Effect Of Printing Orientation Research Articles

Material Investigation and Effect of Printing Orientation, Tensile Speed, and Density on the Mechanical Behaviour of 3D Printed Parts

Additive manufacturing (AM), also known as 3D printing, is becoming one of the main manufacturing sources in most fields, due to its easy manipulation and time, and cost savings. It is the most favourable manufacturing technology for prototyping, unit or limited production size, and personalized objects. However, the AM's most common problem found is the lack of material information due to the different printing parameters and different materials. The fused deposition modelling (FDM) is the mostly used AM technology since it is the cheapest and easiest manufacturing technique. This technology has various materials and printing parameters that affect the mechanical properties. Multiple types of research were made on the effect of the different printing parameters, other on the material properties, and few worked on the effect of different materials. In the scope of our work, the effect of the printing orientation on different materials and the effect of varying the density on the mechanical behaviour are investigated. Moreover, the FDM part’s mechanical behaviour is still on investigation. We investigated the effect of tensile tests with different speeds on the specimens to analyse this behaviour. For this purpose, we printed different tensile specimens with different materials, printing directions, and densities. Then, we studied the effect of each parameter on the mechanical behaviour using tensile tests. It was found out that the printing parameters have a significant impact on the mechanical properties, but the tensile speed doesn’t affect the behaviour if the test is made at an environmental temperature.

Влияние направления печати на характер износа PLA-биоматериала, полученного методом FDM: исследование для имплантата тазобедренного сустава

Introduction: hip joint replacement surgery involves replacing the damaged joint with an implant that can re-create the joint's articulation functionality. 3D printing technology is more promising than the traditional manufacturing process when it comes to producing more complex parts and shapes. The goal of the current research project is to determine how quickly biomaterial implant can be manufactured using 3D printing for hip-joint replacement by studying the wear rate of parts manufactured using different printing orientations. Although there are several additive manufacturing technologies, fuse deposition modeling (FDM) technology has had a significant impact on healthcare, automotive industry, etc. This is mainly due to the adaptability of different polymer-based composite materials and its cost-effectiveness. Such 3D printed polymers need to be further studied to evaluate the wear rate depending on different 3D printing orientations. Polylactic acid (PLA) biomaterials were extensively studied to determine its suitability for use as hip joint materials. Purpose of the work: in this work, an experimental study was carried out on the effect of printing orientation on dry sliding wear of a polylactic acid (PLA) material obtained by fused deposition modeling (FDM) technology using the pin-on-disk (SS 316) scheme. In addition, experimental and empirical models are developed to predict the performance taking into account the influence of load and sliding speed. Grey relational analysis was used to determine the optimal parameters. The methods of investigation: the FDM printing was used to manufacture pins using different printing orientations. Printing direction refers to printing at angles of 0°, 45°, and 90°, while all other 3D printing parameters remained unchanged. Wear testing was performed using the pin-on-disk kinematic scheme. During the experiments, the normal pin load and disk rotation speed were varied. The experiments were methodically designed to study the effect of input parameters on the specific wear rate. About 13 experiments were conducted for each printing orientation with a friction path of 4 kilometers, in the load range of 400–800 N, at a sliding speed of 450–750 rpm. Result and discussion: the study provides important results especially regarding the direction of 3D printing of components. It was found that the lowest sliding wear was observed for the pin printed at an angle of 0°, while slightly higher wear was observed for the pin printed at an angle of 90°. The layer bonding in the pin printed at an angle of 45° deformed under higher load, mainly due to an increase in temperature. The low bond strength in the pin printed at an angle of 45° resulted in high sliding wear. The optimal result was achieved at a sliding speed of 451 rpm and a load of 600 N. The results of the study are very useful for choosing materials for 3D printing of biomedical implants, medical and industrial products.

