Fused Deposition Modeling Material Research Articles

Advancements in Fused Deposition Modeling for Aerospace: Optimizing Lightweight and High- Strength Components

Fused Deposition Modeling (FDM) has emerged as a pivotal technology in aerospace manufacturing, enabling the creation of lightweight and high-strength components. Recent advancements in FDM materials, process optimization, and design methodologies have significantly enhanced its applicability in producing aerospace parts that meet stringent performance criteria. This paper reviews the latest developments in FDM technology, focusing on material innovations, structural optimization techniques, design for additive manufacturing and practical applications in the aerospace sector. Key advancements include the use of high-performance thermoplastics, carbon fiber composites, and hybrid materials, as well as improved printing techniques that reduce defects and enhance mechanical properties. The potential of FDM to revolutionize aerospace manufacturing through cost- effective and efficient production of complex geometries is explored, highlighting ongoing research and future directions in this dynamic field.

Mechanical Characterization of Polylactic Acid, Polycarbonate, and Carbon Fiber-Reinforced Polyamide Specimens Fabricated by Fused Deposition Modeling

This paper investigates the mechanical behavior of polylactic acid (PLA), polycarbonate (PC) and carbon fiber-reinforced high-temperature polyamide (PAHT-CF) specimens fabricated by fused deposition modeling (FDM). PC and PAHT-CF are considered engineering grade materials that exhibit good mechanical properties, suitable for rapid prototypes and functional parts fabrication. PLA, a popular, commonly used FDM material, has been included in this work for comparison purposes. The purpose of the present study is to provide comprehensive experimental data on the materials’ critical properties since limited data is available in the existing literature and there is a lack of comparative analysis regarding the three materials. Mechanical characterization has been carried out on the basis of tensile, three-point bending, impact and creep tests. Measurements of hardness, density and porosity were conducted, and the specimens’ morphology was examined through microscopy. The results showed that the highest strength and flexural modulus of elasticity were observed for the PAHT-CF specimens followed by PC and PLA. PC specimens exhibited the highest impact resistance followed by PAHT-CF and PLA. The highest stage II creep resistance was achieved by PAHT-CF followed by PC and PLA. The optical and scanning electron microscopy images revealed that specimens’ quality depends on the printing parameters.

Sustainable Furniture Joints: Leveraging Fused Deposition Modeling (FDM) for Eco-Friendly Design

Integrating form, function, and material selection has been fundamental in furniture design and production. Traditional methods, particularly in joint creation, demand skilled craftsmanship and time-intensive processes. However, the emergence of 3D printing technology, specifically fused deposition modeling (FDM), has revolutionized furniture joint production. This study investigates the sustainable application of FDM for creating furniture joints, emphasizing eco- friendly design and efficient material utilization. To optimize the joinery system using 3D printing, researchers have conducted structured interviews with experts in the Malaysian 3D printing field. Their insights guided the development of guidelines for selecting appropriate materials and optimizing joint geometries. In furniture manufacturing, FDM enables precise joint components through layer-by- layer construction using thermoplastic materials. Unlike traditional methods that often result in wood waste, FDM minimizes material consumption. Designer- generated joint designs produced seamlessly via 3D printing reduce production time and enhance precision. Cost-effectiveness further positions FDM as a sustainable alternative for furniture production. This research focuses on two commonly used FDM materials: Acrylonitrile Butadiene Styrene (ABS) and Polylactic Acid (PLA). By providing guidelines for selecting appropriate materials, it will eventually empower designers and manufacturers to create furniture joints that align with sustainability goals. The resulting joints exhibit superior accuracy compared to manual craftsmanship, contributing to both environmental conservation and innovation within the Malaysian furniture industry

A review on fused deposition modeling materials with analysis of key process parameters influence on mechanical properties

A review on fused deposition modeling materials with analysis of key process parameters influence on mechanical properties

Study of 3D Metal Printed and Metal Filled Epoxy Materials for Rapid Tooling in Injection Molding

