Fused Deposition Modeling Process Research Articles

A Review on Fabrication and Printing of Carbon Fiber-Reinforced Composite Filaments using FDM Process

This review aims to provide a comprehensive overview of the fabrication and printing of Carbon Fiber-Reinforced composite filaments using the FDM process. Fused Deposition Modelling (FDM) or Fused Filament Fabrication (FFF) is an Additive Manufacturing technology that uses the idea of melting the material and depositing it layer by layer. The filament for this is usually prepared by mixing the metal powder in a polymer. The material extrusion method is the preferred way to fabricate the 3D printed filament. In this article, the main processes behind various base polymers and combinations like PLA, ABS and PETG as base polymers and Carbon Fiber-Reinforced PLA, ABS and PETG as fillers have been discussed and various Mechanical Tests are also done by the 3D printed parts like Tensile, Compression, Hardness and Impact Test. It is concluded that the importance of Carbon Fiber composites in various industries, such as aerospace, automotive and consumer goods etc… the need for innovative manufacturing techniques like FDM.

Effects of Annealing for Strength Enhancement of FDM 3D-Printed ABS Reinforced with Recycled Carbon Fiber.

This study investigates the effect of annealing on the mechanical properties of fused deposition modeling (FDM) 3D-printed recycled carbon fiber (rCF)-reinforced composites. In this study, filaments for FDM 3D printers are self-fabricated from pure acrylonitrile butadiene styrene (ABS) and ABS reinforced with fiber content of 10 wt% and 20 wt% rCF. This study explores the tensile and flexural properties as a function of the annealing temperature and time for the three different fiber content values. In addition, dimensional measurements of the shape changes are performed to determine the suitability of applying annealing in practical manufacturing processes. The results show that annealing improves the mechanical properties by narrowing the voids between the beads, which occur during the FDM process, and by reducing the gaps between the fibers and polymer. Following annealing, the largest tensile and flexural strength improvements are 12.64% and 42.33%, respectively, for the 20 wt% rCF content samples. Moreover, compared with the pure ABS samples, the annealing effect improves the mechanical properties of the rCF-reinforced samples more effectively, and they have higher dimensional stability, indicating their suitability for annealing. These results are expected to expand the application fields of rCF and greatly increase the potential use of FDM-printed parts.

A hybrid metaheuristic and computer vision approach to closed-loop calibration of fused deposition modeling 3D printers

Fused deposition modeling (FDM) is one of the most popular additive manufacturing (AM) technologies for reasons including its low cost and versatility. However, like many AM technologies, the FDM process is sensitive to changes in the feedstock material. Utilizing a new feedstock requires a time-consuming trial-and-error process to identify optimal settings for a large number of process parameters. The experience required to efficiently calibrate a printer to a new feedstock acts as a barrier to entry. To enable greater accessibility to non-expert users, this paper presents the first system for autonomous calibration of low-cost FDM 3D printers that demonstrates optimizing process parameters for printing complex 3D models with submillimeter dimensional accuracy. Autonomous calibration is achieved by combining a computer vision-based quality analysis with a single-solution metaheuristic to efficiently search the parameter space. The system requires only a consumer-grade camera and computer capable of running modern 3D printing software and uses a calibration budget of just 30 g of filament (~ $1 USD). The results show that for several popular thermoplastic filaments, the system can autonomously calibrate a 3D printer to print complex 3D models with an average deviation in dimensional accuracy of 0.047 mm, which is more accurate than the 3D printer’s published tolerance of 0.1–0.4 mm.

Particle based simulation of the polymer penetration into porous structures during the fused deposition modelling

Fused Deposition Modelling (FDM) has applications in an increasing number of fields. Therefore, combinations of different materials have gained popularity and offer new opportunities. Various polymers can be combined, and different materials can be printed on porous structures, for example, textiles, foams, or metals. In these cases, mechanical coupling between the materials is essential for adhesion and is influenced by the printing process parameters.This paper presents a simulation method for the printing of a fused deposition modelling process. A nozzle, porous substrate, and polymer were imported into the simulation environment. The nozzle model moved along the original nozzle path extracted from the G-code. The melted polymer is discretized as particles that flow out of the nozzle to imitate penetration into the porous substrate. After the printing process, the polymer shape and polymer penetration were exported and analysed.The simulation method showed good similarity with the experimental printing results. Variations in the printing process parameters led to similar behaviours in both the experiment and simulation. The polymer penetration into different porous substrates was successfully demonstrated.