Effect of print orientation on the dimensional accuracy and cost-effectiveness of rapid-prototyped dental models using a PolyJet photopolymerization printer: An in vitro study

The purpose of this study was to evaluate the accuracy and cost-effectiveness of the dental models 3D printed in vertical and horizontal orientation as compared to the conventional plaster and digital models. This study involved scanning 50 plaster models using Maestro 3D Desktop Scanner (AGE Solutions, Pisa, Italy). The STL file obtained from the scanner was processed and three-dimensionally (3D) printed in the horizontal and vertical orientation using a PolyJet 3D printer (Objet 30 prime, Stratasys Ltd., Eden Prairie, Minnesota, United States). The accuracy of the rapid-prototyped (3D printed) models was measured from the pre-determined landmarks and was compared among the groups. In addition, determining the cost-effectiveness of the 3D printed models in different orientations was based on the amount of material (resin) utilized during the 3D printing process. ANOVA was used to determine the accuracy of the models. There were statistically insignificant differences (P>0.05) among rapid-prototyped models (≤0.06mm) compared to plaster models and digital models for the linear measurements made in all three planes of space. The dental models printed in the horizontal orientation were found to be more cost-effective than those printed in a vertical orientation in terms of the amount of material (resin) utilized and printing time during the 3D printing process. The accuracy of rapid-prototyped models 3D printed in the horizontal and vertical orientations was comparable to the plaster models and digital models for clinical applications. Horizontally printed models were more cost-effective than vertically printed models.

Effect of printing parameters on impact energy absorption of additively manufactured hierarchical structures

PurposeThis study aims to examine how the thickness of layers and printing speed impact the energy absorption capacity of honeycomb structures through drop-weight experiments. In addition, the effect of printing orientation on the resulting microstructure and mechanical performance was targeted to be examined.Design/methodology/approachIn this paper, after manufacturing test specimens using fused deposition modeling technique with three distinct layer thicknesses (0.16 mm, 0.20 mm and 0.28 mm) and printing speeds (40 mm/min, 50 mm/min and 70 mm/min), drop weight tests were carried out. Then to see the effect of printing orientation on mechanical performance, three-point-bending tests were performed and damage mechanisms were comparatively examined through scanning electron microscopy.FindingsAn increase in layer thickness from 0.16 mm to 0.28 mm resulted in a notable 37% decrease in the impact resistance of the printed part. In addition, increasing the printing speed from 50 to 70 mm/min reduced the energy absorption capacity of the printed part by approximately 36.5%. Moreover, in terms of printing direction, transversely printed specimens showed 10% lower flexural strength than longitudinally printed specimens. Finally, scanning electron microscopy (SEM) observation showed that internal defects were more prominent in transversely printed specimens, resulting in premature failure. Furthermore, delamination was also detected in transversely printed specimens as another damage mechanism accelerating material failure.Originality/valueIt is seen that the effect of printing parameters on the fundamental mechanical properties including tensile strength, strain at break, ductility and elastic modulus were studied by various researchers. However, to the best of authors’ knowledge, the effect of printing speed and layer thickness on the energy absorption of polylactic acid based hexagonal honeycomb was not encountered. In addition, in-depth SEM analysis to discover the influence of printing direction significantly contributes to the literature.

Effects of surface finishes, heat treatments and printing orientations on stress corrosion cracking behavior of laser powder bed fusion 316L stainless steel in high-temperature water

Stress corrosion cracking (SCC) of laser powder bed fusion 316 L stainless steel in oxygenated high-temperature water environments with chloride addition at 288 °C was studied. The influences of surface finishes (as-built, mechanically polished, Hirtisation® and shot peened), heat treatments (solution annealing at 1066 and 1150 °C and hot isostatic pressing) and the printing orientations on SCC were evaluated. Hirtisation resulted in a lower SCC susceptibility than as-built or polished surface while shot peening showed the lowest apparent SCC resistance. A high annealing temperature decreases SCC resistance. The effect of printing orientation is material and environment dependent.

Dimensional Fidelity and Orientation Effects of PolyJet Technology in 3D Printing of Negative Features for Microfluidic Applications.

