Acrylonitrile Butadiene Styrene Material Research Articles

Process parametric optimization of fused deposition modeling for manufacturing of acrylonitrile butadiene styrene parts

Additive manufacturing has been a revolution in the last decade and has led to a number of product innovations. Rapid prototyping (RP) has significantly reduced the product development cycle time and RP techniques are now replacing many conventional plastic processing techniques where production volume is not an issue. In order to ascertain the utility of additive manufacturing techniques for the development of fully functional parts, it’s important to establish the optimal set of process parameters for achieving maximum mechanical performance. In the current experimental investigation, the dogbone-shaped parts of acrylonitrile butadiene styrene (ABS) were fabricated by the fused deposition modeling (FDM) process. The process parameters were optimized for dogbone-shaped specimens fabricated by the FDM process. Among the parameters, it has been found that orientation and infill density are the most dominant factors affecting the tensile strength of FDM parts printed with ABS material.

The Efficiency of a Biological Reactor in a Domestic Wastewater Treatment Plant Operating Based on ABS (Acrylonitrile Butadiene Styrene) Material and Recycled PUR (Polyurethane) Foam

The primary objective of this research was to assess the efficacy of a novel solution under conditions closely resembling those of real-world scenarios. Biological beds, or filters, hold significant potential for widespread implementation in individual households, particularly in areas with dispersed housing. The system’s aim was to improve the quality of wastewater treated in on-site domestic biological treatment plants. A pivotal aspect of the project involved developing a prototype research installation for conducting comprehensive testing. Our installation system consisted of several components designed to create a laboratory-scale model for domestic wastewater treatment. The model comprised four biological reactors filled with ABS material and secured by a PUR frame. Additionally, the tested model included a controller for wastewater dosing control, a septic tank as a reservoir, and four tanks for collecting purified wastewater. Through regression analysis using the Generalized Linear Model (GLM), a correlation between CODCr and TSS was revealed. This study presents the research findings concerning the development of a prototype installation that incorporates an advanced reactor or filter. The data derived from this research have the potential to contribute to the creation of products that enhance the performance and efficiency of household wastewater treatment systems.

Implementation of additive-manufactured hydroforming die for thin metal bellow production – a stride towards additive manufacturing in rapid tooling approach

ABSTRACT The hydroforming die was designed based on the required operating conditions. The Fused Deposition Modeling process, Acrylonitrile Butadiene Styrene material, and sparse mode style were used for the fabrication. The first attempt at using the hydroforming die to create SS316 bellow (0.3 mm thickness x 2 ply) failed due to excessive pressure concentration at the convolution region. The die was redesigned to enhance overhanging convolution imprints and reduce their length to 50% of the original design, followed by an ANSYS simulation to identify critical failure regions. The second trial of the hydroforming die for producing SS316 bellow (0.2 mm thickness x 1 ply) was successful in a brief run. However, the formed metal bellow displayed an increased convolution width, attributed to the reduced convolution imprint length in the redesigned die. The stress analysis indicated maximum Von Mises stress at the convolution imprint and minimum stress at the die’s outer boundary. The sparse mode die showed 18.104% lower material consumption and 16.225% shorter build time than the solid mode, with a porosity difference of 30.668%. A 6.66%-dimensional error occurred due to oversizing in the topmost convolute, suggesting a 30% reduction in convolution imprint length to mitigate this error in future designs.

Experimental analysis of the effects of different production directions on the mechanical characteristics of ABS, PLA, and PETG materials produced by FDM

Abstract One of the most researched technologies among technologies used for producing complex and diverse parts today is additive manufacturing. In additive manufacturing, production can be carried out using thermoplastic and metal materials without requiring an additional process. Among the additive manufacturing technologies, the Fused Filament Fabrication (FFF) method is the most widely used method worldwide due to its affordability and broad application area. FFF is a method in which part formation is achieved by depositing melted materials on each other. In recent years, polymer materials such as polylactic acid (PLA), polyethylene terephthalate glycol (PETG), and acrylonitrile butadiene styrene (ABS) have been frequently used in many industrial areas in the FFF method because they are lightweight, inexpensive, sustainable, and provide sufficient strength for engineering applications. This study conducted tensile, three-point bending, Charpy, and compression tests on PLA, PETG, and ABS materials at angles of 15°–75° and 30°–60°, and the results were compared.