Effect of FDM Processing Conditions on Snap-Fit Characteristic in Assembly

Snap-fit allows plastic products to have assembly and disassembly capabilities without the use of screws, bolts, or other additional parts. For this reason, snap-fit is used in all kinds of plastic products from stationery to automotive parts. Because the mechanical and other functions of a snap-fit are greatly affected by its shape and material properties, it is desirable to fully evaluate them at the design stage. In addition, as the assembly and disassembly of products by snap-fit is generally performed by people, it is important to evaluate not only virtually but also with actual plastic parts. Therefore, there is a strong need to make a prototype and evaluate the feel of the product during assembling and disassembling, before finalizing on the shape and materials. In the past, making precise prototype required expensive molds, but in recent years, additive manufacturing has made it possible to make prototype efficiently and at low cost. In additive manufacturing, fused deposition modeling (FDM) is considered suitable for snap-fit prototype because it can use the same materials as mass-produced products. Thus, it may be possible to make a snap-fit prototype with rigidity, strength, and other characteristics similar to those of mass-produced products. However, FDM has various processing conditions such as tool path, nozzle temperature, and height of one layer. They are expected to have a significant effect on the snap-fit characteristics. Snap-fit is required to meet various requirements depending on the plastic products. The requirements can be divided into three major categories: in assembly, in disassembly, and when to use. In this study, we investigated the effect of FDM processing conditions on snap-fit characteristic in assembly.

An experimental examination on surface finish of FDM 3D printed parts

Three-Dimensional (3D) printing, also known as Additive Manufacturing (AM) and Rapid Prototyping (RP), is a technology that takes information from a computer-aided design and prints it on a 3D printer, which creates a solid object by building up successive layers of material. This technique allows customizations and helps to develop tools that perfectly adapt to the required workspace. The material being added can be in the form of solid, liquid, or powder. Fused Deposition Modeling (FDM) is a method of AM where layers of materials are fused in a pattern to create an object. The material is usually melted and then extruded in a pattern next to or on top of previous extrusions, creating an object layer by layer. This process is used for modeling and prototyping functional and non-functional parts which are further used for various industrial applications. The major drawback associated with this technique is poor surface finish and dimensional inaccuracy of prototypes. In the present research work, the effect of various process parameters on the surface roughness of Polylactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS) samples produced from the FDM process is studied. Also, the samples are subjected to vapor smoothing to improve the surface roughness. The results of the present studies highlight that layer height and wall thickness are dominant factors affecting surface roughness. When ABS samples were subjected to acetone vapor smoothing, there was a noticeable improvement in the surface finish of the samples.

Designing and development of multipurpose night lamp using fused filament fabrication

In the present study, the integration of 3D printing using Fused Deposition Modeling (FDM) and picture printing has been explored. The generation of STL format files from graphical images is achieved using Graphical Image Processing (GIP) to create lithophanes. The user's STL model file is then sliced into layers using Ultimaker Cura, which generates printer-specific g-code and enables the conversion of graphical pictures into workable formats. Computer-aided design modeling is utilized to create the supporting framework, which is subsequently transformed into a 3D printed format. The entire structure is produced using a Creality Ender 3 printer, employing the fused filament fabrication (FFF) technique and utilizing white polylactic acid material. All 3D printed components are assembled with the assistance of auxiliary parts, including a 12 V LED, 3-pin slide switch, and 12 V DC cell. The combination of FDM, FFF, and GIP processes is employed to develop the final product. The functionality of the developed multipurpose night lamp is tested, and it is confirmed that it can serve three major functions as a picture table light, pen stand, and mobile phone holder. Based on the completion of this study, it can be concluded that 3D printing enables the manufacturing of customized multi-purpose products suitable for various applications, including industrial, decorative, and utility purposes.

Layer profile monitoring for fused deposition modelling process using boarder signature method

Fused deposition Modelling (FDM) or Fused Filament Fabrication (FFF) is an Additive Manufacturing process that uses production-grade thermoplastic materials to produce prototypes and in-use parts layer by layer. This technology is widely regarded for its accurate feature details in produced parts and its excellent strength-to-weight ratio. However, this manufacturing process has some issues like excess material deposition while printing, which may lead to uneven shape. Warping is another problem causing the material to shrink during the cooling process. To rectify the defects, a profile monitoring method is developed along with a machine vision system using an image processing technique to detect any abnormalities that occur during the printing process.

