scholarly journals Identification and Mapping of Manufacturability Constraints for Extrusion-Based Additive Manufacturing

2021 ◽  
Vol 5 (2) ◽  
pp. 33
Author(s):  
Albert E. Patterson ◽  
Charul Chadha ◽  
Iwona M. Jasiuk
Keyword(s):  
Fused Deposition Modeling ◽  
Practical Implementation ◽  
Fused Filament Fabrication ◽  
Extensive Discussion ◽  
Design Problems ◽  
Fused Deposition ◽  
Process Characteristics ◽  
Deposition Modeling ◽  
Basic Behavior ◽  
And Behavior

This article develops and demonstrates a set of design-focused manufacturability constraints for the fused deposition modeling/fused filament fabrication (FDM/FFF) process. These can be mapped from the basic behavior and process characteristics and formulated in terms of implicit or explicit design constraints. When the FDM/FFF process is explored and examined for its natural limitations and behavior, it can provide a set of manufacturing considerations (advantages, limitations, and best practices). These can be converted into manufacturing constraints, which are practical limits on the ability of the process. Finally, these can be formulated in terms of design–useful manufacturability constraints. Many of the constants and parameters must be determined experimentally for specific materials. The final list of 54 major manufacturability constraints presented in this work will better inform designers considering using FDM/FFF as a manufacturing process, and help guide design decisions. After derivation and presentation of the constraint set, extensive discussion about practical implementation is provided at the end of the paper, including advice about experimentally determining constants and appropriate printing parameters. Finally, three case studies are presented which implement the constraints for simple design problems.

Adaptive Slicing for Fused Deposition Modeling and Practical Implementation Schemes

2012 ◽  
Vol 428 ◽  
pp. 137-140 ◽  
Author(s):  
Sarat Singamneni ◽  
Roger Anak Joe ◽  
Bin Huang
Keyword(s):  
Fused Deposition Modeling ◽  
Practical Implementation ◽  
Adaptive Slicing ◽  
Air Gaps ◽  
Fused Deposition ◽  
Heterogeneous Structures ◽  
Rapid Product Development ◽  
Deposition Modeling ◽  
Software And Hardware ◽  
Traditional Approaches

Fused Deposition Modeling (FDM) is one of the most popular Rapid Prototyping (RP) techniques. Initially used as means of producing 3D prototypes aiding in rapid product development, FDM found a significant application in medical models and with machine and material improvements is currently destined to be a true manufacturing process, challenging some of the traditional approaches. The material characteristics and part qualities however, are inferior, considering the heterogeneous structures characterized by the air gaps resulting from raster orientations. Current research is focused on improving the mesostructure through appropriate deposition schemes, adaptive slicing being one of the approaches. This paper reviews some of the adaptive slicing schemes and discusses software and hardware developments undertaken for the practical implementation of one of the schemes for producing test parts.

scholarly journals Enhancing 3D Printing Producibility in Polylactic Acid Using Fused Filament Fabrication Fused Deposition Modelling and Machine Learning

2020 ◽  
Author(s):  
Mahmoud Moradi ◽  
M. Saleh Meiabadi ◽  
Mojtaba Karami Moghadam ◽  
Sina Ardabili ◽  
Shahab S. Band ◽  
...  
Keyword(s):  
Neural Network ◽  
Machine Learning ◽  
Production Cost ◽  
Fused Deposition Modeling ◽  
Deformation Property ◽  
Fused Filament Fabrication ◽  
Fused Deposition ◽  
Surface Method ◽  
Deposition Modeling ◽  
Part Thickness

