Effect Of Printing Parameters Research Articles

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

Purpose This 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/approach In 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. Findings An 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/value It 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.

Fabrication of micro-ultrasonic phased array electrode via electric field-driven printing method

The electrode is an important part of a micro-ultrasonic phased array, commonly fabricated by magnetron sputtering technology. However, with the expansion of the application field, the structures of the phased arrays are becoming more complex, making the traditional magnetron sputtering method no longer applicable, and the realization of micro-scale phased array electrodes by direct printing technology still faces great challenges. Herein, an electric field-driven direct printing method was proposed to fabricate micro-ultrasonic phased array electrodes. The influence of sintering parameters on the resistivity and the effect of printing parameters on the geometric size and surface morphology of the electrode were comprehensively explored, and the mathematical model between the electrode line width and the printing parameters was established. The final printed electrodes exhibit superior properties with a resistivity of 2.4 × 10−7 Ω⋅m , a surface roughness range of 460–550 nm, and a line width range of 125–480 µm. Additionally, a micro-scale electrode was printed on the piezoelectric ceramic with PZT-5 as the material, and after polarization treatment, the piezoelectric coefficient can reach 405 pC N−1, which proves that this method can be applied in the field of fabricating phased array electrodes.

Lutein encapsulation into dual-layered starch/zein gels using 3D food printing: Improved storage stability and in vitro bioaccessibility

The ability of 3D printing to encapsulate, protect, and enhance lutein bioaccessibility was investigated under various printing conditions. A spiral-cube-shaped geometry was used to investigate the effects of printing parameters, namely zein concentration (Z; 20, 40, and 60 %) and printing speed (PS; 4, 8, 14, and 20 mm/s). Coaxial extrusion 3D printing was used with lutein-loaded zein as the internal flow material, and corn starch paste as the external flow material. The viscosities of the inks, microstructural properties, storage stability, and bioaccessibility of encapsulated lutein were determined. The sample printed with a zein concentration of 40 % at a printing speed of 14 mm/s (Z-40/PS-14) exhibited the best shape integrity. When lutein was entrapped in starch/zein gels (Z-40/PS-14), only 39 % of lutein degraded after 21 days at 25 °C, whereas 78 % degraded at the same time when crude lutein was studied. Similar improvements were also observed after storing at 50 °C for 21 days. Furthermore, after simulated digestion, the bioaccessibility of encapsulated lutein (9.8 %) was substantially higher than that of crude lutein (1.5 %). As a result, the developed delivery system using 3D printing could be an effective strategy for enhancing the chemical stability and bioaccessibility of bioactive compounds (BCs).

Influences of printing parameters on mechanical properties of recycled PET and PETG using fused granular fabrication technique

This research presents an investigation of the feasibility of recycled polyethylene terephthalate (rPET) and glycol-modified polyethylene terephthalate (rPETG) thermoplastics using the fused granular fabrication (FGF) 3D printing technique. It focuses on the effects of FGF printing parameters on the mechanical properties of rPET and rPETG printed parts using a Gigabot X 3D printer. The design of experiments (DOE) was first performed considering the main FGF 3D printing parameters such as layer thickness, infill density and number of contours. The experimental studies were then carried out to study the effects of printing parameters on the tensile properties based on the DOE. The effect of interlayer bonding of printed parts on the tensile properties was also evaluated using finite element-based multiscale modelling. Scanning electron microscopy (SEM) and Fourier transformation infrared (FTIR) spectroscopy were used to observe the fracture morphology and chemical structure of post-FGF printing products. The tensile test results indicate that the highest tensile strength of 26.4 MPa was obtained for rPET when using a 1.1-mm layer thickness, a 70% infill density, and 3 contours, whereas, for rPETG, the maximum tensile strength of 44.8 MPa was attained with a 1.2-mm layer thickness, a 100% infill density, and 2 contours. FTIR analysis confirms no significant changes of characteristic peaks for PET in the printed products, suggesting that rPET and rPETG are viable materials for FGF printing. Thermal stability studies also reveal that the glass transition temperature and onset degradation temperatures are not significantly affected by the printing parameters. The study demonstrates the potential of rPET and rPETG as sustainable alternatives to virgin materials and provides insights into the optimal processing conditions for achieving high-quality 3D printed parts via the FGF technique.