Alternatif Design of Compliant Mechanism Based Ankle Foot Prosthesis

People with permanent disabilities such as transtibial amputees can be independent and lead normal lives through prosthetics. Foot prosthetics is currently a custom product that is adapted to the features of the amputated leg, so it is more expensive and time consuming. Artificial foot products in Indonesia are still dominated by imported products, so they have high prices and are difficult to reach for lower-middle class amputees. The purpose of this study was to create an alternative design of the ankle foot for users of below-knee prosthetics. The design was made using Solidwork software. Two types of alternative ankle foot designs were produced in this study. Both designs apply a compliant mechanism system to make it more flexible when used. The design is made to meet one of the specified criteria, namely light weight with a mass of less than 2.3883 kg. Three alternative materials are offered in both design alternatives, namely Acrylonitrile Butadiene Styrene (ABS), Poly Oxy Methylene (POM), and AISI 304. Based on the design, it is found that the lightest design is owned by an alternative ankle foot design 1 with ABS material that is equal to 62.69 gram.

Experimental Investigation to Optimize Build Orientation and Raster Angle for PLA and ABS Specimens Generated by FDM Technology

The fused deposition modeling (FDM) process is used increasingly in the manufacture of mechanical parts and more particularly in the automotive and aeronautical fields. The purpose of this work is to optimize build orientation for obtaining polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) samples with the best mechanical properties, dimensional accuracy, surface quality, and minimal total cost. For achieving This, PLA and ABS specimens are fabricated by FDM technology with three build orientations (flat, on edge, upright) and three raster angles (0°, 45°, 90°).at first, the dimensions of the produced samples are measured .secondly, the tensile test, DETLAB equipment was used to obtain tensile stress. In addition, roughness testers were also used to measure surface quality. As a consequence, the findings indicate that the mechanical strength increases with decreasing raster angle and by aligning from upright to flat orientation for both materials due to the fracture mechanism and loading direction. Also, the manufacturing orientation and raster angles significantly affected the dimensional accuracy and total cost. Additionally, there was a big difference in the surface roughness depending on the manufacturing orientation and raster angle; perpendicular measurements increase surface roughness values. We aim to investigate the impact of flat, on-edge, and upright build orientations as well as raster angles on the total cost, tensile strength, dimensional accuracy, and surface roughness of PLA and ABS material through tensile experiments.

Enhanced Flexural Performance of Diamond Latticed Triply Periodic Minimal Surface Sandwich Panels

The additively manufactured bio‐inspired lattice structures have various superior properties in comparison to their solid counterparts as they are lightweight and suitable for fabricating various parts in aerospace sectors. This study limits the investigation of triply periodic minimal surface (TPMS)‐based diamond sheet and solid cellular structures with varying densities (25%, 35%, 45%, and graded) under flexural loading conditions. The sandwich panel structures are made using acrylonitrile butadiene styrene material utilizing the fused filament fabrication (FFF) process. In‐plane flexural performances of the FFF fabricated bio‐inspired TPMS diamond sandwich panels are investigated for the first time. The panels are created to investigate how density and unit cell geometry affect stiffness, strength, and energy absorption. The digital image correlation approach is used to visualize the deflection of the panels subjected to three‐point bending. Also, a theoretical analysis is done to find out the deflection of the sandwich panel structures. An Ashby chart shows the comparison of the specific energy absorption of the TPMS diamond sandwich panels used in this study with several other cellular core sandwich panels available in the literature. This study provides a valuable contribution to the improved energy absorption performance of additively manufactured cellular materials.