Abstract Polylactic Polylactic acid (PLA) is one of the high applicable material which is used in the 3D printers due to some significant features like its deformation property and affordable costacid (PLA) is brittle in nature with extensive deformation property. For improvement of the end-use quality, it is of significant importance to enhance the quality of Fused Filament Fabrication (FFF)fused deposition modeling (FDM)-printed objects in PLA. The purpose of this investigation is to boost toughness and to reduce the production cost of the FDMFFF-printed tensile test samples with the desired part thickness. Due to prevent from many numerous and idle printing samples the response Surface Method (RSM) is used.To attain the research purpose number of experiments are designed and analyzed by the Response Surface Method (RSM). The statistical analysis is performed to deal with this concern considering extruder temperature (ET), infill percentage (IP), and layer thickness (LT) as controlled factors. The tensile test specimens are printed based on the designed experiments, and the tensile strength tests are conducted by SANTAM 150 universal testing machine based on ASTM D638. The pattern for filling is designed based on honeycomb which is applied to produce lightweight and high-strength specimens. The area under Force- Extension curve up to fracture is acquired as the toughness of the printed specimens. This study also developed a modeling process using artificial neural network (ANN) and artificial neural network- genetic algorithm (ANN-GA) techniques to develop an accurate estimation for toughness, part thickness, and production cost dependent variables. Results were evaluated by correlation coefficient and RMSE values. According to the modeling results, ANN-GA as a hybrid machine learning (ML) technique could could successfully improveenhances the accuracy of modeling about 7.5, 11.5 and 4.5 % for toughness, part thickness, and production cost, respectively, in comparison with those for the single ANN method. On the other side, the optimization results confirm that the optimized specimen is cost-effective and able to comparatively undergo deformation, which enables the usability of printed PLA objects. The research is accomplished under the constraints of PLA compatibility with existing Fused Filament Fabrication fused deposition modeling installation, in the absence of the functional assistant of the machine in the absence of the functional assistant of the machine. Although the mechanical properties and dimensional accuracy of PLA have already been studied, there is little literature on the toughness of the printed PLA with honeycomb internal fill pattern.

scholarly journals Applications of 3D-Printed PEEK via Fused Filament Fabrication: A Systematic Review

Polymers ◽  
2021 ◽  
Vol 13 (22) ◽  
pp. 4046
Author(s):  
Rupak Dua ◽  
Zuri Rashad ◽  
Joy Spears ◽  
Grace Dunn ◽  
Micaela Maxwell
Keyword(s):  
Systematic Review ◽  
Fused Deposition Modeling ◽  
Chemical Properties ◽  
Organic Polymer ◽  
Current Status ◽  
Fused Filament Fabrication ◽  
Fused Deposition ◽  
Polyether Ether Ketone ◽  
Deposition Modeling ◽  
3D Printed

Polyether ether ketone (PEEK) is an organic polymer that has excellent mechanical, chemical properties and can be additively manufactured (3D-printed) with ease. The use of 3D-printed PEEK has been growing in many fields. This article systematically reviews the current status of 3D-printed PEEK that has been used in various areas, including medical, chemical, aerospace, and electronics. A search of the use of 3D-printed PEEK articles published until September 2021 in various fields was performed using various databases. After reviewing the articles, and those which matched the inclusion criteria set for this systematic review, we found that the printing of PEEK is mainly performed by fused filament fabrication (FFF) or fused deposition modeling (FDM) printers. Based on the results of this systematic review, it was concluded that PEEK is a versatile material, and 3D-printed PEEK is finding applications in numerous industries. However, most of the applications are still in the research phase. Still, given how the research on PEEK is progressing and its additive manufacturing, it will soon be commercialized for many applications in numerous industries.

Evaluation of the Effect of Infill Pattern on Mechanical Stregnth of Additively Manufactured Specimen

2017 ◽  
Vol 887 ◽  
pp. 128-132 ◽  
Author(s):  
Shaheryar Atta Khan ◽  
Bilal Ahmed Siddiqui ◽  
Muhammad Fahad ◽  
Maqsood Ahmed Khan
Keyword(s):  
Additive Manufacturing ◽  
Open Source ◽  
Fused Deposition Modeling ◽  
Fused Filament Fabrication ◽  
Fused Deposition ◽  
Additive Manufacturing Technology ◽  
Internal Structures ◽  
The World ◽  
Build Time ◽  
Deposition Modeling

Additive manufacturing has stepped down from the world of Sci-Fi into reality. Since its conception in the 1980s the technology has come a long way. May variants of the technology are now available to the consumer. With the advent of custom built (open source) Fused Deposition Modeling based printing technology Fused Filament Fabrication (FFF), FDM/FFF has become the most used Additive Manufacturing technology. The effects of the different infill patterns of FDM/FFF on the mechanical properties of a specimen made from ABS are studied in this paper. It is shown that due to changes in internal structures, the tensile strength of the specimen changes. The study also investigate the effect of infill pattern on the build time of the specimen. Extensive testing yielded the optimal infill pattern for FDM/FFF. An open source Arduino based RepRap printer was used for the preparation of specimen and showed promising results for rapid prototyping of custom built parts to bear high loads. The study can help with the increase in the use of additive manufacturing for the manufacturing of mechanically functioning parts such as prosthetics

scholarly journals Design and Repeatability Analysis of Desktop Tool for Rapid Pre-Cracking of Notched Ductile Plastic Fracture Specimens