A bioinspired optimization strategy: to minimize the travel segment of the nozzle to accelerate the fused deposition modeling process

A bioinspired optimization strategy: to minimize the travel segment of the nozzle to accelerate the fused deposition modeling process

A review on the melt extrusion-based fused deposition modeling (FDM): background, materials, process parameters and military applications

AbstractThe contemporary military sector needs a tailor-made product at a low cost and time. Fused Deposition Modeling (FDM) is a melt extrusion-based Additive Manufacturing technology for processing thermoplastics, composites, and biomaterials. FDM is competent in fabricating complex parts in different industries, including military, aerospace, automotive, biomedical, and jewellery. The FDM can process various materials and is ideal for fabrication prototypes, functional parts, visualization, concept proofs and fast product development. FDM is currently used in the military for novel components developments and maintenance, opening new logistics and supply chain management methods. Integrating sensors into weaponry for real-time physiological feedback and threat information is also possible. Additionally, FDM can fabricate trauma models for surgical planning and educating military surgeons. This paper presents the FDM background, filaments, and process parameters. Also, the work provides information to readers on the applications and possibilities of the FDM process from a military standpoint.

Design of a programmable particle filtering medium using a novel auxetic metamaterial

This study presents the design and development of a 2D auxetic filtering medium with programmable geometric features specifically designed to vary under in-plane tensile strain. This feature empowers the filtering medium to control the particles separation. A novel design and optimisation algorithm developed in Matlab® determines the final optimized geometry of the filtering medium based on the desired particle size input. Upon thorough numerical investigation, an empirical relationship between the linear elastic in-plane tensile strain and aperture size of the proposed metamaterial is revealed. This empirical relation can be used in mechatronic and control systems to steer the proposed filtering medium. A prototype of such filtering medium capable of classification of particles of size 4 mm to 4.5 mm, when subjected to linear strain, is fabricated through fused deposition modelling process. The developed geometry configurations in this research are scalable, providing a potential cost-effective and efficient solution for industrial applications including reconfigurable filtration and segregation systems.

Effect of 3D Printing Process Parameters and Heat Treatment Conditions on the Mechanical Properties and Microstructure of PEEK Parts.

Fused deposition modeling (FDM) processed Poly-ether-ether-ketone (PEEK) materials are widely used in aerospace, automobile, biomedical, and electronics industries and other industries due to their excellent mechanical properties, thermal properties, chemical resistance, wear resistance, and biocompatibility, etc. However, the manufacture of PEEK materials and parts utilizing the FDM process faces the challenge of fine-tuning a list of process parameters and heat treatment conditions to reach the best-suiting mechanical properties and microstructures. It is non-trivial to make the selection only according to theoretical analysis while counting on a vast number of experiments is the general situation. Therefore, in this paper, the extrusion rate, filling angle, and printing orientation are investigated to adjust the mechanical properties of 3D-printed PEEK parts; then, a variety of heat treatment conditions were applied to tune the crystallinity and strength. The results show that the best mechanical performance is achieved at 1.0 times the extrusion rate, varied angle cross-fillings with ±10° intervals, and vertical printing. Horizontal printing performs better with reduced warpage. Additionally, both crystallinity and mechanical properties are significantly improved after heat treatment, and the best state is achieved after holding at 300 °C for 2 h. The resulting tensile strength is close to 80% of the strength of injection-molded PEEK parts.

A comprehensive review on natural fillers reinforced polymer composites using fused deposition modeling

AbstractAdditive manufacturing (AM) is being used more widely because of the simplicity of the operating procedures. It decreases material consumption during part production and eliminates material waste. Fused deposition modeling (FDM), a well‐known AM process, uses thermoplastic polymer as a feedstock to manufacture the end design. Pure thermoplastic‐based products are still utilized as prototypes in several sectors due to their lack of strength and durability. This problem has been solved by strengthening the thermoplastics by adding a reinforcing element. Composites are made of polymers and various constituents known as reinforcing components. This article overviews natural reinforced polymer composites used in the FDM process. Mechanical and Thermal properties are presented based on natural filler percentage, and this article only considered natural composite filaments for the FDM process.

Dynamic and Degradable Imine‐Based Networks for 3D‐Printing of Soft Elastomeric Self‐Healable Devices

AbstractSelf‐healable degradable networks encounter a growing popularity for biomedical applications due to their ability to recover their properties after damage. Self‐healable hydrogels dominate with applications in tissue engineering and drug delivery. On the opposite and despite their potential for medical devices, self‐healable elastomers remain scarce, especially if they must be compatible with fused deposition modeling (FDM) 3D‐printing and self‐heal at physiological temperature under a hydrated state. These unmet challenges are addressed in this work with degradable elastomeric networks based on dynamic imine bonds prepared from multi(aldehyde) and multi(amine) hydrophobic PEG‐PLA star‐shaped copolymers. The star topology of these copolymers is the key feature of the strategy as it allows the design of multifunctional high molecular weights pre‐polymers that ensure an efficient dynamic chemical crosslinking while guaranteeing access to the FDM process generally restricted to thermoplastics. The proposed elastomeric networks combine high self‐healing efficiencies at 37 °C (>97%) with mechanical properties compatible with soft tissues and a linear degradation profile. Their FDM processing to produce self‐healable tubular devices is demonstrated. Finally, their cytocompatibility is assessed and confirm their potential as biodegradable elastomeric networks to be used for the design of self‐healable 3D‐printed devices for biomedical applications.