Additive manufacturing and performance research of aluminum-based ceramic cores

As a ceramic core for forming the cooling structure of the intrinsic cavern of turbine blades, the quality of tubular turbine blades is directly affected by their accuracy and performance. In this paper, based on the DLP photocuring technology, the 50% by volume alumina porcelain suspensions with low viscosity were successfully prepared. Secondly, the effects of printing parameters on the curing characteristics were explored to obtain the best printing parameters. The alumina porcelain properties were analyzed for the heating treatment process effect. As the temperature increases, its mechanical properties increase. In addition, the porosity of the patulous orifice reached 48%. The flexural strength of the alumina porcelain component was 26 MPa, which met the requirements of a high-temperature compound metal blade for the porcelain core.

Acoustic properties of ABS and PLA parts produced by additive manufacturing using different printing parameters

Abstract This study investigates the effect of printing parameters on the acoustic performance of specimens produced using 3D printing technology. The specimens were fabricated with square and hexagonal cell shapes with 10, 20, 30, and 50 % infill ratios from acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) materials. The sound absorption coefficient and sound transmission loss results of the samples were measured with an impedance tube at 1/3 octave band values in the range of 500–6400 Hz. The highest sound absorption coefficient results were determined for cylindrical samples with a square internal structure made of ABS material with a 50 % infill ratio in the frequency range of 2500–3500 Hz. The sound transmission loss values of the samples vary between approximately 13 and 58 dB at 1/3 octave band values in the range of 500 and 6300 Hz. The highest sound transmission loss values were determined in the sample produced of PLA with a square cell shape at a 30 % infill ratio. It was concluded that different geometric shapes, materials, and infill ratios affect the acoustic performance of parts produced by 3D printing technology.

The effect of printing parameters on the bonding strength and electric performance of FDM-printed graphene filaments to mulberry paper for paper electronics

The effect of printing parameters on the bonding strength and electric performance of FDM-printed graphene filaments to mulberry paper for paper electronics

Optimizing surface roughness in soft pneumatic gripper fabricated via FDM: experimental investigation using Taguchi method

Purpose In this study, experimental studies were carried out using different process parameters of the soft pneumatic gripper (SPG) fabricated by the fused deposition modeling method. In the experimental studies, the surface quality of the gripper was examined by determining four different levels and factors. The experiment was designed to estimate the surface roughness of the SPG.Design/methodology/approach The methodology consists of an experimental phase in which the SPG is fabricated and the surface roughness is measured. Thermoplastic polyurethane (TPU) flex filament material was used in the fabrication of SPG. The control factors used in the Taguchi L16 vertical array experimental design and their level values were determined. Analysis of variance (ANOVA) was performed to observe the effect of printing parameters on the surface quality. Finally, regression analysis was applied to mathematically model the surface roughness values obtained from the experimental measurements.Findings Based on the Taguchi signal-to-noise ratio and ANOVA, layer height is the most influential parameter for surface roughness. The best surface quality value was obtained with a surface roughness value of 18.752 µm using the combination of 100 µm layer height, 2 mm wall thickness, 200 °C nozzle temperature and 120 mm/s printing speed. The developed model predicted the surface roughness of SPG with 95% confidence intervals.Originality/value It is essential to examine the surface quality of parts fabricated in additive manufacturing using different variables. In the literature, surface roughness has been examined using different factors and levels. However, the surface roughness of a soft gripper fabricated with TPU material has not been examined previously. The surface quality of parts fabricated using flexible materials is very important.

Three-Dimensional Printing of Biomass–Fungi Biocomposite Materials: The Effects of Mixing and Printing Parameters on Fungal Growth

Biomass–fungi biocomposite materials are derived from sustainable sources and can biodegrade at the end of their service. They can be used to manufacture products that are traditionally made from petroleum-based plastics. There are potential applications for these products in the packaging, furniture, and construction industries. In the biomass–fungi biocomposite materials, the biomass particles (made from agricultural waste such as hemp hurd) act as the substrate, and a network of fungal hyphae grow through and bind the biomass particles together. Typically, molding-based methods are used to manufacture products using these biocomposite materials. Recently, the authors reported a novel extrusion-based 3D printing method using these biocomposite materials. This paper reports a follow-up investigation into the effects of mixing parameters (mixing time and mixing mode) on fungal growth in biomass–fungi mixtures prepared for 3D printing and the effects of printing parameters (printing speed and extrusion pressure) on fungal growth in printed samples. The fungal growth was quantified using the number of fungal colonies that grew from samples. The results show that, when mixing time increased from 15 to 120 s, there was a 52% increase in fungal growth. Changing from continuous to intermittent mixing mode resulted in an 11% increase in fungal growth. Compared to mixtures that were not subjected to printing, samples printed with a high printing speed and high extrusion pressure had a 14.6% reduction in fungal growth, while those with a low printing speed and low extrusion pressure resulted in a 16.5% reduction in fungal growth.

