scholarly journals FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

Polymers ◽  
2020 ◽  
Vol 12 (7) ◽  
pp. 1529 ◽  
Author(s):  
Sachini Wickramasinghe ◽  
Truong Do ◽  
Phuong Tran
Keyword(s):  
Mechanical Performance ◽  
Matrix Material ◽  
Void Formation ◽  
Fused Deposition Modelling ◽  
Treatment Methods ◽  
Fused Deposition ◽  
Raster Angle ◽  
Manufacturing Methods ◽  
The Impact ◽  
Printing Parameters

Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.

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

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.

scholarly journals Additive Manufacturing and Injection Moulding of High-Performance IF-WS2/PEEK Nanocomposites: A Comparative Study

2021 ◽  
Vol 8 ◽  
Author(s):  
Atefeh Golbang ◽  
Mozaffar Mokhtari ◽  
Eileen Harkin-Jones ◽  
Edward Archer ◽  
Alistair Mcilhagger
Keyword(s):  
Mechanical Properties ◽  
Injection Moulding ◽  
High Performance ◽  
Mechanical Performance ◽  
Particle Dispersion ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
3D Printed ◽  
Interlayer Bonding ◽  
The Impact

In this study, PEEK nanocomposites with 0, 0.5, 1, and 2wt% IF-WS2 were manufactured by injection moulding and Fused Deposition Modelling (FDM). To compare the impact of the two processing methods and the incorporated nanoparticles on the morphology, crystallization and final mechanical properties of the nanocomposites, SEM, DSC and tensile testing were performed. In general, a good distribution of nanoparticles was observed in PEEK, although larger agglomerates were visible at 2 wt% IF-WS2. The crystallization degree of PEEK increased with increasing loading of IF-WS2 nanoparticles up to 1wt% and then declined at 2 wt%, due to lower level of particle dispersion in this sample. The 3D printed samples showed slightly higher crystallinity at each IF-WS2 loading in relation to the injection moulded samples and extruded filaments, because of multiple reheating effect from subsequent layer deposition during FDM, causing recrystallization. In general, incorporation of IF-WS2 nanoparticles increased the mechanical properties of pure PEEK in both 3D printed and injection moulded samples. However, this increment was more noticeable in the 3D-printed nanocomposite samples, resulting in smaller gap between the mechanical properties of the 3D-printed samples and the injection moulded counterparts, in respect to pure PEEK, particularly at 1 wt% IF-WS2. This effect is ascribed to the increased inter-layer bonding of PEEK in the presence of IF-WS2 nanoparticles in FDM. In general, the lower mechanical properties of the 3D printed samples compared with the injection moulded ones are ascribed to poor interlayer bonding between the deposited layers and the presence of voids. However, addition of just 1 wt% of IF-WS2 nanoparticles into PEEK increased the tensile strength and Young’s modulus of the FDM PEEK materials to similar levels to those achieved for unfilled injection moulded PEEK. Therefore, incorporation of IF-WS2 nanoparticles into PEEK is a useful strategy to improve the mechanical performance of FDM PEEK.

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.

Performance of Low-Cost 3D Printer in Medical Application

2021 ◽  
Author(s):  
Nor Aiman Sukindar ◽  
Azib Azhari Awang Dahan ◽  
Sharifah Imihezri Syed Shaharuddin ◽  
Nor Farah Huda Abd Halim
Keyword(s):  
Low Cost ◽  
Medical Application ◽  
Fused Deposition Modelling ◽  
3D Printer ◽  
Layer By Layer ◽  
Total Deformation ◽  
Element Analysis ◽  
Porosity Level ◽  
Fused Deposition ◽  
Printing Parameters

