scholarly journals Are We Able to Print Components as Strong as Injection Molded?—Comparing the Properties of 3D Printed and Injection Molded Components Made from ABS Thermoplastic

2021 ◽  
Vol 11 (15) ◽  
pp. 6946
Author(s):  
Bartłomiej Podsiadły ◽  
Andrzej Skalski ◽  
Wiktor Rozpiórski ◽  
Marcin Słoma
Keyword(s):  
Tensile Strength ◽  
Injection Molding ◽  
Mechanical Strength ◽  
Cross Section ◽  
Fused Deposition Modeling ◽  
High Strength ◽  
Large Cross Section ◽  
Fused Deposition ◽  
Injection Molded ◽  
The Cross

In this paper, we are focusing on comparing results obtained for polymer elements manufactured with injection molding and additive manufacturing techniques. The analysis was performed for fused deposition modeling (FDM) and single screw injection molding with regards to the standards used in thermoplastics processing technology. We argue that the cross-section structure of the sample obtained via FDM is the key factor in the fabrication of high-strength components and that the dimensions of the samples have a strong influence on the mechanical properties. Large cross-section samples, 4 × 10 mm2, with three perimeter layers and 50% infill, have lower mechanical strength than injection molded reference samples—less than 60% of the strength. However, if we reduce the cross-section dimensions down to 2 × 4 mm2, the samples will be more durable, reaching up to 110% of the tensile strength observed for the injection molded samples. In the case of large cross-section samples, strength increases with the number of contour layers, leading to an increase of up to 97% of the tensile strength value for 11 perimeter layer samples. The mechanical strength of the printed components can also be improved by using lower values of the thickness of the deposited layers.

Binder Design for Fabricating Internal Crack-Free Injection-Molded Si3N4-Based Ceramics

1991 ◽  
Vol 249 ◽  
Author(s):  
Sophia R. Su
Keyword(s):  
Mass Transfer ◽  
Injection Molding ◽  
Cross Section ◽  
Decomposition Temperature ◽  
Internal Crack ◽  
Large Cross Section ◽  
Binder Removal ◽  
Ceramic Injection Molding ◽  
Injection Molded ◽  
The Right

ABSTRACTBinder design is an important issue in ceramic injection molding technology. The binder decomposition mechanism, which involves thermodynamics, kinetics, as well as heat and mass transfer, controls the binder removal process. This process, in turn, is governed by the thermal and physical characteristics of the organic waxes used, and is the most critical step in injection molding ceramics. In this paper, we present the binder design philosophy and the method of binder selection. A systematic binder removal study focusing on heating rate, setter powder, and sublimable materials was carried out with the selected compositions. As a result of this study, we concluded that the fluid wicking controls the binder removal at the molten temperature of the binder, and the diffusion and permeation-controlled mechanism dominate at the decomposition temperature range of the binder. With the right binder selection, it is feasible to produce internal and external crack-free large cross-section injection-molded ceramic parts.

The effects of moisture and temperature on the mechanical properties of additive manufacturing components: fused deposition modeling

2016 ◽  
Vol 22 (6) ◽  
pp. 887-894 ◽  
Author(s):  
Eunseob Kim ◽  
Yong-Jun Shin ◽  
Sung-Hoon Ahn
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Water Absorption ◽  
Fused Deposition Modeling ◽  
Content Type ◽  
Fused Deposition ◽  
Temperature Conditions ◽  
Molded Parts ◽  
Deposition Modeling ◽  
Injection Molded

