scholarly journals Enhancing Structural Performance of Short Fiber Reinforced Objects through Customized Tool-Path

2020 ◽  
Vol 10 (22) ◽  
pp. 8168
Author(s):  
Jaeyoon Kim ◽  
Bruce S. Kang
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
Mechanical Behavior ◽  
Case Studies ◽  
Fused Deposition Modeling ◽  
Tool Path ◽  
Spur Gear ◽  
Fiber Reinforced ◽  
Printing Process ◽  
Fused Deposition

Fused deposition modeling (FDM) is one of the most common additive manufacturing (AM) technologies for thermoplastic materials. With the development of carbon fiber-reinforced polymer (CFRP) filament for FDM, AM parts with improved strength and functionality can be realized. CFRP is anisotropic material and its mechanical properties have been well studied, however, AM printing strategy for CFRP parts has not been developed. This paper proposes a systematic optimization of the FDM 3D printing process for CFRP. Starting with standard coupon specimen tests to obtain mechanical properties of CFRP, finite element analyses (FEA) were conducted to find principal directions of the AM part and utilized to determine fiber orientations. A specific tool-path algorithm has been developed to distribute fibers with the desired orientations. To predict/assess the mechanical behavior of the AM part, the 3D printing process was simulated to obtain the anisotropic mechanical behavior induced by the customized tool-path printing. Bolt hole plate and spur gear were selected as case studies. FE simulations and associated experiments were conducted to assess their performance. CFRP parts printed by the optimized tool-path shows about 8% higher stiffness than those printed at regular infill patterns. In summary, assisted by FEA, a customized 3D printing tool-path for CFRP has been developed with case studies to verify the proposed AM design optimization methodology for FDM.

scholarly journals 3D Printing of Fiber-Reinforced Plastic Composites Using Fused Deposition Modeling: A Status Review

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4520
Author(s):  
Salman Pervaiz ◽  
Taimur Ali Qureshi ◽  
Ghanim Kashwani ◽  
Sathish Kannan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Reinforced Polymers ◽  
Fused Deposition ◽  
Frp Composites ◽  
Deposition Modeling

Composite materials are a combination of two or more types of materials used to enhance the mechanical and structural properties of engineering products. When fibers are mixed in the polymeric matrix, the composite material is known as fiber-reinforced polymer (FRP). FRP materials are widely used in structural applications related to defense, automotive, aerospace, and sports-based industries. These materials are used in producing lightweight components with high tensile strength and rigidity. The fiber component in fiber-reinforced polymers provides the desired strength-to-weight ratio; however, the polymer portion costs less, and the process of making the matrix is quite straightforward. There is a high demand in industrial sectors, such as defense and military, aerospace, automotive, biomedical and sports, to manufacture these fiber-reinforced polymers using 3D printing and additive manufacturing technologies. FRP composites are used in diversified applications such as military vehicles, shelters, war fighting safety equipment, fighter aircrafts, naval ships, and submarine structures. Techniques to fabricate composite materials, degrade the weight-to-strength ratio and the tensile strength of the components, and they can play a critical role towards the service life of the components. Fused deposition modeling (FDM) is a technique for 3D printing that allows layered fabrication of parts using thermoplastic composites. Complex shape and geometry with enhanced mechanical properties can be obtained using this technique. This paper highlights the limitations in the development of FRPs and challenges associated with their mechanical properties. The future prospects of carbon fiber (CF) and polymeric matrixes are also mentioned in this study. The study also highlights different areas requiring further investigation in FDM-assisted 3D printing. The available literature on FRP composites is focused only on describing the properties of the product and the potential applications for it. It has been observed that scientific knowledge has gaps when it comes to predicting the performance of FRP composite parts fabricated under 3D printing (FDM) techniques. The mechanical properties of 3D-printed FRPs were studied so that a correlation between the 3D printing method could be established. This review paper will be helpful for researchers, scientists, manufacturers, etc., working in the area of FDM-assisted 3D printing of FRPs.

scholarly journals Mechanical behavior of beams with variable stiffness obtained by 3D printing

2021 ◽  
Vol 343 ◽  
pp. 08014
Author(s):  
Laszlo Racz ◽  
Mircea Cristian Dudescu
Keyword(s):  
3D Printing ◽  
Mechanical Behavior ◽  
Cross Section ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Cost Effective ◽  
Variable Stiffness ◽  
Constant Cross Section ◽  
Printing Process ◽  
Fused Deposition

