scholarly journals Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing Technology

Polymers ◽  
2021 ◽  
Vol 13 (21) ◽  
pp. 3700
Author(s):  
Patrich Ferretti ◽  
Gian Maria Santi ◽  
Christian Leon-Cardenas ◽  
Marco Freddi ◽  
Giampiero Donnici ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Deposition Process ◽  
Advanced Materials ◽  
Fused Deposition ◽  
Good Surface ◽  
Fiber Manufacturing

Fused Deposition Modeling (FDM) 3D printing is the most widespread technology in additive manufacturing worldwide that thanks to its low costs, finished component applications, and the production process of other parts. The need for lighter and higher-performance components has led to an increased usage of polymeric matrix composites in many fields ranging from automotive to aerospace. The molds used to manufacture these components are made with different technologies, depending on the number of pieces to be made. Usually, they are fiberglass molds with a thin layer of gelcoat to lower the surface roughness and obtain a smooth final surface of the component. Alternatively, they are made from metal, thus making a single carbon fiber prototype very expensive due to the mold build. Making the mold using FDM technology can be a smart solution to reduce costs, but due to the layer deposition process, the roughness is quite high. The surface can be improved by reducing the layer height, but it is still not possible to reach the same degree of surface finish of metallic or gelcoat molds without the use of fillers. Thermoplastic polymers, also used in the FDM process, are generally soluble in specific solvents. This aspect can be exploited to perform chemical smoothing of the external surface of a component. The combination of FDM and chemical smoothing can be a solution to produce low-cost molds with a very good surface finish.

scholarly journals The Micro–Macro Interlaminar Properties of Continuous Carbon Fiber-Reinforced Polyphenylene Sulfide Laminates Made by Thermocompression to Simulate the Consolidation Process in FDM

Polymers ◽  
2022 ◽  
Vol 14 (2) ◽  
pp. 301
Author(s):  
Jiale Hu ◽  
Suhail Mubarak ◽  
Kunrong Li ◽  
Xu Huang ◽  
Weidong Huang ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Manufacturing Industry ◽  
Fused Deposition Modeling ◽  
Polyphenylene Sulfide ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fused Deposition ◽  
Continuous Carbon Fiber ◽  
Carbon Fiber Reinforced

Three-dimensional (3D) printing of continuous fiber-reinforced composites has been developed in recent decades as an alternative means to handle complex structures with excellent design flexibility and without mold forming. Although 3D printing has been increasingly used in the manufacturing industry, there is still room for the development of theories about how the process parameters affect microstructural properties to meet the mechanical requirements of the printed parts. In this paper, we investigated continuous carbon fiber-reinforced polyphenylene sulfide (CCF/PPS) as feedstock for fused deposition modeling (FDM) simulated by thermocompression. This study revealed that the samples manufactured using a layer-by-layer process have a high tensile strength up to 2041.29 MPa, which is improved by 68.8% compared with those prepared by the once-stacked method. Moreover, the mechanical–microstructure characterization relationships indicated that the compactness of the laminates is higher when the stacked CCF/PPS are separated, which can be explained based on both the void formation and the nanoindentation results. These reinforcements confirm the potential of remodeling the layer-up methods for the development of high-performance carbon fiber-reinforced thermoplastics. This study is of great significance to the improvement of the FDM process and opens broad prospects for the aerospace industry and continuous fiber-reinforced polymer matrix materials.

Development of Rapid Tooling for Investment Casting Using Fused Deposition Modeling Process

2014 ◽  
Vol 970 ◽  
pp. 155-165 ◽  
Author(s):  
Sambasiva Rao Addanki ◽  
Medha A. Dharap ◽  
Jonnalagedda V.L. Venkatesh
Keyword(s):  
Surface Finish ◽  
Chemical Treatment ◽  
Fused Deposition Modeling ◽  
Processing Technique ◽  
Rapid Tooling ◽  
Parent Material ◽  
Fused Deposition ◽  
Good Surface ◽  
Deposition Modeling ◽  
Good Surface Finish

