Multi-Criterion Decision Method for Roughness Optimization of Fused Deposition Modelled Parts

2019 ◽  
pp. 235-262
Author(s):  
Azhar Equbal ◽  
Md. Asif Equbal ◽  
Md. Israr Equbal ◽  
Anoop Kumar Sood
Keyword(s):  
Hybrid Approach ◽  
Processing Parameters ◽  
Air Gap ◽  
Fused Deposition Modelling ◽  
Digital Information ◽  
Factors Affecting ◽  
Fused Deposition ◽  
Raster Angle ◽  
Face Centered ◽  
Anderson Darling

Fused deposition modelling is an extrusion-based automated fabrication process for making 3D physical objects from part digital information. The process offers distinct advantages, but the quality of part lacks in surface finish when compared with other liquid or powder based additive manufacturing processes. Considering the important factors affecting the part quality, the chapter attempted to optimize the raster angle, air gap, and raster width to minimize overall part roughness. Experiments are designed using face-centered central composite design and analysis of variance provides the effects of processing parameters on roughness of part. Suitability of developed model is tested using Anderson-darling normality test. Desirability method propose that roughness of different part faces are affected differently with chosen parameters, and thus, hybrid approach of WPCA based TOPSIS is used to break the correlation between part faces and reduce the overall part roughness. Optimizing shows that lower raster angle, lower air gap, and larger raster width minimizes overall part roughness.

Optimising the FDM additive manufacturing process to achieve maximum tensile strength: a state-of-the-art review

2019 ◽  
Vol 25 (6) ◽  
pp. 953-971 ◽  
Author(s):  
Tessa Jane Gordelier ◽  
Philipp Rudolf Thies ◽  
Louis Turner ◽  
Lars Johanning
Keyword(s):  
Tensile Strength ◽  
Additive Manufacturing ◽  
Material Selection ◽  
Single Point ◽  
Air Gap ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Maximum Tensile Strength ◽  
Fused Deposition ◽  
Raster Angle

Purpose Additive manufacturing or “3D printing” is a rapidly expanding sector and is moving from a prototyping service to a manufacturing service in its own right. With a significant increase in sales, fused deposition modelling (FDM) printers are now the most prevalent 3D printer on the market. The increase in commercial manufacturing necessitates an improved understanding of how to optimise the FDM printing process for various product mechanical properties. This paper aims to identify optimum print parameters for the FDM process to achieve maximum tensile strength through a review of recent studies in this field. Design/methodology/approach The effect of the governing printing parameters on the tensile strength of printed samples will be considered, including material selection, print orientation, raster angle, air gap and layer height. Findings The key findings include material recommendations, such as the use of emerging print materials like polyether-ether-ketone (PEEK), to produce samples with tensile strength over 200 per cent that of conventional materials such as acrylonitrile butadiene styrene (ABS). Amongst other parameters, it is shown that printing in the “upright” orientation should be avoided (samples can be up to 50 per cent weaker in this orientation) and air gap and raster width should be concurrently optimised to ensure good “inter-raster” bonding. The optimal choice of raster angle depends on print material; in ABS for example, selecting a 0° raster angle over a 90° angle can increase tensile strength by up to 100 per cent. Originality/value The paper conclusions provide researchers and practitioners with an up-to-date, single point reference, highlighting a series of robust recommendations to optimise the tensile strength of FDM-printed samples. Improving the mechanical performance of FDM-printed samples will support the continued growth of this technology as a viable production technique.

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.

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.

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

Experimental Investigation on Wear of FDM Processed Part

2012 ◽  
Vol 445 ◽  
pp. 883-888 ◽  
Author(s):  
Anoop Kumar Sood ◽  
Rajkumar Ohdar ◽  
S.S. Mahapatra
Keyword(s):  
Sliding Wear ◽  
Optimal Parameter ◽  
Extensive Study ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Predictive Equation ◽  
Fused Deposition ◽  
Raster Angle ◽  
Bacteria Foraging Optimization Algorithm ◽  
Insight Into

Fused deposition modelling (FDM) is one of the rapid prototyping (RP) processes that build part of any geometry by sequential deposition of material on a layer by layer basis. Unlike other RP systems which involve an array of lasers, powders, resins, this process uses heated thermoplastic filaments which are extruded from the tip of nozzle in a prescribed manner. Present work focuses on extensive study to understand the effect of five important parameters such as layer thickness, part build orientation, raster angle, raster width and air gap on the sliding wear of test specimen built through FDM. The study provides insight into complex dependency of wear on process parameters and proposes a statistically validated predictive equation. Microphotographs are used to explain the mechanism of wear. Finally, the predictive equation is used to find optimal parameter setting through bacteria foraging optimization algorithm (BFOA).

scholarly journals 3D Printing of Polymer Waste for Improving People’s Awareness about Marine Litter

