Fused Deposition Modeling Method Research Articles

Microstructural and Hydrophilic Properties of Polylactide Polymer Samples with Various 3D Printing Patterns.

The aim of the work is to study the effect of the 3D printing process on the microstructural and hydrophilic properties of polylactic acid (PLA) samples with various model printing patterns obtained from the black filament PLA by sequentially applying polymer layers using the FDM (fused deposition modeling) method. X-ray phase analysis revealed the partial crystallization of PLA polymer chains in the printed samples, which occurs under thermal and mechanical action on the original amorphous PLA filament during 3D printing to varying degrees, depending on the geometry of the pattern and the morphology of its surface. At the same time, IR spectroscopy data indicate the preservation of all intrastructural chemical bonds of polylactide. Measured at the original installation, the values of the wetting edge angles on the surface of the printed samples are in the range φ = 50-60°, which is significantly less than the right angle. This indicates the hydrophilic properties of the whole sample's surface. At the same time, the influence of different geometries of model drawings in printed samples was found not only on the morphology of the sample's surface according to SEM data but also on its wettability.

The Influence of Moisture Absorption and Desorption by the ABS Filament on the Properties of Additively Manufactured Parts Using the Fused Deposition Modeling Method.

This paper presents the results of research on the influence of the moisture content in a filament made of ABS polymer on the properties of products manufactured using FDM (fused deposition modeling). Tests were carried out on a standard printer, using the parameters recommended by the manufacturer and the literature on the subject. A special climatic chamber was used to condition the material. A negative impact of ABS filament moisture on the strength and dimensional accuracy of printed products and on the structure of their surface is demonstrated. When the range of the filament moisture is between 0.17% and 0.75%, the strength decreases by 25% and the sample thickness increases by 10%. It is also shown that this effect does not depend on the history of the polymer reaching a given moisture level, i.e., by absorbing moisture in the absorption process or releasing moisture in the desorption process.

Assessing the functional mechanical properties of polycaprolactone stents post-processed by ultrasonic strengthening

In this study, the ultrasonic strengthening process was performed on the stents fabricated by the fused deposition modeling method with polycaprolactone (PCL) material. Functional tests entailing three-point bending, parallel-plate compression and biodegradable tests were performed to evaluate the effect of the ultrasonic strengthening process on the PCL polymeric stents. Results displayed that the bending and compression stiffness ratio improved value by 2.4 and 1.37 times, respectively, more than evidence-based stents without ultrasonic strengthening. Also, records revealed that the ultrasonic strengthening process increases in polymer degradation time by up to 60 %. The dynamic mechanical properties of stents were improved after ultrasonic enhancement. Observation of the surface morphology by Scanning Electron Microscope showed a cavity's size reduction and Adhesion between layers in the cross-section were owned to effect on ultrasonic strengthening process.

Investigation of the Hydrolytic Degradation Kinetics of 3D-Printed PLA Structures under a Thermally Accelerated Regime.

The application of biobased and biodegradable polymers, such as polylactide (PLA), in fused deposition modeling (FDM) 3D-printing technology creates a new prospect for rapid prototyping and other applications in the context of ecology. The popularity of the FDM method and its significance in material engineering not only creates new prospects for the development of technical sciences on an industrial scale, but also introduces new technologies into households. In this study, the kinetics of the hydrolytic degradation of samples obtained by the FDM method from commercially available PLA filaments under a thermally accelerated regime were analyzed. The investigation was conducted at the microstructural, supramolecular, and molecular levels by using methods such as micro-computed tomography (micro-CT), wide-angle X-ray diffraction (WAXD), viscosimetry, and mass erosion measurements. The obtained results clearly present the rapid structural changes in 3D-printed materials during degradation due to their amorphous initial structure. The complementary studies carried out at different scale levels allowed us to demonstrate the relationship between the observed structural changes in the samples and the hydrolytic decomposition of the polymer chains, which made it possible to scientifically understand the process and expand the knowledge on biodegradation.