Fused Deposition Modeling (FDM) process can be used to produce the rapid tooling directly or indirectly. However, rapid tooling application demands good surface finish since the poor surface finish of FDM parts has become a limitation for its tool application. So there is need to improve the surface finish of FDM made tools. In this study, surface roughness of FDM tools are drastically reduced by a post processing technique called chemical treatment process. Surface finish was improved by filling the gap between layers by diffusion of parent material. Thus FDM made tools can be used as direct as well as indirect tools after the chemical treatment. Comparative study was made between Silicon Rubber Moulding and FDM Tooling towards the cost, time, life of mould, quality and feasibility aspects. It was found that FDM tooling is more economical, easy to use, reduced cycle time, improved quality, long life of mould and more feasibility towards complex parts etc.

scholarly journals An overview on 3D Printed Medicine

2021 ◽  
Vol 18 (1) ◽  
pp. 07-13
Author(s):  
Neha Thakur ◽  
Hari Murthy
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Herbal Medicines ◽  
Fused Deposition ◽  
Digitally Controlled ◽  
3D Printed ◽  
Semi Solid

Three-dimensional printing (3DP) is a digitally-controlled additive manufacturing technique used for fast prototyping. This paper reviews various 3D printing techniques like Selective Laser Sintering (SLS), Fused Deposition Modeling, (FDM), Semi-solid extrusion (SSE), Stereolithography (SLA), Thermal Inkjet (TIJ) Printing, and Binder jetting 3D Printing along with their application in the field of medicine. Normal medicines are based on the principle of “one-size-fits-all”. This is not true always, it is possible medicine used for curing one patient is giving some side effects to another. To overcome this drawback “3D Printed medicines” are developed. In this paper, 3D printed medicines forming different Active Pharmaceutical Ingredients (API) are reviewed. Printed medicines are capable of only curing the diseases, not for the diagnosis. Nanomedicines have “theranostic” ability which combines therapeutic and diagnostic. Nanoparticles are used as the drug delivery system (DDS) to damaged cells’ specific locations. By the use of nanomedicine, the fast recovery of the disease is possible. The plant-based nanoparticles are used with herbal medicines which give low-cost and less toxic medication called nanobiomedicine. 4D and 5D printing technology for the medical field are also enlightened in this paper.

scholarly journals Analysis of Applying Ultrasonic Frequency on a Desktop FDM Nozzle

2015 ◽  
Vol 761 ◽  
pp. 329-332 ◽  
Author(s):  
S. Maidin ◽  
Khairul Fahmi Abdul Aziz ◽  
M.K. Muhamad ◽  
E. Pei
Keyword(s):  
Surface Finish ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Ultrasonic Transducer ◽  
Ultrasonic Frequency ◽  
Machining Processes ◽  
Fused Deposition ◽  
Good Surface ◽  
Computer Aided ◽  
Good Surface Finish

Fused deposition modeling (FDM) is an additive manufacturing (AM) process that has an economical advantage compared to other AM processes. However, its biggest drawback is that it requires post processing to achieve a good surface finish. Ultrasound has been applied in various conventional machining processes and produces a good surface finish. However, the application of ultrasound to AM has not been sufficiently explored. This research aims to investigate the application of using ultrasound technology for a desktop FDM system. The idea is to transmit high vibration from the ultrasonic transducer to the FDM system's nozzle, and the objective is to examine whether the nozzle is able to withstand the high vibration being transmitted. Computer-aided design (CAD) software used to develop the 3D model of the extrusion nozzle component and a computer-aided engineering (CAE) software was used to perform static and vibration analysis. A frequency range of 20 to 30kHz and 30 to 40kHz was applied to the nozzle and it was found that the nozzle was able to withstand frequencies up to 40 kHz of vibration. In addition, the lowest Factor of Safety (FoS) obtained was 18.8975, concluding that the nozzle of FDM can withstand the high vibration transmitted from the ultrasonic transducer.

