scholarly journals Fused Filament Fabrication of ONYX-Based Composites Coated with Aluminum Powders: a Preliminary Analysis on Feasibility and Characterization

2021 ◽  
Author(s):  
Alessia Serena Perna ◽  
Antonello Astarita ◽  
Domenico Borrelli ◽  
Antonio Caraviello ◽  
Francesco Delloro ◽  
...  
Keyword(s):  
Fibre Reinforcement ◽  
Carbon Fibres ◽  
Metal Powders ◽  
Fused Filament Fabrication ◽  
Aluminum Powders ◽  
Object A ◽  
Spray Coatings ◽  
Cold Gas Dynamic Spray ◽  
3D Printed ◽  
Composite Substrates

Polymer-based AM methods are the most mature additive technologies for their versatility and variety of products obtainable. The addition of fibre reinforcement can also confer to the manufactures produced good mechanical properties. Unfortunately, several applications are still precluded because polymers cannot guarantee appropriate electrical conductivity, erosion resistance and operating temperature. Aiming to overcome these issues, the metallization of the surfaces emerges as a possible solution. Unfortunately, thermoplastic polymers exhibit thermosensitive behaviour and run the risk of being damaged when traditional metallization techniques, which require the melting of metal powders which will act as a protective coating. For this reason, studies have focused on Cold Gas Dynamic Spray, an additive manufacturing technology, which exploits kinetic energy to favour the adhesion of metal particles rather than the increase in temperature. In this work, a first attempt is made to verify the feasibility of cold spray coatings on 3D printed composite substrates, produced by means of Fused Filament Fabrication (FFF) technique. FFF technology allows the deposition of two different types of filaments by using a double extruder. These composite fibres within 3D printed parts manage to give the object a resistance comparable to that of a metal part with lower production cost and a high degree of automation. These structures, made of ONYX, a Nylon matrix in which short carbon fibres are dispersed, and reinforced with long carbon fibres, are designed to better fit the CS deposition. Aluminium coatings have been produced and a characterization campaign has been carried on.

scholarly journals Manufacturing Of Aluminum Coating On 3D-Printed Onyx With Cold Spray Technology

2021 ◽  
Author(s):  
Roberta Della Gatta ◽  
Antonello Astarita ◽  
Domenico Borrelli ◽  
Antonio Caraviello ◽  
Francesco Delloro ◽  
...  
Keyword(s):  
Composite Materials ◽  
Cold Spray ◽  
Industrial Applications ◽  
Thin Metal Film ◽  
Temperature Sensitive ◽  
Fused Filament Fabrication ◽  
Aluminum Powders ◽  
Thermoplastic Matrix ◽  
Military Applications ◽  
3D Printed

Composite materials are widely used as main parts and structural components in different fields, especially for automotive and military applications. Although these materials supply different advantages comparing to the metals, their implementation in engineering applications is limited due to low electrical and thermal properties and low resistance to erosion. To enhance these above-mentioned properties, the metallization of composite materials by creating a thin metal film on their surface can be achieved. Among different coating deposition techniques, Cold Spray appears to be the most suitable one for the metallization of temperature-sensitive materials such as polymers and composites with a thermoplastic matrix. This process relies on kinetic energy for the formation of the coating rather than on thermal energy and consequent erosion and degradation of the polymer-based composite can be avoided. In the last years, a new method to produce composite materials, as known as Fused Filament Fabrication (FFF), has been developed for industrial applications. This technique consists of a 3D printing process that involves the thermal extrusion of thermoplastic polymer and fibers in the form of filaments from a heated mobile nozzle. The implementation of this new technique is leading to the manufacturing of customized composite materials for the cold spray application. In the presented experimental campaign, Onyx material is used as a substrate. This material is made of Nylon, a thermoplastic matrix, and chopped carbon fibers randomly dispersed in it. Aluminum powders were cold sprayed on the Onyx substrate with a low-pressure cold spray (LPCS) system. This study aims to investigate the possibility of the metalizing 3D-printed composite material by cold spray technology. For this purpose, optical and microscopical analyses are carried out. Based on the results, the feasibility of the process and the influence of the morphology of the substrate are discussed, and optimal spraying conditions are proposed.

scholarly journals On the Influence of Manufacturing Strategy of 3D-Printed Polymer Substrates on Cold Spray Deposition

2021 ◽  
Author(s):  
Antonio Viscusi ◽  
Antonello Astarita ◽  
Domenico Borrelli ◽  
Antonio Caraviello ◽  
Luigi Carrino ◽  
...  
Keyword(s):  
Cold Spray ◽  
Spray Deposition ◽  
Deposition Process ◽  
Potential Method ◽  
Manufacturing Strategy ◽  
Fused Filament Fabrication ◽  
Research Activity ◽  
Aluminum Powders ◽  
3D Printed ◽  
Manufacturing Technologies

