scholarly journals Fused Deposition Modelling of Fibre Reinforced Polymer Composites: A Parametric Review

2021 ◽  
Vol 5 (1) ◽  
pp. 29
Author(s):  
Narongkorn Krajangsawasdi ◽  
Lourens G. Blok ◽  
Ian Hamerton ◽  
Marco L. Longana ◽  
Benjamin K. S. Woods ◽  
...  
Keyword(s):  
Process Parameters ◽  
Mechanical Performance ◽  
Fibre Length ◽  
Processing Parameters ◽  
Thermoplastic Composite ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Fibre Reinforced Polymer ◽  
Printing Parameters

Fused deposition modelling (FDM) is a widely used additive layer manufacturing process that deposits thermoplastic material layer-by-layer to produce complex geometries within a short time. Increasingly, fibres are being used to reinforce thermoplastic filaments to improve mechanical performance. This paper reviews the available literature on fibre reinforced FDM to investigate how the mechanical, physical, and thermal properties of 3D-printed fibre reinforced thermoplastic composite materials are affected by printing parameters (e.g., printing speed, temperature, building principle, etc.) and constitutive materials properties, i.e., polymeric matrices, reinforcements, and additional materials. In particular, the reinforcement fibres are categorized in this review considering the different available types (e.g., carbon, glass, aramid, and natural), and obtainable architectures divided accordingly to the fibre length (nano, short, and continuous). The review attempts to distil the optimum processing parameters that could be deduced from across different studies by presenting graphically the relationship between process parameters and properties. This publication benefits the material developer who is investigating the process parameters to optimize the printing parameters of novel materials or looking for a good constituent combination to produce composite FDM filaments, thus helping to reduce material wastage and experimental time.

Performance of Low-Cost 3D Printer in Medical Application

2021 ◽  
Author(s):  
Nor Aiman Sukindar ◽  
Azib Azhari Awang Dahan ◽  
Sharifah Imihezri Syed Shaharuddin ◽  
Nor Farah Huda Abd Halim
Keyword(s):  
Low Cost ◽  
Medical Application ◽  
Fused Deposition Modelling ◽  
3D Printer ◽  
Layer By Layer ◽  
Total Deformation ◽  
Element Analysis ◽  
Porosity Level ◽  
Fused Deposition ◽  
Printing Parameters

Abstract Fused Deposition Modelling (FDM) is an additive manufacturing (AM) process that produces a physical object directly from a CAD design using layer-by-layer deposition of the filament material that is extruded via a nozzle. In industry, FDM has become one of the most used AM processes for the production of low batch quantity and functional prototypes, due to its safety, efficiency, reliability, low cost, and ability to process manufacturing-grade engineering thermoplastic. Recently, the market is flooded with the availability of low-cost printers produced by numerous companies. This research aims to investigate the effect of different porosity levels on a scaffold structure produced using a low-cost 3D printer. Comparisons of these porous structures were made in terms of Von-Mises strain, total deformation, as well as compressive stress. Various porosity levels were created by varying printing parameters, including layer height, infill density, and shell thickness by slicing the initial solid CAD file using Repetier Host 3D printing software. Finite Element Analysis (FEA) simulation was then performed on the created scaffold structures by using Ansys Workbench 19.2. The simulation result indicates that the greater porosity level will result in higher total deformation of the structure. Meanwhile, the compression test shows that the minimum strength value obtained was favourable at 22 MPa and had exceeded that of the trabecular femur (15 MPa). However, its porosity level (maximum at 52%) was still below that of the minimum threshold of porosity level of 70 percent. However, the printing parameters currently used can be adjusted in the future. Therefore, it was deduced that the low-cost 3D printer offers promising potential to fabricate different porosity structures with multiple outcomes.

