Influence of Layer Thickness and Raster Angle on the Mechanical Properties of 3D-Printed PEEK and a Comparative Mechanical Study between PEEK and ABS

3D printing using fused composite filament fabrication technique (FFF) allows prototyping and manufacturing of durable, lightweight, and customizable parts on demand. Such composites demonstrate significantly improved printability, due to the reduction of shrinkage and warping, alongside the enhancement of strength and rigidity. In this work, we use polypropylene filament reinforced by short glass fibers to demonstrate the effect of fiber orientation on mechanical tensile properties of the 3D printed specimens. The influence of the printed layer thickness and raster angle on final fiber orientations was investigated using X-ray micro-computed tomography. The best ultimate tensile strength of 57.4 MPa and elasticity modulus of 5.5 GPa were obtained with a 90° raster angle, versus 30.4 MPa and 2.5 GPa for samples with a criss-cross 45°, 135° raster angle, with the thinnest printed layer thickness of 0.1 mm.

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Tailoring physico-mechanical properties and rheological behavior of ABS filaments for FDM via blending with SEBS TPE

Rapid Prototyping Journal ◽

10.1108/rpj-06-2019-0173 ◽

2020 ◽

Vol 26 (10) ◽

pp. 1687-1700

Author(s):

Mozhgan Sayanjali ◽

Amir Masood Rezadoust ◽

Foroud Abbassi Sourki

Keyword(s):

Mechanical Properties ◽

Surface Roughness ◽

3D Printing ◽

Impact Strength ◽

Layer Thickness ◽

Melt Mixing ◽

Content Type ◽

Build Orientation ◽

Raster Angle ◽

The Impact

Purpose This paper aims to focus on the development of the three-dimensional (3D) printing filaments based on acrylonitrile butadiene styrene (ABS) copolymer and styrene-ethylene/butylene-styrene (SEBS) block copolymer, with tailored viscoelastic properties and controlled flow during the 3D printing process. Design/methodology/approach In this investigation, ABS was blended with various amounts of SEBS via a melt mixing process. Then the ABS/SEBS filaments were prepared by a single-screw extruder and printed by the FDM method. The rheological properties were determined using an MCR 501 from Anton-Paar. The melt flow behavior of ABS/SEBS filaments was determined. The morphology of the filaments was studied by scanning electron microscope and the mechanical (tensile and impact) properties, surface roughness and void content of printed samples were investigated. Findings The rheological results can accurately interpret what drives the morphology and mechanical properties’ changes in the blends. The impact strength, toughness, elongation-at-break and anisotropy in mechanical properties of ABS samples were improved concurrently by adding 40 Wt.% of SEBS. The optimal tensile properties of blend containing 40 Wt.% SEBS samples were obtained at −45°/+45° raster angle, 0.05 mm layer thickness and XYZ build orientation. Optimized samples showed an 890% increase in elongation compared to neat ABS. Also, the impact strength of ABS samples showed a 60% improvement by adding 40 Wt.% SEBS. Originality/value The paper simultaneously evaluates the effects of material composition and 3D printing parameters (layer thickness, raster angle and build orientation) on the rheology, morphology, mechanical properties and surface roughness. Also, a mechanical properties comparison between printed samples and their compression-molded counterpart was conducted.

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Surface Finishing of FDM-Fabricated Amorphous Polyetheretherketone and Its Carbon-Fiber-Reinforced Composite by Dry Milling

Polymers ◽

10.3390/polym13132175 ◽

2021 ◽

Vol 13 (13) ◽

pp. 2175

Author(s):

Cheng Guo ◽

Xiaohua Liu ◽

Guang Liu

Keyword(s):

Carbon Fiber ◽

Layer Thickness ◽

Surface Quality ◽

Feed Rate ◽

Depth Of Cut ◽

Dry Milling ◽

Staircase Effect ◽

Raster Angle ◽

3D Printed

In recent years, many investigations have been devoted to fused deposition modeling (FDM) of high-performance polymer-polyetheretherketone (PEEK) and carbon-fiber-reinforced PEEK (CF/PEEK) for biomedical and aerospace applications. However, the staircase effect naturally brought about by FDM restricts further applications of 3D-printed PEEK and its composites in high-temperature molds, medical implants, and precision components, which require better or customized surface qualities. Hence, this work aimed to reduce the staircase effect and improve the surface quality of 3D-printed PEEK and CF/PEEK parts by dry milling of the fluctuant exterior surface. The co-dependency between 3D printing parameters (raster angle and layer thickness) and milling parameters (depth of cut, spindle speed, and feed rate per tooth) were investigated through experiments. The difference in removal mechanisms for PEEK and CF/PEEK was revealed. It was confirmed that the smearing effect enhanced the surface quality based on the morphology analysis and the simulation model. Both the raster angle of +45°/−45° and the small layer thickness could improve the surface quality of these 3D-printed polymers after dry milling. A large depth of cut and a large feed rate per tooth were likely to deteriorate the finished polymer surface. The spindle speed could influence the morphologies without significant changes in roughness values. Finally, a demonstration was performed to verify that dry milling of 3D-printed amorphous PEEK and CF/PEEK parts could lead to a high surface quality for critical requirements.