PMCs are anisotropic and heterogeneous structures with excellent performances in terms of mechanical strength and stiffness, coupled with reduced weight, widely used in engineering sectors. The use of PMCs can be further extended by improving their surface properties such as electrical conductivity, erosion, radiation and lightning protection. In this context, the surface metallization seems to be best solution. In particular, the cold spray (CS) technique candidates as a potential method for the manufacturing of a metal coating on PMCs’ surface. However, the design and the manufacturing methods of PMCs can play a crucial role for an effective metallization through CS. The additive manufacturing technologies for composite materials can be used to manufacture customized reinforced polymer-based panels, like PMCs; the most common method for printing them is the Fused Filament Fabrication (FFF) technique which relies on the thermal extrusion of a thermoplastic feedstock from a mobile heated nozzle. Therefore, this research activity aims to manufacture customized PMCs panels by using FFF technology for the substrate and the cold spray technique for the metallization in order to study the influence of the substrate manufacturing strategy on CS deposition process. For this purpose, three kind of 3D-printed PMCs were manufactured through the FFF technology by varying the percentage fill of the Onyx polymeric matrix and aluminum powders were sprayed on the substrates with a low-pressure cold spray (LPCS) system; both FFF and CS process parameters were varied to study the process in its wholeness. Microscope analyses were carried out to analyze the influence of the manufacturing strategy on the coating quality.

scholarly journals Surface modification of fused filament fabrication (FFF) 3D printed substrates by inkjet printing polyimide for printed electronics

2020 ◽  
Vol 36 ◽  
pp. 101544
Author(s):  
Devin J. Roach ◽  
Christopher Roberts ◽  
Janet Wong ◽  
Xiao Kuang ◽  
Joshua Kovitz ◽  
...  
Keyword(s):  
Surface Modification ◽  
Inkjet Printing ◽  
Printed Electronics ◽  
Fused Filament Fabrication ◽  
3D Printed

scholarly journals Evaluation of the Circularity of Recycled PLA Filaments for 3D Printers

2020 ◽  
Vol 10 (24) ◽  
pp. 8967
Author(s):  
Victor Gil Muñoz ◽  
Luisa M. Muneta ◽  
Ruth Carrasco-Gallego ◽  
Juan de Juanes Marquez ◽  
David Hidalgo-Carvajal
Keyword(s):  
Circular Economy ◽  
Protective Equipment ◽  
Fused Filament Fabrication ◽  
Circular Loop ◽  
Material Supply ◽  
3D Printers ◽  
3D Printed ◽  
Circular Economics ◽  
High Level ◽  
Additional Value

The circular economy model offers great opportunities to companies, as it not only allows them to capture additional value from their products and materials, but also reduce the fluctuations of price-related risks and material supply. These risks are present in all kind of businesses not based on the circular economy. The circular economy also enables economic growth without the need for more resources. This is because each unit has a higher value as a result of recycling and reuse of products and materials after use. Following this circular economics framework, the Polytechnic University of Madrid (Universidad Politécnica de Madrid, UPM) has adopted strategies aimed at improving the circularity of products. In particular, this article provides the result of obtaining recycled PLA filament from waste originating from university 3D FFF (fused filament fabrication) printers and waste generated by “Coronamakers” in the production of visors and parts for PPEs (Personal Protective Equipment) during the lockdown period of COVID-19 in Spain. This filament is used in the production of 3D printed parts that university students use in their classes, so the circular loop is closed. The obtained score of Material Circularity Indicator (MCI) of this material has been calculated, indicating its high level of circularity.

scholarly journals The Direct 3D Printing of Functional PEEK/Hydroxyapatite Composites via a Fused Filament Fabrication Approach

Polymers ◽  
2021 ◽  
Vol 13 (4) ◽  
pp. 545
Author(s):  
Krzysztof Rodzeń ◽  
Preetam K. Sharma ◽  
Alistair McIlhagger ◽  
Mozaffar Mokhtari ◽  
Foram Dave ◽  
...  
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Selective Laser Sintering ◽  
Fused Filament Fabrication ◽  
Bone Apposition ◽  
Innovative Solutions ◽  
3D Printed ◽  
Work Samples ◽  
Viable Approach ◽  
Crystalline Domains

The manufacture of polyetheretherketone/hydroxyapatite (PEEK/HA) composites is seen as a viable approach to help enhance direct bone apposition in orthopaedic implants. A range of methods have been used to produce composites, including Selective Laser Sintering and injection moulding. Such techniques have drawbacks and lack flexibility to manufacture complex, custom-designed implants. 3D printing gets around many of the restraints and provides new opportunities for innovative solutions that are structurally suited to meet the needs of the patient. This work reports the direct 3D printing of extruded PEEK/HA composite filaments via a Fused Filament Fabrication (FFF) approach. In this work samples are 3D printed by a custom modified commercial printer Ultimaker 2+ (UM2+). SEM-EDX and µCT analyses show that HA particles are evenly distributed throughout the bulk and across the surface of the native 3D printed samples, with XRD highlighting up to 50% crystallinity and crystalline domains clearly observed in SEM and HR-TEM analyses. This highlights the favourable temperature conditions during 3D printing. The yield stress and ultimate tensile strength obtained for all the samples are comparable to human femoral cortical bone. The results show how FFF 3D printing of PEEK/HA composites up to 30 wt% HA can be achieved.

