Effect Of Printing Parameters Research Articles

Analyzing the effects of printing parameters to minimize the dimensional deviation of polylactic acid parts by applying three different decision-making approaches.

This article examines the influence of various factors on the precision of 3D printed objects produced through Fused Filament Fabrication (FFF) using Polylactic Acid (PLA) as the primary material. While PLA is widely chosen for its compatibility with biological applications, it does suffer from limited dimensional accuracy. The study focuses on investigating the effects of four independent parameters, namely layer height, infill density, printing speed, and the number of top and bottom layers, on accuracy along the three axes of length, width, and depth. The research objective is to identify the optimal levels of these parameters that minimize dimensional errors across all axes. However, due to conflicting requirements among different dimensions, determining a comprehensive decision-making methodology presents a significant challenge. To address this issue, three distinct approaches are proposed, each offering a unique perspective and practical application. Interestingly, the outcomes of these approaches converge on a single solution. Among these parameters, printing speed emerges as the dominant factor, while, the number of layers is the least influential. Moreover, consistent shrinkage is observed in the length and width dimensions, with greater errors evident in longer dimensions. Overall, a preference for lower layer height and infill density, along with higher printing speed and increased top and bottom layers, is recommended. The study findings indicate that the most effective parameter selection for reducing errors in all dimensions involves a layer height of 0.2mm, infill density of 60%, printing speed of 50mm/s, and the use of four top and bottom layers.

A new granule extrusion-based for 3D printing of POE: studying the effect of printing parameters on mechanical properties with “response surface methodology”

A new granule extrusion-based for 3D printing of POE: studying the effect of printing parameters on mechanical properties with “response surface methodology”

Effect of Printing Parameters and Heat Treatments on Microstructure Development of LPBF Manufactured Inconel 718 Alloy

Abstract Processing parameters of the laser powder bed fusion (LPBF) technique strongly govern achieved performances and manufacturing defects of printed alloys. In this work, it was aimed to study the effects of LPBF printing parameters and subsequent heat treatments on resulted microstructure characteristics and tensile properties of Inconel 718 alloy. Inconel samples were fabricated using three different energy densities. Then, microstructure features such as Lave phase, primary dendrite arm spacing, and internal residual stresses as microstrains of both as-built and heat-treated specimens were determined. It was found that in the range of used energy densities, alterations of phase fractions and average sizes of the Laves phase were insignificant. Decreased energy density led to microstructures with smaller primary dendrite arm spacing and thus principally contributed to enhanced yield and tensile strengths of as-printed samples, whereas increased porosity greatly deteriorated elongation. Moreover, their flow stress curves could be significantly increased by direct aging; however, typical cellular and columnar substructures occurring during the LPBF printing remained. Homogenization treatment could entirely eliminate such substructures and otherwise caused different formations of delta phase when it was performed prior to a delta process.

A comprehensive study on the effects of printing parameters on the mechanical properties of PLA

Purpose This study aims to investigate the effects of five different printing parameters, namely, printing speed (PS), printing temperature/nozzle temperature/extrusion temperature, heated-bed temperature, raster angle (RA) and layer height (LT), on mechanical properties. Design/methodology/approach American Society for Testing and Materials (ASTM) standards were used for the specimen design. Then, the Taguchi method was used for the design of the experiment and an L16 orthogonal array was preferred. Tensile, Shore D and surface roughness tests were conducted on polylactic acid test specimens. The test results were analyzed using the signal-to-noise ratio and analysis of variance (ANOVA). Findings As a result of the study, it was seen that RA is the most important parameter for the tensile strength, PS is for the hardness and LT is for the surface roughness. According to the ANOVA results, the effects of the RA, PS and LT on the maximum tensile strength, hardness and surface roughness were 41.59%, 69.51% and 44.6%, respectively. Originality/value To the best of the authors’ knowledge, this study is one of the most comprehensive parameter optimization studies for additive manufacturing in the literature because it includes five different printing parameters and three mechanical test procedures.