Negative features in microdevices find a wide range of applications. The process of 3D printing has revolutionized their fabrication due to the combination of good resolution and integration capability. Herein, we report on a systematic study of the effects of materials and print directions on the 3D printing of microfluidic channels as negative features under PolyJet technology. Specifically, the Statasys Objet500 printer was used for this study. We printed two sets of chips (n=10 each), each of which contains channel pairs of a high-contrast reference material and a sacrificial material, respectively. Both materials were embedded in a clear photopolymer resin. The channel pairs ranged in planned width from 64 to 992 μm. To explore the effect on print orientation, channels were printed either parallel or perpendicular with respect to the jetting head's movement. The width of each channel of a pair was compared for each planned width and each combination of materials. The effect of print orientation on channel morphology was also investigated. We found that reproducibility and accuracy were highest at a planned channel width of approximately ≥600 μm and that channel morphology was most suitable when the jetting head of the printer moved parallel to the channel's longitudinal axis. The results should be of interest to any users who wish to create negative features using PolyJet 3D technology.

Effect of printing orientation on mechanical properties of SLA 3D‐printed photopolymer

AbstractHerein, we conducted tensile and fracture tests on a photopolymer produced with a stereolithography apparatus (SLA), utilizing dog‐bone and semi‐circular bending specimens fabricated in five different orientations. The analysis revealed a direct linear correlation between the tensile strength and printing orientation, highlighting a decrease in tensile strength with an increase in orientation angle. Young's modulus of the printed material remained insensitive to the printing orientation. Conversely, fracture toughness demonstrated a distinct cubic polynomial relationship with the printing orientation. The equivalent material concept in conjunction with the maximum tangential stress criterion was used to predict the fracture behavior of SLA printed polymer. This research sheds light on the significant effect of printing orientation on the mechanical properties of SLA printed materials, offering pivotal insights for optimizing SLA printing across various applications and catalyzing progress in this research field.

Effect of printing orientation on mechanical properties of 3D-printed orthodontic aligners.

The purpose of this study was to assess differences in the fundamental mechanical properties of resin-made three-dimensional (3D) printed orthodontic aligners according to the printing orientation. Twenty resin 3D-printed dumbbell-shaped specimens and 20orthodontic aligners were fabricated and postcured in nitrogen. Half of the specimens and aligners were built in horizontal (H), the other half in vertical (V)directions. The dumbbell-shaped specimens were loaded in atensile testing machine, while parts of the aligners were embedded in acrylic resin, ground, polished, and then underwent instrumented indentation testing (IIT). Mechanical properties that were assessed included the yield strength (YS), breaking strength (BS), plastic strain (ε), Martens hardness (HM), indentation modulus (EIT), elastic index (ηIT), and indentation relaxation (RIT). Data were analyzed statistically with independent t‑tests or Mann-Whitney tests at α = 5%. No significant differences were found between specimens or aligners printed either in ahorizontal or avertical direction (P > 0.05 in all instances). Overall, the 3D-printed aligners showed acceptable mechanical propertied in terms of YS (mean 19.2 MPa; standard deviation [SD] 1.7 MPa), BS (mean 19.6 MPa; SD 1.2 MPa), ε (mean 77%; SD 11%), HM (median 89.0 N/mm2; interquartile range [IQR] 84.5-90.0 NN/m2), EIT (median 2670.5 MPa; IQR 2645.0-2726.0 MPa), ηIT (median 27.5%; IQR 25.9-28.1%), and RIT (mean 65.1%; SD 3.5%). Printing direction seemed to have no effect on the mechanical properties of 3D-printed resin aligners, which are promising for orthodontic use.

