Multi-Axis Multi-Material Fused Filament Fabrication with Continuous Fiber Reinforcement

2018 ◽  
Author(s):  
Wout De Backer ◽  
Arturs P. Bergs ◽  
Michael J. Van Tooren
Keyword(s):  
Fiber Reinforcement ◽  
Continuous Fiber ◽  
Fused Filament Fabrication

scholarly journals Manufacturing a First Upper Molar Dental Forceps Using Continuous Fiber Reinforcement (CFR) Additive Manufacturing Technology with Carbon-Reinforced Polyamide

Polymers ◽  
2021 ◽  
Vol 13 (16) ◽  
pp. 2647
Author(s):  
Roland Told ◽  
Gyula Marada ◽  
Szilard Rendeki ◽  
Attila Pentek ◽  
Balint Nagy ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Medical Devices ◽  
Fiber Reinforcement ◽  
Strong Impact ◽  
Vertical Force ◽  
Continuous Fiber ◽  
Fused Filament Fabrication ◽  
Sem Images ◽  
3D Printed ◽  
Upper Molar

3D printing is an emerging and disruptive technology, supporting the field of medicine over the past decades. In the recent years, the use of additive manufacturing (AM) has had a strong impact on everyday dental applications. Despite remarkable previous results from interdisciplinary research teams, there is no evidence or recommendation about the proper fabrication of handheld medical devices using desktop 3D printers. The aim of this study was to critically examine and compare the mechanical behavior of materials printed with FFF (fused filament fabrication) and CFR (continuous fiber reinforcement) additive manufacturing technologies, and to create and evaluate a massive and practically usable right upper molar forceps. Flexural and torsion fatigue tests, as well as Shore D measurements, were performed. The tensile strength was also measured in the case of the composite material. The flexural tests revealed the measured force values to have a linear correlation with the bending between the 10 mm (17.06 N at 5000th cycle) and 30 mm (37.99 N at 5000th cycle) deflection range. The findings were supported by scanning electron microscopy (SEM) images. Based on the results of the mechanical and structural tests, a dental forceps was designed, 3D printed using CFR technology, and validated by five dentists using a Likert scale. In addition, the vertical force of extraction was measured using a unique molar tooth model, where the reference test was carried out using a standard metal right upper molar forceps. Surprisingly, the tests revealed there to be no significant differences between the standard (84.80 N ± 16.96 N) and 3D-printed devices (70.30 N ± 4.41 N) in terms of extraction force in the tested range. The results also highlighted that desktop CFR technology is potentially suitable for the production of handheld medical devices that have to withstand high forces and perform load-bearing functions.

scholarly journals A Review on Reinforcement Methods for Polymeric Materials Processed Using Fused Filament Fabrication (FFF)

Polymers ◽  
2021 ◽  
Vol 13 (22) ◽  
pp. 4022
Author(s):  
Juan Pratama ◽  
Sukmaji I. Cahyono ◽  
Suyitno Suyitno ◽  
Muhammad A. Muflikhun ◽  
Urip A. Salim ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fiber Reinforcement ◽  
Polymeric Materials ◽  
Short Fiber ◽  
Continuous Fiber ◽  
Fused Filament Fabrication ◽  
Automotive Components ◽  
The Poor ◽  
Powder Addition ◽  
Processed Products

Over the last few years, fused filament fabrication (FFF) has become one of the most promising and widely used techniques for the rapid prototyping process. A number of studies have also shown the possibility of FFF being used for the fabrication of functional products, such as biomedical implants and automotive components. However, the poor mechanical properties possessed by FFF-processed products are considered one of the major shortcomings of this technique. Over the last decade, many researchers have attempted to improve the mechanical properties of FFF-processed products using several strategies—for instance, by applying the short fiber reinforcement (SFR), continuous fiber reinforcement (CFR), powder addition reinforcement (PAR), vibration-assisted FFF (VA-FFF) methods, as well as annealing. In this paper, the details of all these reinforcement techniques are reviewed. The abilities of each method in improving tensile, flexural, and compressive strength are discussed.

scholarly journals Continuous Fiber Angle Topology Optimization for Polymer Composite Deposition Additive Manufacturing Applications

Fibers ◽  
2019 ◽  
Vol 7 (2) ◽  
pp. 14 ◽  
Author(s):  
Delin Jiang ◽  
Robert Hoglund ◽  
Douglas Smith
Keyword(s):  
Mechanical Properties ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Polymer Composite ◽  
Fiber Reinforcement ◽  
Fiber Direction ◽  
Optimization Approach ◽  
Continuous Fiber ◽  
Fiber Angle

Mechanical properties of parts produced with polymer deposition additive manufacturing (AM) depend on the print bead direction, particularly when short carbon-fiber reinforcement is added to the polymer feedstock. This offers a unique opportunity in the design of these structures since the AM print path can potentially be defined in a direction that takes advantage of the enhanced stiffness gained in the bead and, therefore, fiber direction. This paper presents a topology optimization approach for continuous fiber angle optimization (CFAO), which computes the best layout and orientation of fiber reinforcement for AM structures. Statically loaded structures are designed for minimum compliance where the adjoint variable method is used to compute design derivatives, and a sensitivity filter is employed to reduce the checkerboard effect. The nature of the layer-by-layer approach in AM is given special consideration in the algorithm presented. Examples are provided to demonstrate the applicability of the method in both two and three dimensions. The solution to our two dimensional problem is then printed with a fused filament fabrication (FFF) desktop printer using the material distribution results and a simple infill method which approximates the optimal fiber angle results using a contour-parallel deposition strategy. Mechanical stiffness testing of the printed parts shows improved results as compared to structures designed without accounting for the direction of the composite structure. Results show that the mechanical properties of the final FFF carbon fiber/polymer composite printed parts are greatly influenced by the print direction, and optimized material orientation tends to align with the imposed force direction to minimize the compliance.

Automatic Calculation of Material Laying Trajectories When Preparing 3D Models for Five-Axis FFF Printing with Continuous Fiber Reinforcement

2021 ◽  
pp. 282-295
Author(s):  
Ilya Gushchin ◽  
Ivan Torubarov ◽  
Andrey Shvets ◽  
Alexey Yakovlev ◽  
Alexander Plotnikov ◽  
...  
Keyword(s):  
Fiber Reinforcement ◽  
3D Models ◽  
Continuous Fiber ◽  
Automatic Calculation ◽  
Five Axis

scholarly journals Novel Continuous Fiber Bi-Matrix Composite 3-D Printing Technology

Materials ◽  
2019 ◽  
Vol 12 (18) ◽  
pp. 3011 ◽  
Author(s):  
Adi Adumitroaie ◽  
Fedor Antonov ◽  
Aleksey Khaziev ◽  
Andrey Azarov ◽  
Mikhail Golubev ◽  
...  
Keyword(s):  
Matrix Material ◽  
Fiber Reinforced Polymer ◽  
Material System ◽  
The Novel ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
New Paradigm ◽  
Fused Filament Fabrication ◽  
Reinforced Polymer ◽  
Mechanical Performances

A new paradigm in continuous fiber-reinforced polymer fused filament fabrication based on a thermoset-thermoplastic bi-matrix material system is proposed and proved. This totally new 3-D printing concept has the potential to overcome the drawbacks and to combine the advantages of separate thermoset and thermoplastic-based, fused filament fabrication methods and to advance continuous fiber-reinforced polymer 3-D printing toward higher mechanical performances of 3-D printed parts. The novel bi-matrix 3-D printing method and preliminary results related to the 3-D printed composite microstructure and performances are reported.

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