scholarly journals A Comparative Study of the Mechanical Properties of FDM 3D Prints Made of PLA and Carbon Fiber-Reinforced PLA for Thin-Walled Applications

Materials ◽  
2021 ◽  
Vol 14 (22) ◽  
pp. 7062
Author(s):  
Jerzy Bochnia ◽  
Malgorzata Blasiak ◽  
Tomasz Kozior
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
Lean Manufacturing ◽  
Industrial Revolution ◽  
Base Material ◽  
Dimensional Accuracy ◽  
Strength Analysis ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Thin Walled

This study focused on the analysis of the mechanical properties of thin-walled specimens fabricated by fused deposition modelling (FDM). Two materials were considered, i.e., polylactide (PLA) and polylactide with carbon fiber (PLA-CF). The article describes how the specimens with different thicknesses and printing orientations were designed, printed, measured to assess their geometric and dimensional accuracy, subjected to tensile testing, and examined using scanning electron microscopy. The data provided here can be used for further research aimed at improving filament deposition and modifying the base material by combining it with different components, for example carbon fiber. The investigations revealed that the properties of thin-walled elements produced by FDM varied significantly depending on the thickness. So far, this problem has not been investigated extensively. Research by analyzing the key parameter, which is the direction of printing that is important for thin-walled models, provides a lot of new information for designers and technologists and opens the way to further extended scientific research in the field of the strength analysis of thin-walled models produced by 3D printing, which is very applicable to structure optimization in the era of the industrial revolution 4.0 and progress in the LEAN manufacturing process.

scholarly journals Parameters Affecting the Mechanical Properties of Three-Dimensional (3D) Printed Carbon Fiber-Reinforced Polylactide Composites

Polymers ◽  
2020 ◽  
Vol 12 (11) ◽  
pp. 2456
Author(s):  
Demei Lee ◽  
Guan-Yu Wu
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
3D Printing ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Bed Temperature ◽  
3D Printed ◽  
The Impact

Three-dimensional (3D) printing is a manufacturing technology which creates three-dimensional objects layer-by-layer or drop-by-drop with minimal material waste. Despite the fact that 3D printing is a versatile and adaptable process and has advantages in establishing complex and net-shaped structures over conventional manufacturing methods, the challenge remains in identifying the optimal parameters for the 3D printing process. This study investigated the influence of processing parameters on the mechanical properties of Fused Deposition Modelling (FDM)-printed carbon fiber-filled polylactide (CFR-PLA) composites by employing an orthogonal array model. After printing, the tensile and impact strengths of the printed composites were measured, and the effects of different parameters on these strengths were examined. The experimental results indicate that 3D-printed CFR-PLA showed a rougher surface morphology than virgin PLA. For the variables selected in this analysis, bed temperature was identified as the most influential parameter on the tensile strength of CFR-PLA-printed parts, while bed temperature and print orientation were the key parameters affecting the impact strengths of printed composites. The 45° orientation printed parts also showed superior mechanical strengths than the 90° printed parts.

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.

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.

Effect of heat treatment on mechanical properties of 3D printed polylactic acid parts

2021 ◽  
Vol 63 (1) ◽  
pp. 73-78
Author(s):  
Pulkin Gupta ◽  
Sudha Kumari ◽  
Abhishek Gupta ◽  
Ankit Kumar Sinha ◽  
Prashant Jindal
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Polylactic Acid ◽  
Recrystallization Temperature ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Dog Bone ◽  
Heat Treated ◽  
Maximum Decrease ◽  
3D Printed

Abstract Fused deposition modelling (FDM) is a layer-by-layer manufacturing process type of 3D-printing (3DP). Significant variation in the mechanical properties of 3D printed specimens is observed because of varied process parameters and interfacial bonding between consecutive layers. This study investigates the influence of heat treatment on the mechanical strength of FDM 3D printed Polylactic acid (PLA) parts with constant 3DP parameters and ambient conditions. To meet the objectives, 7 sets, each containing 5 dog-bone shaped samples, were fabricated from commercially available PLA filament. Each set was subjected to heat treatment at a particular temperature for 1 h and cooled in the furnace itself, while one set was left un-treated. The temperature for heat treatment (Th) varied from 30 °C to 130 °C with increments of 10 °C. The heat-treated samples were characterized under tensile loading of 400 N and mechanical properties like Young’s modulus (E), Strain % ( ε ) and Stiffness (k) were evaluated. On comparing the mechanical properties of heat-treated samples to un-treated samples, significant improvements were observed. Heat treatment also altered the geometries of the samples. Mechanical properties improved by 4.88 % to 10.26 % with the maximum being at Th of 110 °C and below recrystallization temperature (Tr) of 65 °C. Deformations also decreased significantly at higher temperatures above 100 °C, by a maximum of 36.06 %. The dimensions of samples showed a maximum decrease of 1.08 % in Tr range and a maximum decrease of 0.31 % in weight at the same temperature. This study aims to benefit the society by establishing suitable Th to recover the lost strength in PLA based FDM 3D printed parts.

scholarly journals Dynamic Mechanical Properties of Fused Deposition Modelling Processed Polyphenylsulfone Material

2016 ◽  
Vol 9 (1) ◽  
pp. 1-11 ◽  
Author(s):  
Bolin Huang ◽  
S.H. Masood ◽  
Mostafa Nikzad ◽  
Prabhu Raja Venugopal ◽  
Adhiyamaan Arivazhagan
Keyword(s):  
Mechanical Properties ◽  
Dynamic Mechanical Properties ◽  
Fused Deposition Modelling ◽  
Dynamic Mechanical ◽  
Fused Deposition

On the manufacturability of Inconel 718 thin-walled honeycomb structures by laser powder bed fusion

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
José M. Zea Pérez ◽  
Jorge Corona-Castuera ◽  
Carlos Poblano-Salas ◽  
John Henao ◽  
Arturo Hernández Hernández
Keyword(s):  
Mechanical Properties ◽  
Inconel 718 ◽  
Dimensional Accuracy ◽  
Honeycomb Lattice ◽  
Lattice Structures ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Content Type ◽  
Powder Bed ◽  
Thin Walled

Purpose The purpose of this paper is to study the effects of printing strategies and processing parameters on wall thickness, microhardness and compression strength of Inconel 718 superalloy thin-walled honeycomb lattice structures manufactured by laser powder bed fusion (L-PBF). Design/methodology/approach Two printing contour strategies were applied for producing thin-walled honeycomb lattice structures in which the laser power, contour path, scanning speed and beam offset were systematically modified. The specimens were analyzed by optical microscopy for dimensional accuracy. Vickers hardness and quasi-static uniaxial compression tests were performed on the specimens with the least difference between the design wall thickness and the as built one to evaluate their mechanical properties and compare them with the counterparts obtained by using standard print strategies. Findings The contour printing strategies and process parameters have a significant influence on reducing the fabrication time of thin-walled honeycomb lattice structures (up to 50%) and can lead to improve the manufacturability and dimensional accuracy. Also, an increase in the young modulus up to 0.8 times and improvement in the energy absorption up to 48% with respect to those produced by following a standard strategy was observed. Originality/value This study showed that printing contour strategies can be used for faster fabrication of thin-walled lattice honeycomb structures with similar mechanical properties than those obtained by using a default printing strategy.

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