scholarly journals Environmental and Economic Analysis of FDM, SLS and MJF Additive Manufacturing Technologies

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4161 ◽  
Author(s):  
Vincenzo Tagliaferri ◽  
Federica Trovalusci ◽  
Stefano Guarino ◽  
Simone Venettacci
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Large Scale ◽  
Fused Deposition Modeling ◽  
Production Capacity ◽  
Optimal Choice ◽  
Scale Production ◽  
Fused Deposition ◽  
Manufacturing Technologies ◽  
The Impact

In this study, the authors present a comparative analysis of different additive manufacturing (AM) technologies for high-performance components. Four 3D printers, currently available on the Italian national manufacturing market and belonging to three different AM technologies, were considered. The analysis focused on technical aspects to highlight the characteristics and performance limits of each technology, economic aspects to allow for an assessment of the costs associated with the different processes, and environmental aspects to focus on the impact of the production cycles associated with these technologies on the ecosystem, resources and human health. This study highlighted the current limits of additive manufacturing technologies in terms of production capacity in the case of large-scale production of plastic components, especially large ones. At the same time, this study highlights how the geometry of the object to be developed greatly influences the optimal choice between the various AM technologies, in both technological and economic terms. Fused deposition modeling (FDM) is the technology that exhibits the greatest limitations hindering mass production due to production times and costs, but also due to the associated environmental impact.

scholarly journals Mass-production and Distribution of Medical Face Shields Using Additive Manufacturing and Injection Molding Process for Healthcare System Support During COVID-19 Pandemic in Brazil

2020 ◽  
Author(s):  
Maria Elizete Kunkel ◽  
Mayra Torres Vasques ◽  
João Aléssio Juliano Perfeito ◽  
Nataly Rabelo Mina Zambrana ◽  
Tainara dos Santos Bina ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Mass Production ◽  
Large Scale ◽  
Fused Deposition Modeling ◽  
Public Hospitals ◽  
Injection Molding Process ◽  
Scale Production ◽  
Molding Process ◽  
Fused Deposition

Abstract Face shields have been adopted worldwide as personal protective equipment for healthcare professionals during the COVID-19 pandemic. This device provides a transparent facial physical barrier reducing the exposure to aerosol particles. The fused deposition modeling (FDM) is the most applied process of additive manufacturing due to its usability and low-cost. The injection molding (IM) is the fastest process for mass production. This study is the first to perform a qualitative comparison between the use of FDM and IM processes for mass production and rapid distribution of face shields in a pandemic. The design of the face shield and tests were conducted in prototyping cycles based on requirements of medical, Brazilian standards, manufacturing, and production. The FDM face shields manufacturing was carried out by a volunteer network, and the IM manufacturing was carried out by companies. The volunteers produced 35,000 medical face shields through the FDM process with daily delivery to several hospitals. A total of 80,000 face shields was produced by the IM process and delivered to remote Brazilian regions. The mass production of 115,000 face shields protected health professionals from public hospitals in all states of Brazil. In a pandemic, both FDM and IM processes are suitable for mass production of face shields. Once a committed network of volunteers is formed in strategic regions, the FDM process promotes a fast daily production. The IM process is the best option for large scale production of face shields and delivery to remote areas where access to 3D printing is reduced.

scholarly journals Additive manufacturing and injection molding process for mass-production of face shields during COVID-19 pandemic: A comparative study 

2020 ◽  
Author(s):  
Maria Elizete Kunkel ◽  
Mayra Torres Vasques ◽  
João Aléssio Juliano Perfeito ◽  
Nataly Rabelo Mina Zambrana ◽  
Tainara dos Santos Bina ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Mass Production ◽  
Large Scale ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Injection Molding Process ◽  
Scale Production ◽  
Fused Deposition ◽  
Quality Costs