Preparation and 3D printing parameters of thermo/electrically shape memory PLA/SEBS-g-MA/CB composites

In this work, novel thermo-responsive shape memory blends PLA/SEBS-g-MA and electro-responsive PLA/SEBS-g-MA/carbon black (CB) composites were prepared by melt blending, and were extruded into filaments for 3D printing. SEM images illustrate that the blends possess co-continuous structure at SEBS-g-MA ratio of 30 wt% and showcase remarkable shape memory properties (Rf 100%, Rr 85.3%), which were attributed to effective stress transfer. In the second part, PLA/SEBS-g-MA/CB composites were produced with different amounts of CB nanoparticles. The volume resistivity of composites with CB additions of 13 phr and above is maintained at about 102 Ω.cm, and the printed samples showed superior electro-responsive performance, with response completed in about 40 s at 60 volts DC. In addition, the effect of printing parameters on the mechanical properties was investigated and it was found that the choice of layer thickness was strongly related to tensile and flexural strength.

Achieving uniform distribution of nanoparticles in oxide dispersion strengthened (ODS) SS316L through laser powder bed fusion (L-PBF)

Oxide dispersion strengthened (ODS) SS316L is a promising candidate for the nuclear industry for its enhanced irradiation resistance and high temperature strength. Additionally, additive manufacturing enables the design flexibility of components. Achieving a uniform distribution of oxides in ODS SS316L is one of the remaining challenges in additive manufacturing. In this paper, we investigated the effects of printing parameters on the microstructure and mechanical properties of ODS SS316L (SS316L + 0.5 wt% Y2O3) through laser powder bed fusion (L-PBF) additive manufacturing. The results showed that plate-like Y-Si-rich oxides (∼50 μm) were observed along the molten pool boundary in the ODS SS316L printed with nominal parameters (48.5 J/mm3) for pure SS 316L, resulting from inadequate heat input in molten pool due to the reduced laser absorption rate of powder feedstock. Through higher volumetric energy density (76.2 J/mm3) and remelting, a bimodal distribution of oxides, including nanoparticles and fine spherical oxide (∼2.5 μm), was achieved. Consequently, this contributed to increased ultimate tensile strength (UTS) and strain of ODS SS316L from 685.2.6 ± 31.4 MPa and 27.8 ± 6.2 % to 706.6 ± 36.2 MPa and 33.0 ± 6.1 %, respectively. The exploration of parameters optimization provides valuable insights into the additive manufacturing of ODS alloys with uniformly distributed nanoparticles.

Effects of printing parameters on the mechanical properties of sand molds produced by a novel binder jetting 3D printer

Effects of printing parameters on the mechanical properties of sand molds produced by a novel binder jetting 3D printer

Effect of process parameters on the mechanical performance of fusion-joined additively manufactured segments

PurposeHerein, the authors report the effects of printing parameters, joining method, and annealing conditions on the structural performance of fusion-joined short-beam sections produced by additive manufacturing.Design/methodology/approachThe authors first identified appropriate printing parameters for joining segmented short beams and then used those parameters to print and fusion-join segments with different configurations of stiffeners to form a longer section of a wing or small wind turbine blade structure.FindingsIt was found that the beams with three lateral and three base stiffening ribs give the highest flexural strength among the three beams investigated. Results on joined beams annealed at different conditions showed that annealing at 70 °C for 0.5 h yields higher performance than annealing at the same temperature for longer times. It is also found that in the case of the hot-plate-welded three-dimensional (3D)-printed structures, no annealing is needed for reaching a high strength-to-weight ratio, but annealing is helpful for maximizing the modulus-to-weight ratio. Both thermal buckling and edge wrapping were observed under annealing at 70°C for 0.5 h for 3D-printed beams comprising two lateral and four base stiffening plates.Originality/valueFusion-joining of additively manufactured segments is needed owing to the constraint in building volume of a typical commercial 3D-printer. However, study of the effect of process parameters is needed to quantify their effect on mechanical performance. This investigation has therefore identified key printing parameters and annealing conditions for fusion-joining short segments to form larger structures, from multiple 3D-printed sections, such as wind blade structures.

