Abstract
Significant advances in fused deposition modeling (FDM), as well as its myriad applications, have led to its growing prominence among additive manufacturing (AM) technologies. When the technology was first developed, it was used for rapid prototyping to examine and analyze a product in the design stage. FDM facilitates rapid production, requires inexpensive tools, and can fabricate complex-shaped parts; it, therefore, became popular and its use widespread. However, various FDM processing parameters have proven to affect the printed part’s mechanical properties to different extents. The values for the printing process parameters are carefully selected based on the part’s application. This study investigates the effects of four process parameters (raster angle, layer thickness, infill percentage, and printing speed) on the mechanical behavior of printed parts that are based on available literature data. These process parameter’s influence on part’s mechanical properties varies depending on the FDM material. The study focuses on four FDM materials: polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), polyether ether ketone (PEEK), and polyethylene terephthalate glycol (PETG). This paper summarizes the state-of-the-art literature to show how sensitive the material’s mechanical properties are to each process parameter. The effect of each parameter on each material was quantified and ranked using analysis of variance (ANOVA). The results show that infill percentage then layer thickness are the most influential process parameter on most of the material’s mechanical properties. In addition, this work identifies gaps in existing studies and highlights opportunities for future research.
Highlights
Mechanical and Materials Engineering Department, Faculty of Engineering, University of Jeddah, Abstract: Significant advances in fused deposition modeling (FDM), as well as its myriad applications, have led to its growing prominence among additive manufacturing (AM) technologies
FDM process parameters can be categorized into slicing parameters, build orientation, published maps and institutional affiliations
Samykano showed that ultimate tensile strength (UTS) increases by 20% when the infill percentage increases from 20% to 60%
Summary
AM consists of many technologies that create physical parts by the successive addition of materials. Sometimes called raster orientation, is the direction of the deposited layers with respect to the build platform It usually ranges from 0◦ to 90◦. Extrusion temperature is defined as the heating temperature for a filament material in the nozzle section during the extrusion process It varies depending on the thermoplastic material type and the printing speed. Raster width is the width of a single deposited raster and depends on the extrusion nozzle diameter, printing speed, and the ratio between printing speed and extrusion speed, which is called “extrusion multiplier” [74] The calibration of this parameter is very important for part accuracy and mechanical properties. PLA is a biodegradable thermoplastic filament whose use in FDM has been increasing It requires low energy and temperature (starting melting point: ◦ C) to be extruded and a moderately heated bed during deposition to make an object. It is used in food packaging, cardiovascular implants, and dental scaffolds [24,55]
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