Qualität von additiv hergestellten PLA-Bauteilen*/Quality of additively manufactured PLA components – How the print direction influences the mechanical properties and the distortion of 3D-printed PLA components

2018 ◽  
Vol 108 (06) ◽  
pp. 419-425
Author(s):  
H. Möhring ◽  
T. Stehle ◽  
D. Becker ◽  
R. Eisseler
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Low Cost ◽  
Three Dimensional ◽  
Filling Ratio ◽  
Additive Fertigung ◽  
3D Printed

Die additive Fertigung eröffnet neue Gestaltungs- und Optimierungsfreiheitsgrade für oberflächen- und strukturoptimierte Bauteile. Mit diesen Verfahren lassen sich selbst komplexe räumliche Strukturen kostengünstig herstellen. Der vorliegende Artikel untersucht den Einfluss der Druckrichtung und des Füllgrads auf die mechanischen Eigenschaften, den Verzug sowie die erreichbaren Formgenauigkeiten am Beispiel von mit 3D-Druck über den FDM-Prozess erzeugten PLA-Bauteilen.   Additive manufacturing opens up new possibilities for optimizing components with regard to surfaces and structures. These processes allow producing even the most complex three-dimensional structures at comparatively low cost. This paper analyzes how the print direction and the filling ratio affect the mechanical properties, the distortion, as well as the achievable geometrical accuracies, by using 3D-printed PLA components produced by FDM processes.

scholarly journals Development of Weather-Resistant 3D Printed Structures by Multi-Material Additive Manufacturing

2020 ◽  
Vol 4 (3) ◽  
pp. 94 ◽  
Author(s):  
Arash Afshar ◽  
Roy Wood
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Structural Integrity ◽  
Low Cost ◽  
Acrylonitrile Butadiene Styrene ◽  
Outdoor Environments ◽  
3D Printed ◽  
Novel Method ◽  
Structural Surface

Additive manufacturing, or 3D printing, has had a big impact on the manufacturing world through its low cost, material recyclability, and fabrication of intricate geometries with a high resolution. Three-dimensionally printed polymer structures in aerospace, marine, construction, and automotive industries are usually intended for service in outdoor environments. During long-term exposures to harsh environmental conditions, the mechanical properties of these structures can be degraded significantly. Developing coating systems for 3D printed parts that protect the structural surface against environmental effects and provide desired surface properties is crucial for the long-term integrity of these structures. In this study, a novel method was presented to create 3D printed structures coated with a weather-resistant material in a single manufacturing operation using multi-material additive manufacturing. One group of specimens was 3D printed from acrylonitrile-butadiene-styrene (ABS) material and the other group was printed from ABS and acrylic-styrene-acrylonitrile (ASA) as a substrate and coating material, respectively. The uncoated ABS specimens suffered significant degradation in the mechanical properties, particularly in the failure strain and toughness, during exposure to UV radiation, moisture, and high temperature. However, the ASA coating preserved the mechanical properties and structural integrity of ABS 3D printed structures in aggressive environments.

scholarly journals Additive Manufacturing in Customized Medical Device

2021 ◽  
Author(s):  
Ching Hang Bob Yung ◽  
Lung Fung Tse ◽  
Wing Fung Edmond Yau ◽  
Sze Yi Mak
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Medical Device ◽  
Three Dimensional ◽  
Medical Industry ◽  
New Era ◽  
Medical Needs ◽  
3D Printed ◽  
Traditional Manufacturing

The long-established application of rapid prototyping in additive manufacturing (AM) has inspired a revolution in the medical industry into a new era, in which the clinical-driven development of the customized medical device is enabled. This transformation could only be sustainable if clinical concerns could be well addressed. In this work, we propose a workflow that addresses critical clinical concerns such as translation from medical needs to product innovation, anatomical conformation and execution, and validation. This method has demonstrated outstanding advantages over the traditional manufacturing approach in terms of form, function, precision, and clinical flexibility. We further propose a protocol for the validation of biocompatibility, material, and mechanical properties. Finally, we lay out a roadmap for AM-driven customized medical device innovation based on our experiences in Hong Kong, addressing problems of certification, qualification, characterization of three dimensional (3D) printed implants according to medical demands.

scholarly journals Lightweight Microlattice With Tunable Mechanical Properties Using 3D Printed Shape Memory Polymer