Study on the free vibration analysis and mechanical behaviour of 3D printed composite I shaped beams made up of short carbon fiber reinforced ABS and PLA materials

Rapid prototyping is a process that involves creating physical models of products or components quickly using 3D printing technology. Two of the most used materials for this purpose are Polylactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS). Both have unique properties that make them suitable for different applications. When it comes to constructing buildings, bridges, and other structures, one of the most important components is the beam. Beams are used to support weight and provide stability for a structure. One type of beam that is commonly used in construction projects is a box-shaped beam. Hence in this research work, I shaped beam is designed and fabricated using Fused Filament fabrication method, material used are carbon fiber reinforced PLA and ABS materials. Vibration tests can help determine whether a particular design has sufficient stiffness and damping characteristics for its intended application, which helps reduce the risk of unexpected failures down the line. I shaped beam is subjected to free vibration test using Impulse hammer test condition, natural frequency and damping of the I shaped beam for the considered composites were extracted. Results show that the ABS reinforced with carbon fiber is superior in damping than the PLA reinforced with the same short carbon fiber material. Flexural tests are conducted as per ASTM standards and results were correlated with respect to the stiffness of the material under transverse vibration. The results indicated that the I shaped ABS reinforced with carbon fiber had superior stiffness and damping characteristics than PLA reinforced with the same short carbon fiber material, making it a better choice for design applications which require strength and flexibility.

Structural Model Test for Strength Performance Evaluation of Disconnectable Mooring Apparatuses Installed on Floating-Type Offshore Wind Turbine

The destructive power of typhoons has been continuously increasing due to the influence of global warming. In a situation where the installation of floating wind turbines is increasing around the world, concerns about huge losses and collapses of floating offshore wind turbines due to strong typhoons are deepening. Regarding the safe operation of floating offshore wind turbines, the development of a new type of disconnectable mooring system is required. The newly developed disconnectable mooring apparatuses, such as fairlead chain stoppers (FCS) and submersible mooring pulleys (SMP), considered in this study are devised to more easily attach or detach the floating offshore wind turbine with mooring lines compared to other disconnectable mooring systems. In order to investigate the structural safety of the initial design of FCS and SMP that can be applied to MW class floating-type offshore wind turbines, scaled-down structural models were produced using a 3-D printer, and structural tests were performed on those models. For the structural tests of the scaled-down models, tensile specimens of the acrylonitrile butadiene styrene material used in the 3-D printing process were prepared, and the material properties were evaluated by performing tensile tests. Finite element analyses of FCS and SMP were performed by applying the material properties obtained from the tensile tests and the same load and boundary conditions as in the scaled-down model structural tests. Through the finite element analyses, the weak structural parts of FCS and SMP were reviewed. The structural model tests were performed considering the main load conditions of the fairlead chain stopper, and the test results were compared to the finite element analyses. Through the results of this study, it was possible to experimentally verify the structural safety of the initial design of disconnectable mooring apparatuses. Furthermore, the study results can be used to improve the structural strength of FCS and SMP in a detailed design stage.

Experimental study of manufacturing of human mandible using fusion deposit modeling (rapid prototyping)

Rapid prototyping method is used, for the manufacture of human mandible for replacement for accident victims. Rapid prototyping will make the manufacture of implants much easier and more exact than conventional methods such as titanium implant manufacturing in Alveolar ridge augmentation. After performing the necessary tests, the material selected for usage in the implants was ABS (Acrylonitrile Butadiene Styrene). Tensile tests are performed on ABS for implant manufacturing. Structured Light 3D Scanner is used to scan a life-size human mandible and the Standard Triangular Language (STL) file was created that file has been used in all the processes involved in the modeling and manufacturing of the Human Mandible by Rapid prototyping on ABS. FEM analysis is done on said material at different orientations using ANSYS 2021. From the test results it is found that the ABS material can sustain more than the required average bite force. Furthermore, a comparison of stress and load-bearing ability of bone and ABS is done to confirm the viability as a replacement material for bone in the mandible, which was found to be positive. The biocompatibility of ABS with the bloodstream and the body is researched and found to be positive. Implantation methods and bone powder coating variants are researched, to be able to fit the implant in the temporomandibular joint with the fastest recovery time.

