Maximization of FDM-3D-Objects Gonio-Appearance Effects Using PLA and ABS Filaments and Combining Several Printing Parameters: “A Case Study”

In order to consider 3D objects from suitable Fused Deposition Modelling (FDM) printers as prototypes for the automotive sector, this sample must be able to reproduce textural effects (sparkle or graininess) or metallic or gonio-appearance to reinforce the attractive appeal of these materials. This study worked with two different commercial filaments: grey metallic PLA (poly(lactic acid)) and ABS (acrylonitrile-butadiene-styrene copolymer) with diffractive pigments. For both materials, a statistical design of experiments (DoE) was carried out to find the printing parameters effect on the final 3D-objects gonio-appearance. The selected printing parameters were printing speed (2 levels), layer height (2 levels) and sample thickness (3 levels). Twelve smooth square objects were printed from each material. The ABS-diffractive filaments achieved the most significant flop and higher sparkle values than metallic PLA. Graininess was high when working with PLA filaments instead of ABS. Layer height was the most significant parameter to maximize PLA objects’ flop or sparkle effects. The best result was found when printing at 0.1 mm. For the ABS samples, the stronger flop and sparkle effects were achieved with the 50 mm/s printing speed, the 0.1 mm layer height and the lowest thickness level. This study shows the methodology to study the printing parameters effects and interactions to maximize the FDM-3D-objects gonio-appearance.

Download Full-text

Tensile Mechanical Behaviour of Multi-Polymer Sandwich Structures via Fused Deposition Modelling

Polymers ◽

10.3390/polym12030651 ◽

2020 ◽

Vol 12 (3) ◽

pp. 651 ◽

Cited By ~ 8

Author(s):

David Moises Baca Lopez ◽

Rafiq Ahmad

Keyword(s):

Mechanical Properties ◽

Low Cost ◽

Acrylonitrile Butadiene Styrene ◽

Extrusion Process ◽

Poly Lactic Acid ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

Homogeneous Materials ◽

Flexural Tests ◽

High Level

The application of single homogeneous materials produced through the fused deposition modelling (FDM) technology restricts the production of high-level multi-material components. The fabrication of a sandwich-structured specimen with different material combinations using conventional thermoplastics such as poly (lactic acid) (PLA), acrylonitrile butadiene styrene (ABS) and high impact polystyrene (HIPS) through the filament-based extrusion process can demonstrate an improvement on its properties. This paper aims to assess among these materials, the best material sandwich-structured arrangement design, to enhance the mechanical properties of a part and to compare the results with the homogeneous materials selected. The samples were subjected to tensile testing to identify the tensile strength, elongation at break and Young’s modulus of each material combination. The experimental results demonstrate that applying the PLA-ABS-PLA sandwich arrangement leads to the best mechanical properties between these materials. This study enables users to consider sandwich structure designs as an alternative to manufacturing multi-material components using conventional and low-cost materials. Future work will consider the flexural tests to identify the maximum stresses and bending forces under pressure.

Download Full-text

Tribology behaviour investigation of 3D printed polymers

International Review of Applied Sciences and Engineering ◽

10.1556/1848.2019.0021 ◽

2019 ◽

Vol 10 (2) ◽

pp. 173-181

Author(s):

Muammel M. Hanon ◽

Márk Kovács ◽

László Zsidai

Keyword(s):

Acrylonitrile Butadiene Styrene ◽

Poly Lactic Acid ◽

Fused Deposition Modelling ◽

Tribological Behaviour ◽

Fused Deposition ◽

Motion System ◽

Friction Factors ◽

The Coefficient Of Friction ◽

3D Printed ◽

The Difference

3D printing of Acrylonitrile Butadiene Styrene (ABS) and Poly Lactic Acid (PLA) were used to prepare specimens utilising fused deposition modelling (FDM) technology. Two colours of PLA filament were printed; white and grey, whereas ABS only in white colour. Determining the tribological properties of 3D printed samples have been carried out, through obtaining the frictional features of different 3D printable filaments. Alternating-motion system employed for measuring the tribological factors. Studying the difference between static and dynamic friction factors and the examination of wear values were included. A comparison among the tribological behaviour of the 3D printed polymers has been investigated. The printed white ABS and PLA specimens show insignificant differences in the results tendency. On the contrary, the grey PLA exhibits a considerable variation due to the incredible growth in the coefficient of friction and wear average as well.