Abstract Face shield is a personal protective equipment required for healthcare professionals to decrease the risk of contamination during the COVID-19. Fused deposition modeling (FDM) is the most applied process of additive manufacturing due to its usability and low-cost. The injection molding (IM) is the fastest process for mass industrial production. The comparison between the FDM and IM process to produce plastic parts is well known, but this study is the first to perform a qualitative comparison of these processes for mass-production and distribution of face shields in a pandemic. The design of the face shield was developed in three prototyping cycles based on requirements of medical, Brazilian regulatory standards, manufacturing, and production. The FDM manufacturing of 35,000 face shields was carried out by a volunteer network using low-cost 3D printer and the IM manufacturing of 80,000 was carried out by partner companies. With the production of face shields through the FDM process, it was possible to make daily deliveries of small batches to local hospitals. A total of 80,000 face shields was produced in larger batches by the IM process and delivered to remote regions in Brazil. Considering the manufacturing resilience of the processes (quality, costs, and production time), in a situation such as the current COVID-19 pandemic with disturbances and uncertainties, both FDM and IM processes are suitable for mass production of face shields. The FDM process promotes a fast-daily production once a committed network of volunteers is formed in strategic regions. The IM process was the best option for large scale production of face shields and delivery to remote regions without the availability of 3D printers.

scholarly journals Precision and Energy Usage for Additive Manufacturing

2013 ◽  
Author(s):  
Lee Clemon ◽  
Anton Sudradjat ◽  
Maribel Jaquez ◽  
Aditya Krishna ◽  
Marwan Rammah ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Energy Demand ◽  
Fused Deposition Modeling ◽  
Distinct Pattern ◽  
Energy Usage ◽  
Warm Up ◽  
Part Quality ◽  
Fused Deposition ◽  
Manufacturing Technologies ◽  
Control Part

Market pressures on manufacturing enterprises incentivize minimum resource consumption while maintaining part quality. Facilities with advanced manufacturing tools often utilize rapid prototyping for production of complicated or specialty parts. Additive manufacturing offers an alternative to traditional production methods which are often time and resource expensive. This study aims to explore part quality and energy usage for additive manufacturing through a focused study of Fused Deposition Modeling and Photopolymer Jetting technologies. A control part is developed for maintaining test consistency across different machines. The control part design consists of various positive and negative features including width varied slots and walls, ramps, and curved features so that the manufacturing of different surfaces may be investigated. Several different machine models are tested to evaluate precision for a variety of applications. Part quality is quantified by measuring the surface roughness in two directions for the control test part printed on each machine. Qualitatively, part quality is assessed by positive and negative feature resolution. High quality machines resolve features closely to design specifications. Lower quality machines do not resolve some features. In addition to exploring the effects of advertised print precision, layup density is varied on two machines. Advertised print resolution does not well represent the achievable feature sizes found in this study. Energy usage is quantified by measuring electricity demands while printing the control part on each of the five different machines. Power consumption in additive manufacturing is found to follow a distinct pattern comprised of standby, warm up, printing and idle phases. Measurement and analysis suggest a relationship between the precision of these machines and their respective energy demand. Part quality is found to generally improve with increased initial and process resource investment. The energy and quality assessment methods developed in this study are applicable to a greater variety of additive manufacturing technologies and will assist designers as additive manufacturing becomes more production friendly. The presented data also provides designers and production planners insight for improvements in the process decision making.

Finite Element Analysis of Additive Manufacturing Based on Fused Deposition Modeling: Distortions Prediction and Comparison With Experimental Data

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
Alberto Cattenone ◽  
Simone Morganti ◽  
Gianluca Alaimo ◽  
Ferdinando Auricchio
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Step Size ◽  
Time Step ◽  
Time Step Size ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
The Impact ◽  
Functional Components

Additive manufacturing (or three-dimensional (3D) printing) is constantly growing as an innovative process for the production of complex-shape components. Among the seven recognized 3D printing technologies, fused deposition modeling (FDM) covers a very important role, not only for producing representative 3D models, but, mainly due to the development of innovative material like Peek and Ultem, also for realizing structurally functional components. However, being FDM a production process involving high thermal gradients, non-negligible deformations and residual stresses may affect the 3D printed component. In this work we focus on meso/macroscopic simulations of the FDM process using abaqus software. After describing in detail the methodological process, we investigate the impact of several parameters and modeling choices (e.g., mesh size, material model, time-step size) on simulation outcomes and we validate the obtained results with experimental measurements.

scholarly journals Hydrostatic High-Pressure Post-Processing of Specimens Fabricated by DLP, SLA, and FDM: An Alternative for the Sterilization of Polymer-Based Biomedical Devices

Materials ◽  
2018 ◽  
Vol 11 (12) ◽  
pp. 2540 ◽  
Author(s):  
José Linares-Alvelais ◽  
J. Figueroa-Cavazos ◽  
C. Chuck-Hernandez ◽  
Hector Siller ◽  
Ciro Rodríguez ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Tensile Modulus ◽  
High Pressure Processing ◽  
Biomedical Devices ◽  
Digital Light Processing ◽  
Fused Deposition ◽  
Manufacturing Technologies

