Design and Analysis of Hybrid Fused Filament Fabrication Apparatus for Fabrication of Composites

2021 ◽  
Vol 14 ◽  
Author(s):  
Aniket Yadav ◽  
Piyush Chohan ◽  
Ranvijay Kumar ◽  
Jasgurpreet Singh Chohan ◽  
Raman Kumar
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Design Process ◽  
Low Cost ◽  
Matrix Material ◽  
Fabrication Process ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Composite Manufacturing ◽  
Tool Paths

Background: Additive manufacturing is the most famous technology which requires materials or composites to be fabricated with layer by layer deposition strategy. Due to its lower cost, higher accuracy and less material wastage; this technology is used in almost every sector. But in many applications there is a need to alter the properties of a product in a certain direction with the help of some reinforcements. With the use of reinforcements, composite layers can be fabricated using additive manufacturing technique which will enhance the directional properties. A novel apparatus is designed to spray the reinforcement material into the printed structures in a very neat and precise manner. This spray nozzle is fully automated, which works according to tool-paths generated by slicing software. The alternate deposition of layers of reinforcement and build materials helped to fabricate customized composite products. Objective: The objective of present study is to design and analyze the working principle of novel technique which has been developed to fabricate composite materials using additive manufacturing. The apparatus is numerically controlled by computer according to CAD data which facilitates the deposition of alternate layers of reinforcement and matrix material. The major challenges during the design process and function of each component has been explored. Methods: The design process is initiated after comprehensive literature review performed to study previous composite manufacturing processes. The recent patents published by different patent offices of the world are studied in detail and analysis has been used to design a low cost composite fabrication apparatus. A liquid dispensing device comprises a storage tank attached with a pump and microprocessor. The microprocessor receives the signal from the computer as per tool paths generated by slicing software which decides the spray of reinforcements on polymer layers. The spraying apparatus moves in coordination with the primary nozzle of the Fused Filament Fabrication process. Results: The hybridization of Fused Filament Fabrication [process with metal spray process has been successfully performed. The apparatus facilitates the fabrication of low cost composite materials along with flexibility of complete customization of composite manufacturing process. The anisotropic behaviour of products can be easily controlled and managed during fabrication which can be used for different applications.

Optimization of Metallic Powder Filaments for Additive Manufacturing Extrusion (MEX)

2021 ◽  
Author(s):  
Fábio Silva Cerejo ◽  
Daniel Gatões ◽  
Teresa Vieira
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Metallic Powder ◽  
Powder Injection ◽  
Layer By Layer ◽  
Powder Injection Moulding ◽  
Powder Particles ◽  
Powder Content ◽  
Metallic Parts ◽  
Am Processes

Abstract Additive manufacturing (AM) of metallic powder particles has been establishing itself as sustainable, whatever the technology selected. Material Extrusion (MEX) integrates the ongoing effort to improve AM sustainability, in which low-cost equipment is associated with a decrease of powder waste during manufacturing. MEX has been gaining increasing interest for building 3D functional/structural metallic parts because it incorporates the consolidated knowledge from powder injection moulding/extrusion feedstocks into the AM scope—filament extrusion layer-by-layer. Moreover, MEX as an indirect process can overcome some of the technical limitations of direct AM processes (laser/electron-beam-based) regarding energy-matter interactions. The present study reveals an optimal methodology to produce MEX filament feedstocks (metallic powder, binder and additives), having in mind to attain the highest metallic powder content. Nevertheless, the main challenges are also to achieve high extrudability and a suitable ratio between stiffness and flexibility. The metallic powder volume content (vol.%) in the feedstocks was evaluated by the critical powder volume concentration (CPVC). Subsequently, the rheology of the feedstocks was established by means of the mixing torque value, which is related to the filament extrudability performance.

Green Material for Fused Filament Fabrication

2020 ◽  
pp. 1-27 ◽  
Author(s):  
Mastura Mohammad Taha ◽  
Ridhwan Jumaidin ◽  
Nadlene M. Razali ◽  
Syahibudil Ikhwan Abdul Kudus
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Manufacturing Process ◽  
Extrusion Process ◽  
Fused Filament Fabrication ◽  
Green Material ◽  
Additive Manufacturing Technology ◽  
Green Materials ◽  
Composites Materials ◽  
The Right

Fused filament fabrication (FFF) has been developed in additive manufacturing technology as a fast and simple manufacturing process in product design. Advantage of the process such as flexibility in terms of the materials employment has attracted many researchers to develop new materials for the feed stock filament in the heat extrusion process of FFF. Green materials or bio-composites materials have been found in FFF and successfully commercialized in the market. However, a deep research should have been performed prior the application because of the unique characteristics of the material itself. The challenge for the researchers to develop bio-composite materials as the filament in FFF technology is to determine the right composition of the composites with the right thermal, mechanical, and rheological properties. Therefore, in this study, a review has been conducted to highlight the important requirements of the process and materials. Green materials such as bio-composites have a great potential in the FFF technology and could improve the sustainability impact.