Effect of printing parameters on extrudability and buildability of ultra-low carbon cementitious material

Cement-free cementitious materials are important for reducing the carbon footprint of 3D printing. However, for the ultra-low carbon cementitious material for 3D printing, the effect of printing parameters on its extrusion and stacking morphology has not been fully investigated. In this paper, an ultra-low carbon cement-free cementitious material (UCCCM) with ultra-fine slag and spherical fly ash as main components is developed. The influence of print head size (HS), print head height (HH), and printing speed (PS) on the extrudability and buildability are systematically investigated. Results showed that the HS had a clear influence on the extrudability, and a small print head size negatively affected the continuity of the extrudate. The HH had a greater influence on the buildability, and a low HH led to a height loss rate of more than 5 %. The PS had a greater influence on the buildability. When the PS was too slow, the mortar piled up and the printed specimens collapsed with a height loss rate of up to 35 %. When the PS was too fast, the strip cracked, and the height loss rate reached more than 10 %. The developed UCCCM for 3D printing presented optimal extrudability and buildability at a HS of 20 mm, a HH of 90 % and a PS of 20 mm/s.

3D printing of reprogrammable liquid crystal elastomers with exchangeable boronic ester bonds

Liquid crystal elastomers (LCEs) are a kind of soft actuating materials with large reversible deformation ability, which can work as the “motor” to exhibit complex deformations and drive the locomotion of soft robots. The deformation of LCEs depends on the three-dimensional (3D) shape of whole structure and alignment patterns of mesogens. Various methods have been employed to fabricate the LCE structure with desired shapes and mesogen alignments. However, conventional 3D printed LCEs require continuous thermal energy input to maintain their actuated shapes. The LCEs cannot be reprocessed and reprogrammed once cured. Herein, we introduce dynamic boronic ester bonds into the ink, with which the printed LCE structures are capable of being reprogrammed from polydomain into monodomain state and vice versa. We further explore the effects of printing parameters and content of dynamic covalent bonds on the actuation performance and reprogramming ability. The actuated shape could be well predicted with finite element method. The dynamic printable LCEs developed here offer new strategy and large design space for LCE structures.

Review on digital light processing (DLP) and effect of printing parameters on quality of print

Review on digital light processing (DLP) and effect of printing parameters on quality of print

Optimization of an Aerospace Bracket by Additive Manufacturing with Continuous Fiber Reinforced Plastics

Fused Deposition Modelling (FDM), one of the most widely used methods of Additive Manufacturing Technique known as 3D Printing, is a popular technique used to produce different engineering components using common engineering fibre. Carbon fibre filament. This study presents an experimental study examining the effect of printing parameters on the mechanical properties of components produced with Carbon fibre filaments. The effects of the printing parameters determined as infill pattern, infill density and nozzle temperature on the mechanical strength parameter determined as tensile strength and flexural strength of Carbon fibre samples produced in standard sizes were investigated experimentally. The experimental design was carried out in accordance with the Taguchi L9 orthogonal array, and the relationship between the printing parameters and the mechanical strength parameters was modelled mathematically. The predicted strength values calculated using mathematical models were compared with the experimental test results. The results showed that the tensile strength and flexural strength values were directly proportional to the infill density. Experiments have shown that the most effective 3D printing parameter on the mechanical strength parameters is the infill density parameter with a contribution ratio of 62.09% for tensile strength and 72.83% for flexural strength. As a result of the RSM optimization, it was determined that the infill density 60%, the nozzle temperature value 265 C° and the infill pattern type lines to maximize the flexural strength and tensile strength values. Key Words: Sustainable Material, 3D Printing Parameters, Mechanical Strength Optimization, Response Surface Methodology.

Dimensional Accuracy of a Hole Diameter Produced by Material Extrusion

Abstract Three-dimensional printing technology has become one of the key areas of Industry 4.0, as it allows complex geometries to be produced on site without wasting material. However, there are still shortcomings in terms of product quality and cost. Because dimensional accuracy is one of the most important parameters for product quality, researchers are working to improve dimensional accuracy. However, most studies have focused on the dimensional accuracy of holes in the z-axis. Because additive manufacturing is a layer-by-layer manufacturing method, the dimensional accuracy of holes in the x- and y-axes will be very different from that of holes in the z-axis. In this study, the effect of printing parameters on the dimensional accuracy of holes of different diameters and axes produced by additive manufacturing from different materials was investigated. The Taguchi experimental design was used to avoid wastage of material and time. Analysis of variance was used to determine the most effective parameter, and the experimental results were estimated using artificial neural networks. Because of this study, it was concluded that it is not possible to find a single optimum parameter for holes with different axes and diameters. It was observed that as the hole diameter decreased, the heat generated during production affected the dimensional accuracy by heating the previous hole surfaces, and even small holes were not formed in some parameters.