In this work, we assess the effects of sterilization in materials manufactured using additive manufacturing by employing a sterilization technique used in the food industry. To estimate the feasibility of the hydrostatic high-pressure (HHP) sterilization of biomedical devices, we have evaluated the mechanical properties of specimens produced by commercial 3D printers. Evaluations of the potential advantages and drawbacks of Fused Deposition Modeling (FDM), Digital Light Processing (DLP) technology, and Stereolithography (SLA) were considered for this study due to their widespread availability. Changes in mechanical properties due to the proposed sterilization technique were compared to values derived from the standardized autoclaving methodology. Enhancement of the mechanical properties of samples treated with Hydrostatic high-pressure processing enhanced mechanical properties, with a 30.30% increase in the tensile modulus and a 26.36% increase in the ultimate tensile strength. While traditional autoclaving was shown to systematically reduce the mechanical properties of the materials employed and damages and deformation on the surfaces were observed, HHP offered an alternative for sterilization without employing heat. These results suggest that while forgoing high-temperature for sanitization, HHP processing can be employed to take advantage of the flexibility of additive manufacturing technologies for manufacturing implants, instruments, and other devices.

scholarly journals Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

2011 ◽  
Vol 199-200 ◽  
pp. 1984-1987 ◽  
Author(s):  
Olaf Diegel ◽  
Sarat Singamneni ◽  
Ben Huang ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Conductive Polymer ◽  
Fused Deposition ◽  
National University ◽  
Deposition Modeling ◽  
Plastic Components ◽  
Manufacturing Technologies ◽  
Plastic Parts

This paper describes a curved-layer additive manufacturing technology that has the potential to print plastic components with integral conductive polymer electronic circuits. Researchers at AUT University in New Zealand and the National University of Singapore have developed a novel Fused Deposition Modeling (FDM) process in which the layers of material that make up the part are deposited as curved layers instead of the conventional flat layers. This technology opens up possibilities of building curved plastic parts that have conductive electronic tracks and components printed as an integral part of the plastic component, thereby eliminating printed circuit boards and wiring. It is not possible to do this with existing flat-layer additive manufacturing technologies as the continuity of a circuit could be interrupted between the layers. With curved-layer fused deposition modeling (CLFDM) this problem is removed as continuous filaments in 3 dimensions can be produced, allowing for continuous conductive circuits.

scholarly journals Effect of Process Parameters on Energy Consumption, Physical, and Mechanical Properties of Fused Deposition Modeling

Polymers ◽  
2021 ◽  
Vol 13 (15) ◽  
pp. 2406
Author(s):  
Emmanuel U. Enemuoh ◽  
Stefan Duginski ◽  
Connor Feyen ◽  
Venkata G. Menta
Keyword(s):  
Energy Consumption ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Function Optimization ◽  
Free Form ◽  
Production Time ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
The Impact

The application of the fused deposition modeling (FDM) additive manufacturing process has increased in the production of functional parts across all industries. FDM is also being introduced for industrial tooling and fixture applications due to its capabilities in building free-form and complex shapes that are otherwise challenging to manufacture by conventional methods. However, there is not yet a comprehensive understanding of how the FDM process parameters impact the mechanical behavior of engineered products, energy consumption, and other physical properties for different material stocks. Acquiring this information is quite a complex task, given the large variety of possible combinations of materials–additive manufacturing machines–slicing software process parameters. In this study, the knowledge gap is filled by using the Taguchi L27 orthogonal array design of experiments to evaluate the impact of five notable FDM process parameters: infill density, infill pattern, layer thickness, print speed, and shell thickness on energy consumption, production time, part weight, dimensional accuracy, hardness, and tensile strength. Signal-to-noise (S/N) ratio analysis and analysis of variance (ANOVA) were performed on the experimental data to quantify the parameters’ main effects on the responses and establish an optimal combination for the FDM process. The novelty of this work is the simultaneous evaluation of the effects of the FDM process parameters on the quality performances because most studies have considered one or two of the performances alone. The study opens an opportunity for multiobjective function optimization of the FDM process that can be used to effectively minimize resource consumption and production time while maximizing the mechanical and physical characteristics to fit the design requirements of FDM-manufactured products.