Purpose This paper aims to investigate the water absorption behaviors and mechanical properties, according to water absorption and temperature, of components fabricated by fused deposition modeling (FDM) and injection molding. The mechanical properties of FDM and injection molded parts were studied under several environmental conditions. Design/methodology/approach FDM components can be used as load-carrying elements under a range of moisture and temperature conditions. FDM parts show anisotropic mechanical properties according to build orientation. Components were fabricated from acrylonitrile-butadiene-styrene in three different orientations. The mechanical properties of parts fabricated by FDM were compared to injection molded components made from the same material. Water absorption tests were conducted in distilled water between 20 and 60°C to identify the maximum water absorption rate. Both moisture and temperature were considered as environmental variables in the tensile tests, which were conducted under various conditions to measure the effects on mechanical properties. Findings The water absorption behavior of FDM components obeyed Fickian diffusion theory, irrespective of the temperature. High temperatures accelerated the diffusion rate, although the maximum water absorption rate was not affected. The tensile strength of FDM parts under dry, room temperature conditions, was approximately 26-56 per cent that of injection molded parts, depending on build orientation. Increased temperature and water absorption had a more significant effect on FDM parts than injection molded components. The tensile strength was decreased by 67-71 per cent in hot, wet environments compared with dry, room temperature conditions. Originality/value The water absorption behavior of FDM components was investigated. The quantitative effects of temperature and moisture on tensile strength, modulus and strain were also measured. These results will contribute to the design of FDM parts for use under various environmental conditions.

scholarly journals Fused Deposition Modeling of Microfluidic Chips in Polymethylmethacrylate

Micromachines ◽  
2020 ◽  
Vol 11 (9) ◽  
pp. 873 ◽  
Author(s):  
Frederik Kotz ◽  
Markus Mader ◽  
Nils Dellen ◽  
Patrick Risch ◽  
Andrea Kick ◽  
...  
Keyword(s):  
Injection Molding ◽  
Cross Section ◽  
Fused Deposition Modeling ◽  
Channel Cross Section ◽  
Microfluidic Chips ◽  
Protein Patterns ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed ◽  
Industrial Materials

Polymethylmethacrylate (PMMA) is one of the most important thermoplastic materials and is a widely used material in microfluidics. However, PMMA is usually structured using industrial scale replication processes, such as hot embossing or injection molding, not compatible with rapid prototyping. In this work, we demonstrate that microfluidic chips made from PMMA can be 3D printed using fused deposition modeling (FDM). We demonstrate that using FDM microfluidic chips with a minimum channel cross-section of ~300 µm can be printed and a variety of different channel geometries and mixer structures are shown. The optical transparency of the chips is shown to be significantly enhanced by printing onto commercial PMMA substrates. The use of such commercial PMMA substrates also enables the integration of PMMA microstructures into the printed chips, by first generating a microstructure on the PMMA substrates, and subsequently printing the PMMA chip around the microstructure. We further demonstrate that protein patterns can be generated within previously printed microfluidic chips by employing a method of photobleaching. The FDM printing of microfluidic chips in PMMA allows the use of one of microfluidics’ most used industrial materials on the laboratory scale and thus significantly simplifies the transfer from results gained in the lab to an industrial product.

The Influence of Layer Thickness on Mechanical Properties of the 3D Printed ABS Polymer by Fused Deposition Modeling

2016 ◽  
Vol 706 ◽  
pp. 63-67 ◽  
Author(s):  
Pritish Shubham ◽  
Arnab Sikidar ◽  
Teg Chand
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Impact Strength ◽  
Injection Molding ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Molding Method ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed

3D Printed ABS polymer samples were investigated for understanding the effect of layer thickness on the various mechanical properties of the component. Standard samples with varying layer thickness were prepared by 3D printing machine which works on the principle of Fused Deposition modeling (FDM) method and compared with sample prepared by standard injection molding method. Results show that tensile strength (36 MPa), impact strength (103.6 J/m) and hardness (R107) were highest for the samples made by injection molding method. Furthermore, among 3D printed samples, properties were better with smaller layer thickness. With increase in layer thickness, there was negative effect on mechanical properties as tensile strength, impact strength and hardness decreased. Exception with hardness of 3D printed ABS samples was found; for largest layer thickness hardness further increased instead of decreasing.