Characterization of microstructure and magnetic properties of 3D printed bonded magnets made by fused deposition modeling

Abstract Bonded magnets are composite materials consisting of polymer matrix and magnetic powders, prepared by rapid solidification processes from Nd-Fe-B alloys. They are synthesised by the compounding process on a twin-screw extruder, whereby, the finished products of complex shapes can be made from bonded magnets using injection moulding or 3D printing by fused deposition modelling method (FDM). The main advantages of 3D printing are the possibility to produce parts with complex geometries that are not possible with traditional manufacturing techniques and low-cost production of small batches. The aim of the research work was to identify the optimum processing parameters, which would give 3D printed bonded magnets characteristics similar to those produced by injection moulding. The characterization of the microstructure of bonded magnets was made on cryo-fractured, conventionally mechanically prepared and ion beam polished samples. The microstructures of bonded magnets were analysed by stereo, optical and scanning electron microscopy. Additionally, the influence of the 3D printing parameters on the magnetic properties has been examined. The results of the research work have shown that desired magnetic properties of 3D printed bonded magnets can be obtained by optimizing the thickness of the printed layer, printing speed and flowrate. In addition, it was revealed that selection of the materialographic preparation method plays a crucial step for correct microstructural characterization. Namely, the impropriate sample preparation results in artifacts that are mostly misinterpreted as microstructural defects (pores, cracks, non-adherent layers, etc.) accidently caused during 3d printing.

Optimizing 3D printed diamond lattice structure and investigating the influence of process parameters on their mechanical integrity using nature-inspired machine learning algorithms

This research investigates the effect of process parameters on the mechanical integrity of 3D-printed Polylactic Acid (PLA+) lattice structures, with a focus on diamond lattice configurations. Adhering to ASTM D695 standards, the study employs compression testing to analyze the impact of various factors, including layer height, infill pattern, cell size, and infill density. The printing process utilizes the Ultimaker Cura Fused Deposition Modelling method, ensuring accuracy and uniformity in sample production. Mechanical properties were assessed using a Universal Testing Machine, highlighting the influence of the studied parameters on compressive strength and specific energy absorption (SEA). Innovatively, this study integrates nature-inspired machine-learning algorithms for hyperparameter tuning. Particle Swarm Optimization (PSO) is employed to optimize the settings of Random Forest and XGBoost models, enhancing their predictive capabilities. Results indicate that XGBoost, fine-tuned with PSO, slightly outperforms its counterpart in predicting key mechanical properties. Furthermore, feature significance assessments reveal cell size as a critical factor for compressive strength. This research not only provides a comprehensive analysis of mechanical properties in 3D-printed structures but also introduces a novel approach to applying nature-inspired algorithms for machine learning optimization in additive manufacturing.

Application of artificial neural network to evaluation of dimensional accuracy of 3D‐printed polylactic acid parts

AbstractAdditive manufacturing (AM) has begun to replace traditional fabrication because of its advantages, such as easy manufacturing of parts with complex geometry, and mass production. The most important limitation of AM is that dimensional accuracy cannot be achieved in all parts. Dimensional accuracy is essential for high reliability, high performance, and useful final products. This study investigates the impact of printing parameters on the dimensional accuracy of samples fabricated through fused deposition modeling (FDM), an additive manufacturing (AM) method utilizing polylactic acid (PLA) material. The experimental design process was performed using Taguchi methodology. ANOVA was used to determine the most important parameter affecting accuracy. Based on experimental studies, the optimal printing parameters for parts are determined as follows: concentric infill pattern, 3 mm wall thickness, 70% infill density, and a layer thickness of 200 μm. Artificial neural network (ANN) was used in the evaluation and prediction of the results. The R‐square (R2) performance evaluation criterion was above 95% from the ANN results. This value shows that the results are significant. The data acquired from this study may assist in identifying optimal parameters that contribute to the fabrication of samples with high dimensional accuracy using the FDM method.

Amalgamation of nano and 3-D printing technology: Design, optimization, and assessment

Personalized medicine is the need of today's era, as one therapy does not fit all. The study aims to develop a novel patient-customized formulation using the integration of 3-D printing and Nanotechnology concepts. Valsartan (VLS) was chosen as a model drug for the study due to its poor bioavailability and dose-dependent toxicity. The Polycaprolactone (PCL)-VLS bionanoparticles (PCVBio) were formulated using a modified solvent evaporation method, inculcating the approach of Quality by Design (QbD). The amount of PCL and Polaxomer-188 (PLX) significantly influenced the PCVBio properties, which central composite design (CCD) ascertained. The results of DSC confirm the conversion of crystalline to amorphous structure. The zeta potential, PDI, and particle size ensure stability and nano size. The optimized PCVBio was further loaded into the multi-channel 3-D printed tablet (M3DPT). M3DPT was formulated by the fused deposition modeling method. The process parameters,% infill, and layer height significantly influenced the tablet's quality. The PCVbio M3DPT was able to release the VLS up to 12 h. The optimal formulation was found stable and effective. The new conjugated advanced formulation will improve the effectiveness, safety, and patient adherence. It unlocks the new research direction toward improving patients' lives.