Additive manufacturing or 3D printing gained a widespread popularity in recent years due to the ability of the method to manufacture components with high geometrical complexity. The most cost-effective process to manufacture plastic parts using 3D printing is the fused deposition modeling (FDM) method. Process parameters as the infill rates but also the printed pattern of different layers and their orientation have a significant influence on the mechanical properties of specimens fabricated by FDM. Controlling the process parameters is possible to generate materials with variable mechanical proprieties. The paper presents the analysis of a beam with constant cross-section but variable stiffness. Variable stiffness is achieved by changes in different cross-sections of the beam of the infill rates of the printing process. The mechanical behavior consisting of force-displacements curves is analyzed by three-point bending tests of variable stiffness samples and comparison with similar beams having constant infill rate. The results consist of E-modulus variation, maximum force and deflection curve. Analytical calculations and finite element analyses are employed to predict the mechanical behavior of the specimens printed with variable infill rate. The obtained results proved the concept of equal stress-beam with constant cross-section obtained by 3D printing process parameters variation.

scholarly journals 3D printing of Continuous Fiber Reinforced Composites: A Review of the Processing, Pre- and Post-Processing Effects on Mechanical Properties

2021 ◽  
Author(s):  
Faraz Safari ◽  
Abdolvahed Kami ◽  
Vahid Abedini
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Fiber Reinforced Composites ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Post Processing ◽  
Continuous Fiber ◽  
Fused Deposition ◽  
Production Techniques

The main objective of this study is to review existing research on the application of fused deposition modeling (FDM) for 3D printing of continuous fiber reinforced composites (CFRCs). An overview of additive manufacturing (AM) technology production techniques is provided first, followed by a look into FDM technology. The articles on CFRC printing were then summarized. The type of reinforcing material and matrix utilized, the research subject, the mechanical properties investigated, and the sample dimensions are all listed. Various pre-processing, processing, and post-processing conditions, as well as their impact on CFRC mechanical properties, were also discussed.

Hochproduktiver fertigungsangepasster 3D-Druck/Productive and manufacturing adjusted 3D printing

2017 ◽  
Vol 107 (07-08) ◽  
pp. 520-523
Author(s):  
J. Prof. Bliedtner ◽  
M. Schilling
Keyword(s):  
3D Printing ◽  
Research And Development ◽  
Fused Deposition Modeling ◽  
Dynamic Properties ◽  
Development Project ◽  
Efficient Production ◽  
Large Format ◽  
Printing Process ◽  
Fused Deposition ◽  
Deposition Modeling

Das FDM (Fused Deposition Modeling)-Verfahren ist aufgrund der Vielzahl von industriellen und privaten Anwendungen gegenwärtig das erfolgreichste 3D-Druck-Verfahren. Ziel des Forschungs- und Entwicklungsprojektes „HP3D“ ist die effiziente Herstellung von großformatigen Bauteilen in einem echten 3D-Verfahren aus frei wählbaren thermoplastischen Kunststoffen. An die Umsetzung des Projekts wurde sehr komplex herangegangen, um zu garantieren, dass die mechanischen und dynamischen Eigenschaften der aufgebauten Teile den konzipierten Eigenschaften entsprechen.   The FDM process is currently the most successful 3D printing process due to the multitude of industrial and private applications. The aim of the research and development project HP3D is the efficient production of large-format components in a real 3D process made of freely selectable thermoplastics. The implementation of the project has been very complex in order to ensure that the mechanical and dynamic properties of the assembled parts correspond to the designed properties.

scholarly journals The Micro–Macro Interlaminar Properties of Continuous Carbon Fiber-Reinforced Polyphenylene Sulfide Laminates Made by Thermocompression to Simulate the Consolidation Process in FDM

Polymers ◽  
2022 ◽  
Vol 14 (2) ◽  
pp. 301
Author(s):  
Jiale Hu ◽  
Suhail Mubarak ◽  
Kunrong Li ◽  
Xu Huang ◽  
Weidong Huang ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Manufacturing Industry ◽  
Fused Deposition Modeling ◽  
Polyphenylene Sulfide ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fused Deposition ◽  
Continuous Carbon Fiber ◽  
Carbon Fiber Reinforced