Download Full-text

Modelling and Investigation of Crack Growth for 3D-Printed Acrylonitrile Butadiene Styrene (ABS) with Various Printing Parameters and Ambient Temperatures

Polymers ◽

10.3390/polym13213737 ◽

2021 ◽

Vol 13 (21) ◽

pp. 3737

Author(s):

Yousef Lafi A. Alshammari ◽

Feiyang He ◽

Muhammad A. Khan

Keyword(s):

3D Printing ◽

Crack Growth ◽

Three Dimensional ◽

Acrylonitrile Butadiene Styrene ◽

Fused Deposition Modelling ◽

Structural Dynamic ◽

Fused Deposition ◽

Nozzle Size ◽

Printing Parameters ◽

Butadiene Styrene

Three-dimensional (3D) printing is one of the significant industrial manufacturing methods in the modern era. Many materials are used for 3D printing; however, as the most used material in fused deposition modelling (FDM) technology, acrylonitrile butadiene styrene (ABS) offers good mechanical properties. It is perfect for making structures for industrial applications in complex environments. Three-dimensional printing parameters, including building orientation, layers thickness, and nozzle size, critically affect the crack growth in FDM structures under complex loads. Therefore, this paper used the dynamic bending vibration test to investigate their influence on fatigue crack growth (FCG) rate under dynamic loads and the Paris power law constant C and m. The paper proposed an analytical solution to determine the stress intensity factor (SIF) at the crack tip based on the measurement of structural dynamic response. The experimental results show that the lower ambient temperature, as well as increased nozzle size and layer thickness, provide a lower FCG rate. The printing orientation, which is the same as loading, also slows the crack growth. The linear regression between these parameters and Paris Law’s coefficient also proves the same conclusion.

Download Full-text

Mechanical properties of an additive manufactured CF-PLA/ABS hybrid composite sheet

Journal of Thermoplastic Composite Materials ◽

10.1177/0892705719869407 ◽

2019 ◽

pp. 089270571986940

Author(s):

Syed Waqar Ahmed ◽

Ghulam Hussain ◽

Khalid A Al-Ghamdi ◽

Khurram Altaf

Keyword(s):

Fused Deposition Modeling ◽

Mechanical Performance ◽

Hybrid Composites ◽

Desirability Function ◽

Acrylonitrile Butadiene Styrene ◽

Composite Sheet ◽

Layer Height ◽

Fused Deposition ◽

Laminar Composites ◽

Printing Speed

Laminar composites have widespread applications in the automotive and aircraft industry. This research was aimed to investigate the suitability of fused deposition modeling to produce multi-material laminar composites. Composites comprising of two dissimilar laminates, named as hybrid composites, were printed from acrylonitrile butadiene styrene filament and carbon fiber-reinforced polylactic acid filament (a composite filament) by varying different printing parameters. Tensile tests were conducted to examine the mechanical performance of the produced composite sheet. A detailed analysis of the results revealed that a high ultimate tensile strength is primarily achieved by setting low values of printing speed, layer height, and clad ratio while high elongation is obtained by employing low printing speed, medium layer height, and high clad ratio. The optimum printing conditions were sought out through desirability function with an objective to simultaneously enhance all the considered properties. Further, the composite sheet exhibited a reasonably good combination of tensile properties as compared to its monolithic constituent sheets. Based on the results, it is concluded that the bi-material laminating approach employed herein can produce printed structures with desired properties.

Download Full-text

Influence of ABS print parameters on a 3D open-source, self-replicable printer

Rapid Prototyping Journal ◽

10.1108/rpj-10-2019-0267 ◽

2020 ◽

Vol 26 (10) ◽

pp. 1733-1738

Author(s):

André Luiz Alves Guimarães ◽

Vicente Gerlin Neto ◽

Cesar Renato Foschini ◽

Maximiliano dos Anjos Azambuja ◽

Luiz Antonio Vasques Hellmeister

Keyword(s):

