scholarly journals A Review on Reinforcement Methods for Polymeric Materials Processed Using Fused Filament Fabrication (FFF)

Polymers ◽  
2021 ◽  
Vol 13 (22) ◽  
pp. 4022
Author(s):  
Juan Pratama ◽  
Sukmaji I. Cahyono ◽  
Suyitno Suyitno ◽  
Muhammad A. Muflikhun ◽  
Urip A. Salim ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fiber Reinforcement ◽  
Polymeric Materials ◽  
Short Fiber ◽  
Continuous Fiber ◽  
Fused Filament Fabrication ◽  
Automotive Components ◽  
The Poor ◽  
Powder Addition ◽  
Processed Products

Over the last few years, fused filament fabrication (FFF) has become one of the most promising and widely used techniques for the rapid prototyping process. A number of studies have also shown the possibility of FFF being used for the fabrication of functional products, such as biomedical implants and automotive components. However, the poor mechanical properties possessed by FFF-processed products are considered one of the major shortcomings of this technique. Over the last decade, many researchers have attempted to improve the mechanical properties of FFF-processed products using several strategies—for instance, by applying the short fiber reinforcement (SFR), continuous fiber reinforcement (CFR), powder addition reinforcement (PAR), vibration-assisted FFF (VA-FFF) methods, as well as annealing. In this paper, the details of all these reinforcement techniques are reviewed. The abilities of each method in improving tensile, flexural, and compressive strength are discussed.

scholarly journals Manufacturing a First Upper Molar Dental Forceps Using Continuous Fiber Reinforcement (CFR) Additive Manufacturing Technology with Carbon-Reinforced Polyamide

Polymers ◽  
2021 ◽  
Vol 13 (16) ◽  
pp. 2647
Author(s):  
Roland Told ◽  
Gyula Marada ◽  
Szilard Rendeki ◽  
Attila Pentek ◽  
Balint Nagy ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Medical Devices ◽  
Fiber Reinforcement ◽  
Strong Impact ◽  
Vertical Force ◽  
Continuous Fiber ◽  
Fused Filament Fabrication ◽  
Sem Images ◽  
3D Printed ◽  
Upper Molar

3D printing is an emerging and disruptive technology, supporting the field of medicine over the past decades. In the recent years, the use of additive manufacturing (AM) has had a strong impact on everyday dental applications. Despite remarkable previous results from interdisciplinary research teams, there is no evidence or recommendation about the proper fabrication of handheld medical devices using desktop 3D printers. The aim of this study was to critically examine and compare the mechanical behavior of materials printed with FFF (fused filament fabrication) and CFR (continuous fiber reinforcement) additive manufacturing technologies, and to create and evaluate a massive and practically usable right upper molar forceps. Flexural and torsion fatigue tests, as well as Shore D measurements, were performed. The tensile strength was also measured in the case of the composite material. The flexural tests revealed the measured force values to have a linear correlation with the bending between the 10 mm (17.06 N at 5000th cycle) and 30 mm (37.99 N at 5000th cycle) deflection range. The findings were supported by scanning electron microscopy (SEM) images. Based on the results of the mechanical and structural tests, a dental forceps was designed, 3D printed using CFR technology, and validated by five dentists using a Likert scale. In addition, the vertical force of extraction was measured using a unique molar tooth model, where the reference test was carried out using a standard metal right upper molar forceps. Surprisingly, the tests revealed there to be no significant differences between the standard (84.80 N ± 16.96 N) and 3D-printed devices (70.30 N ± 4.41 N) in terms of extraction force in the tested range. The results also highlighted that desktop CFR technology is potentially suitable for the production of handheld medical devices that have to withstand high forces and perform load-bearing functions.

scholarly journals Continuous Fiber Angle Topology Optimization for Polymer Composite Deposition Additive Manufacturing Applications

Fibers ◽  
2019 ◽  
Vol 7 (2) ◽  
pp. 14 ◽  
Author(s):  
Delin Jiang ◽  
Robert Hoglund ◽  
Douglas Smith
Keyword(s):  
Mechanical Properties ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Polymer Composite ◽  
Fiber Reinforcement ◽  
Fiber Direction ◽  
Optimization Approach ◽  
Continuous Fiber ◽  
Fiber Angle