Dimensional Accuracy of Acrylonitrile Butadiene Styrene Material Produced by Additive Manufacturing Method

Dimensional Accuracy of Acrylonitrile Butadiene Styrene Material Produced by Additive Manufacturing Method

Design and development of customized elbow orthosis using additive manufacturing

The orthosis is an assistive device to help people with disabilities. Orthosis, further known as braces, is used to support and modify the characteristics of human neuromuscular and musculoskeletal systems. In this study, elbow hyperextension is considered a significant cause of hand deformity. The elbow hyperextension occurs when the elbow joint in hand is being bend beyond its normal range of motion. Most commonly, orthosis was employed to treat the elbow hyperextension externally. In recent times, elbow orthosis design is customized ergonomically to fit a specific patient. The design is based on the customized profile of the human hand from the three-dimensional (3D) scanner. Sense 3D body scanner is used for scanning the human hand and 3D modeling of orthosis is done in SolidWorks. In order to reduce material consumption, topological optimization was performed. A developed novel mechanism was validated for failure analysis. The developed elbow orthosis is produced by additive manufacturing processes namely fused deposition modeling (FDM) and PolyJet technology. In FDM, acrylonitrile butadiene styrene material has been used whereas in the case of PolyJet printing, vero white material is used. The developed ergonomically designed orthosis can be worn for a long period of time without causing pain and therefore curing time is faster. A significant advantage of this proposed elbow orthosis is a self-operated novel mechanism.

Influence of 3D printing properties on relative dielectric constant in PLA and ABS materials.

Nowadays, it is well known that on the ship, free space is at a premium. Unfortunately, every part on the ship has its duration before the failure, and the spare parts occupy the space. The broken part must be replaced when the failure occurs to maintain the ship's operation. Developing 3D printer technology and particular material technology, it has become possible to print a spare part that can replace broken. However, due to hazardous environments (salt, humidity, vibrations, etc.), printed parts change their properties. Electrical capacity and further dielectric permittivity is a parameter or metric that has to be monitored since it directly influences the printed part material structure. Therefore, this paper aims to research the impact of relative dielectric constant in additive manufacturing on printed ship's spare parts since infill patterns and density were changed due to a hazardous environment. The experiment, in which the three shaped material samples are created, consists of the following equipment, the Ultimaker S5 3D printer, Polylactic Acid (PLA) and Acrylonitrile-Butadiene-Styrene (ABS) materials, and LC HM 8018m. Results show relative dielectric constant changes between 1.7778 and 2.8141 for PLA and between 2.1979 and 2.9989 for ABS, depending on infill density and pattern. ANOVA test for ABS is performed to investigate how the calculated dielectric constant relates to the infill density for various infill shapes. Scores are: F = 154.3773, Fcrit = 5.1432, and p = 6.9269·10-6. ANOVA test for PLA resulted in scores F = 18.911, Fcrit = 5.1432, and p = 0.0022.

Prediction of the Influence of Printing Parameters on the Residual Stress Using Numerical Simulation

Abstract Fused Deposition Modeling is an additive manufacturing technology that is used to create a wide range of parts and applications. Along with its benefits, there are some challenges regarding the printed parts’ mechanical properties, which are associated with printing parameters like layer thickness, printing speed, infill density, printing temperature, bed temperature, infill pattern, chamber temperature, and printing orientation. One of the most crucial challenges in additive manufacturing technology is the residual stress, which significantly affects the parts like fatigue life, cracks propagation, distortions, dimensional accuracy, and corrosion resistance. Residual stress is hard to detect in the components and sometimes is costly to investigate. Printing specimens with different parameters costs money and is time-consuming. In this work, numerical simulation using Digimat-AM software was employed to predict and minimize the residual stress in printed Acrylonitrile Butadiene Styrene material using Fused Deposition Modeling technology. The printing was done by choosing six different printing parameters with three values for each parameter. The results showed a significant positive correlation between residual stress and printing temperature and infill percentage and a negative correlation with layer thickness and printing speed. At the same time, we found no effect of the bed temperature on the residual stress. Finally, the minimum residual stress was obtained with a concentric infill pattern.