Common rapid tooling techniques can be classified as indirect and direct methods. As indirect methods, casting a mixture of epoxy and metallic powder over a pattern to obtain the mold shape is currently a fast and reliable method. As direct methods, Additive Manufacturing (AM) technologies such as Selective Laser Melting (SLM) can directly manufacture a mold ready for operation. Recently, progress in Fused Deposition Modeling (FDM) materials have brought into play a large variety of 3D printed polymers with high percentage of fiber metals that can be more easily printed using the FDM technology instead of SLM or other more advance techniques. In this paper, a study is conducted to analyze the main characteristics of different FDM materials with metal fibers and different epoxy metal filled materials for rapid tooling in injection molding. The study analyzes the properties of these materials such as yield strength, tensile strength, thermal conductivity and wear resistance, and compares them with those from common traditional machined materials for molding such as tool steels and aluminum. Furthermore, the paper shows a comparison of costs and advantages and drawbacks of using these materials for a standard molding insert in industry.

The Impact Of Carbon Fiber on the surface properties of the 3D Printed PEGT Product

The primary focus of this work is the development of a hybrid composite material for 3D filaments. Polyethylene phthalate glycol (PETG) and (PETG/Carbon) fiber composite materials have their surface properties (surface roughness, Shore hardness, and micro hardness) tested. A ratio of 15% carbon fiber (in the form of carbon filaments) was used as the reinforcing filler. Using FDM (fused deposition modeling material) technology, the surface properties of PETG material used in 3D printed objects were enhanced. An ENDER 3D printer was used to create three PETG and PETG/Carbon fiber samples, using the printer setting 240°C temperature, 80°C build plate temperature, 55mm/s speed, 0.2mm layer height and speed fan 100mm/s. After that, an optical microscope and FT-IR technologies were used to investigate the samples. Results showed that as compared to PETG, the surface roughness of PETG/Carbon was reduced by 32.7%. This allowed carbon fiber to break doubly bonded in the PETG structure and also enhanced sample flow and adhesion. The PETG/Carbon samples had a Shore hardness D that was 2.16% lower than PETG's, but a slightly higher Micro hardness, making them more comparable to 10.4 HV than to 9.6 HV. However, the carbon fiber was reinforced and showed high compatibility with a PETG polymer matrix at the samples' buried structures, demonstrating that a 3D printer is an effective production tool for producing homogenized composite materials. According to claims, these features enhance the carbon fiber's ability to slide in PETG/Carbon samples.

First Proof-of-Principle of PolyJet 3D Printing on Textile Fabrics.

Possibilities of direct 3D printing on textile fabrics have been investigated with increasing intensity during the last decade, leading to composites which can combine the positive properties of both parts, i.e., the fast production and lateral strength of textile fabrics with the flexural strength and point-wise definable properties of 3D printed parts. These experiments, however, were mostly performed using fused deposition modeling (FDM), which is an inexpensive and broadly available technique, but which suffers from the high viscosity of the molten polymers, often impeding a form-locking connection between polymer and textile fibers. One study reported stereolithography (SLA) to be usable for direct printing on textile fabrics, but this technique suffers from the problem that the textile material is completely soaked in resin during 3D printing. Combining the advantages of FDM (material application only at defined positions) and SLA (low-viscous resin which can easily flow into a textile fabric) is possible with PolyJet modeling (PJM) printing. Here, we report the first proof-of-principle of PolyJet printing on textile fabrics. We show that PJM printing with a common resin on different textile fabrics leads to adhesion forces according to DIN 53530 in the range of 30-35 N, which is comparable with the best adhesion forces yet reported for fused deposition modeling (FDM) printing with rigid polymers on textile fabrics.

