Parametric Study on Surface Roughness of Metallized Parts Manufactured by Additive Manufacturing

2019 ◽  
Vol 821 ◽  
pp. 137-143 ◽  
Author(s):  
Pavan Kumar Gurrala ◽  
Brijesh Tripathi
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Acrylonitrile Butadiene Styrene ◽  
Etching Time ◽  
Fused Deposition Modelling ◽  
Technological Evolution ◽  
Fused Deposition ◽  
Copper Electroplating ◽  
Optimal Value ◽  
Butadiene Styrene

In the current technological evolution, additive manufacturing is taking a lead role in manufacturing of components for both prototyping as well as finished products. Metallization of the polymer parts has high potential to add value in-terms of metallic luster, improved strength, long shelf-life and better radiation resistance. Standard acid copper plating process has been adopted for deposition of copper on polymer parts manufactured by fused deposition modelling (FDM) technique. The parameters namely the etching time, voltage and the surface finish of the manufactured FDM parts are studied for their influence on the surface quality. Experiments have been designed using design of experiments strategy. Experiments have been conducted and surface roughness has been measured. Influence of each of the three parameters has been discussed in detail. For the reported process the optimal value of etching time of Acrylonitrile Butadiene Styrene (ABS) has been found in the range of 30 to 60 minutes along with applied voltage in the range of 1.5 to 2.5 Volts for copper electroplating.

Printing with mechanically interlocked extrudates using a custom bi-extruder for fused deposition modelling

2018 ◽  
Vol 24 (6) ◽  
pp. 921-934 ◽  
Author(s):  
Mohammad Abu Hasan Khondoker ◽  
Asad Asad ◽  
Dan Sameoto
Keyword(s):  
Cross Sections ◽  
Acrylonitrile Butadiene Styrene ◽  
Easy Access ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Immiscible Polymers ◽  
Fused Deposition ◽  
Functionally Gradient ◽  
Different Sources ◽  
Butadiene Styrene

Purpose This paper aims to target to print functionally gradient materials (FGM) devices made of immiscible polymers in multi-material fused deposition modelling (FDM) systems. The design is intended to improve adhesion of dissimilar thermoplastics without the need for chemical compatibilization so that filaments from many different sources can be used effectively. Therefore, there is a need to invent an alternative solution for printing multiple immiscible polymers in an FDM system with the desired adhesion. Design/methodology/approach In this study, the authors have developed a bi-extruder for FDM systems which can print two thermoplastics through a single nozzle with a static intermixer to enhance bonding between input materials. The system can also change the composition of extrudates continuously. Findings The uniqueness of this extruder is in its easy access to the internal channel so that a static intermixer can be inserted, enabling deposition of mechanically interlocked extrudates composed of two immiscible polymers. Without this intermixer, the bi-extruder extrudes with simple side-by-side co-extrusion having no mechanical interlocking. The bi-extruder was characterized by printing objects using pairs of materials including polylactic acid, acrylonitrile butadiene styrene and high impact polystyrene. Microscope images of the cross-sections of the extrudates confirm the ability of this bi-extruder to control the composition as desired. It was also found that the mechanically interlocked extrudates composed of two immiscible polymers substantially reduces adhesion failures within and between filaments. Originality/value In this study, the first-ever FDM extruder with a mechanical blending feature next to the nozzle has been designed and used to successfully print FGM objects with improved mechanical properties.

Electrical Properties of Additively Manufactured Acrylonitrile Butadiene Styrene/Carbon Nanotube Nanocomposite

2018 ◽  
Author(s):  
Dominic Thaler ◽  
Nahal Aliheidari ◽  
Amir Ameli
Keyword(s):  
Electrical Conductivity ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Functional Materials ◽  
Acrylonitrile Butadiene Styrene ◽  
Extrusion Process ◽  
Print Quality ◽  
Fused Deposition ◽  
Order Of Magnitude ◽  
Butadiene Styrene

Additive manufacturing is an emerging method to produce customized parts with functional materials without big investments. As one of the common additive manufacturing methods, fused deposition modeling (FDM) uses thermoplastic-based feedstock. It has been recently adapted to fabricate composite materials too. Acrylonitrile butadiene styrene (ABS) is the most widely used material as FDM feedstock. However, it is an electrically insulating polymer. Carbon Nanotubes (CNTs) on the other hand are highly conductive. They are attractive fillers because of their high aspect ratio, and excellent mechanical and physical properties. Therefore, a nanocomposite of these two materials can give an electrically conductive material that is potentially compatible with FDM printing. This work focuses on the investigation of the relationships between the FDM process parameters and the electrical conductivity of the printed ABS/CNT nanocomposites. Nanocomposite filaments with CNT contents up to 10wt% were produced using a twin-screw extruder followed by 3D printing using FDM method. The starting material was pellets from a masterbatch containing 15 wt% CNT. Compression-molded samples of ABS/CNT were also prepared as the bulk baselines. The effects of CNT content and nozzle size on the through-layer and in-layer electrical conductivity of the printed nanocomposites were analyzed. Overall, a higher percolation threshold was observed in the printed samples, compared to that of the compression-molded counterparts. This resulted in the conductivity of the printed samples that is at least one order of magnitude lower. Moreover, at CNT contents up to 5 wt%, the in-layer conductivity of the printed samples was almost two orders of magnitudes higher than that in the through-layer direction. In ABS/3 wt% CNT samples, the through-layer conductivity continuously decreased as the nozzle diameter was decreased from 0.8 mm to 0.35 mm. These variations in the electrical conductivity were explained in terms of the CNT alignment, caused by the extrusion process during the print, quality of interlayer bonding during deposition, and the voids created due to the discrete nature of the printing process.

