FDM Technology Research Articles

3D printing by Fused Deposition Modeling - FDM technology - with PETG type filament in horizontal position A

3D printing by Fused Deposition Modeling - FDM technology - with PETG type filament in horizontal position A

3D printing by Fused Deposition Modeling - FDM technology - with PETG type filament in horizontal position

3D printing by Fused Deposition Modeling - FDM technology - with PETG type filament in horizontal position

Determination of the influence of infill pattern and fiberglass reinforcement on the tensile properties of additively manufactured material by FDM technology

Determination of the influence of infill pattern and fiberglass reinforcement on the tensile properties of additively manufactured material by FDM technology

Surface Quality Optical Measurement of Part Inclined Planes Manufactured by FDM Technology

Fused Filament Deposition (FDM) additive manufacturing technology allows the generation of three-dimensional parts by overlapping layers of an extruded polymer. The staircase effect caused by overlapping is well known and makes the manufactured parts have poor surface quality. This problem has been focused on by numerous works trying to optimize the surface quality by studying the process technological parameters or part geometry. Also, post-processing techniques have been developed that improve this roughness, but which involve an increase in manufacturing time and cost. In this work, a methodology to measure the roughness based on laser confocal microscopy is proposed. To evaluate the methodology, an experimental study is carried out that relates the surface roughness of parts manufactured with FDM with the building orientation and the layer height. The main objective of this study is to compare two roughness measurement methodologies: a mechanical measurement with a conventional contact roughness meter, and an optical measurement with a confocal microscope. The contact roughness meter provides a direct value of the roughness of the part wall profile, while the confocal microscope provides an image of the three-dimensional surface of the part wall, which must be processed. The data from the confocal microscope are evaluated with the Internet-based software Surface Metrology Algorithm Testing System (SMATS) developed by the National Institute of Standards and Technology (NIST) of the USA. The SMATS will provide an average value of the roughness of the analyzed surface. The test results with both methodologies are very similar, with an average difference of 5%. These results show the influence of the printed plane inclination angle on the roughness, which is higher for low values of the angle. It can also be seen that this influence decreases for low-layer heights.

Comparative Examination of Friction Between Additive Manufactured Plastics and Steel Surface

Nowadays, the increasing use of plastic materials in friction and wear applications, particularly in industrial robotic grippers, is a growing trend in modern industry. Plastics are replacing traditional materials like metals and composites due to their unique properties and significant advantages. Plastic materials used in industrial robotic grippers offer several advantages, such as their low friction coefficient, enabling smooth and precise movement of the gripper and minimizing the risk of damaging the objects being manipulated. This paper presents a comparative study and analysis of the friction coefficient between various plastic materials and the C45 alloy steel, a superior alloy used in industrial applications. The investigated materials include PETG, PLA, PLA with aluminum, ABS, two types of TPU, and two types of UV-sensitive resins. This study aims to evaluate the friction performance of these materials in order to identify the most suitable options for friction and wear applications, such as industrial robotic grippers. To achieve this, dry kinetic friction tests were conducted between 3D printed plastic material samples manufactured by using FDM and SLA technologies, and the C45 alloy steel on the CETR UMT-2 tribometer. The friction coefficient was measured by recording the force required for displacement in two horizontal directions.

Predictive modelling and analysis of roundness of cylindrical parts 3D printed with FDM technology

Predictive modelling and analysis of roundness of cylindrical parts 3D printed with FDM technology

Stress recovery and stress relaxation behaviors of PVC 4D printed by FDM technology for high-performance actuation applications

Stress recovery and stress relaxation behaviors of PVC 4D printed by FDM technology for high-performance actuation applications

Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing.

Metal FDM technology overcomes the problems of high cost, high energy consumption and high material requirements of traditional metal additive manufacturing by combining FDM and powder metallurgy and realizes the low-cost manufacturing of complex metal parts. In this work, 15-5PH stainless steel granules with a powder content of 90% and suitable for metal FDM were developed. The flowability and formability of the feedstock were investigated and the parts were printed. A two-step (solvent and thermal) debinding process is used to remove the binder from the green part. After being kept at 75 °C in cyclohexane for 24 h, the solvent debinding rate reached 98.7%. Following thermal debinding, the material's weight decreased by slightly more than 10%. Sintering was conducted at 1300 °C, 1375 °C and 1390 °C in a hydrogen atmosphere. The results show that the shrinkage of the sintered components in the X-Y-Z direction remains quite consistent, with values ranging from 13.26% to 19.58% between 1300 °C and 1390 °C. After sintering at 1390 °C, the material exhibited a relative density of 95.83%, a hardness of 101.63 HRBW and a remarkable tensile strength of 770 MPa. This work realizes the production of metal parts using 15-5PH granules' extrusion additive manufacturing, providing a method for the low-cost preparation of metal parts. And it provides a useful reference for the debinding and sintering process settings of metal FDM. In addition, it also enriches the selection range of materials for metal FDM.