Statistical modelling and optimization of mechanical properties for PLA and PLA/Wood FDM materials

This investigation examines the results of two variable parameters during the fused deposition modeling (FDM) 3D printing process of conventional polylactic acid (PLA) and organic biocompatible compound material with wood (PLA/W; coconut flour), on ultimate tensile strength, UTS (MPa) and modulus of elasticity E (MPa). The parameter optimization is based on a customized response surface (RSM) design and uses an L9 orthogonal array. The control variables investigated were nozzle temperature (NT, oC) and layer thickness (LT, mm), whilst regression models for UTS and E of both materials, i.e., PLA and PLA/W, were constructed to correlate the control parameters. Proper analysis was preceded based on response surface analysis through contour plots. The regression models were further useded as objective functions to maximize UTS and E (MPa) for both filament materials by applying the grey-wolf optimization genetic algorithm (GWO).

Tissue equivalence of 3D printing materials with respect to attenuation and absorption of X-rays used for diagnostic and interventional imaging.

Three-dimensional printing is a promising technology to produce phantoms for quality assurance and dosimetry in X-ray imaging. Crucial to this, however, is the use of tissue equivalent printing materials. It was thus the aim of this study to evaluate the properties of a larger number of commercially available printing filaments with respect to their attenuation and absorption of X-rays. Apparent kerma attenuation coefficients (AKACs) and absorbed doses for different X-ray spectra (tube voltages, 70-140kV) were measured and simulated by Monte-Carlo computations for a larger number of fused-deposition-modeling (FDM) materials. The results were compared with the respective values simulated for reference body tissues. In addition, the properties of polylactide acid samples printed with reduced infill densities were investigated. Measured and simulated AKACs and absorbed doses agreed well with each other and in case of AKACs also with attenuation coefficients derived from the reference database of the National Institute of Standards and Technology (NIST). For lung, adipose, muscle, and bulk soft tissue as well as for spongiosa (cancellous bone), printed materials with equivalent attenuation as well as absorption properties could be identified. In contrast, none of the considered printed materials was equivalent to cortical bone. Several FDM materials have been identified as well-suited substitutes for body tissues in terms of the investigated material characteristics. They can therefore be used for in-house production of individualized and task-specific phantoms for image quality assessment and dose measurements in X-ray imaging.

Comparative Study of the Sensitivity of PLA, ABS, PEEK, and PETG’s Mechanical Properties to FDM Printing Process Parameters

Significant advances in fused deposition modeling (FDM), as well as its myriad applications, have led to its growing prominence among additive manufacturing (AM) technologies. When the technology was first developed, it was used for rapid prototyping to examine and analyze a product in the design stage. FDM facilitates rapid production, requires inexpensive tools, and can fabricate complex-shaped parts; it, therefore, became popular and its use widespread. However, various FDM processing parameters have proven to affect the printed part’s mechanical properties to different extents. The values for the printing process parameters are carefully selected based on the part’s application. This study investigates the effects of four process parameters (raster angle, layer thickness, infill percentage, and printing speed) on the mechanical behavior of printed parts that are based on available literature data. These process parameter’s influence on part’s mechanical properties varies depending on the FDM material. The study focuses on four FDM materials: polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), polyether ether ketone (PEEK), and polyethylene terephthalate glycol (PETG). This paper summarizes the state-of-the-art literature to show how sensitive the material’s mechanical properties are to each process parameter. The effect of each parameter on each material was quantified and ranked using analysis of variance (ANOVA). The results show that infill percentage then layer thickness are the most influential process parameter on most of the material’s mechanical properties. In addition, this work identifies gaps in existing studies and highlights opportunities for future research.

3D Printing with Flexible Materials – Mechanical Properties and Material Fatigue

Abstract3D printed objects are nowadays not only used in prototyping, but also in small‐scale production down to lot‐size 1. While different 3D printing techniques can be applied for this purpose, a large amount of products is prepared by the simple and inexpensive fused deposition modeling (FDM) technique, applying a polymer which is molten, pressed through a nozzle, and deposited layer‐by‐layer on a printing bed and on the previous layers, respectively. This technology, however, has the disadvantage of often insufficient mechanical properties due to the available materials and due to the construction method, which often supports air cavities inside objects, reducing the adhesion between neighboring strands and thus the overall mechanical properties. Such problems can partly be solved by chemical after‐treatments. Here, the authors report on tensile tests and load changes of the soft FDM materials FilaFlex and PLA soft (PLA = polylactic acid) in comparison with common PLA. They also show the different inner structure of objects 3D printed from these materials and their correlation with mechanical properties and material fatigue.