2018 ◽  
Author(s):  
Chen Yang ◽  
Manish Boorugu ◽  
Andrew Dopp ◽  
Howon Lee
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Shape Memory ◽  
Shape Memory Polymer ◽  
Three Dimensional ◽  
Temperature Shift ◽  
Spatial Arrangement ◽  
Mechanical Metamaterials ◽  
3D Printed ◽  
Varying Environments

Metamaterials are architected artificial materials engineered to exhibit properties not typically found in natural materials. Increasing attention has recently been given to mechanical metamaterials with unprecedented mechanical properties including high stiffness, strength, or/and resilience even at extremely low density. These unusual mechanical performances emerge from the three-dimensional (3D) spatial arrangement of the micro-structural elements designed to effectively distribute mechanical loads. Recent advances in additive manufacturing in micro-/nano-scale have catalyzed the growing interest in this field. This work presents a new lightweight microlattice with tunable and recoverable mechanical properties using a three-dimensionally architected shape memory polymer (SMP). SMP microlattices were fabricated utilizing our micro additive manufacturing technique called projection micro-stereolithography (PμSL), which uses a digital micro-mirror device (DMD™) as a dynamically reconfigurable photomask. We use a photo-crosslinkable and temperature-responsive SMP which can retain its large deformation until heated for spontaneous shape recovery. In addition, it exhibits remarkable elastic modulus changes during this transition. We demonstrate that mechanical responses of the micro 3D printed SMP microlattice can be reversibly tuned by temperature control. Mechanical testing result showed that stiffness of a SMP microlattice changed by two orders of magnitude by a moderate temperature shift by 60°C. Furthermore, the shape memory effect of the SMP allows for full restitution of the original shape of the microlattice upon heating even after substantial mechanical deformation. Mechanical metamaterials with lightweight, reversibly tunable properties, and shape recoverability can potentially lead to new smart structural systems that can effectively react and adapt to varying environments or unpredicted loads.

AM-Serienproduktion für die Automobilindustrie/AM series production for the automotive industry

2020 ◽  
Vol 110 (11-12) ◽  
pp. 752-757
Author(s):  
Lukas Weiser ◽  
Marco Batschkowski ◽  
Niclas Eschner ◽  
Benjamin Häfner ◽  
Ingo Neubauer ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Automotive Industry ◽  
Series Production ◽  
Production Scale ◽  
Additive Fertigung ◽  
Small Series ◽  
Start Up ◽  
3D Printed ◽  
Component Quality

Die additive Fertigung schafft neue Gestaltungsfreiheiten. Im Rahmen des Prototypenbaus und der Kleinserienproduktion kann das Verfahren des selektiven Laserschmelzens genutzt werden. Die Verwendung in der Serienproduktion ist bisher aufgrund unzureichender Bauteilqualität, langen Anlaufzeiten sowie mangelnder Automatisierung nicht im wirtschaftlichen Rahmen möglich. Das Projekt „ReAddi“ möchte eine erste prototypische Serienfertigung entwickeln, mit der additiv gefertigte Bauteile für die Automobilindustrie wirtschaftlich produziert werden können. Additive manufacturing (AM) offers new freedom of design. The selective laser-powderbed fusion (L-PBF) process can be used for prototyping and small series production. So far, it has not been economical to use it on a production scale due to insufficient component quality, long start-up times and a lack of automation. The project ReAddi aims to develop a first prototype series production to cost-effectively manufacture 3D-printed components for the automotive industry.

scholarly journals Gold, Silver, and Electrum Electroless Plating on Additively Manufactured Laser Powder-Bed Fusion AlSi10Mg Parts: A Review

Coatings ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 422
Author(s):  
Dana Ashkenazi ◽  
Alexandra Inberg ◽  
Yosi Shacham-Diamand ◽  
Adin Stern
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Ion Beam ◽  
Surface Finishing ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Finishing Process ◽  
Gold Silver ◽  
3D Printed