Performance Analysis of PLA Material Based Micro-Turbines for Low Wind Speed Applications.

Various studies have been conducted in recent years to find solutions to the issues in wind energy conversion systems. A 100W horizontal axis micro wind turbine is built for low wind speed applications in this work. The Blade Element Momentum theory approach was used to design the 100W micro wind turbine blade. The wind turbine blade 3D model was created using the CREO CAD 3.0 software. Based on the aerodynamic studies, the airfoil S9000 is chosen among others for generating high power at low wind speed. The density, Young’s modulus, and the Poisson ratio of the proposed wind turbine blade model with acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) materials were compared. ABS and PLA materials were investigated using a 0.33 mm layer of infill ranging from 10% to 100%. PLA and ABS output values were compared in terms of deformation, equivalent stress, and equivalent strain. PLA materials, on the other hand, have less deformation and greater structural properties than ABS materials. The wind blade structural analysis was performed in ANSYS 15 software, and the details of experimental and simulated results are presented in this paper.

Estimation of three-point bending behavior using finite element method for 3D-printed polymeric sandwich structures with honeycomb and reentrant core

Sandwich structures are known as ultra-light porous materials. Because the structure has advantages in terms of acoustics, fatigue, and impact resistance that conventional stiffened plates cannot match, it has become a popular material in aerospace, automotive, marine, windmill, and architectural applications. One promising method for decreasing production waste and enhancing flexural stress is to employ Additive Manufacture (AM) technologies for sandwich structure manufacturing. In this study, polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), and polyethylene terephthalate glycol (PETG) sandwich structures with reentrant and honeycomb cores were designed and then a finite element analysis (FEA) was carried out to compare the stress distributions in these sandwich composites. According to the findings, higher flexure stresses and specific energy absorption were obtained in the reentrant sandwich structures compared to honeycomb sandwich structures. A minimum equivalent stress value was found in the ABS material, while a maximum equivalent stress value was found in the PLA material.

Effect of process variables on adhesion of acrylonitrile butadiene styrene and carbon fiber reinforced acrylonitrile butadiene styrene materials printed using additive manufacturing

Additive manufacturing has the capacity to manufacture functional parts with complicated geometries, fused filament fabrication is a viable additive manufacturing method and an alternative to standard processes for the creation of polymer and fiber-reinforced polymer composites. The influence of process parameters such as layer thickness, infill density, and infill pattern on the interlaminar bonding performance of three-dimensional printed composites was examined in this study. Due to the existence of high porosity and inadequate layer to layer bond, interlaminar shear strength values increase as layer height increases from 0.15 mm to 0.2 mm and decrease by 0.3 mm. The specimens were also subjected to a wettability test to determine the printed material’s adhesive behavior. Scanning electron microscope was used to perform fractography analysis, and fractured specimens were seen. The test findings revealed that carbon fiber reinforced ABS specimens have good interlaminar shear strength and layer adhesive. When comparing carbon fiber reinforced ABS specimens to ABS specimens, the test results demonstrated that interlaminar shear strength and good adhesion between the layers are attained in carbon fiber reinforced ABS specimens.