Abstract Fused Deposition Modelling (FDM) is an additive manufacturing (AM) process that produces a physical object directly from a CAD design using layer-by-layer deposition of the filament material that is extruded via a nozzle. In industry, FDM has become one of the most used AM processes for the production of low batch quantity and functional prototypes, due to its safety, efficiency, reliability, low cost, and ability to process manufacturing-grade engineering thermoplastic. Recently, the market is flooded with the availability of low-cost printers produced by numerous companies. This research aims to investigate the effect of different porosity levels on a scaffold structure produced using a low-cost 3D printer. Comparisons of these porous structures were made in terms of Von-Mises strain, total deformation, as well as compressive stress. Various porosity levels were created by varying printing parameters, including layer height, infill density, and shell thickness by slicing the initial solid CAD file using Repetier Host 3D printing software. Finite Element Analysis (FEA) simulation was then performed on the created scaffold structures by using Ansys Workbench 19.2. The simulation result indicates that the greater porosity level will result in higher total deformation of the structure. Meanwhile, the compression test shows that the minimum strength value obtained was favourable at 22 MPa and had exceeded that of the trabecular femur (15 MPa). However, its porosity level (maximum at 52%) was still below that of the minimum threshold of porosity level of 70 percent. However, the printing parameters currently used can be adjusted in the future. Therefore, it was deduced that the low-cost 3D printer offers promising potential to fabricate different porosity structures with multiple outcomes.

scholarly journals The Influence of Manufacturing Parameters on the Mechanical Behaviour of PLA and ABS Pieces Manufactured by FDM: A Comparative Analysis

Materials ◽  
2018 ◽  
Vol 11 (8) ◽  
pp. 1333 ◽  
Author(s):  
Adrián Rodríguez-Panes ◽  
Juan Claver ◽  
Ana Camacho
Keyword(s):  
Tensile Strength ◽  
Mechanical Behaviour ◽  
Mechanical Performance ◽  
Acrylonitrile Butadiene Styrene ◽  
Polymer Materials ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Layer Orientation ◽  
Lower Variability

This paper presents a comparative study of the tensile mechanical behaviour of pieces produced using the Fused Deposition Modelling (FDM) additive manufacturing technique with respect to the two types of thermoplastic material most widely used in this technique: polylactide (PLA) and acrylonitrile butadiene styrene (ABS). The aim of this study is to compare the effect of layer height, infill density, and layer orientation on the mechanical performance of PLA and ABS test specimens. The variables under study here are tensile yield stress, tensile strength, nominal strain at break, and modulus of elasticity. The results obtained with ABS show a lower variability than those obtained with PLA. In general, the infill percentage is the manufacturing parameter of greatest influence on the results, although the effect is more noticeable in PLA than in ABS. The test specimens manufactured using PLA perform more rigidly and they are found to have greater tensile strength than ABS. The bond between layers in PLA turns out to be extremely strong and is, therefore, highly suitable for use in additive technologies. The methodology proposed is a reference of interest in studies involving the determination of mechanical properties of polymer materials manufactured using these technologies.

scholarly journals Strength Comparison of FDM 3D Printed PLA Made by Different Manufacturers

TEM Journal ◽  
2020 ◽  
pp. 966-970
Author(s):  
Damir Hodžić ◽  
Adi Pandžić ◽  
Ismar Hajro ◽  
Petar Tasić
Keyword(s):  
Experimental Study ◽  
Additive Manufacturing ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Manufacturing Technique ◽  
Plastic Materials ◽  
Wide Range ◽  
3D Printed ◽  
The Difference ◽  
Printing Parameters

Widely used additive manufacturing technique for plastic materials is Fused Deposition Modelling (FDM). The FDM technology has gained interest in industry for a wide range of applications, especially today when large number of different materials on the market are available. There are many different manufacturers for the same FDM material where the difference in price goes up to 50%. This experimental study investigates possible difference in strength of the 3D printed PLA material of five different manufacturers. All specimens are 3D printed on Ultimaker S5 printer with the same printing parameters, and they are all the same colour.

Use of polymer concrete for large-scale 3D printing

2021 ◽  
Vol 27 (3) ◽  
pp. 465-474
Author(s):  
Martin Krčma ◽  
David Škaroupka ◽  
Petr Vosynek ◽  
Tomáš Zikmund ◽  
Jozef Kaiser ◽  
...  
Keyword(s):  
3D Printing ◽  
Large Scale ◽  
Mechanical Performance ◽  
Construction Material ◽  
Polymer Concrete ◽  
Fused Deposition Modelling ◽  
Cast State ◽  
Content Type ◽  
Fused Deposition ◽  
3D Printed