Analysis and Optimization of Process Parameters Affecting on the Tensile Strength of PLA and Iron-Reinforced PLA Samples Fabricated by Fused Deposition Modeling Method

This study focuses on investigating the effect of process parameters on the tensile strength of PLA and iron-reinforced PLA samples produced using FDM technology. Filament material (PLA and iron-reinforced PLA), infill ratio (20, 40 and 60%), layer thickness (0.1, 0.2 and 0.3 mm), printing speed (40, 60 and 80 mm/s) and raster angle (30, 45 and 60°) were selected as process parameters. The experimental design was based on the Taguchi L18 index. Signal-to-Noise (S/N) ratio, variance analysis (Anova) and regression analyses were used to statistically analyze the tensile strength values obtained as a result of experimental measurements. The outcomes of this study show that the filament material plays an important role in tensile strength and iron reinforcement to PLA material decreases the tensile strength and increases the % elongation. The maximum tensile strength was measured as 33.55 MPa at 60% infill rate, 0.3 mm layer thickness, 60 mm/s printing speed and 60° raster angle in PLA filament material, which is the optimum process parameters.

Three-Dimensional Printing of Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) [P(3HB-co-3HV)] Biodegradable Scaffolds: Properties, In Vitro and In Vivo Evaluation.

The results of constructing 3D scaffolds from degradable poly(3-hydrosbutyrpate-co-3-hydroxyvalerate) using FDM technology and studying the structure, mechanical properties, biocompatibility in vitro, and osteoplastic properties in vivo are presented. In the process of obtaining granules, filaments, and scaffolds from the initial polymer material, a slight change in the crystallization and glass transition temperature and a noticeable decrease in molecular weight (by 40%) were registered. During the compression test, depending on the direction of load application (parallel or perpendicular to the layers of the scaffold), the 3D scaffolds had a Young's modulus of 207.52 ± 19.12 and 241.34 ± 7.62 MPa and compressive stress tensile strength of 19.45 ± 2.10 and 22.43 ± 1.89 MPa, respectively. SEM, fluorescent staining with DAPI, and calorimetric MTT tests showed the high biological compatibility of scaffolds and active colonization by NIH 3T3 fibroblasts, which retained their metabolic activity for a long time (up to 10 days). The osteoplastic properties of the 3D scaffolds were studied in the segmental osteotomy test on a model defect in the diaphyseal zone of the femur in domestic Landrace pigs. X-ray and histological analysis confirmed the formation of fully mature bone tissue and complete restoration of the defect in 150 days of observation. The results allow us to conclude that the constructed resorbable 3D scaffolds are promising for bone grafting.

Gender differences in Glenoid and Coracoid Dimensions evaluated through 3D Printed bone models in the context of Anterior Shoulder Instability Surgery – An exploratory study