Three-dimensional (3D) printing of continuous fiber-reinforced composites has been developed in recent decades as an alternative means to handle complex structures with excellent design flexibility and without mold forming. Although 3D printing has been increasingly used in the manufacturing industry, there is still room for the development of theories about how the process parameters affect microstructural properties to meet the mechanical requirements of the printed parts. In this paper, we investigated continuous carbon fiber-reinforced polyphenylene sulfide (CCF/PPS) as feedstock for fused deposition modeling (FDM) simulated by thermocompression. This study revealed that the samples manufactured using a layer-by-layer process have a high tensile strength up to 2041.29 MPa, which is improved by 68.8% compared with those prepared by the once-stacked method. Moreover, the mechanical–microstructure characterization relationships indicated that the compactness of the laminates is higher when the stacked CCF/PPS are separated, which can be explained based on both the void formation and the nanoindentation results. These reinforcements confirm the potential of remodeling the layer-up methods for the development of high-performance carbon fiber-reinforced thermoplastics. This study is of great significance to the improvement of the FDM process and opens broad prospects for the aerospace industry and continuous fiber-reinforced polymer matrix materials.

A Heuristic Scaling Strategy for Multi-Robot Cooperative Three-Dimensional Printing

2020 ◽  
Vol 20 (4) ◽  
Author(s):  
Laxmi Poudel ◽  
Chandler Blair ◽  
Jace McPherson ◽  
Zhenghui Sha ◽  
Wenchao Zhou
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Evaluation Framework ◽  
Geometric Constraints ◽  
Mathematical Representation ◽  
Printing Process ◽  
Fused Deposition ◽  
3D Printers ◽  
Printing Time

Abstract While three-dimensional (3D) printing has been making significant strides over the past decades, it still trails behind mainstream manufacturing due to its lack of scalability in both print size and print speed. Cooperative 3D printing (C3DP) is an emerging technology that holds the promise to mitigate both of these issues by having a swarm of printhead-carrying mobile robots working together to finish a single print job cooperatively. In our previous work, we have developed a chunk-based printing strategy to enable the cooperative 3D printing with two fused deposition modeling (FDM) mobile 3D printers, which allows each of them to print one chunk at a time without interfering with the other and the printed part. In this paper, we present a novel method in discretizing the continuous 3D printing process, where the desired part is discretized into chunks, resulting in multi-stage 3D printing process. In addition, the key contribution of this study is the first working scaling strategy for cooperative 3D printing based on simple heuristics, called scalable parallel arrays of robots for 3DP (SPAR3), which enables many mobile 3D printers to work together to reduce the total printing time for large prints. In order to evaluate the performance of the printing strategy, a framework is developed based on directed dependency tree (DDT), which provides a mathematical and graphical description of dependency relationships and sequence of printing tasks. The graph-based framework can be used to estimate the total print time for a given print strategy. Along with the time evaluation metric, the developed framework provides us with a mathematical representation of geometric constraints that are temporospatially dynamic and need to be satisfied in order to achieve collision-free printing for any C3DP strategy. The DDT-based evaluation framework is then used to evaluate the proposed SPAR3 strategy. The results validate the SPAR3 as a collision-free strategy that can significantly shorten the printing time (about 11 times faster with 16 robots for the demonstrated examples) in comparison with the traditional 3D printing with single printhead.

scholarly journals Proper Blends of Biodegradable Polycaprolactone and Natural Rubber for 3D Printing

Polymers ◽  
2020 ◽  
Vol 12 (10) ◽  
pp. 2416
Author(s):  
Thossapit Wissamitanan ◽  
Charoenyutr Dechwayukul ◽  
Ekwipoo Kalkornsurapranee ◽  
Wiriya Thongruang
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
Natural Rubber ◽  
Shape Recovery ◽  
Fused Deposition Modeling ◽  
Melt Flow ◽  
Melt Flow Rate ◽  
Fused Deposition ◽  
Compression Set ◽  
Deposition Modeling