Purpose This paper aims to focus on the evaluation of a polymer concrete as a three-dimensional (3D) printing material. An associated company has developed plastic concrete made from reused unrecyclable plastic waste. Its intended use is as a construction material. Design/methodology/approach The concrete mix, called PolyBet, composed of polypropylene and glass sand, is printed by the fused deposition modelling process. The process of material and parameter selection is described. The mechanical properties of the filled material were compared to its cast state. Samples were made from castings and two different orientations of 3D-printed parts. Three-point flex tests were carried out, and the area of the break was examined. Computed tomography of the samples was carried out. Findings The influence of the 3D printing process on the material was evaluated. The mechanical performance of the longitudinal samples was close to the cast state. There was a difference in the failure mode between the states, with cast parts exhibiting a tougher behaviour, with fractures propagating in a stair-like manner. The 3D-printed samples exhibited high degrees of porosity. Originality/value The results suggest that the novel material is a good fit for 3D printing, with little to no degradation caused by the process. Layer adhesion was shown to be excellent, with negligible effect on the finished part for the longitudinal orientation. That means, if large-scale testing of buildability is successful, the material is a good fit for additive manufacturing of building components and other large-scale structures.

scholarly journals Lignin: A Biopolymer from Forestry Biomass for Biocomposites and 3D Printing

Materials ◽  
2019 ◽  
Vol 12 (18) ◽  
pp. 3006 ◽  
Author(s):  
Mihaela Tanase-Opedal ◽  
Eduardo Espinosa ◽  
Alejandro Rodríguez ◽  
Gary Chinga-Carrasco
Keyword(s):  
3D Printing ◽  
Radical Scavenging Activity ◽  
Matrix Material ◽  
Thermo Gravimetric Analysis ◽  
Radical Scavenging ◽  
Fused Deposition Modelling ◽  
Gravimetric Analysis ◽  
Scanning Calorimetry ◽  
Biobased Materials ◽  
Fused Deposition

Biopolymers from forestry biomass are promising for the sustainable development of new biobased materials. As such, lignin and fiber-based biocomposites are plausible renewable alternatives to petrochemical-based products. In this study, we have obtained lignin from Spruce biomass through a soda pulping process. The lignin was used for manufacturing biocomposite filaments containing 20% and 40% lignin and using polylactic acid (PLA) as matrix material. Dogbones for mechanical testing were 3D printed by fused deposition modelling. The lignin and the corresponding biocomposites were characterized in detail, including thermo-gravimetric analysis (TGA), differential scanning calorimetry (DSC), Fourier transform infrared (FTIR) spectroscopy, X-ray diffraction analysis (XRD), antioxidant capacity, mechanical properties, and scanning electron microscopy (SEM). Although lignin led to a reduction of the tensile strength and modulus, the reduction could be counteracted to some extent by adjusting the 3D printing temperature. The results showed that lignin acted as a nucleating agent and thus led to further crystallization of PLA. The radical scavenging activity of the biocomposites increased to roughly 50% antioxidant potential/cm2, for the biocomposite containing 40 wt % lignin. The results demonstrate the potential of lignin as a component in biocomposite materials, which we show are adequate for 3D printing operations.

Characterization of Micro-Features in Polymeric Drug Delivery Devices Using FDM

2007 ◽  
Author(s):  
S. H. Masood ◽  
Shivdeep Singh
Keyword(s):  
Drug Delivery ◽  
Controlled Drug Release ◽  
Fused Deposition Modelling ◽  
Drug Delivery Device ◽  
Fused Deposition ◽  
Polymeric Drug Delivery ◽  
Raster Angle ◽  
Polymeric Drug ◽  
Micro Features ◽  
Work Done

This paper presents the results of the experimental work done in applying the Fused Deposition Modelling (FDM) rapid prototyping technique to fabricate and characterise the porous polymeric matrix for controlled drug delivery device (DDD). With FDM technique, both macro and micro level structures of the device matrix can be produced and controlled, which provide several advantages over the conventional techniques of DDD fabrication. The paper investigates effect of various FDM parameters viz. Raster Width, Contour Width, Air-gap and Raster Angle on the controlled drug release profiles, drug infiltration and porosity of fabricated device matrices. The paper concludes that effective DDD matrices with desired release regimes can be fabricated using FDM technology with careful selection of FDM control parameters.

Raster angle mechanics in fused deposition modelling

2014 ◽  
Vol 49 (3) ◽  
pp. 363-383 ◽  
Author(s):  
Bin Huang ◽  
Sarat Singamneni
Keyword(s):  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Raster Angle
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