Parametric study on tensile and flexural properties of ULTEM 1010 specimens fabricated via FDM

2021 ◽  
Vol 27 (2) ◽  
pp. 429-451
Author(s):  
Chrysoula Pandelidi ◽  
Tobias Maconachie ◽  
Stuart Bateman ◽  
Ingomar Kelbassa ◽  
Sebastian Piegert ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
High Temperature ◽  
Process Parameters ◽  
Computer Aided Design ◽  
High Performance ◽  
Mechanical Performance ◽  
Fused Deposition Modelling ◽  
Controlled Cooling ◽  
Content Type ◽  
Fused Deposition

Purpose Fused deposition modelling (FDM) is increasingly being explored as a commercial fabrication method due to its ability to produce net or near-net shape parts directly from a computer-aided design model. Other benefits of technology compared to conventional manufacturing include lower cost for short runs, reduced product lead times and rapid product design. High-performance polymers such as polyetherimide, have the potential for FDM fabrication and their high-temperature capabilities provide the potential of expanding the applications of FDM parts in automotive and aerospace industries. However, their relatively high glass transition temperature (215 °C) causes challenges during manufacturing due to the requirement of high-temperature build chambers and controlled cooling rates. The purpose of this study is to investigate the mechanical properties of ULTEM 1010, an unfilled polyetherimide grade. Design/methodology/approach In this research, mechanical properties were evaluated through tensile and flexural tests. Analysis of variance was used to determine the significance of process parameters to the mechanical properties of the specimens, their main effects and interactions. The fractured surfaces were analysed by scanning electron microscopy and optical microscopy and porosity was assessed by X-ray microcomputed tomography. Findings A range of mean tensile and flexural strengths, 60–94 MPa and 62–151 MPa, respectively, were obtained highlighting the dependence of performance on process parameters and their interactions. The specimens were found to fracture in a brittle manner. The porosity of tensile samples was measured between 0.18% and 1.09% and that of flexural samples between 0.14% and 1.24% depending on the process parameters. The percentage porosity was found to not directly correlate with mechanical performance, rather the location of those pores in the sample. Originality/value This analysis quantifies the significance of the effect of each of the examined process parameters has on the mechanical performance of FDM-fabricated specimens. Further, it provides a better understanding of the effect process parameters and their interactions have on the mechanical properties and porosity of FDM-fabricated polyetherimide specimens. Additionally, the fracture surface of the tested specimens is qualitatively assessed.

scholarly journals FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

Polymers ◽  
2020 ◽  
Vol 12 (7) ◽  
pp. 1529 ◽  
Author(s):  
Sachini Wickramasinghe ◽  
Truong Do ◽  
Phuong Tran
Keyword(s):  
Mechanical Performance ◽  
Matrix Material ◽  
Void Formation ◽  
Fused Deposition Modelling ◽  
Treatment Methods ◽  
Fused Deposition ◽  
Raster Angle ◽  
Manufacturing Methods ◽  
The Impact ◽  
Printing Parameters

Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.

Modeling and Optimization of 3D Printed PLA Material for Maximum Flexural Strength Using Multiple Nonlinear Neuro Regression Analysis

2021 ◽  
Author(s):  
Melih Savran ◽  
Asil Ayaz ◽  
Tuğrul Uslu
Keyword(s):  
Mechanical Properties ◽  
Regression Analysis ◽  
Flexural Strength ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Fused Deposition Modelling ◽  
Complex Objects ◽  
Manufacturing Method ◽  
Fused Deposition ◽  
Printing Parameters

Fused deposition modelling (FDM) is a growing additive manufacturing method to produce complex objects without geometrical limitations. In addition, mechanical strength, dimensional accuracy, product development cycle time, and surface properties can be improved depending on the application of the best settings of design variables. There are various printing parameters which influence the mechanical properties and quality of FDM parts. In this study, appropriate printing parameters were determined to obtain desired quality on mechanical properties and dimensional accuracy. Then full factorial design was employed to form experiment set including process parameters. Multiple nonlinear neuro-regression analysis was used for modeling of FDM process. The present study aims at optimization of the FDM process parameters including infill pattern, infill density and build orientation on flexural strength and strain for polylactide (PLA) material. In this regard, optimization algorithms Differential Evolution and Nelder Mead were used to find the best design or elite designs. Third-order polynomial model and hybrid model including polynomial and logarithmic terms were employed as an objective function to define physical phenomena regarding flexural strength and strain, respectively. It was found that (i) maximum flexural strength as 99.66 MPa using a cubic pattern, flat orientation, and 90 % infill density, (ii) minimum ultimate strain as 1.102 % for gyroid pattern, flat orientation, and 47 % infill density.