Improving the properties of TiC steel bonded cemented carbides by optimizing the slurry rheology, printing path and shape design of 3D gel printing

TiC steel bonded cemented carbide was modeled by an extrusion-based 3D gel printing(3DGP) method. The rheological behavior of slurry was studied to control the slurry extrusion and modeling. The effects of printing parameters, printing path and modeling complexity were researched to get a printed sample without defects. The results indicated that the slurry with a solid loading of 50 vol% (85 wt%) was prepared, and its viscosity change is very little during 24 h in case of a higher shear rate like a nozzle. The viscosity of the slurry decreases with increasing the extrusion pressure and nozzle diameter. The skewed pattern of filaments eliminated pores in printed samples in comparison with the rectangular pattern under the condition of straight lines of the printing path. Pores at the corners of a model can be eliminated by changing the printing path from concentric lines to zigzag lines or two sets of slanted parallel lines. The modeling complexity without a support structure can be revealed by printing tilt cylinders with different angles, and the local parts on a model with a tilt angle of <45° can be printed accurately without designing a support structure. Improving the 3DGP procedure based on these experiences, the TiC steel bonded cemented carbide samples had properties similar to those prepared by conventional powder metallurgy methods.

Pressure‐assisted binder jetting for additive manufacturing of mock energetic composites

AbstractAdditive manufacturing (AM) has emerged as a promising approach to achieve energetic materials (EMs) with intricate geometries and controlled microstructures, which are crucial for safety and performance optimization. However, current AM methods still face limitations such as limited densities and inadequate solids loading. To overcome these limitations, we have developed a pressure‐assisted binder jet (PBJ) process that has the potential to allow for the fabrication of intricate EMs while preserving their desired properties. This study aims to investigate the effects of printing parameters on the microstructures and properties of EMs, including density, solids loading, mechanical properties, and heterogeneity. Our results demonstrate that the PBJ process achieves exceptional properties in EMs, including densities up to 83.4 % and solids loading up to 95.4 %, surpassing those achieved by existing AM processes. Furthermore, the mechanical properties of the fabricated EMs are comparable to those achieved using conventional fabrication techniques, including a compressive strength of 3.32 MPa, a Young's modulus of 16.68 MPa, a Poisson's ratio of 0.45, a shear modulus of 5.73 MPa, and a bulk modulus of 21.01 GPa. Various test cases were printed to showcase the ability of the PBJ process to create EMs with complex structures and exceptional properties. Micro‐computed tomography was employed to analyze the influence of printing parameters on the internal composition and microstructures of the printed specimens.

Effects of printing parameters on hardness and wear characteristics of 3D printed polyetheretherketone (PEEK) polymer

The present work focuses on the fabrication of polyetheretherketone (PEEK) specimens through fused deposition modeling technique and investigating the hardness and wear behavior of the specimens. Four unique specimens were fabricated at different combinations of layer thickness and printing speed. The microhardness evaluation was done using Vicker’s microhardness tester and wear behavior was analyzed through the pin-on-disc method. The wear test was performed under 20 N, 40 N, and 60 N load conditions while maintaining the rest of the parameters constant.This study examined how process parameters affected mechanical properties. Of the four distinct specimens, specimen 3, having a layer thickness of 0.15 mm and printing speed of 20 mm/s, showed a better average hardness value of about 26.3 HV and a low wear rate and wear loss of about 0.17 x 10-9 mm3/Nm and 0.0016 g with a frictional force of 23 N and coefficient of friction of 0.34. These results suggest that the test specimen produced using the parameter comprising a printing speed of 20 mm/s and a layer thickness of 0.15 mm displayed better wear and hardness properties when compared to the other test specimens.

Microstructure and Mechanical Properties of Cost-Efficient 3D Printed Concrete Reinforced with Polypropylene Fibers

Studying emerging and cutting-edge digital construction techniques, especially the utilization of 3D printing for concrete/mortar materials, holds significant importance due to the potential benefits that these technologies might offer over the traditional approach of casting concrete in place. In this study, a mixture composed of Portland cement, water, sand, limestone filler and polypropylene fibers was utilized for 3D printed concrete production towards the sustainable constructions approach. The benefits that sustain this statement include reduced construction time and material requirements, diminished error and cost, increase in construction safety, flexibility of architectural design, and improved quality with much less construction cost and waste. The microstructure, fresh and hardened mechanical properties of the polypropylene fiber reinforced 3D concrete were investigated. The results indicated that it is essential to attain a slump measurement of approximately 40 mm and a slump flow within the range of 140 to 160 mm, as stipulated by relevant standards (ASTM C1437 and C230/C230 M), in order to create a 3D concrete mixture suitable for extrusion. Also, the effects of printing parameters, fiber dosage, material composition, and other factors on the 3D printed concrete strength were discussed, and the corresponding adjustments were addressed.