Mechanical properties of parts produced with polymer deposition additive manufacturing (AM) depend on the print bead direction, particularly when short carbon-fiber reinforcement is added to the polymer feedstock. This offers a unique opportunity in the design of these structures since the AM print path can potentially be defined in a direction that takes advantage of the enhanced stiffness gained in the bead and, therefore, fiber direction. This paper presents a topology optimization approach for continuous fiber angle optimization (CFAO), which computes the best layout and orientation of fiber reinforcement for AM structures. Statically loaded structures are designed for minimum compliance where the adjoint variable method is used to compute design derivatives, and a sensitivity filter is employed to reduce the checkerboard effect. The nature of the layer-by-layer approach in AM is given special consideration in the algorithm presented. Examples are provided to demonstrate the applicability of the method in both two and three dimensions. The solution to our two dimensional problem is then printed with a fused filament fabrication (FFF) desktop printer using the material distribution results and a simple infill method which approximates the optimal fiber angle results using a contour-parallel deposition strategy. Mechanical stiffness testing of the printed parts shows improved results as compared to structures designed without accounting for the direction of the composite structure. Results show that the mechanical properties of the final FFF carbon fiber/polymer composite printed parts are greatly influenced by the print direction, and optimized material orientation tends to align with the imposed force direction to minimize the compliance.

scholarly journals Investigating the Effects of Annealing on the Mechanical Properties of FFF-Printed Thermoplastics

2020 ◽  
Vol 4 (2) ◽  
pp. 38 ◽  
Author(s):  
Javaid Butt ◽  
Raghunath Bhaskar
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Surface Finish ◽  
Ultrasonic Testing ◽  
Tensile Testing ◽  
Amorphous Materials ◽  
Microstructural Analysis ◽  
Polymeric Materials ◽  
Fused Filament Fabrication ◽  
Manufacturing Method

Fused filament fabrication (FFF) is a cost-effective additive manufacturing method that makes use of thermoplastics to produce customised products. However, there are several limitations associated with FFF that are adversely affecting its growth including variety of materials, rough surface finish and poor mechanical properties. This has resulted in the development of metal-infused thermoplastics that can provide better properties. Furthermore, FFF-printed parts can be subjected to post-processes to improve their surface finish and mechanical properties. This work takes into consideration two commonly used polymeric materials, i.e., ABS (acrylonitrile butadiene styrene) and PLA (polylactic acid) and compares the results with two metal-infused thermoplastics i.e., copper-enhanced PLA and aluminium-enhanced ASA (acrylonitrile styrene acrylate). The four different materials were subjected to a post-process called annealing to enhance their mechanical properties. The effect of annealing on these four materials was investigated through dimensional analysis, ultrasonic testing, tensile testing, microstructural analysis and hardness testing. The results showed that annealing affects the materials differently. However, a correlation among ultrasonic testing, tensile testing and microstructural analysis was observed for all the materials based on their crystallinity. It was found that the semi-crystalline materials (i.e., PLA and copper enhanced PLA) showed a considerable increase in tensile strength post-annealing. However, the amorphous materials (ABS and aluminium-enhanced ASA) showed a comparatively lower increase in tensile strength, demonstrating that they were less receptive to annealing. These results were supported by higher transmission times and a high percentage of voids in the amorphous materials. The highest hardness values were observed for the ASA material and the lowest for the ABS material. This work provides a good comparison for the metal-infused thermoplastics and their applicability with the commonly used PLA and ABS materials.

scholarly journals CaCO3 Polymorphs Used as Additives in Filament Production for 3D Printing

Polymers ◽  
2022 ◽  
Vol 14 (1) ◽  
pp. 199
Author(s):  
Lucie Zárybnická ◽  
Radek Ševčík ◽  
Jaroslav Pokorný ◽  
Dita Machová ◽  
Eliška Stránská ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
Polymeric Materials ◽  
Common Type ◽  
Organic Additives ◽  
Fused Filament Fabrication ◽  
Industrial Sectors ◽  
Beneficial Impact ◽  
Testing Techniques ◽  
Enhanced Properties