scholarly journals Influence of orientation on mechanical properties in fused deposition modelling

2020 ◽  
Vol 68 (4) ◽  
pp. 4-8
Author(s):  
Suzana Kutnjak-Mravlinčić ◽  
Ana Pilipović ◽  
Damir Godec
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Complex Geometry ◽  
Processing Parameters ◽  
Flexural Properties ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Working Space ◽  
Small Series

In the footwear industry, increasing attention is paid to design-shaped heels. But that design involves production of the complicated geometry, personalised heels (i.g. small series), light weight heels and if possible cheap production. Technology that enables and combines that is additive manufacturing (AM). One of AM low budget technology and machine is fused deposition modeling (FDM). In FDM, product is built layer by layer and with different types and density of inside mesh structures which enables complex geometry and low mass. When walking, the heel is loaded from above with compression force of the person's weight, while lateral, heel is loaded with flexural force and impact. Considering the design of the heel itself, it is necessary to orientate the product correctly in the working space of the machine. Orientation further raises the question of mechanical properties on such produced heel. In this paper it is tested flexural properties of two different orientation considering production of the actual heel. Furthermore, the analysis of the processing parameters (layer thickness, infill density and temperature) have been done to determine their influence on the flexural properties in these two orientations.

Effect of Process Parameters on Compressive Properties of ULTEM 9085 Produced by FDM Process

2018 ◽  
Author(s):  
Aboma Wagari Gebisa ◽  
Hirpa G. Lemu
Keyword(s):  
Process Parameters ◽  
High Performance ◽  
Fused Deposition Modeling ◽  
Compressive Strain ◽  
Processing Parameters ◽  
Air Gap ◽  
Layer By Layer ◽  
Compressive Properties ◽  
Significant Interaction Effect ◽  
Fused Deposition

Fused deposition modeling (FDM), one of the additive manufacturing (AM) technologies, is a promising digital manufacturing technique that produces parts, layer by layer, by heating, extruding and depositing filaments of thermoplastic polymers. The properties of FDM-produced parts apparently depend on the processing parameters. These processing parameters have conflicting advantages that need to be investigated. This paper investigates the effect of process parameters on the compressive properties of parts produced by the FDM process. The study is carried out on a high performance polymeric material called ULTEM 9085. Full factorial design of experiment is used to analyze the effects of process parameters on the compressive properties of the material. Five parameters: namely, air gap, raster width, raster angle, contour number and contour width, of the FDM machine are considered in the current study. The results show that, with the exception of the raster width, all other considered parameters have significant interaction effect on the compressive strength. For the compressive strain, air gap, contour number and contour width showed substantial interaction effects.

Research on the Effect of Technical Attributes on the Tensile Strength of FDM Products

2020 ◽  
Vol 863 ◽  
pp. 33-50
Author(s):  
Huu Nghi Huynh ◽  
Trong Hieu Bui ◽  
Thi Thu Ha Thai ◽  
Huu Tho Nguyen
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Absolute Error ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Ann Model ◽  
Fused Deposition ◽  
Artificial Neural Network Ann ◽  
The Relationship ◽  
Subsequent Layer