On the effect of printing orientation on the surface roughness of an additive manufactured composite vertical tail

On the effect of printing orientation on the surface roughness of an additive manufactured composite vertical tail

Compression behavior of the wood-inspired cellular structure of acrylonitrile butadiene styrene

Abstract In wood science and technology, researchers increasingly focus on the additive manufacturing in different aspects through assembly, mechanical, and physical characterization of the printed parts. One of the main parameters influence the wood features is the inhomogeneity of cellular structure. The effect of dislocation on the compression behavior was evaluated over the wood-inspired cellular structure. The 4.4 × 4.4 mm cross-cut–sized cell (0.8 mm cell wall thickness and 2.8 mm lumen diameter) with 10 mm thickness was arrayed by 6 columns and 3 rows to design the control model. The middle row was 0.8, 1.6, and 2.4 mm dislocated to obtain irregular models. Objects were fabricated through the deposition of acrylonitrile butadiene styrene filament using DaVinci 1.0 all in one three-dimensional printer. The effect of printing orientation (vertical and horizontal) on compression behavior was also figured out. The compression test was performed to obtain the load–deformation behavior of samples. According to the results, the horizontally printed samples presented better performance. Furthermore, horizontal alignment, rectilinear infill type, 90 % infill density, and 0.2 mm layer height combination presented the highest (5719 N) load-carrying capacity. The statistical analysis (P < 0.05) figured out that cell dislocation has significant influences on mechanical properties.

Effect of print orientation, storage conditions, and storage time on intaglio surface accuracy of implant surgical guides fabricated by using a stereolithography technology

The accuracy of printed implant surgical guides can be affected by different factors that negatively impact the planned implant position. How print orientation, storage time, and conditions influence manufacturing accuracy remains uncertain. The purpose of this in vitro study was to evaluate the influence of print orientation, storage conditions, and storage time on the intaglio surface accuracy of implant surgical guides manufactured by using a stereolithography (SLA) printer. A tooth-supported maxillary implant surgical guide design (control file) was used to fabricate the specimens (N=40, n=10). Four groups were created based on the print orientation used: 0 (Group 0), 45 (Group 45), 70 (Group 70), and 90 degrees (Group 90). The specimens were fabricated using an SLA printer (Form 3B+) and a biocompatible dental resin (Surgical Guide Resin V1) following the manufacturer's recommended protocol. Each group was divided into 2 subgroups based on the storage conditions: light (L subgroup) and dark (D subgroup) settings. Each specimen was digitized by using a desktop scanner (Medit T710) at days 0, 1, 7, and 14. The control file and each digitized specimen were superimposed by using the best-fit technique with a metrology program (Geomagic Control X). The root mean square (RMS) error was used to calculate the discrepancies between the control files and specimen files. Three-way ANOVA and pairwise comparison Tukey tests were used to analyze trueness. The Levene test was used to assess precision (α=.05). Significant trueness discrepancies were found among the groups tested (P<.001), but no significant differences were found among the subgroups (P=.100) and the storage times analyzed (P=.609). Additionally, the Tukey test showed significant RMS error mean value discrepancies between Group 0 and Group 45 (P<.001), Group 0 and Group 90 (P<.001), Group 45 and Group 70 (P<.001), and Group 70 and Group 90 (P<.001). The Levene test revealed significant SD discrepancies among the groups tested (P<.05). The trueness and precision of the intaglio surface of the implant surgical guides manufactured by using the printer and material tested were affected by the print orientation. However, storage conditions over a 14-day period did not impact the intaglio accuracy of the specimens.

The effect of orientation on tensile strength 3D printing with ABS and PLA materials

3D printing has revolutionized the manufacturing industry, offering unique opportunities for rapid prototyping and customized production. Acrylonitrile Butadiene Styrene (ABS) and Polylactic Acid (PLA) are widely used thermoplastics in 3D printing due to their versatility and mechanical properties. Tensile strength is a critical mechanical property that determines the load-bearing capacity of printed parts. However, the orientation of the printed layers during the additive manufacturing process can significantly affect the printed parts’ tensile strength and overall mechanical behaviour. The effect of printing orientation on the tensile strength of 3D printed ABS and PLA materials was investigated. The printing orientation of printed tensile samples varies from 0°, 45°, and 90°, layer thickness of 0.1 mm, and refers to ASTM D638 standard. Tensile testing is carried out with the Tensilon machine. The results showed that the orientation influence the tensile strength of the ABS and PLA samples. The change of orientation from 0° to 90° causes a decrease in tensile strength of 44.3% of ABS and 52.8% of PLA materials. The findings of this study will provide valuable insights into the mechanical behaviour of 3D printed parts and inform design considerations for optimizing printing orientations to achieve enhanced tensile strength.