2019 ◽  
Author(s):  
Albert E. Patterson ◽  
Charul Chadha ◽  
Iwona M. Jasiuk ◽  
James T. Allison
Keyword(s):  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Technical Note ◽  
Razor Blade ◽  
Ductile Materials ◽  
Fused Deposition ◽  
Plastic Materials ◽  
Deposition Modeling ◽  
And Behavior

Fracture testing is a useful mechanical testing process to explore the properties and behavior of materials, one that has seen much development and refinement in recent decades. One of the most important steps in preparing samples for testing is the production of a sharp pre-crack to initiate crack propagation in a predictable way. While several methods have been developed for doing this, particularly for metals and brittle plastic materials, a quick and reliable method for more ductile materials is lacking. This technical note describes the design and verification of a simple desktop-sized pre-cracking device which safely uses a razor blade and hammer to quickly produce straight and sharp pre-cracks of consistent depth in ductile polymeric material samples. To verify its capability and consistency, a series of tests were performed using both molded and 3-D printed acrylonitrile butadiene styrene (ABS). First, a series of 40 notched 25 mm x 9.5 mm ABS bars were pre-cracked, and the distance under the crack measured on both sides of the bar. Several bars were then broken along the cracks to examine the quality of the pre-crack front. These tests were then repeated 20 times each for two print orientations of fused deposition modeling (FDM) ABS printed at 100% density. All 80 pre-cracks were found to be straight, sharp, and within 1% of the nominal distance under the crack for all samples. The consistency of the pre-cracks throughout the sample cross-section was also observed to be excellent, with all 80 tests showing less than 0.25 mm of deviation, even on the highly-anisotropic FDM samples.

scholarly journals Influence of Process Parameters on Tensile Strength of Additive Manufactured PLA Parts using Taguchi Method

2019 ◽  
Vol 8 (3) ◽  
pp. 7635-7639
Keyword(s):  
Tensile Strength ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Optimal Parameter ◽  
Fused Filament Fabrication ◽  
Influence Of Process Parameters ◽  
Layer Height ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Nozzle Temperature

Influence of layer thickness nozzle temperature and angle on tensile strength of PLA fabricated with FDM (FFF) was experimentally investigated. Polylactic Acid (PLA) is a semi-crystalline and bio-friendly thermoplastic polymer has identified as important material in different applications due to its mechanical characteristics. Fused Deposition Modeling (FDM) is a one of the proved technology in Fused Filament Fabrication (FFF) technique in additive manufacturing process. In present investigation different specimens were fabricated using FDM technique with different layer height and different layer angles for finding influence of these manufacturing parameters on tensile strength of the specimen. Specimens were fabricated and tested as per ASTM D638 standard. It is clearly observed that tensile strength is more for +450 /-450 layer angle than the +00 /-0 0 layer angle for a given layer height(h=0.10 mm, h=0.15mm and h=0.20mm).The TAGUCHI analysis is carried with nozzle temperature, layer thickness and angle finding optimal values. It has been observed that, the optimal parameter is angle, which is equal to 30 0 .the ANOVA variation of angle layer with tensile strength has been observed that 18.10-31.90.

scholarly journals Effect of the filling percentage on tensile strength in 3D desktop printing for different printing patterns, using a randomized design of experiments

Enfoque UTE ◽  
2019 ◽  
Vol 10 (4) ◽  
pp. 13-27
Author(s):  
Juan Carlos Parra Mena ◽  
Erling Ricardo Gallardo Vizuete ◽  
Erick Damian Torres Peñaloza
Keyword(s):  
Tensile Strength ◽  
Design Of Experiments ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Single Factor ◽  
Fused Filament Fabrication ◽  
Fused Deposition ◽  
Randomized Design ◽  
Filling Pattern ◽  
Deposition Modeling

The evaluation of the tensile strength of printed parts by means of fused deposition modeling (FDM) or fused filament fabrication (FFF) is essential, since parts whose resistance does not differ significantly depending on the percentage of filling used can be obtained, optimizing the use of the material. The present work details the analysis of polylactic acid (PLA) specimens manufactured according to ASTM D 638 with different percentages for the most commonly used filling patterns (Honeycomb, Octagram, Stars, Archimedean, Hilbert and Triangles). With the help of an analysis of variance and a design of experiments with a single factor, the appropriate percentages for printing parts according to the desired filling pattern are obtained.