Mechanical Properties ◽

Tensile Strength ◽

Open Source ◽

Layer Thickness ◽

Acrylonitrile Butadiene Styrene ◽

Influential Factor ◽

Fused Deposition Modelling ◽

Content Type ◽

Fused Deposition ◽

Printing Parameters

Purpose The purpose of this paper is to investigate and discuss the influence of printing parameters on the mechanical properties of acrylonitrile butadiene styrene (ABS) print by fused deposition modelling (FDM). The mechanical properties of ABS are highly influenced by printing parameters, and they determine the final product quality of printed pieces. Design/methodology/approach For the paper’s purpose, five main parameters (extrusion temperature, infill pattern, air gap, printing speed and layer thickness) were selected and varied during ABS printing on an open-source and self-replicable FDM printer. Three different colors of commercially available ABS were also used to investigate color and printing parameter’s influence on the tensile strength. Findings The research results suggest that two parameters (infill pattern and layer thickness) were most influential on the mechanical properties of print ABS, being able to enhance its tensile strength. Another key influential factor was material color selected prior to printing, which influenced the tensile strength of the print specimen. Originality/value This study provides information on print parameters’ influence on the tensile strength of ABS print on replicable open-source three-dimensional (3D) printers. It also suggests the influence of materials’ color on print pieces’ tensile strength, indicating a new parameter for materials selection for 3D printing.

Download Full-text

Increasing the Tensile Strength of 3d printed Poly lactic Acid (PLA) Using Design of Experiments (DOE)

Advances in Nanoscience and Nanotechnology ◽

10.33140/ann.03.02.4 ◽

2019 ◽

Vol 3 (2) ◽

Keyword(s):

Tensile Strength ◽

Low Cost ◽

Poly Lactic Acid ◽

Fused Deposition Modelling ◽

Environmental Friendliness ◽

Fused Deposition ◽

3D Printed ◽

Nozzle Temperature ◽

Plastic Parts ◽

Printing Speed

Experimental design has been used to determine outlying factors that affect tensile strength of fused deposition modelling 3D printed PLA parts. A two level, three factor full factorial experiments were utilized to determine the best combination of factors that yielded the highest tensile strength of PLA tensile dog bones manufactured in accordance with ASTM D638-14. PLA is particularly desirable due to its environmental friendliness, biodegradability, low cost, and low melting point, allowing it to be built on a non-heated platform without risk of toxic fumes. Increasing the tensile strength of PLA will allow PLA to be used in a wider range of applications that demand stronger plastic parts. The chosen factors were infill percentage, nozzle temperature, and printing speed. The tensile strength was affected by all factors and combinations except for high levels of infill percentage, nozzle temperature, and printing speed combined.

Download Full-text

Effect of Printing Parameters on the Mechanical Properties of Parts Fabricated with Open-Source 3D Printers in PLA by Fused Deposition Modeling

Mechanics and Mechanical Engineering ◽

10.2478/mme-2018-0070 ◽

2020 ◽

Vol 22 (4) ◽

pp. 895-908

Author(s):

M. Ouhsti ◽

B. El Haddadi ◽

S. Belhouideg

Keyword(s):

Mechanical Properties ◽

Polylactic Acid ◽

Fused Deposition Modeling ◽

Acrylonitrile Butadiene Styrene ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

3D Printers ◽

Deposition Modeling ◽

Printed Materials ◽

Printing Parameters

Abstract3D polymer-based printers have become easily accessible to the public. Usually, the technology used by these 3D printers is Fused Deposition Modelling (FDM). The majority of these 3D printers mainly use acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) to fabricate 3D objects. In order for the printed parts to be useful for specific applications, the mechanical properties of the printed parts must be known. The aim of this study is to determine the tensile strength and elastic modulus of printed materials in polylactic acid (PLA) according to three important printing parameters such as deposition angle, extruder temperature and printing speed. The central composite design (CCD) was used to reduce the number of tensile test experiments. The obtained results show that the mechanical properties of printed parts depend on printing parameters. Empirical models relating response and process parameters are developed. The analysis of variance (ANOVA) was used to test the validity of models relating response and printing parameters. The optimal printing parameters are determined for the desired mechanical properties.