Realization of Modified Elliptical Shaped Dielectric Lens Antenna for X Band Applications with 3D Printing Technology

2020 ◽  
Vol 35 (8) ◽  
pp. 916-921
Author(s):  
Aysu Belen ◽  
Evrim Tetik
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
High Gain ◽  
Printing Technology ◽  
Lens Antenna ◽  
3D Printing Technology ◽  
Fused Deposition ◽  
Dielectric Lens ◽  
3D Em

Placing dielectric lens structures into an antenna's aperture has proven to be one of the most reliable methods of enhancing its gain. However, the selected material and the prototyping method usually limit their fabrication process. With the advances in 3D printing technology and their applications, the microwave designs that were either impractical or impossible in the past to manufacture using traditional methods, are now feasible. Herein, a novel prototyping method by using 3D-printer technology for low-cost, broadband, and high gain dielectric lens designs has been presented. Firstly, the elliptical lens design has been modeled in the 3D EM simulation environment. Then fused deposition modeling based 3D-printing method has been used for the fabrication of the dielectric lens. The measured results of the 3D printed antenna show that the lens antenna has a realized gain of 17 to 20.5 dBi over 8-12 GHz. Moreover, the comparison of the prototyped antenna with its counterpart dielectric lens antenna in the literature has indicated that the proposed method is more efficient, more beneficial, and has a lower cost.

Multi material 3D printing of PLA-PA6/TiO2 polymeric matrix: Flexural, wear and morphological properties

2020 ◽  
pp. 089270572095319 ◽  
Author(s):  
Sudhir Kumar ◽  
Rupinder Singh ◽  
Mohit Singh ◽  
TP Singh ◽  
Ajay Batish
Keyword(s):  
3D Printing ◽  
Wear Rate ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Polymeric Composite ◽  
Wear Testing ◽  
Morphological Properties ◽  
Poly Lactic Acid ◽  
Fused Deposition ◽  
Fractured Surface

The poly-lactic acid (PLA), bio compatible polyamide (PA6) and TiO2 has established bio-medical applications especially in 3D printing of scaffolds. But hitherto little has been reported on improving the performance of multi-material matrix for PLA-PA6/TiO2 especially in 3D printing application of biomedical scaffolds. The anti-bacterial properties of PA6/TiO2 make it worthy to be explored with PLA matrix in multi layered fashion on the platform of fused deposition modeling (FDM) being low cost 3D printing technology for in house development of scaffolds. In this work an effort has been made for in-house development of feedstock filaments of PLA and PA6/TiO2 based polymeric composite matrix on twin screw extrusion (TSE) machine. Further the feedstock filament wires were used on FDM to establish the flexural, wear and morphological properties of multi-material 3D printed functional prototype. The results of the study suggest that for flexural strength, infill speed: 90mm/s; infill pattern: triangular and layer combination as 5 consecutive layers of PLA and 5 consecutive layers of PA6/TiO2 are the optimized conditions for FDM printing. The wear testing results suggest that the composite of PA6/TiO2 held low wear rate (823 µm) in comparison to PLA (wear rate: 1092 µm). Further porosity testing (based upon optical photomicrographs) at ×100 and fractured surface analysis at ×30 supported the observed trends for flexural and wear testing. The photomicrographs of fractured surface were 3D rendered to predict the role of surface roughness (Ra) profile for flexural properties. The mechanical and morphological observations are also supported with scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) analysis.

scholarly journals The digital code driven autonomous synthesis of ibuprofen automated in a 3D-printer-based robot

2016 ◽  
Vol 12 ◽  
pp. 2776-2783 ◽  
Author(s):  
Philip J Kitson ◽  
Stefan Glatzel ◽  
Leroy Cronin
Keyword(s):  
3D Printing ◽  
Open Source ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Automated System ◽  
One Pot ◽  
3D Print ◽  
Fused Deposition ◽  
Python Programming ◽  
Reaction Vessels

An automated synthesis robot was constructed by modifying an open source 3D printing platform. The resulting automated system was used to 3D print reaction vessels (reactionware) of differing internal volumes using polypropylene feedstock via a fused deposition modeling 3D printing approach and subsequently make use of these fabricated vessels to synthesize the nonsteroidal anti-inflammatory drug ibuprofen via a consecutive one-pot three-step approach. The synthesis of ibuprofen could be achieved on different scales simply by adjusting the parameters in the robot control software. The software for controlling the synthesis robot was written in the python programming language and hard-coded for the synthesis of ibuprofen by the method described, opening possibilities for the sharing of validated synthetic ‘programs’ which can run on similar low cost, user-constructed robotic platforms towards an ‘open-source’ regime in the area of chemical synthesis.