scholarly journals Integration of Additive Manufacturing, Parametric Design, and Optimization of Parts Obtained by Fused Deposition Modeling (FDM). A Methodological Approach

Polymers ◽  
2020 ◽  
Vol 12 (9) ◽  
pp. 1993 ◽  
Author(s):  
Amabel García-Dominguez ◽  
Juan Claver ◽  
Miguel A. Sebastián
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Parametric Design ◽  
Methodological Approach ◽  
Visual Programming ◽  
Design And Optimization ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Manufacturing Technologies ◽  
General Geometry

The use of current computer tools in both manufacturing and design stages breaks with the traditional conception of productive process, including successive stages of projection, representation, and manufacturing. Designs can be programmed as problems to be solved by using computational tools based on complex algorithms to optimize and produce more effective solutions. Additive manufacturing technologies enhance these possibilities by providing great geometric freedom to the materialization phase. This work presents a design methodology for the optimization of parts produced by additive manufacturing and explores the synergies between additive manufacturing, parametric design, and optimization processes to guide their integration into the proposed methodology. By using Grasshopper, a visual programming application, a continuous data flow for parts optimization is defined. Parametric design tools support the structural optimization of the general geometry, the infill, and the shell structure to obtain lightweight designs. Thus, the final shapes are obtained as a result of the optimization process which starts from basic geometries, not from an initial design. The infill does not correspond to pre-established patterns, and its elements are sized in a non-uniform manner throughout the piece to respond to different local loads. Mass customization and Fused Deposition Modeling (FDM) systems represent contexts of special potential for this methodology.

scholarly journals 3D PRINTER DESIGN, MANUFACTURING AND EFFECT OF INFILL PATTERNS ON MECHANICAL PROPERTlES

2020 ◽  
Vol 4 (1) ◽  
pp. 13-24
Author(s):  
Hande Güler Özgül ◽  
Onur Tatlı
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Tensile Force ◽  
Three Dimensional ◽  
Charpy Impact ◽  
3D Printer ◽  
Direct Production ◽  
Fused Deposition ◽  
Technological Developments ◽  
Manufacturing Technologies

Along with the technological developments, it is an expected situation to discover new developed production methods. Additive manufacturing technologies, such as three-dimensional (3D) printers are one of these methods, allowing direct production of parts with complex geometries that cannot be produced by conventional methods. The most popular and inexpensive method among additive manufacturing technologies is FDM (Fused Deposition Modeling) method. This method is particularly interesting for the manufacture of parts with low production volumes. In this study, a 3D-FDM printer with a print volume of 200x200x210 mm has been designed and manufactured.PLA (polylactic acid) test samples having 2 different infill geometries were produced with the 3D printer. Tensile, three-point bending and charpyimpact tests were applied to these samples to investigate the effect of inner filling geometry on mechanical properties. The inner filling geometries are in the form of grid and gyroid. According to the results, while the geometry with the tensile force is "grid", while the geometry with the maximum bending force is "gyroid".It was concluded that different inner filling geometries do not have a significant impact on Charpy impact strength.

scholarly journals Getting Rid of the Wires: Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

2011 ◽  
Vol 467-469 ◽  
pp. 662-667 ◽  
Author(s):  
Olaf Diegel ◽  
Sarat Singamneni ◽  
Ben Huang ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Conductive Polymer ◽  
Plastic Shell ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Plastic Components ◽  
Manufacturing Technologies ◽  
Plastic Parts

This paper describes an additive manufacturing technology that has the potential to print plastic components with integral conductive polymer electronic circuits. This could have a major impact in the fields of robotics and mechatronics as it has the potential to allow large wiring looms, often an issue with complex robotic systems, to be printed as an integral part of the products plastic shell. This paper describes the development of a novel Fused Deposition Modeling (FDM) process in which the layers of material that make up the part are deposited as curved layers instead of the conventional flat layers. This opens up possibilities of building curved plastic parts that have conductive electronic tracks and components printed as an integral part of the plastic component, thereby eliminating printed circuit boards and wiring. It is not possible to do this with existing flatlayer additive manufacturing technologies as the continuity of a circuit could be interrupted between the layers. With curved-layer fused deposition modeling (CLFDM) this problem is removed as continuous filaments in 3 dimensions can be produced, allowing for continuous conductive circuits.

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