Freeze-thaw stabilization of fused deposition modeling 3D-printed SABIC structures

Fused deposition modeling (FDM) is a widely applied rapid prototyping technology that produces layered models from specially designed thermoplastic filaments. Thermoplastic materials can be layered using several parameters that influence the mechanical properties of the printed object. In this study, the effects of freeze–thaw cycles on the physical characteristics of FDM objects printed using the ULTEM 9085 filament is assessed. The samples used in this study were printed with an air gap of –0.025 mm and at raster angles of 0°, 45°, and 90°. The results indicate that freeze–thaw conditioning reduces the tensile properties of FDM samples. Results also can help enhance FDM material properties to withstand significant temperature changes whilst having a prolonged service life.

Surface Morphology of Three-Dimensionally Printed Replicas of Upper Dental Arches

The aim of our study was to analyze the precision of fused-deposition modeling (FDM), polyjet technology (PJ), stereolithography (SLA) and selective laser sintering (SLS) and to evaluate some interesting indications of these methods in clinical practice. Forty upper dental arches were scanned using a 3Shape Trios 3R optical scanner system and 3D models were made. An Atos II 400 optical 3D scanner was used for calculating the coordinates of points by optical triangulation, photogrammetry and fringe projection. Each model was scanned from a minimum of 56 positions to evaluate global coordinates. Surface morphology was evaluated with an Alpha Step IQ profilometer and a JSM 5510 LV scanning electron microscope. From the measurements in cross-sections it was evident that the deviation shifted by approximately 0.1 mm. The smoothest and most homogeneous sample was SLA. SLS and SLA samples showed the most similar results in comparison of perpendicular directions (homogeneity). FDM and PJ materials exhibited significantly greater roughness in the printing direction than in the perpendicular one, which is most likely caused by the technology selected and/or print parameters. Clinical applications have demonstrated unusual treatment options for patients with rare diseases.

Fused Deposition Modelling Filament with Recyclate Fibre Reinforcement

The legacy of composite waste from manufacturing processes or end of life products is a growing and urgent challenge to be solved. An emerging idea is to incorporate composite recyclate in additive manufacturing. The focus of this work was to develop this capability and research the functional performance of additive manufactured parts through incorporating recyclate fibre in fused deposition modeling material. The research focused on additive manufacturing with virgin acrylonitrile butadiene styrene (ABS) and recyclate fibre reinforced ABS. The effect on tensile strength for different fibres (recycled by pyrolysis and mechanical process) was evaluated. Tensile test result showed an improvement by 43%, 49% and 69% when ABS was reinforced with mechanically recycled fibre, Pyrolysis recycled fibre and virgin carbon fibre respectively. The work identified the key potential for additive manufacturing to utilize recyclate and functional benefits as well as the areas for further scientific research. This is important for new innovations for use of composite recyclate to improve the functionality of additively manufactured parts.

Fused deposition modeling 3D printing of boron nitride composites for neutron radiation shielding

Abstract

Strengthening of plasma treated 3D printed ABS through epoxy infiltration

3D printed fused deposition modeling (FDM) material parts have distinct anisotropic mechanical properties based upon their as-built print orientation. The strength of material printed perpendicular to the deposition layers can be as low as 50% of values for injection molded parts due to less than optimum interlayer fusion, limiting their use for critical applications. The focus of this work is to present a novel way of utilizing design freedoms available in FDM to improve strength in weak orientations. Vertically processed FDM ABS parts were manufactured with cavities printed perpendicular to the interlayer direction and were subsequently plasma surface treated, filled with an epoxy resin, and mechanically tested. Plasma treatment was shown to beneficially modify the surface chemistry, which resulted in a 50% improvement in shear strength over untreated specimens. Samples that underwent plasma treatment and epoxy infiltration demonstrated a 130% increase in flexural strength over that of as-printed FDM material. The failure strain was also shown to increase by two-fold. The addition of milled carbon fiber (MCF) filler within the epoxy infiltrate was also evaluated and was shown to increase the flexural modulus by as much as 76% at 10 wt% loading levels, though negligible increases in strength were observed.