Mechanical performance of honeycomb sandwich structures built by FDM printing technique

2021 ◽  
pp. 089270572199789
Author(s):  
S Gohar ◽  
G Hussain ◽  
A Ali ◽  
H Ahmad
Keyword(s):  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Sandwich Structures ◽  
Weight Ratio ◽  
High Strength ◽  
Core Material ◽  
Interfacial Bond Strength ◽  
Fused Deposition ◽  
Competitive Prices ◽  
Composite Face

Honey Comb Sandwich Structures (HCSS) have numerous applications in aerospace, automobile, and satellite industry because of their properties like high strength to weight ratio, stiffness and impact strength. Fused Deposition Modeling (FDM) is a process which, through its flexibility, simple processing, short manufacturing time, competitive prices and freedom of design, has an ability to enhance the functionality of HCSS. This paper investigates the mechanical behavior (i.e. flexural, edgewise compression and Interfacial bond strength) of FDM-built HCSS. The influence of face/core material was examined by manufacturing four types of specimens namely ABS core with Composite (PLA + 15% carbon fibers) face sheets, ABS core with PLA face sheets, TPU core with composite face sheets and TPU core with PLA face sheets. To measure the effect of face sheets geometry, raster layup was varied at 0°/90° and 45°/−45°. The mechanical characterization revealed that an optimum combination of materials is ABS core with composite face sheets having raster layup of 0°/90°. This study indicates that HCSS with complex lamination schemes and adequate mechanical properties could be manufactured using FDM which may widen the applications of FDM on an industrial scale.

scholarly journals Energy and Eco-Impact Evaluation of Fused Deposition Modeling and Injection Molding of Polylactic Acid

2021 ◽  
Vol 13 (4) ◽  
pp. 1875
Author(s):  
Emmanuel Ugo Enemuoh ◽  
Venkata Gireesh Menta ◽  
Abdulaziz Abutunis ◽  
Sean O’Brien ◽  
Labiba Imtiaz Kaya ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Injection Molding ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Plastic Injection Molding ◽  
Measurement Models ◽  
Fused Deposition ◽  
Dog Bone ◽  
Deposition Modeling ◽  
Plastic Injection

There is limited knowledge about energy and carbon emission performance comparison between additive fused deposition modeling (FDM) and consolidation plastic injection molding (PIM) forming techniques, despite their recent high industrial applications such as tools and fixtures. In this study, developed empirical models focus on the production phase of the polylactic acid (PLA) thermoplastic polyester life cycle while using FDM and PIM processes to produce American Society for Testing and Materials (ASTM) D638 Type IV dog bone samples to compare their energy consumption and eco-impact. It was established that energy consumption by the FDM layer creation phase dominated the filament extrusion and PLA pellet production phases, with, overwhelmingly, 99% of the total energy consumption in the three production phases combined. During FDM PLA production, about 95.5% of energy consumption was seen during actual FDM part building. This means that the FDM process parameters such as infill percentage, layer thickness, and printing speed can be optimized to significantly improve the energy consumption of the FDM process. Furthermore, plastic injection molding consumed about 38.2% less energy and produced less carbon emissions per one kilogram of PLA formed parts compared to the FDM process. The developed functional unit measurement models can be employed in setting sustainable manufacturing goals for PLA production.

Springback law of high-strength 21-6-9 stainless steel tube in numerical control bending under different process parameters

2015 ◽  
Vol 231 (10) ◽  
pp. 1783-1792 ◽  
Author(s):  
Jun Fang ◽  
Shiqiang Lu ◽  
Kelu Wang ◽  
Zhengjun Yao
Keyword(s):  
Stainless Steel ◽  
Friction Coefficient ◽  
Cross Section ◽  
Process Parameters ◽  
High Strength ◽  
Steel Tube ◽  
Numerical Control ◽  
Stainless Steel Tube ◽  
Outer Diameter ◽  
The Cross

In order to achieve the precision bending deformation, the effects of process parameters on springback behaviors should be clarified preliminarily. Taking the 21-6-9 high-strength stainless steel tube of 15.88 mm × 0.84 mm (outer diameter × wall thickness) as the objective, the multi-parameter sensitivity analysis and three-dimensional finite element numerical simulation are conducted to address the effects of process parameters on the springback behaviors in 21-6-9 high-strength stainless steel tube numerical control bending. The results show that (1) springback increases with the increasing of the clearance between tube and mandrel Cm, the friction coefficient between tube and mandrel fm, the friction coefficient between tube and bending die fb, or with the decreasing of the mandrel extension length e, while the springback first increases and then remains unchanged with the increasing of the clearance between tube and bending die Cb. (2) The sensitivity of springback radius to process parameters is larger than that of springback angle. And the sensitivity of springback to process parameters from high to low are e, Cb, Cm, fb and fm. (3) The variation rules of the cross section deformation after springback with different Cm, Cb, fm, fb and e are similar to that before springback. But under same process parameters, the relative difference of the most measurement section is more than 20% and some even more than 70% before and after springback, and a platform deforming characteristics of the cross section deformation is shown after springback.

