) by using a polylactic acid in 3D machine printing and their tensile tested and the parameters include different fill density, layer high of 0.1 mm , 0.2mm and 0.3 have an effect on the mechanical characterized while the time of printing the sample would be increased with increasing of fill density%. The tensile strength of polylactic acid samples was found at different fill density and a layer thickness. According to test measuring results that the tensile strength, maximum 47.1,47.4, and 48 MPa at 30%,40%,and 50% fill density respectively and 0.1mm height layer and the tensile strength minimum at 60% and 70 % fill density and 0.1 mm height layer thickness. The higher strength results as higher layer thickness 0.3 mm as compared with 0.1 and 0.2 at 30%fill density.

scholarly journals Mechanical Properties, Structure and Fracture Behavior of Additive Manufactured FFF-ABS Specimens

2020 ◽  
Vol 31 ◽  
pp. 71-78
Author(s):  
O. Gewelber ◽  
Y. Rosenthal ◽  
D. Ashkenazi ◽  
A. Stern
Keyword(s):  
Mechanical Properties ◽  
Flexural Strength ◽  
Bending Test ◽  
Fused Filament Fabrication ◽  
Surface Appearance ◽  
Three Point Bending ◽  
Cad Modelling ◽  
Strength Difference ◽  
The One ◽  
Visual Testing

The Fused Filament Fabrication (FFF) method is one of the most important additive manufacturing (AM) technologies. This technology is used today with various kinds of thermoplastic materials, including ABS. The present study deals with the flexural strength and axial deflection of ABS specimens versus relative density, to observe the influence of build-orientations, build model and microscopic level defects of these properties. In this study, the mechanical and structural characterization of AM-FFF ABS material was studied by CAD modelling of different orientations, three point bending mechanical testing, visual testing, and multifocal light microscopy observation, including fractography analysis. To that end, three different standard building orientations (Flat, On Edge and Upright) were printed, and each was built in two different angle orientations (-45o/+45o and 0°/90o). Based on the three point bending testing results, it was found that the specimen with the highest flexural strength was not necessarily the one with the highest deflection. It was also observed that On Edge 0/+90o orientations showed a relatively larger flexural strength difference in comparison to other building orientations (Flat and Upright). When the mechanical properties achieved from a bending test next to the building platform were compared to the properties far from the building platform, only a slight difference was found, which means that the flexural strength difference results from the building strategy and it is not related to the specific bending surface. Based on fractography observation, there is a major difference in the mechanical properties and fracture surface appearance, when the samples are bent between the layers (Upright orientation) or when the samples are bent through the layers (Flat and On Edge orientation).

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