An application of the preference selection index decision making method for parameters selection of FDM printing process

3D printing is an innovative technology used for producing functional prototypes and visualizing complex physical designs. Different 3D printing methods have been developed to cope with wide variety of mechanical components and materials. These techniques also speed up the mass manufacturing of complex components by quickly producing working prototypes. The performance of the 3D printing process can be assessed by the achieved outputs such as the mechanical qualities of the produced porotype, printing mass, and printing duration. Like any manufacturing process, how a process performs basically depends on the preference of the decision maker; whether all outputs are important or only a set of these outputs. Determining the desired performance is attained by the proper adjustment of process parameters. Selecting the optimal set of printing parameters, canE therefore, be thought of as multi-criteria decision-making (MCDM) problem since conflicting performance metrics are involved in the decision process. Substantial work has been made primarily on choosing printing machines and studying the effects of printing parameters, but with little focus on deciding parameters settings suitable for achieving the desired printing performance. For this purpose, a preference selection index (PSI)-MCDM model is proposed in this paper. The model is demonstrated using a ZORTRAX- M300 plus plastic 3D-printer as a case study. Multiple scenarios with different sets of decision criteria are presented to reflect users’ predilections. The outcomes show the model's capability to rank parameter combinations in a methodical manner.

The effect of 3D printing parameters on the tensile strength of acrylonitrile butadiene styrene filament for designing CNC router machine gears

Print parameters are factors that influence the mechanical strength of 3D printed objects. Based on a literature review, the parameters of layer thickness, printing speed, and fill geometry percentage value influence the mechanical strength of 3D printed objects. This study focuses on a combination of robust 3D printing parameters for designing CNC router machine gears. The purpose of this research was to determine the effect of printing parameters on the mechanical strength of tensile loads on 3D printed objects. From the experimental results, it was found that by providing a combination of layer thickness parameters, printing speed parameters, and fill percentage parameters, it has an effect on the mechanical strength resistance of 3D printed objects to accept tensile loads. From the research it was found that the ideal layer thickness parameter of 0.1 to 0.2 mm does not exceed half the size of the nozzle diameter of 0.4 mm to produce fine raster fibers. From the research it was found that the ideal speed parameter for printing gears with ABS filament material is at speed 30 mm/s to 50 mm/s to produce a stable raster fiber size and the percentage parameter of a good fill for printing gears is at a value of 20% to 40%. The results of the research found the best printing parameters for printing gears with a print parameter formula with a 3D print parameter formula layer height 0.15mm, gyroid infill 20%, with a speed of 30mm/s maximum tensile strength reaching 30.7 MPa with the results of wheel loading simulation analysis gear is able to withstand a maximum workload of 85 Kg

What controls layer thickness effects on the mechanical properties of additive manufactured polymers

3D printed artefacts are becoming more common and the effect of printing parameters on their properties is key to their performance in applications. Although parameters like build orientation and raster direction are well-studied the effect of layer thickness (and its introduction of size effects into the properties of the material) is less well-known. This study determines the influence of layer thickness on the mechanical properties of polylactic acid (PLA), acrylonitrile butadiene styrene (ABS) and PETG (polyethlene terephtalate glycol) 3D printed specimens made with fused filament fabrication (FFF). Samples were printed with differing layer thickness and tensile tested according to ASTM D638. The study also found that when increasing the layer thickness the mechanical properties of the specimens for both ABS and PLA decreased. When it came to ultimate tensile strength, the effect of layer thickness on PLA was more significant than on ABS with PETG being in much less significant. The differences were attributed to differences in additive layer adhesion and the effect of the structure and defects introduced by the additive layer process.

