Basic Technology for Smart Multifunctional Components with Embedded Electronics using Fused Filament Fabrication

Abstract

In this work, we discuss the use of the space-proven Fused Filament Fabrication (FFF) technology for the realization of smart multifunctional components. FFF is an Additive Manufacturing (AM) technology from the Material Extrusion set. The typical FFF procedure, intended to produce plastic component for rapid prototyping applications, is firstly introduced. A modified approach enabling the implementation of electric connections and inclusion of components in the manufacturing process is presented. All the phases of the digital manufacturing, as AM is also known, must be reconsidered to allow the insertion of internal circuitry. Key points such as material characterization and digital model creation are discussed. As far as this last point is concerned, several strategies for 3D digital model creation are presented along with a description of essential constituting elements and FFF-specific fabrication timelines. These are organized according to user’s will to insert or FFF-manufacture electric connections and part-consolidation considerations. All these strategies come along with illustrative test cases, demonstrating the effectiveness of the procedure proposed in this work. This work presents an alternative method enabling to turn a typical rapid-prototyping system into a system to potentially fabricate smart components.