On improving the surface finish of 3D printing polylactic acid parts by corundum blasting

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ana Pilar Valerga Puerta ◽  
J.D. Lopez-Castro ◽  
Adrián Ojeda López ◽  
Severo Raúl Fernández Vidal
Keyword(s):  
Layer Thickness ◽  
Polylactic Acid ◽  
Surface Quality ◽  
Fused Deposition Modeling ◽  
Fused Filament Fabrication ◽  
High Exposure ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling

Purpose Fused filament fabrication or fused deposition modeling (FFF/FDM) has as one of its main restrictions the surface quality intrinsic to the process, especially linked to the layer thickness used during manufacture. The purpose of this paper is to study the possibility of improving the surface quality of polylactic acid (PLA) parts manufactured by FFF using the shot blasting technique. Design/methodology/approach The influence of corundum blasting on 0.2 mm layer thickness FDM PLA parts treated with two sizes of abrasive, different exposure times and different incidence pressures. Findings As a result, improvements of almost 80% were obtained in the surface roughness of the pieces with high exposure times, and more than 50% in just 20 s. Originality/value This technique is cheap, versatile and adaptable to different part sizes and geometries. Furthermore, it is a fast and environmentally friendly technique compared to conventional machining or vapor smoothing. Despite this, no previous studies have been carried out to improve the quality of this technology.

Comparison of Fused Deposition Modeling and Color Jet 3D Printing Technologies for the Printing of Mathematical Geometries

2020 ◽  
pp. 1-13
Author(s):  
Nosheen Fatma ◽  
Abid Haleem ◽  
Mohd Javaid ◽  
Shahbaz Khan
Keyword(s):  
Fused Deposition Modeling ◽  
Research Field ◽  
Molecular Chemistry ◽  
Fused Deposition ◽  
Area Of Interest ◽  
Trefoil Knot ◽  
Deposition Modeling ◽  
Jet Printing ◽  
Energy Absorbing ◽  
And Behavior

Many mathematical geometries act as an optimal structure for functional applications and have always been an area of interest in the research field. Their topology offers properties which are crucial and can be used effectively in various domains. Apart from that, some have a resemblance to naturally occurring compounds which can help us to study their different transformations and behavior. In this paper, we present two such geometries, first, gyroid, which is an iso-minimal surface and second a three-crossing knot, also known as trefoil knot. The structure of gyroid makes it unique and is considered suitable in developing energy-absorbing, structural and lightweight applications. Similarly, some types of knots resemble the DNA structure and have found use in molecular chemistry. This paper discusses different application areas of these geometries. Further, this paper presents modeling and printing by using fused deposition modeling (FDM) and color jet printing (CJP). Comparative analysis has been done by considering various parameters. This paper discusses the potential of these two rapid prototyping technologies and their suitability for specific printing applications.

scholarly journals A Comparative Analysis of Selected Methods for Determining Young’s Modulus in Polylactic Acid Samples Manufactured with the FDM Method

Materials ◽  
2021 ◽  
Vol 15 (1) ◽  
pp. 149
Author(s):  
Bartosz Pszczółkowski ◽  
Konrad W. Nowak ◽  
Wojciech Rejmer ◽  
Mirosław Bramowicz ◽  
Łukasz Dzadz ◽  
...  
Keyword(s):  
Young’S Modulus ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Young's Modulus ◽  
Acrylonitrile Butadiene Styrene ◽  
Tensile Tests ◽  
Fused Filament Fabrication ◽  
Fused Deposition ◽  
Static Tensile ◽  
Deposition Modeling

The objective of this study was to compare three methods for determining the Young’s modulus of polylactic acid (PLA) and acrylonitrile-butadiene-styrene (ABS) samples. The samples were manufactured viathe fused filament fabrication/fused deposition modeling (FFF/FDM) 3D printing technique. Samples for analysis were obtained at processing temperatures of 180 °C to 230 °C. Measurements were performed with the use of two nondestructive techniques: the impulse excitation technique (IET) and the ultrasonic (US) method. The results were compared with values obtained in static tensile tests (STT), which ranged from 2.06 ± 0.03 to 2.15 ± 0.05 GPa. Similar changes in Young’s modulus were observed in response to the processing temperatures of the compared methods. The values generated by the US method were closer to the results of the STT, but still diverged considerably, and the error exceeded 10% in all cases. Based on the present findings, it might be concluded that the results of destructive and nondestructive tests differ by approximately 1 GPa.

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