IntroductionNonrecognition of smaller bone anatomy in the context of the Latarjet procedure may increase the chance of complications and worsen it outcomes, and this should be addressed preoperatively by accurate measuring of bone anatomy. Measurement of bone dimension can be performed through 3d printed bone models nowadays and therefore we aimed to evaluate glenoid and coracoid process dimensions obtained in 3D printed bone models, assess differences between genders, and compare the results with previously published anatomical studies. We hypothesized that the values obtained in the 3D models would be similar to those previously reported in other anatomical studies and gender differences would also be present. MethodsWe retrospectively retrieved shoulder computer tomography scans from 39 adult patients with uninjured scapula. Using the DICOM file of the CT, we performed three-dimensional reconstructions of the scapula, including the glenoid and coracoid. The resulting digital model was then printed in an FDM technology 3D printer. With the 3D Printed models, one of the authors measured the models using a digital caliper. The measurements collected on the Glenoid were Glenoid Superior-Inferior length (GlenSI); and Glenoid Antero-Inferior length (GlenAP) .On the coracoid, the measurements collected were the Coracoid Anterior-Posterior length (CoracAP), the Coracoid Medial-Lateral (CoracML) distance and the Coracoid Superior-Inferior (CoracSI) distance. Those measurements were summarized and underwent statistical comparison between genders. The results were compared with other anatomical studies in the same bone anatomy. ResultsWe recorded a mean glenoid length (GlenAP) of 28.03 mm (SD = 0.45) and mean glenoid height (GlenSI) of 37,18 mm (SD =0,55). The mean glenoid dimensions differ significantly between male and female gender (p=0,002 and p=0,001, respectively).The coracoid mean length was 22,35 mm (SD=0.47), mean coracoid width was 14,97 mm (SD=0,30), mean coracoid height was9,51 mm (SD=0,22), and those measures also differ significantly between genders. The observed mean values were similar to those previously reported in other anatomical studies. DiscussionWe observed that coracoid and glenoid dimensions significantly vary between genders for all of the measurements performed. Measurements obtained in this series are comparable with other similar anatomic studies. Although some limitations exists in our study, we consider 3D-printed bone models in the setting of anatomical studies as a relevant option to traditional cadaveric studies. ConclusionGender differences in coracoid and glenoid dimensions were observed and must be considered for the Latarjet procedure. Our results suggest that 3d printed bone models may be used for such evaluation with a good degree of reproducibility of the measurements observed in already published anatomic studies.

Experimental investigation of mechanical stiffness in lattice structures fabricated with PLA using fused deposition modelling

The objective of the paper is to design and characterise with polylactic acid (PLA) material three cellular structures in the form of lattices which are diagonal-octet-centred shapes for two sizes 6x6x6 and 12x12x12 with a compression test to examine their stiffness using FDM technology compared to polyjet technology.The study used two analytical approaches to investigate lattice structures: experimental analysis and theoretical analysis. Experimental methods such as compression tests were conducted to determine the characteristics of lattice structures. In addition, theoretical analysis was conducted using Hook's law and Ashby's Gibson model to predict appropriate behaviour. The combination of experimental and theoretical methods provided a comprehensive understanding of lattice structures and their properties.The experimental study examined the impact of the shape and size of a lattice structure on the stiffness and lightness of objects 3D printed with FDM technology by PLA material. The research revealed that the 6x6x6 diagonal lattice structure size provided a good balance between stiffness and lightness. While the 6x6x6 byte structure was even lighter, with a mass ratio of 2.09 compared to the diagonal structure, it was less rigid, with a ratio of 0.43, making the diagonal structure more suitable for certain applications. The study highlights the importance of considering both the shape and size of the lattice structure when designing 3D-printed objects with specific mechanical properties; the chosen structure could be a good choice for applications where stiffness and lightness are important.The limitations of the research lie in its limited scope, focusing primarily on the effect of shape (octet-diagonal centred) and unit cell size on Young's modulus of PLA material. Other aspects of 3D printing, such as material selection and thermal properties, were not considered. Furthermore, the results obtained are specific to the printing parameters and experimental conditions chosen, which limits their generalizability to other 3D printing configurations or methods. However, these results have important implications for optimising the PLA printing process. They enable the identification of optimal parameters, such as unit cell shape and size, to produce stiffer, higher-quality structures. In addition, the research is helping to improve the mechanical properties of 3D-printed lattice parts, paving the way for more efficient manufacturing methods and stronger components.Our analysis can be used as a decision aid for the design of FDM lattice parts. Indeed, we can choose the diagonal structure of 6x6x6, which would provide favourable stiffness for functional parts.The paper explores the compression test of lattice structures using FDM technology, which presents a new direction for additive manufacturing. The study takes an experimental approach to evaluate the reliability of various additive manufacturing technologies for creating lattice structures. The study results provide insight into the most reliable technology for producing lattice structures.