Download Full-text

3D FDM production and mechanical behavior of polymeric sandwich specimens embedding classical and honeycomb cores

Curved and Layered Structures ◽

10.1515/cls-2018-0007 ◽

2018 ◽

Vol 5 (1) ◽

pp. 80-94 ◽

Cited By ~ 11

Author(s):

Salvatore Brischetto ◽

Carlo Giovanni Ferro ◽

Roberto Torre ◽

Paolo Maggiore

Keyword(s):

Low Cost ◽

Acrylonitrile Butadiene Styrene ◽

Poly Lactic Acid ◽

Fused Deposition Modelling ◽

Structural Elements ◽

Honeycomb Core ◽

Three Point Bending ◽

Fused Deposition ◽

Small Uav ◽

Honeycomb Cores

Abstract Desktop 3D FDM (Fused Deposition Modelling) printers are usually employed for the production of nonstructural objects. In recent years, the present authors tried to use this technology also to produce structural elements employed in the construction of small UAVs (Unmanned Aerial Vehicles). Mechanical stresses are not excessive for small multirotor UAVs. Therefore, the FDM technique combined with polymers, such as the ABS (Acrylonitrile Butadiene Styrene) and the PLA(Poly Lactic Acid), can be successfully employed to produce structural components. The present new work is devoted to the production and preliminary structural analysis of sandwich configurations. These new lamination schemes could lead to an important weight reduction without significant decreases of mechanical properties. Therefore, it could be possible, for the designed application (e.g., a multifunctional small UAV produced via FDM), to have stiffener and lighter structures easy to be manufactured with a low-cost 3D printer. The new sandwich specimens here proposed are PLA sandwich specimens embedding a PLA honeycomb core produced by means of the same extruder, multilayered specimens with ABS external layers and an internal homogeneous PLA core using different extruders for the two materials, sandwich specimens with external ABS skins and an internal PLA honeycomb core using different extruders for the two materials, and sandwich specimens where two different extruders have been employed for PLA material used for skins and for the internal honeycomb core. For all the proposed configurations, a detailed description of the production activity is given.Moreover, several preliminary results about three-point bending tests, different mechanical behaviors and relative delamination problems for each sandwich configuration will be discussed in depth.

Download Full-text

Effects of vacuum exposure on mechanical properties of thermoplastic materials

Revista Brasileira de Aplicações de Vácuo ◽

10.17563/rbav.v40.1193 ◽

2021 ◽

Vol 40 (1) ◽

Author(s):

Tiago Rodrigues Dos Santos ◽

Isla Kalleny Marques Brandão ◽

Mateus Silva Sant'Ana ◽

Pedro Henrique dos Santos Alves ◽

Rana Mayeli Piêgas Taborda ◽

...

Keyword(s):

Mechanical Properties ◽

Additive Manufacturing ◽

Polymeric Materials ◽

Acrylonitrile Butadiene Styrene ◽

Pressure Oscillation ◽

Bending Test ◽

Poly Lactic Acid ◽

Fused Deposition Modelling ◽

Space Applications ◽

Fused Deposition

The present paper proposes the study of the behavior of three thermoplastic materials: acrylonitrile butadiene styrene (ABS), poly(lactic acid) (PLA), and polyethylene glycol terephthalate (PETG), processed by additive manufacturing type fused deposition modelling (FDM) when exposed to low vacuum. The experiment was composed of three moments consisting of tridimensional modeling and manufacturing of the specimens, drying process and vacuum exposure for 24 hours, according to American Society for Testing and Materials (ASTM) D6653/D6653M standards, and bending test for the determination of mechanical properties, based on ASTM D790 standards. The vacuum chamber tests exposed oscillations in the pressure indicating gases releasing from the specimen, but none of the samples showed visible deformations. Subjecting the materials exposed to low vacuum to bending tests and comparing them to the unexposed material, we observed a significant increase in the calculated modulus of elasticity and a change in the slope of graphic force versus deflection in all materials. This behavior demonstrates that it is possible to submit polymeric materials to vacuum, and low vacuum exposure can be a treatment for thermoplastic materials. In the future, a study using a spectrometer will be necessary to verify which gases are present during pressure oscillation in the chamber, thus making it possible to understand which factor has increased the mechanical properties of the materials. In sequence, experiments will be necessary to validate the vacuum exposure as a form of treatment of materials and to verify the possibility of applying thermoplastics commonly used in additive manufacturing for low-impact space applications.

Download Full-text

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

Journal of Composites Science ◽

10.3390/jcs5010029 ◽

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.

Download Full-text