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Printability and properties of 3D-printed poplar fiber/polylactic acid biocomposite

BioResources ◽

10.15376/biores.16.2.2774-2788 ◽

2021 ◽

Vol 16 (2) ◽

pp. 2774-2788

Author(s):

Zhaozhe Yang ◽

Xinhao Feng ◽

Min Xu ◽

Denis Rodrigue

Keyword(s):

Mechanical Properties ◽

3D Printing ◽

Rheological Properties ◽

Layer Thickness ◽

Polylactic Acid ◽

Physical And Mechanical Properties ◽

Longitudinal Stripe ◽

3D Printed ◽

First Time ◽

Printing Parameters

To efficiently and economically utilize a wood-plastic biocomposite, an eco-friendly biocomposite was prepared using modified poplar fiber and polylactic acid (PLA) via 3D printing technology for the first time. First, the effects of poplar fiber (0, 1, 3, 5, 7, and 9%) on the mechanical and rheological properties of the printed biocomposites were investigated. Subsequently, the printing parameters, including printing temperature, speed, and layer thickness, were optimized to obtain the biocomposite with superior properties. Finally, four printing orientations were applied to the biocomposite based on the optimized printing parameters to study the effect of filament orientation on the properties of the biocomposite. Favorable printability and mechanical properties of the biocomposite were obtained at 5% poplar fiber. The optimal printing temperature of 220 °C, speed of 40 mm/s, and layer thickness of 0.2 mm were obtained to produce the desired mechanical properties of the biocomposite with the printing orientation in a longitudinal stripe. However, the printing parameters should be chosen according to the applications, where different physical and mechanical properties are needed to achieve efficient and economical utilization of the biocomposites.

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Effect of layer thickness and raster angle on the tribological behavior of 3D printed materials

Materials Today Proceedings ◽

10.1016/j.matpr.2021.09.139 ◽

2021 ◽

Author(s):

Muhammad Syahmi Amirruddin ◽

Khairul Izwan Ismail ◽

Tze Chuen Yap

Keyword(s):

Layer Thickness ◽

Tribological Behavior ◽

Raster Angle ◽

3D Printed ◽

Printed Materials

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Optimization of FDM process parameters for tensile properties of polylactic acid specimens using Taguchi design of experiment method

Journal of Thermoplastic Composite Materials ◽

10.1177/0892705720964560 ◽

2020 ◽

pp. 089270572096456

Author(s):

M Heidari-Rarani ◽

N Ezati ◽

P Sadeghi ◽

MR Badrossamay

Keyword(s):

Mechanical Properties ◽

Tensile Properties ◽

Layer Thickness ◽

Polylactic Acid ◽

Process Parameters ◽

Design Of Experiment ◽

Taguchi Design Of Experiment ◽

Experiment Method ◽

3D Printed ◽

Printing Speed

Fused deposition modeling (FDM) is the most common method for additive manufacturing of polymers, which is expanding in various engineering applications due to its ability to make complex parts readily. The mechanical properties of 3D printed parts strongly depend on the correct selection of the process parameters. In this study, the effect of three important process parameters such as infill density, printing speed and layer thickness were investigated on the tensile properties of polylactic acid (PLA) specimens. Taguchi design of experiment method is applied to reduce the number of experiments and find the optimal parameters for maximum mechanical properties, minimum weight and minimum printing time. Experimental results showed that the optimum process parameters for the modulus of elasticity and ultimate tensile strength were infill density of 80%, printing speed of 40 mm/s and layer thickness of 0.1 mm, while for the failure strain were the infill density of 80%, printing speed of 40 mm/s and layer thickness of 0.2 mm. Finally, the accuracy of the Taguchi method was assessed for prediction of mechanical properties of FDM-3D printed specimens.

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Effects of printing layer thickness on mechanical properties of 3D-printed custom trays

Journal of Prosthetic Dentistry ◽

10.1016/j.prosdent.2020.08.025 ◽

2020 ◽

Author(s):

Yanping Liu ◽

Wei Bai ◽

Xian Cheng ◽

Jiehua Tian ◽

Donghao Wei ◽

...

Keyword(s):

Mechanical Properties ◽

Layer Thickness ◽

3D Printed

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Statistical models for the mechanical properties of 3D printed external medical aids

Rapid Prototyping Journal ◽

10.1108/rpj-02-2020-0033 ◽

2020 ◽

Vol ahead-of-print (ahead-of-print) ◽

Cited By ~ 1

Author(s):

Rafael Moreno ◽

Diego Carou ◽

Daniel Carazo-Álvarez ◽

Munish Kumar Gupta

Keyword(s):

Mechanical Properties ◽

Tensile Strength ◽

Ultimate Tensile Strength ◽

Statistical Models ◽

Mechanical Response ◽

Content Type ◽

Raster Angle ◽

Medical Aids ◽

3D Printed ◽

Printing Parameters

Purpose 3D printing is gaining attention in the medical sector for the development of customized solutions for a wide range of applications such as temporary external implants. The materials used for the manufacturing process are critical, as they must provide biocompatibility and adequate mechanical properties. This study aims to evaluate and model the influence of the printing parameters on the mechanical properties of two biocompatible materials. Design/methodology/approach In this study, the mechanical properties of 3D-printed specimens of two biocompatible materials (ABS medical and PLActive) were evaluated. The influence of several printing parameters (infill density, raster angle and layer height) was studied and modelled on three response variables: ultimate tensile strength, deformation at the ultimate tensile strength and Young’s modulus. Therefore, statistical models were developed to predict the mechanical responses based on the selected printing parameters. Findings The used methodology allowed obtaining compact models that show good fit, particularly, for both the ultimate tensile strength and Young’s modulus. Regarding the deformation at ultimate tensile strength, this output was found to be influenced by more factors and interactions, resulting in a slightly less precise model. In addition, the influence of the printing parameters was discussed in the work. Originality/value The presented paper proposed the use of statistical models to select the printing parameters (infill density, raster angle and layer height) to optimize the mechanical response of external medical aids. The models will help users, researchers and firms to develop optimized solutions that can reduce material costs and printing time but guaranteeing the mechanical response of the parts.

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