Flexible thermoplastic elastomers (TPE) were prepared for fused deposition modeling (FDM) or 3D printing. These materials can be used for medical purposes such as disposable soft splints and other flexible devices. Blends of 50% epoxidized natural rubber (ENR-50) and block rubber (Standard Thai Rubber 5L (STR5L)) with polycaprolactone (PCL) were produced and compared. The purpose of this study was to investigate the properties of natural rubber (NR) and PCL in simple blends with PCL contents of 40%, 50%, and 60% by weight (except at 75% for morphology study) in the base mixture (NR/PCL). The significant flow factors for FDM materials, such as melting temperature (Tm) and melt flow rate (MFR), were observed by differential scanning calorimetry (DSC) and via the melt flow index (MFI). In addition, the following mechanical properties were also determined: tensile strength, compression set, and hardness. The results from DSC showed that the melting temperature changed slightly (1–2 °C) with amount of PCL used, and there was a suspicious point in the 50/50 blends with both types of rubber. The lowest melting enthalpy of both blends was found at the 50/50 blended composition. The MFI results showed that PCL significantly affected the melt flow rate of both blends. The ENR-50/PCL blend flowed better than the STR5L/PCL blend. The conclusion was that this was due to the morphology of its phase structure having better uniformity than that of the STR5L/PCL blend. In compression set testing or measuring shape recovery, rubber directly influenced the recovery in all blends. The ENR-50/PCL blend had less recovery than the STR5L/PCL blend, probably due to the functional effects of epoxide groups and polarity mismatch. The hard phase PCL significantly affected the hardness of samples but improved shape recovery of the material. The ENR-50/PCL blend had better tensile properties than the STR5L/PCL blend. The elongation at break of both blends improved with a high rubber content. Hence, the ENR-50/PCL blend was superior to STR5L/PCL for printing purposes due to its better miscibility, uniformity, and flow, which are the keys to success for optimizing the fused deposition modeling conditions as well as the overall mechanical properties of products. Most blends in this study were only slightly different, but the 50/50 blend of ENR-50/PCL seemed to be near optimal for 3D printing.

scholarly journals Effect of Extrusion Temperature on the Physico-Mechanical Properties of Unidirectional Wood Fiber-Reinforced Polylactic Acid Composite (WFRPC) Components Using Fused Deposition Modeling

Polymers ◽  
2018 ◽  
Vol 10 (9) ◽  
pp. 976 ◽  
Author(s):  
Teng-Chun Yang
Keyword(s):  
Mechanical Properties ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Wood Fiber ◽  
Color Difference ◽  
Extrusion Temperature ◽  
Fiber Reinforced ◽  
Substantial Impact ◽  
Fused Deposition ◽  
Deposition Modeling

Wood fiber-reinforced polylactic acid (PLA) composites (WFRPCs) were used as a filament to manufacture the unidirectional WFRPC components by means of fused deposition modeling (FDM). The physico-mechanical properties of the WFRPC components printed at different extrusion temperatures (200, 210, 220, and 230 °C) were determined. The results revealed that most of the physical properties (moisture content, surface roughness, water absorption rate, and thickness swelling rate) of the printed WFRPC component were not significantly influenced by extrusion temperature, while its density and color difference increased as the extrusion temperature increased. Additionally, the tensile and flexural properties of the FDM-printed WFRPC component decreased when the extrusion temperature was more than 200 °C, whereas the compressive strength and internal bond strength increased by 15.1% and 24.3%, respectively, when the extrusion temperature was increased from 200 to 230 °C. Furthermore, scanning electronic microscopy (SEM) demonstrated that the fracture surface of the tensile component printed at a higher extrusion temperature exhibited a better compatibility at fiber/PLA interfaces and good adhesion between the extruded filament segments. These results indicate that the FDM printing process using different extrusion temperatures has a substantial impact on the surface color, density, and mechanical properties of the printed WFRPC component.

scholarly journals Polymer Composites Used in Rapid Prototyping Technology

2020 ◽  
Vol 44 (1) ◽  
pp. 15-20
Author(s):  
Katarzyna Bulanda ◽  
Mariusz Oleksy ◽  
Rafał Oliwa ◽  
Grzegorz Budzik ◽  
Tadeusz Markowski
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
New Materials ◽  
Fused Deposition ◽  
The Matrix ◽  
Molded Parts ◽  
Deposition Modeling ◽  
Injection Molded ◽  
The Impact

AbstractNew materials and filaments dedicated to 3D printing were obtained using the fused deposition modeling method, and the properties of the produced materials were investigated. Polylactide was used as a polymer base for the assays because of the desired properties of the polymer, mainly biodegradability, and the matrix was refilled by the addition of metallic nanofillers, such as bronze, copper, brass, and steel. For the composites obtained, mechanical properties were investigated to determine the dependence of the obtained results on the content and type of filler used and on the method of fabrication of the fittings. It was found that the additives present in the polymer matrix increased the fluidity of the material. The best results were obtained for the compositions with bronze and steel in which the mass flow rate was 72.97 and 79.99 g/10 min, respectively. The filled material that had lower hardness was measured by Rockwell and the impact strength was measured by Charpy. In addition, it was found that injection-molded parts obtained much better mechanical properties than those obtained by 3D printing.

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