scholarly journals Modelling and Investigation of Crack Growth for 3D-Printed Acrylonitrile Butadiene Styrene (ABS) with Various Printing Parameters and Ambient Temperatures

Polymers ◽  
2021 ◽  
Vol 13 (21) ◽  
pp. 3737
Author(s):  
Yousef Lafi A. Alshammari ◽  
Feiyang He ◽  
Muhammad A. Khan
Keyword(s):  
3D Printing ◽  
Crack Growth ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
Structural Dynamic ◽  
Fused Deposition ◽  
Nozzle Size ◽  
Printing Parameters ◽  
Butadiene Styrene

Three-dimensional (3D) printing is one of the significant industrial manufacturing methods in the modern era. Many materials are used for 3D printing; however, as the most used material in fused deposition modelling (FDM) technology, acrylonitrile butadiene styrene (ABS) offers good mechanical properties. It is perfect for making structures for industrial applications in complex environments. Three-dimensional printing parameters, including building orientation, layers thickness, and nozzle size, critically affect the crack growth in FDM structures under complex loads. Therefore, this paper used the dynamic bending vibration test to investigate their influence on fatigue crack growth (FCG) rate under dynamic loads and the Paris power law constant C and m. The paper proposed an analytical solution to determine the stress intensity factor (SIF) at the crack tip based on the measurement of structural dynamic response. The experimental results show that the lower ambient temperature, as well as increased nozzle size and layer thickness, provide a lower FCG rate. The printing orientation, which is the same as loading, also slows the crack growth. The linear regression between these parameters and Paris Law’s coefficient also proves the same conclusion.

scholarly journals Additive Manufacturing Applications on Flexible Actuators for Active Orthoses and Medical Devices

2019 ◽  
Vol 2019 ◽  
pp. 1-11
Author(s):  
Michele Gabrio Antonelli ◽  
Pierluigi Beomonte Zobel ◽  
Francesco Durante ◽  
Terenziano Raparelli
Keyword(s):  
Additive Manufacturing ◽  
Acrylonitrile Butadiene Styrene ◽  
Variable Stiffness ◽  
Fused Deposition Modelling ◽  
Research Projects ◽  
Element Analysis ◽  
Pneumatic Actuators ◽  
Fused Deposition ◽  
Manufacturing Applications ◽  
Manufacturing Technologies

This paper describes the results of research projects developed at the University of L’Aquila by the research group of the authors in the field of biomedical engineering, which have seen an important use of additive manufacturing technologies in the prototyping step and, in some cases, also for the realization of preindustrialization prototypes. For these projects, commercial 3D printers and technologies such as fused deposition modelling (FDM) were used; the most commonly used polymers in these technologies are acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA). The research projects concern the development of innovative actuators, such as pneumatic muscles and soft pneumatic actuators (SPAs), the development of active orthoses, such as a lower limb orthosis and, finally, the development of a variable-stiffness grasper to be used in natural orifice transluminal endoscopic surgery (NOTES). The main aspects of these research projects are described in the paper, highlighting the technologies used such as the finite element analysis and additive manufacturing.

scholarly journals Geometric accuracy of an acrylonitrile butadiene styrene canine tibia model fabricated using fused deposition modelling and the effects of hydrogen peroxide gas plasma sterilisation

2020 ◽  
Vol 16 (1) ◽  
Author(s):  
Chi-Pin Hsu ◽  
Chen-Si Lin ◽  
Chun-Hao Fan ◽  
Nai-Yuan Chiang ◽  
Ching-Wen Tsai ◽  
...  
Keyword(s):  
Hydrogen Peroxide ◽  
Cross Sections ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
3D Ct ◽  
Geometric Accuracy ◽  
Fused Deposition ◽  
Gas Plasma ◽  
Butadiene Styrene