Nowadays, Fused Deposition Modelling (FDM) method has been growing rapidly, which can be used to fabricate complex parts within a reasonable time. The fabrication principle of FDM method is “layer by layer” so that the previous layer and subsequent layer don’t deposit each other to create the interface between two adjacent layers. Thus, the tensile strength of FDM product along building direction depends on various process parameters. In this study, five important process parameters such as layer thickness, build orientation, build style, infill density, and print temperature are considered. The effect on tensile strength is evaluated based on the tensile test of Polylactic Acid (PLA) part. The Design of experiment (DOE) based on the Central Composite Design (CCD) to consider the relationship between the process parameters and their response through the experimental data are gathered. The suitability of model is validated by Analysis of Variance (ANOVA) and t-test. Moreover, Artificial Neural Network (ANN) is also applied to predict the response for experimental model and compared with regression equation obtained from Response surface analysis (FCCCD). The results show that the predict value of ANN model is approximate to experiment value (R2 = 0.964), and the mean absolute error (MAE) of ANN model is smaller than those of FCCCD model. It is proved that ANN model is applicable to predict accurately the relationship between the process parameters and their response.

Evaluation of geometrical benchmark artifacts containing multiple overhang lengths fabricated using material extrusion technique

2020 ◽  
Vol 14 (3) ◽  
pp. 7296-7308
Author(s):  
Siti Nur Humaira Mazlan ◽  
Aini Zuhra Abdul Kadir ◽  
N. H. A. Ngadiman ◽  
M.R. Alkahari
Keyword(s):  
3D Model ◽  
Laser Scanner ◽  
Dimensional Accuracy ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Layer Technique ◽  
Subtractive Manufacturing ◽  
Manufacturing Features ◽  
Layer Problem

Fused deposition modelling (FDM) is a process of joining materials based on material entrusion technique to produce objects from 3D model using layer-by-layer technique as opposed to subtractive manufacturing. However, many challenges arise in the FDM-printed part such as warping, first layer problem and elephant food that was led to an error in dimensional accuracy of the printed parts especially for the overhanging parts. Hence, in order to investigate the manufacturability of the FDM printed part, various geometrical and manufacturing features were developed using the benchmarking artifacts. Therefore, in this study, new benchmarking artifacts containing multiple overhang lengths were proposed. After the benchmarking artifacts were developed, each of the features were inspected using 3D laser scanner to measure the dimensional accuracy and tolerances. Based on 3D scanned parts, 80% of the fabricated parts were fabricated within ±0.5 mm of dimensional accuracy as compared with the CAD data. In addition, the multiple overhang lengths were also successfully fabricated with a very significant of filament sagging observed.

scholarly journals Current State and Challenges of Natural Fibre-Reinforced Polymer Composites as Feeder in FDM-Based 3D Printing

Polymers ◽  
2021 ◽  
Vol 13 (14) ◽  
pp. 2289
Author(s):  
Nishata Royan Rajendran Royan ◽  
Jie Sheng Leong ◽  
Wai Nam Chan ◽  
Jie Ren Tan ◽  
Zainon Sharmila Binti Shamsuddin
Keyword(s):  
Mechanical Properties ◽  
Natural Fibre ◽  
Critical Discussion ◽  
Fused Deposition Modelling ◽  
Preparation Methods ◽  
Fused Deposition ◽  
Current State ◽  
Future Challenges ◽  
Raster Angle ◽  
Fibre Reinforced Polymer

As one of the fastest-growing additive manufacturing (AM) technologies, fused deposition modelling (FDM) shows great potential in printing natural fibre-reinforced composites (NFRC). However, several challenges, such as low mechanical properties and difficulty in printing, need to be overcome. Therefore, the effort to improve the NFRC for use in AM has been accelerating in recent years. This review attempts to summarise the current approaches of using NFRC as a feeder for AM. The effects of fibre treatments, composite preparation methods and addition of compatibilizer agents were analysed and discussed. Additionally, current methods of producing feeders from NFRCs were reviewed and discussed. Mechanical property of printed part was also dependent on the printing parameters, and thus the effects of printing temperature, layer height, infill and raster angle were discussed, and the best parameters reported by other researchers were identified. Following that, an overview of the mechanical properties of these composites as reported by various researchers was provided. Next, the use of optimisation techniques for NFRCs was discussed and analysed. Lastly, the review provided a critical discussion on the overall topic, identified all research gaps present in the use of NFRC for AM processes, and to overcome future challenges.

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