Polymers ◽  
2020 ◽  
Vol 12 (8) ◽  
pp. 1738
Author(s):  
Francesca Ferrari ◽  
Carola Esposito Corcione ◽  
Francesco Montagna ◽  
Alfonso Maffezzoli
Keyword(s):  
Mechanical Response ◽  
Tensile Tests ◽  
Processing Parameters ◽  
Fused Deposition Modelling ◽  
Polymer Waste ◽  
Marine Litter ◽  
Fused Deposition ◽  
Degradation Temperature ◽  
3D Printed ◽  
The Difference

This work is aimed at proposing demonstrative actions devoted to show reprocessing and recyclability of PET originating from bottles collected from the seaside, in order to increase the consumer awareness on the importance of recycling plastics. To this purpose, collected bottles were washed, cut, grinded, extruded in the form of a thin wire adopting different cooling rates, which leads to a modulation of the crystallinity content. Once having optimized the processing parameters, the extruded wire was used to produce 3D printed samples through the fused deposition modelling (FDM). The changes in the crystalline structure due to the different processing conditions were assessed by DSC and XRD analyses, while rheological tests were performed in order to evaluate any modification in the viscosity of PET after repeated processing cycles. The reduction in thermal stability was confirmed by TGA analysis, which showed a progressive decrease in the degradation temperature as processing cycles increased. Finally, tensile tests highlighted the difference in the mechanical response due to the predominance of the crystalline or amorphous phase in the tested sample. In particular, a good mechanical behavior was found for the 3D-printed samples.

Investigating the Mechanical Behavior of 3D Printed PLA-Coco Coir Composites

2021 ◽  
Vol 1046 ◽  
pp. 125-132
Author(s):  
Paul Eric C. Maglalang ◽  
Blessie A. Basilia ◽  
Araceli Magsino Monsada
Keyword(s):  
Mechanical Properties ◽  
Particle Size ◽  
3D Printing ◽  
Fused Deposition Modelling ◽  
Coir Fiber ◽  
Fiber Concentration ◽  
Fused Deposition ◽  
Twin Screw ◽  
Raster Angle ◽  
Composite Filament

It is quite amazing that the use of 3D printing techniques, especially the Fused Deposition Modelling (FDM) has delivered such significance in terms of cost reduction, time saver features where a different variety of thermoplastic and composite materials (Biodegradable and Non-biodegradable) are well developed. Different sectors have continually developed natural organic materials that are also both structurally composite in nature. Similarly, the use of different fibers that are abundantly accessible and considered as renewable resources which can be optionally combined with other biodegradable materials is a great challenge through the use of the FDM printing method. The study aims to determine the effect of different particle size and raster angle at a certain fiber concentration which could affect the mechanical properties of the composite by developing a printable composite filament made of Polylactic Acid (PLA) and Coco Coir materials using a filament maker and FDM printer. The composite filament was fabricated and optimized using a twin-screw extruder and 3D Devo Filament maker. 3D printing of samples for mechanical testing was conducted using three (3) raster angles (45o, 60o, and 75o) and various particle sizes of coco coir fiber reinforcement in the PLA matrix. Results showed that the < 74μm particle size of the coco-coir exhibited a 24% and 175% increase in tensile strength and izod impact strength compared to the pure PLA at 60o and 75o raster angles, respectively. Likewise, the reinforcement of <149μm particle size coco coir at 45o raster angle contributes to an increase of 4.8% flexural and 176% compressive strength compared to pure PLA. The study concludes that there is an improvement in the mechanical properties of the PLA-Coco Coir composite at a certain particle size and raster angle in 3D printing.

scholarly journals Feasibility Study: Investigation of Polymer Nano-Composites (PNC) Material for Biomedical Application via Fused Deposition Modelling (FDM) Routes

2015 ◽  
Vol 773-774 ◽  
pp. 267-271
Author(s):  
M. Hashim Rahman ◽  
Mohd Sallehuddin Yusof ◽  
Mohd Halim Irwan Ibrahim ◽  
S.A. Osman
Keyword(s):  
Mechanical Properties ◽  
Rapid Prototyping ◽  
Polymer Nanocomposites ◽  
Biomedical Application ◽  
Processing Parameters ◽  
Raw Material ◽  
Laser Raman Spectroscopy ◽  
Synthesis Process ◽  
Fused Deposition Modelling ◽  
Fused Deposition

Polymer nanocomposites (PNC) have emerged as new materials which can show significantly enhanced mechanical properties over other polymer based materials through the addition of relatively small amounts of nanoscale additives. Rapid prototyping is impacting biomedical in several important ways. This research aims to investigate the potential of using new polymer nanocomposites (PNC) as a raw material for fused deposition modelling machine (FDM). Here, PNCs materials containing a polyamide (PA) and nanoparticles (<5wt%) will be synthesis by mechanical blending using twin extruder compounder to produce 0.85mm diameter of PNC. Dispersion analysis of the nanoparticles in the polymer matrix will be analyzed during the preparation and synthesis process. Futhermore, molecular binding and mixture structure will be investigated by using XPS analysis & Laser Raman Spectroscopy. Material will be characterized for their thermal properties using DSC and processed using FDM, the commercial rapid prototyping (RP) machine. The RP processing parameters will be established and used to produce test specimens to evaluate the mechanical properties of the PNC.

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