scholarly journals Optimisation of Strength Properties of FDM Printed Parts—A Critical Review

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1587
Author(s):  
Daniyar Syrlybayev ◽  
Beibit Zharylkassyn ◽  
Aidana Seisekulova ◽  
Mustakhim Akhmetov ◽  
Asma Perveen ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Complex Geometry ◽  
Positive Impact ◽  
Dimensional Accuracy ◽  
Strength Properties ◽  
Fused Filament Fabrication ◽  
Fused Deposition

Additive Manufacturing is currently growing fast, especially fused deposition modeling (FDM), also known as fused filament fabrication (FFF). When manufacturing parts use FDM, there are two key parameters—strength of the part and dimensional accuracy—that need to be considered. Although FDM is a popular technology for fabricating prototypes with complex geometry and other part product with reduced cycle time, it is also limited by several drawbacks including inadequate mechanical properties and reduced dimensional accuracy. It is evident that part qualities are greatly influenced by the various process parameters, therefore an extensive review of the effects of the following process parameters was carried out: infill density, infill patterns, extrusion temperature, layer thickness, nozzle diameter, raster angle and build orientation on the mechanical properties. It was found from the literature that layer thickness is the most important factor among the studied ones. Although manipulation of process parameters makes significant differences in the quality and mechanical properties of the printed part, the ideal combination of parameters is challenging to achieve. Hence, this study also includes the influence of pre-processing of the printed part to improve the part strength and new research trends such as, vacuum-assisted FDM that has shown to improve the quality of the printing due to improved bonding between the layers. Advances in materials and technologies that are currently under development are presented. For example, the pre-deposition heating method, using an IR lamp of other technologies, shows a positive impact on the mechanical properties of the printed parts.

scholarly journals Comparative Study of the Sensitivity of PLA, ABS, PEEK, and PETG’s Mechanical Properties to FDM Printing Process Parameters

Crystals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 995
Author(s):  
Mohammed Algarni ◽  
Sami Ghazali
Keyword(s):  
Mechanical Properties ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Process Parameter ◽  
Design Stage ◽  
Future Research ◽  
Printing Process ◽  
Fused Deposition

Significant advances in fused deposition modeling (FDM), as well as its myriad applications, have led to its growing prominence among additive manufacturing (AM) technologies. When the technology was first developed, it was used for rapid prototyping to examine and analyze a product in the design stage. FDM facilitates rapid production, requires inexpensive tools, and can fabricate complex-shaped parts; it, therefore, became popular and its use widespread. However, various FDM processing parameters have proven to affect the printed part’s mechanical properties to different extents. The values for the printing process parameters are carefully selected based on the part’s application. This study investigates the effects of four process parameters (raster angle, layer thickness, infill percentage, and printing speed) on the mechanical behavior of printed parts that are based on available literature data. These process parameter’s influence on part’s mechanical properties varies depending on the FDM material. The study focuses on four FDM materials: polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), polyether ether ketone (PEEK), and polyethylene terephthalate glycol (PETG). This paper summarizes the state-of-the-art literature to show how sensitive the material’s mechanical properties are to each process parameter. The effect of each parameter on each material was quantified and ranked using analysis of variance (ANOVA). The results show that infill percentage then layer thickness are the most influential process parameter on most of the material’s mechanical properties. In addition, this work identifies gaps in existing studies and highlights opportunities for future research.

Investigation of the effect of FDM process parameters on mechanical properties of 3D printed PA12 samples using Taguchi method

2021 ◽  
pp. 089270572110064
Author(s):  
Menderes Kam ◽  
Ahmet İpekçi ◽  
Ömer Şengül
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Impact Strength ◽  
Taguchi Method ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Occupancy Rate ◽  
Fused Deposition ◽  
Occupancy Rates

This study investigated the effects of FDM (Fused Deposition Modeling) process parameters on mechanical properties (tensile strength, elongation, and impact strength) of 3D (three-dimensional) printed PA12 (Polyamide12) samples using Taguchi method. In the experimental design (L8), four different layer thickness (0.1, 0.15, 0.2, 0.25 mm), extruder temperature (250 and 260°C), filling structure (Rectilinear and Full Honeycomb), and occupancy rate (25 and 50%) were determined. The tensile and impact strength test samples were printed with the FDM method. Tensile and impact strength of the test samples were carried out according to ISO 527 and ISO 180 test standards. The findings obtained from tests were analyzed and compared. As a result, the layer thickness is most effective factor for enhance the mechanical properties instead extruder temperature, occupancy rate, and filling structure. The optimum tensile strength of determined for process parameters (layer thickness, occupancy rates, filling structures and extruder temperature) were 0.25 mm, 50%, Rectilinear, and 250°C, respectively. The optimum impact strength of determined for process parameters (layer thickness, occupancy rates, extruder temperature, and filling structures) were 0.25 mm, 50%, 250°C, and Rectilinear, respectively. PA12 filament material can be used to printing for sleeve bearing due to their mechanical properties. It can be used in the production of many machine parts and components due to its tensile strength, impact strength resistance and damping properties.