Additive manufacturing (AM) revolutionary technologies open new opportunities and challenges. They allow low-cost manufacturing of parts with complex geometries and short time-to-market of products that can be exclusively customized. Additive manufactured parts often need post-printing surface modification. This study aims to review novel environmental-friendly surface finishing process of 3D-printed AlSi10Mg parts by electroless deposition of gold, silver, and gold–silver alloy (e.g., electrum) and to propose a full process methodology suitable for effective metallization. This deposition technique is simple and low cost method, allowing the metallization of both conductive and insulating materials. The AlSi10Mg parts were produced by the additive manufacturing laser powder bed fusion (AM-LPBF) process. Gold, silver, and their alloys were chosen as coatings due to their esthetic appearance, good corrosion resistance, and excellent electrical and thermal conductivity. The metals were deposited on 3D-printed disk-shaped specimens at 80 and 90 °C using a dedicated surface activation method where special functionalization of the printed AlSi10Mg was performed to assure a uniform catalytic surface yielding a good adhesion of the deposited metal to the substrate. Various methods were used to examine the coating quality, including light microscopy, optical profilometry, XRD, X-ray fluorescence, SEM–energy-dispersive spectroscopy (EDS), focused ion beam (FIB)-SEM, and XPS analyses. The results indicate that the developed coatings yield satisfactory quality, and the suggested surface finishing process can be used for many AM products and applications.

scholarly journals 3-D Printable Polymer Pelletizer Chopper for Fused Granular Fabrication-Based Additive Manufacturing

Inventions ◽  
2018 ◽  
Vol 3 (4) ◽  
pp. 78 ◽  
Author(s):  
Aubrey Woern ◽  
Joshua Pearce
Keyword(s):  
Additive Manufacturing ◽  
Open Source ◽  
Low Cost ◽  
Three Dimensional ◽  
High Tolerance ◽  
Entire Process ◽  
Composite Fabrication ◽  
The Us ◽  
Color Mixing ◽  
Returns On Investment

Although distributed additive manufacturing can provide high returns on investment, the current markup on commercial filament over base polymers limits deployment. These cost barriers can be surmounted by eliminating the entire process of fusing filament by three-dimensional (3-D) printing products directly from polymer granules. Fused granular fabrication (FGF) (or fused particle fabrication (FPF)) is being held back in part by the accessibility of low-cost pelletizers and choppers. An open-source 3-D printable invention disclosed here allows for precisely controlled pelletizing of both single thermopolymers as well as composites for 3-D printing. The system is designed, built, and tested for its ability to provide high-tolerance thermopolymer pellets with a number of sizes capable of being used in an FGF printer. In addition, the chopping pelletizer is tested for its ability to chop multi-materials simultaneously for color mixing and composite fabrication as well as precise fractional measuring back to filament. The US$185 open-source 3-D printable pelletizer chopper system was successfully fabricated and has a 0.5 kg/h throughput with one motor, and 1.0 kg/h throughput with two motors using only 0.24 kWh/kg during the chopping process. Pellets were successfully printed directly via FGF as well as indirectly after being converted into high-tolerance filament in a recyclebot.

scholarly journals Effect of Porosity on Mechanical Properties of 3D Printed Polymers: Experiments and Micromechanical Modeling Based on X-Ray Computed Tomography Analysis

Polymers ◽  
2019 ◽  
Vol 11 (7) ◽  
pp. 1154 ◽  
Author(s):  
Wang ◽  
Zhao ◽  
Fuh ◽  
Lee
Keyword(s):  
Computed Tomography ◽  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Micromechanical Model ◽  
Micromechanical Modeling ◽  
X Ray ◽  
Fused Deposition ◽  
3D Printed ◽  
X Ray Computed

Additive manufacturing (commonly known as 3D printing) is defined as a family of technologies that deposit and consolidate materials to create a 3D object as opposed to subtractive manufacturing methodologies. Fused deposition modeling (FDM), one of the most popular additive manufacturing techniques, has demonstrated extensive applications in various industries such as medical prosthetics, automotive, and aeronautics. As a thermal process, FDM may introduce internal voids and pores into the fabricated thermoplastics, giving rise to potential reduction on the mechanical properties. This paper aims to investigate the effects of the microscopic pores on the mechanical properties of material fabricated by the FDM process via experiments and micromechanical modeling. More specifically, the three-dimensional microscopic details of the internal pores, such as size, shape, density, and spatial location were quantitatively characterized by X-ray computed tomography (XCT) and, subsequently, experiments were conducted to characterize the mechanical properties of the material. Based on the microscopic details of the pores characterized by XCT, a micromechanical model was proposed to predict the mechanical properties of the material as a function of the porosity (ratio of total volume of the pores over total volume of the material). The prediction results of the mechanical properties were found to be in agreement with the experimental data as well as the existing works. The proposed micromechanical model allows the future designers to predict the elastic properties of the 3D printed material based on the porosity from XCT results. This provides a possibility of saving the experimental cost on destructive testing.