Nowadays, additive manufacturing—also called 3D printing—represents a well-established technology in the field of the processing of various types of materials manufacturing products used in many industrial sectors. The most common type of 3D printing uses the fused filament fabrication (FFF) method, in which materials based on thermoplastics or elastomers are processed into filaments. Much effort was dedicated to improving the properties and processing of such printed filaments, and various types of inorganic and organic additives have been found to play a beneficial role. One of them, calcium carbonate (CaCO3), is standardly used as filler for the processing of polymeric materials. However, it is well-known from its different applications that CaCO3 crystals may represent particles of different morphologies and shapes that may have a crucial impact on the final properties of the resulting products. For this reason, three different synthetic polymorphs of CaCO3 (aragonite, calcite, and vaterite) and commercially available calcite powders were applied as fillers for the fabrication of polymeric filaments. Analysis of obtained data from different testing techniques has shown significant influence of filament properties depending on the type of applied CaCO3 polymorph. Aragonite particles showed a beneficial impact on the mechanical properties of produced filaments. The obtained results may help to fabricate products with enhanced properties using 3D printing FFF technology.

scholarly journals Sustainable Additive Manufacturing: Mechanical Response of Polypropylene over Multiple Recycling Processes

2020 ◽  
Vol 13 (1) ◽  
pp. 159
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Lazaros Tzounis ◽  
Athena Maniadi ◽  
Emmanouil Velidakis ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Mechanical Response ◽  
Polymeric Materials ◽  
Fused Filament Fabrication ◽  
Scanning Calorimetry ◽  
3D Printed ◽  
Thermomechanical Processes ◽  
Multiple Recycling ◽  
Plastic Parts ◽  
Polymer Crystallinity

The recycling of polymeric materials has received a steadily growing scientific and industrial interest due to the increase in demand and production of durable and lightweight plastic parts. Recycling of such materials is mostly based on thermomechanical processes that significantly affect the mechanical, as well as the overall physicochemical properties of polymers. The study at hand focuses on the recyclability of Fused Filament Fabrication (FFF) 3D printed Polypropylene (PP) for a certain number of recycling courses (six in total), and its effect on the mechanical properties of 3D printed parts. Namely, 3D printed specimens were fabricated from non-recycled and recycled PP material, and further experimentally tested regarding their mechanical properties in tension, flexion, impact, and microhardness. Comprehensive dynamic scanning calorimetry (DSC), thermogravimetric analysis (TGA), Raman spectroscopy, and morphological investigations by scanning electron microscopy (SEM) were performed for the different 3D printed PP samples. The overall results showed that there is an overall slight increase in the material’s mechanical properties, both in tension and in flexion mode, while the DSC characterization indicates an increase in the polymer crystallinity over the recycling course.

scholarly journals Saccaharum Cilliare Fiber Reinforced Polymer Composites

2008 ◽  
Vol 5 (4) ◽  
pp. 782-791 ◽  
Author(s):  
A. S. Singha ◽  
Vijay Kumar Thakur
Keyword(s):  
Mechanical Properties ◽  
Urea Formaldehyde ◽  
Thermal Studies ◽  
Natural Fibers ◽  
Fiber Reinforcement ◽  
Short Fiber ◽  
Urea Formaldehyde Resin ◽  
Formaldehyde Resin ◽  
Fiber Reinforced ◽  
Fiber Reinforced Materials

Renewable resources such as natural fibers in the field of fiber reinforced materials with their new range of applications represent an important basis in order to fulfill the ecological objective of creating eco-friendly materials. In views of enormous advantages a study on green composites usingSaccaharum cilliarefiber as a reinforcing material and urea-formaldehyde (UF) as a novel matrix has been made. First of all urea-formaldehyde resin synthesized was reinforced withSaccaharum cilliarefiber. Reinforcement of the fiber was accomplished in three different forms particle (200 micron) reinforcement, short fiber (3 mm.) reinforcement and long fiber (6 mm) reinforcement. Present work reveals that mechanical properties such as: tensile strength, compressive strength and wear resistance of urea -formaldehyde resin (UF) increases to a significant extent when reinforced withSaccaharum cilliarefiber which is found in outsized amount in the Himalayan Region. These mechanical properties mainly depend upon the dimensions of the fiber used. Analysis of results shows that particle reinforcement is more effective as compared to short and long fiber reinforcement. Morphological and thermal studies of these composites have also been carried out.

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