scholarly journals Process Parameter Optimization in Fused Deposition Modeling (FDM) Using Response Surface Methodology (RSM)

2020 ◽  
Author(s):  
Muhammad Salman Mustafa ◽  
Muhammad Qasim Zafar ◽  
Muhammad Arslan Muneer ◽  
Muhammad Arif ◽  
Farrukh Arsalan Siddiqui ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Response Surface Methodology ◽  
Impact Strength ◽  
Response Surface ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Experimental Results ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Printing Parameters

Abstract Fused Deposition Modeling (FDM) is a widely adopted additive manufacturing process to produce complex 3D structures and it is typically used in the fabrication of biodegradable materials e.g. PLA/PHA for biomedical applications. However, FDM as a fabrication process for such material needs to be optimized to enhance mechanical properties. In this study, dogbone and notched samples are printed with the FDM process to determine optimum values of printing parameters for superior mechanical properties. The effect of layer thickness, infill density, and print bed temperature on mechanical properties is investigated by applying response surface methodology (RSM). Optimum printing parameters are identified for tensile and impact strength and an empirical relation has been formulated with response surface methodology (RSM). Furthermore, the analysis of variance (ANOVA) was performed on the experimental results to determine the influence of the process parameters and their interactions. ANOVA results demonstrate that 44.7% infill density, 0.44 mm layer thickness, and 20C° printing temperatures are the optimum values of printing parameters owing to improved tensile and impact strength respectively. The experimental results were found in strong agreement with the predicted theoretical results.

Effect of process parameters on flexural strength and surface roughness in fused deposition modeling of PC-ABS material

2021 ◽  
pp. 251659842110311
Author(s):  
Shrikrishna Pawar ◽  
Dhananjay Dolas1
Keyword(s):  
Surface Roughness ◽  
Flexural Strength ◽  
Response Surface ◽  
Layer Thickness ◽  
Process Parameters ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Build Orientation ◽  
Fused Deposition ◽  
Deposition Modeling

Fused deposition modeling (FDM) is one of the most commonly used additive manufacturing (AM) technologies, which has found application in industries to meet the challenges of design modifications without significant cost increase and time delays. Process parameters largely affect the quality characteristics of AM parts, such as mechanical strength and surface finish. This article aims to optimize the parameters for enhancing flexural strength and surface finish of FDM parts. A total of 18 test specimens of polycarbonate (PC)-ABS (acrylonitrile–butadiene–styrene) material are printed to analyze the effect of process parameters, viz. layer thickness, build orientation, and infill density on flexural strength and surface finish. Empirical models relating process parameters with responses have been developed by using response surface regression and further analyzed by analysis of variance. Main effect plots and interaction plots are drawn to study the individual and combined effect of process parameters on output variables. Response surface methodology was employed to predict the results of flexural strength 48.2910 MPa and surface roughness 3.5826 µm with an optimal setting of parameters of 0.14-mm layer thickness and 100% infill density along with horizontal build orientation. Experimental results confirm infill density and build orientation as highly significant parameters for impacting flexural strength and surface roughness, respectively.

Effect of layer thickness on irreversible thermal expansion and interlayer strength in fused deposition modeling

2017 ◽  
Vol 23 (5) ◽  
pp. 943-953 ◽  
Author(s):  
Anthony A. D’Amico ◽  
Analise Debaie ◽  
Amy M. Peterson
Keyword(s):  
Mechanical Properties ◽  
Thermal Expansion ◽  
Flexural Strength ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Thermal Strain ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
The Impact