Effect of variation of process parameters on printed component using FDM technology

Effect of variation of process parameters on printed component using FDM technology

Bifurcations and Stability of Nonlinear Vibrations of a Three-Layer Composite Shell with Moderate Amplitudes

The authors derived a mathematical model of geometrically nonlinear vibrations of three-layer shells, which describes the vibrations of the structure with amplitudes comparable to its thickness. The high-order shear theory is used in the derivation of this model. Rotational inertia is also taken into account. At the same time, the middle layer is a honeycomb structure made thanks to additive FDM technologies. In addition, each shell layer is described by five variables (three displacement projections and two rotation angles of the normal to the middle surface). The total number of unknown variables is fifteen. To obtain a model of nonlinear vibrations of the structure, the method of given forms is used. The potential energy, which takes into account the quadratic, cubic, and fourth powers of the generalized displacements of the structure, is derived. All generalized displacements are decomposed by generalized coordinates and eigenforms, which are recognized as basic functions. It is proved that the mathematical model of shell vibrations is a system of nonlinear non-autonomous ordinary differential equations. A numerical procedure is used to study nonlinear periodic vibrations and their bifurcations, which is a combination of the continuation method and the shooting method. The shooting method takes into account periodicity conditions expressed by a system of nonlinear algebraic equations with respect to the initial conditions of periodic vibrations. These equations are solved using Newton's method. The properties of nonlinear periodic vibrations and their bifurcations in the area of subharmonic resonances are numerically studied. Stable subharmonic vibrations of the second order, which undergo a saddle-node bifurcation, are revealed. An infinite sequence of bifurcations leading to chaotic vibrations is not detected.

A facile, semi-automatic protocol for the design and production of 3D printed, anatomical customized orthopedic casts for forearm fractures

Closed fractures of distal radius and ulna are one of the most common skeletal injuries, occurring at all ages. Temporary arm immobilization through cast is part of the standard treatments. However, traditional casting procedures are time consuming, operator's skill dependent and do not always guarantee a satisfactory outcome. From a clinical perspective, casts are often considered uncomfortable and can be associated to skin lesions. To overcome these limitations, the recent growth of 3D technologies has enabled new standardized casting procedures: additive manufacturing (AM) is a technique that creates highly customized cast models from anatomical 3D data by using digitally controlled and operated material laying tools. Compared with conventional casts, those produced with AM technique could potentially reduce skin complications and satisfy both mechanical and clinical requirements of functionality, comfort, and aesthetics.The objective of this study is to describe the new practical methodology to produce a 3D printable cast for upper arm immobilization. The parametric modelling tool, employed to develop a semi-automatic design system for generating the printable cast model, reduces the complex process of orthosis design to a few minutes and all the manufacturing operations remain unaffected by CAD skills of the operator. Specific hardware and software tools (3D scanner, modelling software and FDM technology) were chosen to mitigate design and production costs while guaranteeing suitable levels of data accuracy, process efficiency and design versatility. To highlight the effectiveness of the proposed solution, a finite element analysis simulation was performed on models with different geometry, highlighting the mechanical strength of generated structures.The final result is a personalized 3D printed cast with a highly ventilated structure that is lightweight but still maintains a high level of strength and provides hygienic benefits, reducing the risk of cutaneous complications, potentially improving treatment efficacy and increasing patient satisfaction.

COMPARATIVE ANALYSIS ОF GEOMETRIC DEVIATIONS IN CONTACT MEASURING INSTRUMENTS FOR CONTROL AND LASER CONTACTLESS SCANNING

The factors affecting the dimensional accuracy of 3D scanning using a measuring arm with an integrated scanner and a custom open source 3D printer using FDM technology are researched in this paper, with the purpose of isolating and reducing the sources of errors affecting the results. A consumer 3D printer is analyzed in terms of achieving accurate physical dimensions, consistent shapes, and predictable surface coverage.

RESEARCH OF PROPERTIES OF CERAMIC COMPOSITE FIBER PRINTED USING FUSED DEPOSITION MODELING TECHNOLOGY

This research article presents a comprehensive study on ceramic materials using Fused filament fabrication of ceramic (FFFC) for the production of test samples. The study investigates the effects of different production strategies on three types of ceramic materials: experimental ceramic composite fiber (e.c.c.f.)(composite material produced by STU FCHPT), Zirconium Silicate, and White Zirconia. The primary objective is to compare the production times of the different strategies and investigate their effects on the properties of the samples. This research is important because production time is a crucial factor in the manufacturing industry, and minimizing production time without compromising quality is essential. The study aims to explore the impact of various production strategies on the production time and properties of the test samples, such as hardness, porosity, and flexural strength. The experimental procedure involves printing test samples using a MakerBot METHOD X 3D Printer with FDM technology and varying the layer thickness, raster angle, infill density, and other production strategies. The study aims to identify the optimal production strategy for each ceramic material, which can significantly reduce production time while maintaining the desired quality of the parts. Overall, the research provides valuable insights into the optimal production strategies for different types of ceramic materials and contributes to the development of novel, cost-effective, and efficient manufacturing processes for ceramic composites.