Mechanical, microstructural and numerical investigations of 3D printed carbon fiber reinforced PEEK

In the frame of technology development, fused deposition modeling is adapted in this study to elaborate composite material from 20% short carbon fiber reinforced polyether ether ketone (CF/PEEK) filament. This printing technology has attached widespread intention as it provides a rapid prototyping parts with high performances in diverse fields. For this purpose, a set of experimental tensile and bending tests are carried out to focus on the effect of printing orientation on the mechanical properties of the designed samples. Three raster angles are considered in this investigation: 0°, ±45°, and 90°. The obtained results indicate that the printing orientation of 0°, which is parallel to the tensile loading path and perpendicular to the flexural one exhibits higher mechanical strength compared to the other orientations. Evolution of Young modulus, total elongation at failure, yield and ultimate strengths as well as deflection are also discussed. Experimental work is supported by numerical simulation and a good agreement is revealed. Microstructural analysis is performed in order to argue the observed mechanical behavior. Through the fractured section morphology, the effect of tensile loading on CF/PEEK microstructure, at various printing orientation is emphasized.

Effect of print orientation on tensile and shear properties of 3D printed lap joints

Additive manufacturing (AM) is a cutting-edge manufacturing technique that uses additive manufacturing-capable materials such as ceramics, polymers, metals, titanium, base metals, and composites to create components with precise characteristics and complicated designs. A 3D printing method that is quickly expanding is fused deposition modelling (FDM). Nevertheless, the majority of fused deposition modelling (FDM) technology only accepts acrylonitrile butadiene styrene (ABS) or poly lactic acid (PLA) as printing media. In this study, the effect of printing orientation on mechanical and shear characteristics of PLA specimens made using fused deposition modelling (FDM) has been examined. Tensile analysis depicted that loading along the direction (0°) has higher tensile strength and elongation compared to other orientations like perpendicular to the loading direction (90°) and inclined to the loading direction (45°). The 3D-printed single-lap joint (SLJ) has been prepared and tested under tensile behaviour, and shear properties indicated that samples prepared using (0°) print orientation have the highest load-carrying capacity of 2865 N and shear strength of 4.58 MPa compared to other printing orientations. Field emission scanning electron microscopy (FESEM) was performed on the 3D printed SLJ failed samples to evaluate the failure analysis.

Effect of printing orientation on mechanical properties of components in stainless steel obtained using the Bound Metal Deposition technology

Effect of printing orientation on mechanical properties of components in stainless steel obtained using the Bound Metal Deposition technology

INFLUENCE OF PROCESS PARAMETERS ON MECHANICAL STRENGTHS OF 3D-PRINTED CARBON-PLA BASED COMPOSITES FOR ORTHOTICS AND PROSTHETICS APPLICATIONS

The objective of the present work is to study the influence of process parameters on the mechanical behavior of composite material parts developed by Fused Deposition Modeling (FDM). Carbon-PLA-based composite specimens are used in the present work. Experimental results have shown that with increases in printing temperature from 225&amp;deg;C and 240&amp;deg;C, there is an increase in tensile strength, whereas flexural strength decreases with the temperature rise. The effect of printing orientation is the same on both tensile and flexural strength. Tensile and flexural strengths are higher for flat orientation (0&amp;deg;) than for upright orientation (90&amp;deg;). It is also found that when layer height decreases from 0.3 mm to 0.2 mm, both the tensile and flexural strength increases. The experimental results of the present study signify the importance of Carbon-PLA-based composites for orthotic and prosthetic devices due to their high strength, low cost, and biocompatibility.