scholarly journals In Search of the Optimal Conditions to Process Shape Memory Alloys (NiTi) Using Fused Filament Fabrication (FFF)

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4718
Author(s):  
Pedro Carreira ◽  
Fábio Cerejo ◽  
Nuno Alves ◽  
Maria Teresa Vieira
Keyword(s):  
Additive Manufacturing ◽  
Shape Memory Alloys ◽  
Shape Memory ◽  
Sintering Temperature ◽  
Production Costs ◽  
Layer By Layer ◽  
Secondary Phases ◽  
Fused Filament Fabrication ◽  
Near Net Shape ◽  
Niti Shape Memory Alloys

This research was performed so as to investigate the additive manufacturing of NiTi shape memory alloys, which is associated with direct processes, such as selective laser melting. In addition to its expensive production costs, NiTi readily undergoes chemical and phase modifications, mainly as a result of Ni loss during processing as a result of high temperatures. This research explores the potential usefulness of NiTi as well as its limitations using indirect additive processes, such as fused filament fabrication (FFF). The first step was to evaluate the NiTi critical powder volume content (CPVC) needed to process high-quality filaments (via extrusion). A typical 3D printer can build a selected part/system/device layer-by-layer from the filaments, followed by debinding and sintering (SDS), in order to generate a near-net-shape object. The mixing, extruding (filament), printing (shaping), debinding, and sintering steps were extensively studied in order to optimize their parameters. Moreover, for the sintering step, two main targets should be met, namely: the reduction of contamination during the process in order to avoid the formation of secondary phases, and the decrease in sintering temperature, which also contributes to reducing the production costs. This study aims to demonstrate the possibility of using FFF as an additive manufacturing technology for processing NiTi.

Design Considerations for Hybridizing Additive Manufacturing and Direct Write Technologies

2014 ◽  
Author(s):  
K. Blake Perez ◽  
Christopher B. Williams
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Manufacturing Process ◽  
Layer By Layer ◽  
Direct Write ◽  
Systematic Design ◽  
Flexible Polymers ◽  
Conductive Materials ◽  
Design Considerations ◽  
Embedded Electronics

The layer-by-layer nature of additive manufacturing (AM) allows for access to the entire build volume of an artifact during manufacture, including its internal structure. Internal voids are accessible during the build process and allow for components to be embedded and sealed with subsequently printed layers. When AM is combined with Direct Write (DW) of conductive materials, the resulting hybrid process enables the direct manufacture of parts with embedded electronics, including interconnects and sensors. However, the hybridization of DW and AM technologies is non-trivial due to (i) identifying DW materials and processes that are compatible with AM infrastructure, throughput and resolution, (ii) temperature processing requirements, and (iii) interactions between the two materials. In this paper, the authors explore DW technologies and materials to identify those that are most compatible with AM. From this exploration, the authors abstract a set of generalized design considerations for the design of a hybrid AM and DW process. These considerations are then employed in a systematic design process in which a DW system for depositing conductive materials during the PolyJet manufacturing process is realized. The resulting system is able to create embedded functional electronic interconnects and sensors in printed parts composed of both stiff and flexible polymers.

scholarly journals A 3D weaving infill pattern for fused filament fabrication

2021 ◽  
Author(s):  
Yuan Yao ◽  
Cheng Ding ◽  
Mohamed Aburaia ◽  
Maximilian Lackner ◽  
Lanlan He
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Repetitive Structure ◽  
Mechanical Linkage ◽  
Manufacturing Technologies ◽  
Dimensional Object ◽  
Anisotropy Of Mechanical Properties ◽  
3D Weaving

Abstract The Fused Filament Fabrication process is the most used additive manufacturing process due to its simplicity and low operating costs. In this process, a thermoplastic filament is led through an extruder, melted, and applied to a building platform by the axial movements of an automated Cartesian system in such a way that a three-dimensional object is created layer by layer. Compared to other additive manufacturing technologies, the components produced have mechanical limitations and are often not suitable for functional applications. To reduce the anisotropy of mechanical strength in fused filament fabrication (FFF), this paper proposes a 3D weaving deposit path planning method that utilizes a 5-layer repetitive structure to achieve interlocking and embedding between neighbor slicing planes to improve the mechanical linkage within the layers. The developed algorithm extends the weaving path as an infill pattern to fill different structures and makes this process feasible on a standard three-axis 3D printer. Compared with 3D weaving printed parts by layer-to-layer deposit, the anisotropy of mechanical properties inside layers is significantly reduced to 10.21% and 0.98%.

scholarly journals THE PREPARATION OF COMPOSITE MATERIALS BASED ON MAGNETITE NANOPARTICLES AND SODIUM ALGINATE FOR WASTE WATER PURIFICATION