Algorithm to Reduce Leading and Lagging in Conformal Direct-Print

2018 ◽  
Vol 140 (10) ◽  
Author(s):  
Morteza Vatani ◽  
Faez Alkadi ◽  
Jae-Won Choi
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
3D Model ◽  
Three Dimensional ◽  
Motion Direction ◽  
B Spline ◽  
And Topology ◽  
Printing System ◽  
3D Printed ◽  
Printed Patterns

A novel additive manufacturing algorithm was developed to increase the consistency of three-dimensional (3D) printed curvilinear or conformal patterns on freeform surfaces. The algorithm dynamically and locally compensates the nozzle location with respect to the pattern geometry, motion direction, and topology of the substrate to minimize lagging or leading during conformal printing. The printing algorithm was implemented in an existing 3D printing system that consists of an extrusion-based dispensing module and an XYZ-stage. A dispensing head is fixed on a Z-axis and moves vertically, while the substrate is installed on an XY-stage and moves in the x–y plane. The printing algorithm approximates the printed pattern using nonuniform rational B-spline (NURBS) curves translated directly from a 3D model. Results showed that the proposed printing algorithm increases the consistency in the width of the printed patterns. It is envisioned that the proposed algorithm can facilitate nonplanar 3D printing using common and commercially available Cartesian-type 3D printing systems.

scholarly journals Effect of T6 Heat Treatment Parameters on Technological Quality of the AlSi7Mg Alloy

2016 ◽  
Vol 16 (4) ◽  
pp. 95-100 ◽  
Author(s):  
J. Pezda ◽  
A. Jarco
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Low Cost ◽  
Dispersion Hardening ◽  
Recycling Potential ◽  
Low Mass ◽  
Technological Quality ◽  
New Applications ◽  
Casting Design

Abstract Very well-known advantages of aluminum alloys, such as low mass, good mechanical properties, corrosion resistance, machining-ability, high recycling potential and low cost are considered as a driving force for their development, i.e. implementation in new applications as early as in stage of structural design, as well as in development of new technological solutions. Mechanical and technological properties of the castings made from the 3xx.x group of alloys depend mainly on correctly performed processes of melting and casting, design of a mould and cast element, and a possible heat treatment. The subject-matter of this paper is elaboration of a diagrams and dependencies between parameters of dispersion hardening (temperatures and times of solutioning and ageing treatments) and mechanical properties obtained after heat treatment of the 356.0 (EN AC AlSi7Mg) alloy, enabling full control of dispersion hardening process to programming and obtaining a certain technological quality of the alloy in terms of its mechanical properties after performed heat treatments. Obtained results of the investigations have enabled obtainment of a dependencies depicting effect of parameters of the solutioning and ageing treatments on the mechanical properties (Rm, A5 and KC impact strength) of the investigated alloy. Spatial diagrams elaborated on the basis of these dependencies enable us to determine tendencies of changes of the mechanical properties of the 356.0 alloy in complete analyzed range of temperature and duration of the solutioning and ageing operations.

scholarly journals Impact of Honeycomb Polylactide Infill% in FDM Printed PLA/Nylon for Improved Mechanical Properties

2020 ◽  
Vol 8 (5) ◽  
pp. 3662-3668
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Conventional Process ◽  
Improved Accuracy ◽  
Made In

In conventional manufacturing procedures liable upon the forces acting on the materials may lead to breakage during motion of the part undergoing construct which is inevitable to no change its shape and position. In pretty much every case, materials have anisotropic by its nature and virtue. As additive manufacturing (AM) techniques embedded undergoing processes with improved accuracy of the parts being developed. Since there is far disadvantage of the quality of the AM product, constantly improvements made the process of AM is being escalating than conventional process. The assessment of the product and the complexity of the parts can’t be resolved or found before it developing a methodology which impact mechanical properties of the printed parts. An effort has been made in the present work to improve the products mechanical properties by increasing the infill percentage. Study has been carried out as in view of increased infill with elaborated percentages of 15%, 30%, 40% and 50% to enhance the mechanical properties of the parts.

Sign in / Sign up

Export Citation Format

Share Document