Abstract Background Three-dimensional (3D) printing techniques have been used to produce anatomical models and surgical guiding instruments in orthopaedic surgery. The geometric accuracy of the 3D printed replica may affect surgical planning. This study assessed the geometric accuracy of an acrylonitrile butadiene styrene (ABS) canine tibia model printed using fused deposition modelling (FDM) and evaluated its morphological change after hydrogen peroxide (H2O2) gas plasma sterilisation. The tibias of six canine cadavers underwent computed tomography for 3D reconstruction. Tibia models were fabricated from ABS on a 3D printer through FDM. Reverse-engineering technology was used to compare morphological errors (root mean square; RMS) between the 3D-FDM models and virtual models segmented from original tibia images (3D-CT) and between the models sterilised with H2O2 gas plasma (3D-GAS) and 3D-FDM models on tibia surface and in cross-sections at: 5, 15, 25, 50, 75, 85, and 95% of the tibia length. Results The RMS mean ± standard deviation and average positive and negative deviation values for all specimens in EFDM-CT (3D-FDM vs. 3D-CT) were significantly higher than those in EGAS-FDM (3D-GAS vs. 3D-FDM; P < 0.0001). Mean RMS values for EFDM-CT at 5% bone length (proximal tibia) were significantly higher than those at the other six cross-sections (P < 0.0001). Mean RMS differences for EGAS-FDM at all seven cross-sections were nonsignificant. Conclusions The tibia models fabricated on an FDM printer had high geometric accuracy with a low RMS value. The surface deviation in EFDM-CT indicated that larger errors occurred during manufacturing than during sterilisation. Therefore, the model may be used for surgical rehearsal and further clinically relevant applications in bone surgery. Graphical abstract

scholarly journals Effects of In-Process Temperatures and Blending Polymers on Acrylonitrile Butadiene Styrene Blends

Inventions ◽  
2021 ◽  
Vol 6 (4) ◽  
pp. 93
Author(s):  
Muhammad Harris ◽  
Johan Potgieter ◽  
Hammad Mohsin ◽  
Karnika De Silva ◽  
Marie-Joo Le Guen
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Large Scale ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
High Thermal Resistance ◽  
3D Printed ◽  
First Time ◽  
Butadiene Styrene

Acrylonitrile butadiene styrene (ABS) is a renowned commodity polymer for additive manufacturing, particularly fused deposition modelling (FDM). The recent large-scale applications of 3D-printed ABS require stable mechanical properties than ever needed. However, thermochemical scission of butadiene bonds is one of the contemporary challenges affecting the overall ABS stability. In this regard, literature reports melt-blending of ABS with different polymers with high thermal resistance. However, the comparison for the effects of different polymers on tensile strength of 3D-printed ABS blends was not yet reported. Furthermore, the cumulative studies comprising both blended polymers and in-process thermal variables for FDM were not yet presented as well. This research, for the first time, presents the statistical comparison of tensile properties for the added polymers and in-process thermal variables (printing temperature and build surface temperature). The research presents Fourier transform infrared spectroscopy (FTIR) and thermogravimetric analysis (TGA) to explain the thermochemical reasons behind achieved mechanical properties. Overall, ABS blend with PP shows high tensile strength (≈31 MPa) at different combinations of in-process parameters. Furthermore, some commonalities among both blends are noted, i.e., the tensile strength improves with increase of surface (bed) and printing temperature.

scholarly journals Shape accuracy of an acrylonitrile butadiene styrene canine tibia model fabricated using fused deposition modelling and the effects of hydrogen peroxide gas plasma sterilisation

2020 ◽  
Author(s):  
Chi-Pin Hsu ◽  
Chen-Si Lin ◽  
Chun-Hao Fan ◽  
Nai-Yuan Chiang ◽  
Ching-Wen Tsai ◽  
...  
Keyword(s):  
Hydrogen Peroxide ◽  
Cross Sections ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Deposition Modelling ◽  
3D Ct ◽  
Shape Accuracy ◽  
Fused Deposition ◽  
Gas Plasma ◽  
Butadiene Styrene

Abstract Background Three-dimensional (3D) printing techniques have been used for anatomical models and surgical guiding instruments in orthopaedic surgery. The accuracy of these surgical guiding tools is important for obtaining good clinical outcomes. This study assessed the shape accuracy of an acrylonitrile butadiene styrene (ABS) canine tibia model printed using fused deposition modelling (FDM) and evaluated its morphological change after hydrogen peroxide (H2O2) gas plasma sterilisation. The tibias of six canine cadavers underwent computed tomography for 3D reconstruction. Tibia models were fabricated from ABS on a 3D printer through FDM. Reverse-engineering technology was used to compare morphological errors (root mean square; RMS) between the 3D-FDM models and virtual models segmented from original tibia images (3D-CT) and between the models sterilised with H2O2 gas plasma (3D-GAS) and 3D-FDM models on tibia surface and in cross-sections at: 5%, 15%, 25%, 50%, 75%, 85%, and 95% of the tibia length. Results The RMS mean ± standard deviation and average positive and negative deviation values for all specimens in G1 (3D-FDM vs. 3D-CT) were significantly higher than those in G2 (3D-GAS vs. 3D-FDM; P < 0.0001). Mean RMS values for G1 at 5% bone length (proximal tibia) were significantly higher than those at the other six cross-sections (P < 0.0001). Mean RMS differences for G2 at all seven cross-sections were nonsignificant. Conclusions Our tibia model fabricated on an FDM printer had high shape accuracy with a low RMS value. The surface deviation in G1 indicated that larger errors occurred during manufacturing than during sterilisation. Therefore, the model may be clinically acceptable for bone surgery and surgical rehearsal.

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