Effect Of Printing Parameters Research Articles

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.

Effects of printing parameters on the mechanical characteristics and mathematical modeling of FDM-printed PETG

Effects of printing parameters on the mechanical characteristics and mathematical modeling of FDM-printed PETG

Effect of 3D printing process parameters on the mechanical properties of silica/polyethyleneimine composites using direct‐ink writing

AbstractDirect‐ink writing (DIW) 3D printing technology has the advantages of simple process and high efficiency, and enables the molding of materials at room temperature. These characteristics make DIW technology widely applicable in the field of monolithic molding. In this study, a composite slurry of SiO2 and polyethyleneimine (PEI) was molded using direct‐ink writing 3D printing technology. Fourier transform infrared spectroscopy, x‐ray diffraction, and thermogravimetric were used to analyze the structure and thermal characteristics of the composites. Additionally, the study investigated the extrusion flow under different pressures and the impact of ink formula on their rheological behavior and printability, along with an examination of the effects of printing parameters on the mechanical properties of the monolithic structures. The results indicate that the tensile strength of the dumbbell‐shaped specimen increases with greater sample density and reduced nozzle diameter. At a filling angle of ±45°, the void rate is minimal, and the tensile strength reaches a maximum of 1.73 MPa. The tensile strength is maximum when the nozzle diameter is 0.8 mm. On the other hand, the compressive strength of the specimen is directly proportional to the layer thickness – it increases upon reducing the layer thickness. When the layer thickness is 0.3 mm, the compressive strength reaches 0.13 MPa. This study provides insights into direct‐ink writing 3D printing technology and its relationship with the mechanical properties of SiO2/PEI composites monolithic structures.Highlights Self‐standing fumed silica/polyethyleneimine (PEI) composite monoliths were shaped by Direct Ink Writing (DIW) technology. The impact of composite slurry composition on their rheological behavior and printability was examined. Printing parameters effects on mechanical properties of monolithic structures assessed. Significant insights into the relationship between extrusion pressure and forming structure of the composite monoliths are revealed by our research, thereby contributing to the optimization of printing processes.

Laser Powder Bed Fusion Additive Manufacturing of Maraging Steel: A Review

Abstract Laser powder bed fusion (PBF/L) is a popular metal additive manufacturing (AM) process used to manufacture complex metallic 3D components. Maraging steel is one of the metals used in AM and it belongs to the class of ultra-high-strength steels used in aerospace and tooling industries. In the PBF/L process, a laser beam is used to melt and fuse the metal powder particles. This creates a high thermal gradient and rapid cooling of the melt pool results in columnar grains. The microstructure of AM part is entirely different from the conventionally manufactured case and this necessitates post-AM heat treatments. The current paper reviews the effects of printing parameters and heat treatment on microstructure and mechanical properties of PBF/L produced maraging steel 300 alloy. Tensile, impact, fracture, and fatigue properties of as-built and heat-treated PBF/L parts are discussed in detail.

Effect of printing parameters on the sensing performance of a 3D printed elastomeric pressure sensor

Additive manufacturing processes have created new opportunities for the printing of functional electronics. Commercial 3D printers fall short in providing the capabilities to directly print with functional inks, especially, with thermosetting non-Newtonian materials. Also, open-source slicing software are generally designed to generate g-code for thermoplastics. In this work, we modified an inexpensive commercial 3D printer to print functional inks for electronics. A plunger-based extrusion mechanism was developed using a stepper motor and lead screw. The heated extruder in the commercial printer was replaced by the new mechanism. Next, the system was employed to print ionic liquid-based soft pressure sensors, followed by an ultraviolet light curing process to polymerize the printed structure. Sensor ink was prepared by mixing ionic liquid into an acrylate-based monomer. To obtain proper rheology for printing, fumed silica was added to the ink. The effect of different printing parameters on the sensing performance of the printed sensors was studied and presented. The parameters studied were sensor thickness, nozzle diameter, extrusion rate, and raster angle. Multiple sets of sensors were printed by changing these parameters, and they are evaluated for their sensitivity. The sensitivity was measured in terms of relative change in the voltage output from the sensor system. The results show that varying the printing parameters significantly affects the sensing performance. The sensitivity increases with the decrease in sensor thickness, increase in nozzle diameter, and increase in print flow rate. The findings from this study can be employed to modulate the sensitivity of a sensor for different applications by changing various print parameters.

Influence of fused filament fabrication parameters on the flexural strength of nylon

Additive manufacturing (AM), particularly Fused Filament Fabrication (FFF) is a fast-growing and affordable layer-by-layer manufacturing process. The mechanical properties of the printed parts directly depend on the FFF process parameters. The purpose of this study was to assess the effect of printing parameters on flexural strength and identify the optimum parameters for nylon material. The controllable printing conditions selected for the Ultimaker Nylon material were layer thickness, print speed, infill geometry, and nozzle temperature. The specimens were subjected to a three-point bending test. Taguchi L9 optimization method, ANOVA, and the interaction plot were used to investigate the influence of the process parameters. The main results indicate that layer thickness is the most influential parameter, followed by infill pattern and print speed, while nozzle temperature showed the lowest significance on flexural strength. The optimum printing parameters were found to be 0.1 mm layer thickness, 40 mm/s print speed, gyroid infill pattern, and 250 °C nozzle temperature. The work examines the flexural performance of nylon material which is understudied in the available literature.

Effect of printing parameters on extrusion-based additive manufacturing using highly filled CuSn12 filament

Typical additive manufacturing (AM) processes for producing metal and ceramic parts are highly energy-consuming and expensive to install and maintain. On the other hand, material extrusion AM (MEAM) technologies are conventionally used to produce polymeric parts but only marginally to process metallic materials. A feasible alternative is to process polymeric filaments loaded with metal particles. Debinding and sintering processes are then required to join the metal particles and obtain the final parts. In recent years, highly filled metal filaments consisting of a polymer loaded with a high concentration of metal powder have been commercialized for this purpose. In this study, the printability of a commercial CuSn12 filament was investigated by evaluating the influence of the process parameters on the density, shrinkage, porosity, and mechanical properties of the additively manufactured samples using a low-cost desktop 3D printer. Parameters such as the flow rate and ironing had the greatest influence on the density of the green samples. The correct selection of these parameters may reduce shrinkage after sintering. Furthermore, the obtained bronze had a notable ultimate tensile strength (mean value of 107 MPa), high stiffness (E values range from 38 to 50 GPa), and a greater elongation at break (mean value of 13%) than that of cast bronze of the same CuSn12 type. In this case, the extrusion pattern and ironing had the most significant influence on the final mechanical performance. The study provides insights into the use of highly filled bronze filaments combined with MEAM to produce functional parts for engineering applications.