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.

Damage Behavior of Multilayer Axisymmetric Shells Obtained by the FDM Method

This research rigorously explores the additive synthesis of structural components, focusing on unraveling the challenges and defect mechanisms intrinsic to the fused deposition modeling (FDM) process. Leveraging a comprehensive literature review and employing theoretical modeling and finite element analysis using ANSYS software, the study meticulously investigates the behavior of multilayer axisymmetric shells under varying internal pressure conditions. Critical parameters are identified, and the impact of design factors, including material properties, geometric parameters, and internal pressure, is quantitatively assessed using a rich digital dataset. In a series of model experiments, the study reveals specific numerical results that underscore the progressive nature of damage development in FDM-produced multilayer axisymmetric shells. Notably, under increasing internal pressure, stresses on the tank’s inner walls reach up to 27.5 MPa, emphasizing the critical importance of considering material properties in the design phase. The research also uncovers that the thickness of tank walls, while significant in resulting stresses, does not markedly impact the damage development mechanism. However, it places a premium on selecting rational parameters for the honeycomb system, including shell thickness, honeycomb height, honeycomb wall thickness, and honeycomb cell size, to minimize stress concentrations and enhance structural integrity. The inclusion of honeycomb structures in the tank design, as evidenced by specific results, provides enhanced thermal insulation properties. The research demonstrates that this design feature helps localize damage and mitigates the formation of significant trunk cracks, particularly along generative cracks.

Evaluation of stress-controlled high-cycle fatigue characteristics in PLA-wood fused deposition modeling 3D-printed parts under bending loads.

PLA (Poly-lactic acid)-wood provides more biodegradability through natural fibers, a significant advantage of pure PLA. Nevertheless, these bio-composites may have inferior mechanical properties compared to non-degradable polymer composites, considering the lower strength of natural particles compared to synthetic fibers. This research examines the fatigue behavior of additive-manufactured biopolymer PLA-wood and assesses its comparability with pure PLA. Therefore, solid fatigue test samples were printed using the FDM (fused deposition modeling) method. Afterward, fully reversed rotary bending fatigue experiments were performed at 4 different stress levels (7.5 to 15 MPa) to extract the S-N curve of PLA-wood. Moreover, the fatigue fracture surfaces of the PLA-wood were investigated and compared at the highest and lowest stress levels using an FE-SEM (Field Emission Scanning Electron Microscopy), indicating more ductile fracture marks at higher stress levels. The fatigue lifetime of the PLA-wood decreased by 87.48% at the highest stress level (15 MPa), rather than the result at the lowest stress level (7.5 MPa). Additionally, the results demonstrated that the fatigue characteristics of the printed pure PLA and PLA-wood were comparable, suggesting that the 3D-printed PLA-wood with the used printing parameters can be an alternative choice.

Stereolitografi ve eriyik yığma modellemesi eklemeli imalat yöntemleriyle üretilen numunelerin mekanik özelliklerinin karşılaştırılması

Additive manufacturing (AM) technology has attracted significant attention with the rapid fabri-cation of 3D parts for various applications. With fused deposition modeling (FDM) and stereo-lithography (SLA), the most used methods in this technology, it is possible to produce functional parts with complex shapes quickly and cheaply. Determining the mechanical properties of the parts produced by these methods is important in terms of efficient operation in the relevant fields. This study, 45 test specimens were fabricated using three different polymer materials (UVR, PLA, and ABS) in SLA and FDM type 3D printers, including tensile, compression, and 3-point bending tests. Samples are printed at a 75% fill rate according to ASTM standards. Experimental studies were carried out to determine the mechanical properties of the samples. Among the samples, the highest strength values in tensile, compression and bending test samples made of UVR material were 60.39 MPa, 127.74 MPa and 118.35 MPa, respectively. In addition to mechanical properties, hardness, and SEM analyses were performed to examine the surface roughness, surface topography, and composition of the samples. As a result, the effects on the mechanical properties of the samples fabricated by the UVR-based SLA method and the PLA-ABS-based FDM method were examined and compared.