2016 ◽  
Vol 7 (1) ◽  
Author(s):  
Ayse Z. Aroguz ◽  
Vesna Teofilović ◽  
Sinem Karademir ◽  
Ljiljana Tanasić ◽  
Sibel Aydogan ◽  
...  
Keyword(s):  
Waste Water ◽  
Composite Materials ◽  
Sodium Alginate ◽  
Water Purification ◽  
Magnetite Nanoparticles ◽  
Low Cost ◽  
Chemical Precipitation ◽  
Layer By Layer ◽  
Paper Manufacturing ◽  
Composite Beads

The use of synthetic chemical dyes in various industries, including plastics, paper manufacturing, cloth dyeing, printing and leather treatment, has increased considerably over the last years, resulting in the release of dye-containing effluents into the aquatic and soil ecosystems. There are many techniques to remove the waste after dying process (coagulation, chemical precipitation, reverse osmosis, extraction, filtration, biological treatment and adsorption). The releasing of dyes from many industrial plants is environmentally hazardous. The most important goal for the waste water purification is to find the low-cost adsorbents with high selectivity and long life. In our study, an effort has been made to prepare efficient composite materials for dyes removal from aqueous solution based on medium molecular weights deacetylated chitin i.e. poly(D-glucosamine) and a bio-degradable nontoxic anionic polysaccharide sodium alginate filled with magnetite nanoparticles. Alginate composite beads coated with poly(D-glucosamine) were prepared using layer-by-layer (LbL) deposition method. During the adsorption process the concentrations of dyes in solution waste were determined according to the general spectrophotometer method.

Dynamic Mechanical Analysis of ABS From Hybrid Additive Manufacturing by Fused Filament Fabrication and Shot Peening

2020 ◽  
Author(s):  
Haitham Hadidi ◽  
Brady Mailand ◽  
Tayler Sundermann ◽  
Ethan Johnson ◽  
Rakeshkumar Karunakaran ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Dynamic Mechanical Analysis ◽  
Shot Peening ◽  
Extrusion Process ◽  
Dynamic Mechanical Properties ◽  
Mechanical Analysis ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Dynamic Mechanical

Abstract The mechanical properties of 3D printed polymers parts are process parameter dependent. Defects such as inadvertent voids between deposited rasters and layers lead to weakness in produced parts, which results in inferior mechanical properties as compared to injection molding. An alternative method to change energy absorption and stiffness of a polymer is hybrid additive manufacturing (AM). Hybrid-AM is the use of additive manufacturing with one or more secondary processes that are fully coupled and synergistically affect part quality, functionality, and/or process performance. In this study, fused filament fabrication (FFF) was coupled with layer-by-layer shot peening to study the dynamic mechanical properties of ABS 430 polymer using dynamic mechanical analysis (DMA). FFF is a heated extrusion process. Shot peening is a mechanical surface treatment that impinges a target with a stochastically dispersed, high velocity stream of beads. Compressive residual stress was imparted to preferential layer intervals during printing to modify the elasticity (stiffness), viscosity, toughness, and glass transition temperature. Viscoelastic and dynamic mechanical properties are important to the performance of polymers in automotive, aerospace, electronics, and medical components. Coupling printing and peening increased the storage and loss moduli as well as the tangent delta. DMA results suggest that preferential layer sequences exist that possess higher elasticity and better absorb energy upon sinusoidal dynamic loading.

On the Capabilities of a Multi-Modality 3D Bioprinter for Customized Biomedical Devices

2015 ◽  
Author(s):  
Prashanth Ravi ◽  
Panos S. Shiakolas ◽  
Tre Welch ◽  
Tushar Saini ◽  
Kristine Guleserian ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Device Fabrication ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Stl File ◽  
Diverse Application ◽  
Multiple Materials ◽  
Manufacturing Platform ◽  
Single Construct ◽  
Manufacturing Technologies

Currently, there is a major shift in medical device fabrication research towards layer-by-layer additive manufacturing technologies; mainly owing to the relatively quick transition from a solid model (.STL file) to an actual prototype. The current manuscript introduces a Custom Multi-Modality 3D Bioprinter (CMMB) developed in-house, combining the Fused Filament Fabrication (FFF), Photo Polymerization (PP), Viscous Extrusion (VE), and Inkjet (IJ) printing technologies onto a single additive manufacturing platform. Methodologies to address limitation in the ability to customize construct properties layer-by-layer and to incorporate multiple materials in a single construct have been evaluated using open source 3D printing softwares Slic3r and Repetier-Host. Such customization empowers the user to fabricate constructs with tailorable anisotropic properties by combining different print technologies and materials. To this end, procedures which allow the integration of more than one distinct modality of the CMMB during a single print session were developed and evaluated, and are discussed. The current setup of the CMMB provides the capability to fabricate personalized medical devices using patient data from an MRI or a CT scan. Initial experiments and fabricated constructs demonstrate the potential of the CMMB for research in diverse application areas within biomedical engineering.

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