scholarly journals Optimization of Geometrical Parameters of Hollow-core Slabs by Formwork-free Shaping for Construction in Seismic Areas

2020 ◽  
Vol 8 (6) ◽  
pp. 4973-4977
Keyword(s):  
Cross Section ◽  
High Strength ◽  
Geometrical Parameters ◽  
Hollow Core ◽  
Constructive Solution ◽  
Industrial Buildings ◽  
Operational Load ◽  
Wide Range ◽  
Hollow Core Slab ◽  
The Cross

The building norms and standards of Uzbekistan on the reinforced concrete structures do not regulate the design of hollow-core slabs of formwork-free shaping, reinforced with prestressed wire reinforcement. The manufacturing technology of such slabs allows creating a wide range of products that increase the possibility of their use in various structural systems in residential, civil and industrial buildings, but in non-seismic areas only. The aim of this work is to develop a constructive solution for the cross section of a prestressed hollow-core floor slab of bench formwork-free shaping, reinforced with high-strength wire reinforcement, in order to create a wide range of products intended for construction in seismic areas. To achieve the goal, the problem of determining the optimal combination of height and configuration parameters of the cross section of such a slab is solved, meeting the normalized operational requirements and limitations of earthquake-resistant building standards. The main variable parameters are the height and the void degree of the section, characterized by the size and shape of voids. In calculating the cross-section of a hollow-core slab when substantiating the theoretical basis for the calculation, the cross section is reduced to the equivalent I-section. As a result of research, a constructive solution was developed for the slab cross section of the maximum parameter values (the span, operational load) set by the customer. The parameters of the slab cross-section are: the height 190 mm, the hollowness 38%, the height of the upper thickened flange (compared with the height of the lower flange) of the given section is 0.27h, the height of the lower flange is 0.17h, the reduced (total) thickness of all ribs “b” is 0.32 of the width of the upper flange. The voids in the section along the height of the slab are arranged asymmetrically. A patent for a utility model has been received for the proposed constructive solution of the slab cross section.

Deposition-induced effects of isotactic polypropylene and polycarbonate composites during fused deposition modeling

2017 ◽  
Vol 23 (5) ◽  
pp. 869-880 ◽  
Author(s):  
Ying-Guo Zhou ◽  
Bei Su ◽  
Lih-sheng Turng
Keyword(s):  
Mechanical Properties ◽  
Design Methodology ◽  
Fused Deposition Modeling ◽  
Content Type ◽  
Fused Deposition ◽  
Close Relationship ◽  
Molded Parts ◽  
Deposition Modeling ◽  
Injection Molded ◽  
First Time

Purpose Although the feasibility and effectiveness of the fused deposition modeling (FDM) method have been proposed and developed, studies of applying this technology to various materials are still needed for researching its applicability, especially with regard to polymer blends and composites. The purpose of this paper is to study the deposition-induced effect and the effect of compatibilizers on the mechanical properties of polypropylene and polycarbonate (PP/PC) composites. Design/methodology/approach For this purpose, three different deposition modes for PP/PC composites with or without compatibilizers were used for the FDM method and tested for tensile properties. Also, parts with the same materials were made by injection molding and used for comparison. In addition, different deposition speeds were used to investigate the different deposition-induced effects. Furthermore, the behavior of the mechanical properties was clarified with scanning electron microscope images of the fracture surfaces. Findings The research results suggest that the deposition orientation has a significant influence on the mechanical behavior of PP/PC composite FDM parts. The results also indicate that there is a close relationship between the mechanical properties and morphological structures which are deeply influenced by compatibilization. Compared with injection molded parts, the ductility of the FDM parts can be dramatically improved due to the formation of fibrils and micro-fibrils by the deposition induced during processing. Originality/value This is the first paper to investigate a PP/PC composite FDM process. The results of this paper verified the applicability of PP/PC composites to FDM technology. It is also the first time that the deposition-induced effect during FDM has been investigated and studied.

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