The effect of printing parameters on the mechanical properties of fiber-reinforced PA6 matrix composites in material extrusion-based additive manufacturing

PurposeThis study aims to understand the effect of the use of different proportions and types of fibers in the polyamide 6 (PA6) matrix during material extrusion-based additive manufacturing (MEX) and the effect of the manufacturing parameters on the mechanical properties. The mechanical, thermal and morphological properties of PA composites that are reinforced with carbon fiber (CF), glass fiber (GF) and as well as hybrid fiber (HF) were investigated.Design/methodology/approachIn this study, the effect of nozzle temperature and layer thickness on the mechanical properties of composite samples was investigated in terms of their behavior under tensile, impact and compression loads, manufacturing parameters as well as fiber ratio and type. The results were also consolidated by scanning electron microscopy.FindingsAt 20 Wt.% CF reinforcement PA6 samples, a tensile strength value of 125 MPa was obtained with a 60% increase in tensile strength value compared to neatPA6. The HF-reinforced ones also measured a tensile strength value of 106.69 MPa. This corresponds to an increase of 38% compared to neatPA6. The results also show that HF reinforcement can be an important component for many composites and a suitable material for use under compression loading.Originality/valuePA6, an engineering polymer, can be produced by MEX, which offers several advantages for complex geometries and customized designs. There are studies on different carbon and GF ratios in the PA6 matrix. Using these fibers together in a HF, the examination of their mechanical properties in the MEX method and the examination of the effect of GF reinforcement in the hybrid structure, which has a cost-reducing effect, has been an innovative approach. In this study, the results of the optimization of the parameters affecting the mechanical properties in the production of samples reinforced with different ratios and types of fibers in the PA6 matrix by the MEX method are presented.

Quantification of the effects of print parameters on the mechanical performance of low force stereolithography parts

The objectives of this work are threefold: (1) quantify the effects that certain print parameters have on the mechanical performance of parts produced by Low Force Stereolithography (LFS), (2) demonstrate the relative impact that certain print parameters have on the mechanical performance of LFS parts and (3) propose theoretical parameter schemas to optimize LFS prints. This work presents the mechanical properties of LFS parts with respect to distinct LFS print parameters, namely print orientation (PO), print layer thickness (LT), post-print cure time (CM) and post-print cure temperature (CT) at three (3) levels apiece. To date, LFS has been largely unstudied; however, as a novel approach with unique engineering material availability, it is important to quantify its overall performance. Using D638-22 to analyze this additive method, it was found that the Segment Modulus (SE), Ultimate Strength (US), percent elongation (%e), Poisson's ratio (ν) and Toughness (T) all varied greatly across the nine (9) distinct sample types designed for the study. Specifically, SE, US, %e, ν and T achieved a minimum/maximum of 331/463 ksi, 4.39/9.07 ksi, 1.20/3.55%, 0.377/.450 and 0.033/.200 ksi, respectively, depending on the parameters chosen. This wide range of property data must be coupled to LFS print parameters if the technology is to be implemented as a viable approach to manufacture end-use or provisional tooling. Furthermore, it is essential to understand the relationship between a given property and a specific parameter. S/N plots were used to quantify both of these relationships. The results indicate that all print parameters influence the mechanical performance of LFS parts.

The effect of printing parameters on the properties of 17-4 PH stainless steel fabricated by material extrusion additive manufacturing

The 17-4PH stainless steel filament was characterised and utilised to study the effect of printing parameters, i.e. printing temperature, layer thickness, infill pattern and extrusion multiplier on the physical properties. The as-printed and as-sintered internal structures were analysed. The results showed that the as-printed density increases with increasing printing temperature and extrusion multiplier and decreasing layer thickness. The use of the line infill pattern also provided slightly higher as-printed density than the concentric infill pattern due to the low fraction of void between deposited paths. After sintering, the trace of these voids can be observed together with smaller-size residual pores from the spaces between powders, which is the nature of the pressureless sintering process. The microstructure of the as-sintered specimens was similar to the typical microstructure of the 17-4PH alloy fabricated by metal injection moulding process, which contains delta ferrite, martensite and Si-rich phases. In additions, the internal void generated during debinding and sintering results in unexpectedly low tensile properties and results in the difference in tensile properties between the concentric and line infill patterns.

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.

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.