Fused Deposition Modeling 3D Printing for (Bio)analytical Device Fabrication: Procedures, Materials, and Applications.

In this work, the use of fused deposition modeling (FDM) in a (bio)analytical/lab-on-a-chip research laboratory is described. First, the specifications of this 3D printing method that are important for the fabrication of (micro)devices were characterized for a benchtop FDM 3D printer. These include resolution, surface roughness, leakage, transparency, material deformation, and the possibilities for integration of other materials. Next, the autofluorescence, solvent compatibility, and biocompatibility of 12 representative FDM materials were tested and evaluated. Finally, we demonstrate the feasibility of FDM in a number of important applications. In particular, we consider the fabrication of fluidic channels, masters for polymer replication, and tools for the production of paper microfluidic devices. This work thus provides a guideline for (i) the use of FDM technology by addressing its possibilities and current limitations, (ii) material selection for FDM, based on solvent compatibility and biocompatibility, and (iii) application of FDM technology to (bio)analytical research by demonstrating a broad range of illustrative examples.

Engineering Thermoplastics for Additive Manufacturing: A Critical Perspective with Experimental Evidence to Support Functional Applications.

Among additive manufacturing techniques, the filament-based technique involves what is referred to as fused deposition modeling (FDM). FDM materials are currently limited to a selected number of polymers. The present study focused on investigating the potential of using high-end engineering polymers in FDM. In addition, a critical review of the materials available on the market compared with those studied here was completed. Different engineering thermoplastics, ranging from industrial grade polycarbonates to novel polyetheretherketones (PEEKs), were processed by FDM. Prior to this, for innovative filaments based on PEEK, extrusion processing was carried out. Mechanical properties (i.e., tensile and flexural) were investigated for each extruded material. An industrial-type FDM machine (Stratasys Fortus® 400 mc) was used to fully characterize the effect of printing parameters on the mechanical properties of polycarbonate. The obtained properties were compared with samples obtained by injection molding. Finally, FDM samples made of PEEK were also characterized and compared with those obtained by injection molding. The effect of raster to raster air gap and raster angle on tensile and flexural properties of printed PC was evidenced; the potential of PEEK filaments, as novel FDM material, was highlighted in comparison to state of the art materials. Comparison with injection molded parts allowed to better understand FDM potential for functional applications. The study discussed pros and cons of the different materials. Finally, the development of novel PEEK filaments achieved important results offering a novel solution to the market when high mechanical and thermal properties are required.

Influence of processing and orientation print effects on the mechanical and thermal behavior of 3D-Printed ULTEM® 9085 Material

In this paper, we investigate the print orientation effects on the macrostructure, the mechanical and thermal properties, and the strain field behavior of ULTEM® 9085 using a Stratasys Fused deposition modeling (FDM) 400 Printer. The tensile strength, failure strain, Poisson’s ratio, coefficient of thermal expansion and modulus were all shown to vary significantly depending on the build orientation of identical dogbones. FDM parts ranged in strength from 46 to 85% of strengths attainable from comparable injection-molded parts. The coefficient of variation (CV) increased from 2 to 13% as the primary layer orientation deviated from the primary load direction. CAT scan and SEM were employed to relate the corresponding macrostructure to the mechanical response of the material along the parts’ 3-primary directions, using digital image correlation (DIC). The fracture surfaces of these parts further suggest that 3D FDM materials behave more like laminated composite structures than isotropic cast resins and therefore design allowables should reflect actual part build configurations.

WITHDRAWN: Mechanical Behavior of Fused Deposition Modeling Material

WITHDRAWN: Mechanical Behavior of Fused Deposition Modeling Material