Purpose The aim of this paper is to examine the impact of layer thickness on irreversible thermal expansion, residual stress and mechanical properties of additively manufactured parts. Design/methodology/approach Samples were printed at several layer thicknesses, and their irreversible thermal expansion, tensile strength and flexural strength were determined. Findings Irreversible thermal strain increases with decreasing layer thickness, up to 22 per cent strain. Tensile and flexural strengths exhibited a peak at a layer thickness of 200 μm although the maximum was not statistically significant at a 95 per cent confidence interval. Tensile strength was 54 to 97 per cent of reported values for injection molded acrylonitrile butadiene styrene (ABS) and 29 to 73 per cent of those reported for bulk ABS. Flexural strength was 18 to 41 per cent of reported flexural strength for bulk ABS. Practical implications The large irreversible thermal strain exhibited that corresponding residual stresses could lead to failure of additively manufactured parts over time. Additionally, the observed irreversible thermal strains could enable thermally responsive shape in additively manufactured parts. Variation in mechanical properties with layer thickness will also affect manufactured parts. Originality/value Tailorable irreversible thermal strain of this magnitude has not been previously reported for additively manufactured parts. This strain occurs in parts made with both high-end and consumer grade fused deposition modeling machines. Additionally, the impact of layer thickness on tensile and flexural properties of additively manufactured parts has received limited attention in the literature.

scholarly journals The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer

2015 ◽  
Vol 21 (5) ◽  
pp. 604-617 ◽  
Author(s):  
Antonio Lanzotti ◽  
Marzio Grasso ◽  
Gabriele Staiano ◽  
Massimo Martorelli
Keyword(s):  
Mechanical Properties ◽  
Open Source ◽  
Process Parameters ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Testing Machine ◽  
Main Process ◽  
Content Type ◽  
Fused Deposition ◽  
The Impact

Purpose – This study aims to quantify the ultimate tensile strength and the nominal strain at break (ɛf) of printed parts made from polylactic acid (PLA) with a Replicating Rapid prototyper (Rep-Rap) 3D printer, by varying three important process parameters: layer thickness, infill orientation and the number of shell perimeters. Little information is currently available about mechanical properties of parts printed using open-source, low-cost 3D printers. Design/methodology/approach – A computer-aided design model of a tensile test specimen was created, conforming to the ASTM:D638. Experiments were designed, based on a central composite design. A set of 60 specimens, obtained from combinations of selected parameters, was printed on a Rep-Rap Prusa I3 in PLA. Testing was performed using a JJ Instruments – T5002-type tensile testing machine and the load was measured using a load cell of 1,100 N. Findings – This study investigated the main impact of each process parameter on mechanical properties and the effects of interactions. The use of a response surface methodology allowed the proposition of an empirical model which connects process parameters and mechanical properties. Even though results showed a high variability, additional ideas on how to understand the impact of process parameters are suggested in this paper. Originality/value – On the basis of experimental results, it is possible to obtain practical suggestions to set common process parameters in relation to mechanical properties. Experiments discussed in the present paper provide a variety of data and insight regarding the relationship among the main process parameters and the stiffness and strength of fused deposition modeling-printed parts made from PLA. In particular, this paper underlines the shortage in existing literature concerning the impact of process parameters on the elastic modulus and the strain to failure for the PLA. The experimental data produced show a good degree of compliance with analytical formulations and other data found in literature.

Parameters Optimization of FDM for the Quality of Prototypes Using an Integrated MCDM Approach

2019 ◽  
pp. 199-220
Author(s):  
Jagadish ◽  
Sumit Bhowmik
Keyword(s):  
Process Parameters ◽  
Shell Thickness ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Parameters Optimization ◽  
Layer Height ◽  
Fused Deposition ◽  
Optimal Setting ◽  
Deposition Modeling

Fused deposition modeling (FDM) is one of the emerging rapid prototyping (RP) processes in additive manufacturing. FDM fabricates the quality prototype directly from the CAD data and is dependent on the various process parameters, hence optimization is essential. In the present chapter, process parameters of FDM process are analyzed using an integrated MCDM approach. The integrated MCDM approach consists of modified fuzzy with ANP methods. Experimentation is performed considering three process parameters, namely layer height, shell thickness, and fill density, and corresponding response parameters, namely ultimate tensile strength, dimensional accuracy, and manufacturing time are determined. Thereafter, optimization of FDM process parameters is done using proposed method. The result shows that exp.no-4 yields the optimal process parameters for FDM and provides optimal parameters as layer height of 0.08 mm, shell thickness of 2.0 mm and fill density of 100%. Also, optimal setting provides higher ultimate TS, good DA, and lesser MT as well as improving the performance and efficiency of FDM.

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