The Impact of Fused Filament Fabrication (FFF) Printing Profiles on 17‐4 PH Green and Sintered Parts

AbstractThe aim of this research is to characterize parts from innovative hybrid printing method for obtaining dense metal components using affordable fused filament fabrication (FFF). The introduction of Desktop Metal technology in 2015 really attracts an increase in industrial interest in the FFF printing of highly metal‐filled filament. Even though FFF is a well‐known process, there are not many studies on how to optimize the printing parameters for these feedstocks.The effects of the printing setting on producing high‐quality green parts and enhancing the mechanical properties of the finished 17‐4 PH metallic parts are investigated in this work. The influence of four printing profiles provided by a BASF plugin for Ultimaker Cura slicing software, obtained by combining different printing parameters is investigated.The ASTM E8 tensile test is used to determine the mechanical characteristics of the finished metal components. To identify differences in morphology, optical and scanning electron microscopy (SEM) observations are made on both sections of green and sintered samples. The effect of printing parameters on shrinkage and density are also taken into consideration.The findings demonstrate the importance of optimizing the printing of the green parts in order to produce full metal components that are both strong and dense.

Investigation on the Crashworthiness Performance of Thin-Walled Multi-Cell PLA 3D-Printed Tubes: A Multi-Parameter Analysis

The effect of printing parameters (nozzle diameter, layer height, nozzle temperature, and printing speed), dimensions (wall thickness), and filament material on the crashworthiness performance of 3D-printed thin-walled multi-cell structures (TWMCS) undergoing quasi-static compression is presented. The ideal combination of parameters was determined by employing the Signal-to-Noise ratio (S/N), while Analysis of Variance (ANOVA) was utilized to identify the significant parameters and assess their impact on crashworthiness performance. The findings indicated that the ideal parameters for the specific energy absorption (SEA) consisted of a nozzle diameter of 0.6 mm, layer height of 0.3 mm, nozzle temperature of 220 °C, printing speed of 90 mm/s, wall thickness of 1.6 mm, and PLA(+) filament material. Afterward, the optimal parameters for crushing force efficiency (CFE) included a nozzle diameter of 0.8 mm, layer height of 0.3 mm, nozzle temperature of 230 °C, print speed of 90 mm/s, wall thickness of 1.6 mm, and PLA(ST) filament material. The optimum parameter to minimize manufacturing time is 0.3 mm for layer height and 90 mm/s for printing speed. This research presents novel opportunities for optimizing lightweight structures with enhanced energy absorption capacities. These advancements hold the potential to elevate passenger safety and fortify transportation systems. By elucidating the fundamental factors governing the crashworthiness of thin-walled multi-cell PLA 3D-printed tubes, this study contributes to a deeper understanding of the field.

Understanding the influence of alloying elements on the print quality of powder bed fusion-based metal additive manufacturing: Ta and Cu addition to Ti alloy

ABSTRACT Alloy design coupled with metal additive manufacturing (AM) opens many opportunities for materials innovation. Investigating the effect of printing parameters for alloy design is essential to achieve good part quality. Among different factors, laser absorptivity, heat diffusivity, and in situ intermetallic phase formations are critical. In this study, the first step employed was a reduction in Al and V contents in Ti6Al4 V to design Ti3Al2 V alloy, and further 10 wt.% tantalum (Ta) and 3 wt.% copper (Cu) were added to Ti3Al2 V. A synergistic effect of Ta and Cu addition in Ti3Al2 V negated their effect with higher porosities in Ti3Al2V-Ta-Cu. Ti3Al2V-Ta composition was more sensitive to the laser power, whereas Ti3Al2V-Ta-Cu to the overall energy density. Understanding the effect of energy density on these alloys’ microstructural evolution and mechanical properties highlights the need for process-property optimisation during alloy design using AM.

A mist-based crosslinking technique for coaxial bioprinting of hollow hydrogel fibers

In this paper, a mist-based method for coaxial three-dimensional bioprinting of ionically crosslinking hydrogel hollow fibers is presented. Unlike current techniques of coaxial bioprinting that utilize the crosslinker in liquid or sacrificial form, the developed method introduces the core crosslinking agent in mist form. The use of mist as a core flow provides adequate pressure and sufficient crosslinking to maintain the tubular shape of a hollow fiber. Through controlled exposure of crosslinker, the developed system prevents poor resolution and layer adhesion caused by the accumulation of liquid crosslinker on the printbed. Furthermore, it eliminates additional processing steps, such as partial crosslinking of the hydrogel prior- or removal of sacrificial material post-printing. The printability and mechanical properties of hollow fiber scaffolds printed using various mist and hydrogel concentrations are studied. It is shown that mist concentration influences the gelation rate of the hollow fiber, impacting the shape fidelity, layer adhesion, and mechanical properties of the printed structures. Moreover, the effects of printing parameters, including the mist core pressure and hydrogel flowrate, on the diameter and wall thickness of the hollow fiber are investigated. Finally, scaffolds printed and crosslinked using mist exhibit over 90% cell viability. The developed mist-based coaxial system enables direct printing of continuous hollow fibers.