Experimental Investigation of Nozzle Clogging Using Vibration Signal-Based Condition Monitoring for Fused Deposition Modeling

2021 ◽  
Vol 1037 ◽  
pp. 55-64
Author(s):  
Durwesh Jhodkar ◽  
Ankit Nayak ◽  
Kapil Gupta
Keyword(s):  
3D Printing ◽  
Condition Monitoring ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Vibration Signal ◽  
Nozzle Clogging ◽  
Vibration Signals ◽  
Fused Deposition ◽  
Material Deposition ◽  
Deposition Modeling

Fused deposition modeling (FDM) or 3D printing is one of the promising techniques widely preferred to fabricate complex and customized 3D objects or prototypes for various engineering and non-engineering applications. With the growing demands of customized prototypes, researchers are facing a major challenge for maintaining effective part quality with adequate surface finish and strength; and minimizing the cost, defects, and waste in 3D printing. Condition monitoring is one of the strategies to achieve the aforementioned. It has a huge potential to minimize defects and print failures in 3D printing. The main objective of this research work is to perform online condition monitoring of the nozzle status with the help of vibration signals in fused deposition modelling process. The effect of nozzle clogging on the consistency of material deposition and its effect on surface finish has experimentally investigated in this work. The set of experiments were performed by artificially creating the condition of nozzle clogging to investigate the effect of nozzle clogging on print quality (surface finish). Nozzle clogging condition was created by increasing the feed rate of polylactic acid (PLA) filament at a low heat supply rate to the nozzle by modifying the commands of 3D printer. The layer thickness was varied throughout the experiments to observe the nozzle clogging. The vibrations signals were acquired by using an accelerometer that was mounted near the nozzle. The data acquisition frequency of the accelerometer was 12500Hz. Further, the acquired vibration signals were analyzed using the Fast Fourier transformation (FFT) signal processing technique. Results revealed that nozzle clogging severely affects surface quality and geometrical accuracy of the fabricated 3D part due to nozzle vibration and non-uniform material deposition. Moreover, nozzle clogging and its relevant consequences like non uniform material deposition can be monitored using vibration signal-based condition monitoring during part fabrication and based upon that appropriate measures can be taken for defects and waste elimination.

scholarly journals Carbon Fiber Reinforced PEEK Composites Based on 3D-Printing Technology for Orthopedic and Dental Applications

2019 ◽  
Vol 8 (2) ◽  
pp. 240 ◽  
Author(s):  
Xingting Han ◽  
Dong Yang ◽  
Chuncheng Yang ◽  
Sebastian Spintzyk ◽  
Lutz Scheideler ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Fiber Reinforced ◽  
Printing Technology ◽  
3D Printing Technology ◽  
Fused Deposition ◽  
Peek Composite ◽  
Carbon Fiber Reinforced ◽  
Mechanical Strengths

Fused deposition modeling (FDM) is a rapidly growing three-dimensional (3D) printing technology and has great potential in medicine. Polyether-ether-ketone (PEEK) is a biocompatible high-performance polymer, which is suitable to be used as an orthopedic/dental implant material. However, the mechanical properties and biocompatibility of FDM-printed PEEK and its composites are still not clear. In this study, FDM-printed pure PEEK and carbon fiber reinforced PEEK (CFR-PEEK) composite were successfully fabricated by FDM and characterized by mechanical tests. Moreover, the sample surfaces were modified with polishing and sandblasting methods to analyze the influence of surface roughness and topography on general biocompatibility (cytotoxicity) and cell adhesion. The results indicated that the printed CFR-PEEK samples had significantly higher general mechanical strengths than the printed pure PEEK (even though there was no statistical difference in compressive strength). Both PEEK and CFR-PEEK materials showed good biocompatibility with and without surface modification. Cell densities on the “as-printed” PEEK and the CFR-PEEK sample surfaces were significantly higher than on the corresponding polished and sandblasted samples. Therefore, the FDM-printed CFR-PEEK composite with proper mechanical strengths has potential as a biomaterial for bone grafting and tissue engineering applications.

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