Eriyik Yığma Modelleme ile Üretilen PLA, ABS VE PETG Polimerlerinin Özellikleri Üzerinde Kafes Tasarımı ve Proses Parametrelerinin Etkisi

In this study, tensile strengths of different polymer-based materials PLA (Polylactic Acid), ABS (Acrylonitrile Butadiene Styrene), and PETG (Polyethylene Terephthalate Glycol) were investigated by applying BCC (Body-Centered Cubic), FCC (Face-Centered Cubic) and Gyroid lattice designs with FDM (Fused Deposition Modeling) method which one of the additive manufacturing methods. In addition, weight reduction was performed in the materials with the lattice designs applied. After the mechanical tests, it was determined that the lattice structure has an important role in tensile strengths. Especially in the gyroid lattice structure, which is one of the TPMS (Triply Periodic Minimal Surface) lattice types, it was determined that the maximum strength was obtained in PLA material. In terms of % deformation, the maximum elongation was obtained for PETG material in the gyroid lattice structure. In addition, weight reduction was aimed by using lattice structure patterns, and the maximum weight reduction was found in the BCC lattice structure.

Effect of using 3D-printed shell structure for reinforcement of ultra-high-performance concrete

This study aims to investigate the effect of 3D-printed polymer shell reinforcemen ton ultra-high-performance concrete. The mechanical properties of ultra-high-performance polymer reinforced concrete have been investigated. At first, the 3D-printed shell reinforcements were designed using 3D Max and Rhino 6 software. Then, each was fabricated through the fused deposition modeling method and positioned into the cubic, cylindrical, and prismatic molds. In the next step, the prepared Ultra-High-Performance Concrete mixture was poured into the molds, and the samples were cured for 28 days. Finally, the compressive, tensile, and flexural strength tests were carried out on the samples. The results indicated that the compressive, tensile, and flexural strengths of reinforced samples were lower than that of the unreinforced ones, respectively. Although including 3D-printed reinforcement decreased the mechanical properties of the Ultra-High-Performance Concrete samples, it changed the fracture mechanism of concrete from brittle to ductile.

Study on the mechanism and performance of 3D-printed PLA/epoxy composite for stab resistance

PurposeStab-resistant body armor (SRBA) is used to protect the body from sharp knives. However, most SRBA materials currently have the disadvantages of large weight and thickness. This paper aims to prepare lightweight and high-performance SRBA by 3D printing truss structure and resin-filling method.Design/methodology/approachThe stab resistance truss structure was prepared by the fused deposition modeling method, and the composite structure was formed after filling with resin for dynamic and quasi-static stab tests. The optimized structural plate can meet the standard GA68-2019. Digital image correlation technology was used to analyze the local strain changes during puncture. The puncture failure mode was summarized by the final failure morphologies. The explicit dynamics module in ANSYS Workbench was used to analyze the design of the overlapped structure stab resistance process in this paper.FindingsThe stab resistance performance of the 3D-printed structural plate is affected by the internal filling pattern. The stab resistance performance of 3D-printed structural parts was significantly improved after resin filling. The 50%-diamond-PLA-epoxy, with a thickness of only 5 mm was able to meet the stab resistance standard. Resins are used to increase the strength and hardness of the material but also to increase crack propagation and reduce the toughness of the material. The overlapping semicircular structure was inspired by the exoskeleton structure of the demon iron beetle, which improved the stab resistance between gaps. The truss structure can effectively disperse stress for toughening. The filled resin was reinforced by absorbing impact energy.Originality/valueThe 3D-printed resin-filled truss structure can be used to prepare high-performance stab resistance structural plates, which balance the toughness and strength of the overall structure and ultimately reduce the thickness and weight of the SRBA.