Effect of Printing Orientation and Layer Thickness on Microstructure and Mechanical Properties of PLA Parts

Due to the layer-by-layer printing process, additively manufactured objects frequently display directional dependencies in their structure. It affects the material properties of the fabricated parts concerning various process parameters of the machine. This paper presents the effect of layer thickness and printing orientation on the mechanical properties and microstructure of polylactic acid (PLA)3D printed parts fabricated by Fused Deposition Modeling (FDM). Computer-aided design models of a tensile and compression test specimen were created, conforming to the ASTM: D638 (Type 1 and Type IV) and ASTM D695, respectively. The microstructure was evaluated using a Scanning Electron Microscope (SEM) on the fracture surface during the tensile test and optical microscopy on the compression specimens. The finding shows that a low layer thickness setting contributes to the highest tensile strength in the 0° printing orientation, while a medium and high layer thickness results in a better tensile strength for a 45° and 90° printing orientation. Therefore, printing orientation is more influential than layer thickness in the tensile test. As for the compressive strength, the stress decreases when the layer thickness increases and the low layer thickness setting offers the highest compressive strength at all printing orientations. The microstructure shows more significant interlayer gaps, incomplete filling, and weak bonding on the cross-sectional samples of the fractured tensile surface with lower strength. The 0° printing orientation offers better tensile strength for all layer thicknesses, minimum build time, and good compressive strength compared to other printing orientations.

Mechanical characterization of 3D printed samples under vibration: Effect of printing orientation and comparison with subtractive manufacturing

This paper describes dynamical characterization of mechanical structures manufactured by Selective Laser Melting (SLM) process at various orientations. The samples are also compared to subtractive component. The additive metal samples were manufactured by a 3D printer (Renishaw AM 250, Renishaw) and were tested using vibration analysis of embedded-free beam installation. Experimental setup was replicated using the same geometry of samples printed at various orientations and submitted to low velocity impact. Accelerometers allowed recording mechanical responses of all the specimens, allowing characterizing the dynamic behavior of each component and the effect of the printing orientation and printing angles.

An insight into the effect of printing orientation on tensile strength of multi-infill pattern 3D printed specimen: Experimental study

This research aims to investigate printing orientation effect on tensile properties of Multi-Infill Pattern (MIP) specimens fabricated by Fused Deposition Modelling (FDM). The material selected for fabrication of specimen is Poly-lactic Acid (PLA), and the thermal stability of PLA material was examined using Thermal Gravimetric Analysis (TGA). The print orientation selected in this study were flat and on-edge orientation. The up-right orientation was not considered because, in this orientation, the parts are built along the z-axis, which results in minimum strength. The MIP consists of honeycomb, triangular and rectilinear patterns fabricated with 25%, 50%, 75% and 100% infill density. The tensile specimen has been designed as per the ASTM D638 standard. The result represents that the printing orientation has influenced the tensile strength of MIP specimen. Higher tensile strength and tensile strength/mass ratio are observed in the on-edge orientation of MIP specimen. The specimen in on-edge orientation with 100% infill density has resulted in higher tensile strength of 30.91 MPa and tensile strength/mass ratio of 3.87 MPa/g. Based on the literature study, the tensile strength of rectilinear, honeycomb and triangular infill pattern PLA specimen with 80% infill density was 10.48 MPa, 10.72 MPa and 20.39 MPa respectively. Hence it can be concluded that the specimen with a MIP has more tensile strength compared to a single infill pattern specimen. Also, trans-layer failure was observed in MIP specimens printed in both orientations.

Relaksacja naprężeń w próbkach wykonanych z akrylonitrylu-butadienu-styrenu wytworzonych metodą FDM

Increased interest in fused deposition modeling (FDM) resulting, for example, from its use in the production of utility models determines the undertaking of research on mechanical and rheological properties of materials. Mechanical and rheological properties of models made of materials used in FDM technology depend on technological parameters. In this paper, the effect of 0° and 90° print orientation on stress relaxation was analyzed. Additionally, the usefulness of the rheological model to describe the relaxation curve was evaluated. Stress relaxation tests were performed by tensile testing. The five-parameter Maxwell-Wiechert model was used to describe stress relaxation. The tests showed little effect of print orientation on the rheological parameters of the five-parameter model. The Maxwell-Wiechert model showed a very good approximation to the stress relaxation curves.