Fused Filament Fabrication 3D Printed Polylactic Acid Electroosmotic Pumps

Lab on a Chip ◽  
2021 ◽  
Author(s):  
Liang Wu ◽  
Stephen Beirne ◽  
Joan-Marc Cabot Canyelles ◽  
Brett Paull ◽  
Gordon G. Wallace ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Polylactic Acid ◽  
Fused Filament Fabrication ◽  
Flexible Approach ◽  
Electroosmotic Pump ◽  
3D Printed ◽  
Electroosmotic Pumps

Additive manufacturing (3D printing) offers a flexible approach for the production of bespoke microfluidic structures such as the electroosmotic pump. Here a readily accessible fused filament fabrication (FFF) 3D printing...

scholarly journals Essential work of fracture assessment of acrylonitrile butadiene styrene (ABS) processed via fused filament fabrication additive manufacturing

2021 ◽  
Author(s):  
Pawan Verma ◽  
Jabir Ubaid ◽  
Andreas Schiffer ◽  
Atul Jain ◽  
Emilio Martínez-Pañeda ◽  
...  
Keyword(s):  
Acrylonitrile Butadiene Styrene ◽  
Essential Work ◽  
Fused Filament Fabrication ◽  
Essential Work Of Fracture ◽  
Fracture Properties ◽  
Raster Angle ◽  
3D Printed ◽  
Printing Direction ◽  
Work Of Fracture ◽  
Butadiene Styrene

AbstractExperiments and finite element (FE) calculations were performed to study the raster angle–dependent fracture behaviour of acrylonitrile butadiene styrene (ABS) thermoplastic processed via fused filament fabrication (FFF) additive manufacturing (AM). The fracture properties of 3D-printed ABS were characterized based on the concept of essential work of fracture (EWF), utilizing double-edge-notched tension (DENT) specimens considering rectilinear infill patterns with different raster angles (0°, 90° and + 45/− 45°). The measurements showed that the resistance to fracture initiation of 3D-printed ABS specimens is substantially higher for the printing direction perpendicular to the crack plane (0° raster angle) as compared to that of the samples wherein the printing direction is parallel to the crack (90° raster angle), reporting EWF values of 7.24 kJ m−2 and 3.61 kJ m−2, respectively. A relatively high EWF value was also reported for the specimens with + 45/− 45° raster angle (7.40 kJ m−2). Strain field analysis performed via digital image correlation showed that connected plastic zones existed in the ligaments of the DENT specimens prior to the onset of fracture, and this was corroborated by SEM fractography which showed that fracture proceeded by a ductile mechanism involving void growth and coalescence followed by drawing and ductile tearing of fibrils. It was further shown that the raster angle–dependent strength and fracture properties of 3D-printed ABS can be predicted with an acceptable accuracy by a relatively simple FE model considering the anisotropic elasticity and failure properties of FFF specimens. The findings of this study offer guidelines for fracture-resistant design of AM-enabled thermoplastics. Graphical abstract

scholarly journals Metallization of Thermoplastic Polymers and Composites 3D Printed by Fused Filament Fabrication

Technologies ◽  
2021 ◽  
Vol 9 (3) ◽  
pp. 49
Author(s):  
Alessia Romani ◽  
Andrea Mantelli ◽  
Paolo Tralli ◽  
Stefano Turri ◽  
Marinella Levi ◽  
...  
Keyword(s):  
Physical Vapor Deposition ◽  
Test Sample ◽  
Tensile Tests ◽  
Layer By Layer ◽  
Post Processing ◽  
Thermoplastic Polymers ◽  
Fused Filament Fabrication ◽  
Scanning Calorimetry ◽  
3D Printed ◽  
Manufacturing Technologies

Fused filament fabrication allows the direct manufacturing of customized and complex products although the layer-by-layer appearance of this process strongly affects the surface quality of the final parts. In recent years, an increasing number of post-processing treatments has been developed for the most used materials. Contrarily to other additive manufacturing technologies, metallization is not a common surface treatment for this process despite the increasing range of high-performing 3D printable materials. The objective of this work is to explore the use of physical vapor deposition sputtering for the chromium metallization of thermoplastic polymers and composites obtained by fused filament fabrication. The thermal and mechanical properties of five materials were firstly evaluated by means of differential scanning calorimetry and tensile tests. Meanwhile, a specific finishing torture test sample was designed and 3D printed to perform the metallization process and evaluate the finishing on different geometrical features. Furthermore, the roughness of the samples was measured before and after the metallization, and a cost analysis was performed to assess the cost-efficiency. To sum up, the metallization of five samples made with different materials was successfully achieved. Although some 3D printing defects worsened after the post-processing treatment, good homogeneity on the finest details was reached. These promising results may encourage further experimentations as well as the development of new applications, i.e., for the automotive and furniture fields.

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