Bending behavior of 3D printed sandwich structures with different core geometries and thermal aging durations

In recent years, the Fused Deposition Modeling (FDM) method has been employed in the production of small-scale structural elements with moderate loads, such as small-unmanned aerial vehicles, sports equipment, dental implant molds, and similar applications. In these cases, the FDM technique can utilize polymers like Polyamide (PA), Polylactic Acid (PLA), and Acrylonitrile Butadiene Styrene (ABS) to manufacture structural components. Lightweight sandwich structures are utilized as structural elements in various industries due to their unique characteristics, high stiffness-to-weight ratio, and energy absorption capabilities. Although the number of studies on the mechanical properties of sandwich structures manufactured with FDM has increased in recent years, experimental data on the mechanical characteristics of sandwich structures manufactured with FDM under different thermal aging durations are still insufficient. Driven by this motivation, the energy absorption capabilities of sandwich structures with different four core geometries (i.e., circular, hexagonal, square, and triangular) were experimentally investigated under different thermal aging durations. The sandwich structures were manufactured from PLA material by the FDM method. Four different thermal aging durations, 0, 15, 30 and 45 days, were considered for environmental conditions. Quasi-static three-point bending experiments were conducted to assess the energy absorption capability of lightweight sandwich structures featuring diverse core topologies. The bending test results demonstrate that the core topology significantly affects the energy absorption abilities of sandwich structures. Moreover, fractographic analysis using scanning electron microscopy (SEM) was conducted to gain deeper insights into the impact of thermal aging on aged specimens. In addition, it was concluded that the energy absorption performances of all sandwich structures with different core structure topologies were adversely affected by increasing the thermal aging time.

Determination of Energy Consumption During The Tensile Test Sample Production in 3D Printer Working with The Fused Deposition Modeling Method

Today, 3-dimensional (3D) printers are developing increasingly, and rapid progress is being made to become an alternative to traditional production methods. 3D printers, which produce with the Fused Deposition Modeling (FDM) method, commonly produce by using polymer materials in the form of filament with a diameter of 1.75 mm or 2.85 mm. This study, tensile test specimens were produced using PLA filaments of different diameters (1.75 mm and 2.85 mm) with two different 3D printers. The electricity consumption of 3D printers during the production of tensile test samples was measured. The energy consumed by both 3D printers in producing tensile test specimens was compared. Instead of simultaneously producing a single test sample, it has been determined that the power consumption per test sample will be reduced by producing many test samples together.

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.

Printing strategies to fabricate a disk through the fused deposition modeling method

The fused deposition modeling (FDM) technique is widely used in different industries due to its low cost and ability to produce complex geometries from polymers. In this technique, some manufacturing parameters are essential because of their effects on the mechanical performance of the final fabricated part. The current study investigated the impact of path strategy and printing speed, two key manufacturing factors, on the mechanical performance of printed disks. Six types of path strategies of rasters corresponding to the loading direction, namely unidirectional-vertical, unidirectional-horizontal, unidirectional-45, cross, cross-45, and concentrate, were used for printing some disks, and compressive tests were done on them. The results showed that these path strategies’ average compressive failure loads were 2955, 4957, 2342, 4640, 3971, and 5893 N, respectively. The lower compressive strength of the unidirectional path pattern was due to the weak zones that were located between the printed layers and rasters. Besides, three printing speeds of 40, 60, and 80 mm/s were considered to fabricate the disks with a concentrate path pattern, and compressive experiments were performed. The results showed that the 40 mm/s printing speed conducted a compressive failure load of 4544 N, while 60 and 80 mm/s resulted in 3008 and 2828 N, respectively. Finally, inter-layer strength as a major factor in controlling the compressive strength of the disks was comprehensively discussed.

INVESTIGATION OF 3D PRINTING PARAMETERS AFFECTING THE DEVIATION OF PRODUCT BY TAGUCHI METHOD

Fused deposition modeling (FDM) printing method is widely used in the manufacture of technical parts. The article aims to present the survey results of 3D printing parameters (layer height, printing speed, wall thickness) that affect the deviation of product created by the FDM printing method. In this study, 3D scanning technology was applied to measure and check the error of each printed hole. Taguchi method is used in the experiment to design and process data in Minitab software to generate results to evaluate the input values of the investigation. The research results show that the print speed parameter has the highest influence on the error whereas the print wall thickness parameter has the lowest effect. The research results can be used to eliminate the error in making samples by the FDM method.