Energy absorbing 4D printed meta-sandwich structures: load cycles and shape recovery

The present study investigates the behavior of solid cellular structures in polylactic acid (PLA) achieved by FDM technology (fusion deposition modelling). The geometries are permanently deformed by compressive stress and then subjected to shape recovery through the application of a thermal stimulus. The structures are submitted to medium–high and medium–low compression stresses, evaluating the mechanical properties and the absorption energy as the number of cycles varies. The study shows that the ability to absorb energy is related to the density of the model, as well as the degree of damage observed, which increases with increasing number of load cycles. The strongest geometry is the lozenge grid, which is the most reliable. It shows no damage with increasing compression cycles and keeps its capability to absorb energy almost constant. The increase in lozenge grid density leads to an improvement in both mechanical strength and absorption energy, as well as a lower incidence of microcracks in the geometry itself due to the repeated load cycles. These results open up a broad spectrum of applications of custom-designed solid cellular structures in the field of energy absorption and damping.

Development and Evaluation of an FDM Printed Nasal Device for CPZ Solid Nanoparticles.

Nasal drug delivery has been a focus of scientific interest for decades. A number of drug delivery systems and devices are available and have been highly successful in providing better and more comfortable therapy. The benefits of nasal drug delivery are not in question. The nasal surface provides an excellent context for the targeted delivery of active substances. In addition to the large nasal surface area and intensive absorption, the active substances delivered through the nose overcome the blood-brain barrier and can be delivered directly to the central nervous system. Formulations for nasal administration are typically solutions or liquid dispersed systems such as emulsions or suspensions. Formulation techniques for nanostructures have recently undergone intensive development. Solid-phase heterogeneous dispersed systems represent a new direction in pharmaceutical formulations. The wide range of possible examples and the variety of excipients allow for the delivery of a wide range of active ingredients. The aim of our experimental work was to develop a solid drug delivery system that possesses all of the above-mentioned advantageous properties. In developing solid nanosystems, we not only exploited the advantages of size but also the adhesive and penetration-enhancing properties of excipients. During formulation, several amphiphilic compounds with adhesion properties and penetration enhancing effects were incorporated. We used chlorpromazine (CPZ), which is mainly used in the treatment of psychotic disorders such as schizophrenia and bipolar disorder. Chlorpromazine has been previously investigated by our team in other projects. With the availability of previous methods, the analytical characterization of the drug was carried out effectively. Due to the frequent and severe side effects of the drug, the need for therapeutic dose reduction is indisputable. In this series of experiments, we succeeded in constructing drug delivery systems. Finely divided Na nanoparticles were formed using a Büchi B90 nanospray dryer. An important step in the development of the drug carrier was the selection of suitable inert carrier compounds. Particle size determination and particle size distribution analysis were performed to characterize the prepared nanostructures. As safety is the most important aspect of any drug formulation, all components and systems were tested with different biocompatibility assays. The tests performed demonstrated the safe applicability of our systems. The bioavailability of chlorpromazine was studied as a function of the ratio of the active ingredient administered nasally and intravenously. As described above, most nasal formulations are liquids, but our system is solid, so there is currently no tool available to accurately target this system. As a supplement of the project, a nasal dosing device was developed, corresponding to the anatomical structure; a prototype of the device was made using 3D FDM technology. Our results lay the foundation for the design and industrial scaling of a new approach to the design and production of a high-bioavailability nasal medicinal product.

Experimental study of wax-material support structure for fused deposition modeling printed parts with overhanging sections

Additive manufacturing of PLA parts using wax-based filament as a support structure was investigated by implementing the 2-level 3-factors full factorial design of experiments (DoE). The aim of the experiments was to identify significant FDM factors that affect the surface roughness of the parent part in the PLA/Wax interfacial region. In addition, the important factors influencing bonding strength between PLA and wax were identified using the same full factorial DoE. The printing parameters chosen for the analysis are printing temperature, nozzle speed, and the pattern type at the interfacial area. The findings of the study show that the wax-based filament can be effectively used as support material with the condition that the PLA printing temperature is at its lowest value and the nozzle speed is close to 40 mm/s. With the optimal printing condition, the surface roughness value (Ra) can reach as low as 18 μm value and the bonding strength of 0.27 MPa at the interfacial area. The results of the study have revealed the capability of FDM technology to join materials having considerably dissimilar properties.