Investigation of the Impact Resistance Behavior of Customized Hair Clipper Comb Fabricated by Fused Deposition Modeling

This study consists of the development of a hair clipper comb finite element (FE) model, impact test analysis on the FE model, fabrication of the product using commercially available materials, followed by physical impact testing of the comb. Moreover, microscopic examination of the combs was performed to analyze the quality of the product and correlate the defects with the failure mechanism. The 3D model of comb for a Philips hair clipper was developed using ONSHAPE software, followed by a design study to understand the impact resistance of the product. The design study was performed using finite element analysis (FEA) explicit dynamic module, where two hair clipper comb designs, one with a solid body and the other with a shell were subjected to drop test simulation in two orientations: leg and head drop. Two readily available 3D printable plastic materials, Acrylonitrile Butadiene Styrene (ABS) and Polylactic acid (PLA) were selected for the FEA simulation while the comb was subjected to free fall from a height of 5 ft (1.67 m). The comb was dropped in two orientations: the head drop configuration and the leg drop configuration. For all combinations, the maximum stresses generated as a result of impact were noted and experiments performed to validate the simulation results. The four models were fabricated using fused deposition modeling (FDM) technique and were manually dropped from the same height. In line with the simulated results, models prepared from PLA material failed upon the impact while ABS samples having a comparatively better impact resistance sustained the impact without failure. Finally, fracture surface morphologies of the failed PLA component and the surface of ABS in as-printed condition were analyzed using Scanning Electron Microscopy (SEM). Based on the obtained results, the shell model made of ABS material turns out to be the most suitable choice out of all the designs considered.

Strength and stiffness of 3D-printed connectors compared with the wooden mortise and tenon joints for chairs

ABSTRACT In this study, 3D-printed connectors to replace the typical L-shaped joints in the construction of a chair were developed, tested and numerically analysed. Different connectors were designed and manufactured with a fused deposition modelling (FDM) 3D printer using acrylonitrile butadiene styrene (ABS) with the aim to find a simple shaped connector which could be used to build chairs and withstand standard chair loading requirements. The strength and stiffness of the joints were tested and compared with traditional beech mortise-and-tenon joints. Numerical stress and strain analyses were performed with the finite element method for an orthotropic linear-elastic model. The experimental results showed that joints with 3D-printed connectors achieved lower strength than the traditional wooden mortise-and-tenon joints with similar dimensions. The results indicate that the effect of reinforcement of the connector were not recognised due to the small thickness and inadequate geometric position and arrangement of the reinforcement ABS material. The chair assembled with 3D-printed connectors could withstand the loads for seating, but failed the backrest test according to standard EN 1728:2002. The connectors need to be optimised and reinforced to withstand standard loads.

Computational investigation of the post-yielding behavior of 3D-printed polymer lattice structures

Abstract Sandwich structures are widely used due to their light weight, high specific strength, and high specific energy absorption. Three-dimensional (3D) printing has recently been explored for creating the lattice cores of these sandwich structures. Experimental evaluation of the mechanical response of lattice cell structures (LCSs) is expensive in time and materials. As such, the finite element analysis (FEA) can be used to predict the mechanical behavior of LCSs with many different design variations more economically. Though there have been several reports on the use of FEA to develop models for predicting the post-yielding stages of 3D-printed LCSs, they are still insufficient to be a more general purpose due to the limitations associated with the lattice prediction behavior of specific features, certain geometries, and common materials along with showing sometimes poor prediction due to the computationally cheap elements out of which these models have been composed in most cases. This study focuses on the response of different LCSs at post-yielding stages based on the hexahedral elements to capture accurately the behaviors of 3D-printed polymeric lattices made of the Acrylonitrile Butadiene Styrene material. For this reason, three types of lattices such as body centered cubic, tetrahedron with horizontal struts, and pyramidal are considered. The FEA models are developed to capture the post-yielding compressive behavior of these different LCSs. These models are used to understand and provide detailed information of the failure mechanisms and relation between post-yielding deformations and the topologies of the lattice. All of these configurations were tested before experimentally during compression in the z-direction under quasi-static conditions and are compared here with the FEA results. The post-yielding behavior obtained from FEA matches reasonably well with the experimental observations, providing the validity of the FEA models.