A novel method to combine fused deposition modelling and inkjet printing in manufacturing multifunctional parts for aerospace application

Nowadays, the fabrication of smart product with sensing capability is still an arduous task due to the difficulties in integrating multifunctional materials using conventional method. To address this problem, this study presents a novel method to manufacture the multifunctional parts using fused deposition modeling (FDM) and inkjet printing (IJP) technologies. Firstly, the influence of process parameters on building time (BT), surface roughness (SR) and ultimate tensile strength (UTS) of poly-ether-ether-ketone (PEEK) samples manufactured by FDM was studied. Then, IJP was used to fabricate conductive lines on the surface of printed PEEK substrates. Finally, the process-structure–property relationship of PEEK parts before and after printing the conductive line was investigated. It is concluded that the BT and the SR of PEEK parts are significantly increased with an increased layer thickness, while the UTS increases steadily with an increase of nozzle temperature. Moreover, the maximum SR of 35.352 μm and the maximum UTS of 73.649 MPa are obtained at the infill angle of 45°. Furthermore, the warping deformation of PEEK samples will greatly affect SR during the real manufacturing, especially at both ends of the printed parts. Printed lines showing good aesthetic quality and the lowest electrical resistance (6.838 Ω/cm) are obtained on PEEK samples with the infill angle of 90°. This study demonstrates the possibility of manufacturing structure-integrated antenna by the combination of FDM and IJP processes.

High-Pressure FDM 3D Printing in Nitrogen [Inert Gas] and Improved Mechanical Performance of Printed Components

Fundamentally, the mechanical characteristics of 3D-printed polymeric objects are determined by their fabrication circumstances. In contrast to traditional polymer processing processes, additive manufacturing requires no pressure during layer consolidation. This study looks at how a high-pressure autoclave chamber without oxygen affects layer consolidation throughout the fused deposition modelling process, as well as the mechanical qualities of the products. To attain high strength qualities for 3D-printed components such as injection-molded specimens, an experimental setup consisting of a 3D printer incorporated within a bespoke autoclave was designed. The autoclave can withstand pressures of up to 135 bar and temperatures of up to 185 °C. PLA 3D printing was carried out in the autoclave at two different pressures in compressed air and nitrogen atmospheres: 0 bar and 5 bar. Furthermore, injection molding was done using the same PLA material. Tensile, flexural, and Charpy tests were carried out on samples that were 3D printed and injection molded. In nitrogen, oxidation of the environment was prevented by autoclave preheating before printing, and autoclave pressure during printing considerably promotes layer consolidation. This imprinted mechanical strength on the 3D-printed items, which are virtually as strong as injection-molded components.

Effect of post-process treatments on mechanical properties and surface characteristics of 3D printed short glass fiber reinforced PLA/TPU using the FDM process

The extrusion-based fused deposition modeling (FDM) has become the most frequently used additive manufacturing method because of its shorten production time and cost. However, low surface quality remains a limitation to meet the regulatory standards set by traditional manufacturing, which requires post-processing to improve it. In this work, annealing and acetone vapor treatments are applied to short glass fiber reinforced PLA/TPU composites parts obtained by FDM, respectively. Their effects on the surface finishing, dimensional accuracy and mechanical properties of FDM parts using different post-processing methods are compared. The result shows that the annealing treatment dramatically improves the surface finish, but can reduce the dimensional accuracy and ductility of the FDM parts. Better ductility and dimensional accuracy but lower tensile strength are obtained by using acetone vapor treatment.

Modeling and flow analysis of FDM based dual extruder

The creation of solid items in three dimensions through the utilization of computer-aided design (CAD) software is the process known as additive manufacturing. The FDM (Fused Deposition Modeling) process is one type of additive manufacturing (AM) process, and the extruder is the most important part of that process. In particular, the design of a multi-material extruder is an example of a typical problem. The purpose of this study is to make an attempt to design a multi-material extruder that can mix materials and colors at the printhead of an FDM process printer. Additionally, a CFD study is carried out with the modeled component in order to comprehend the thermal properties. During material flow in the mixing chamber, a typical temperature distribution and flow analysis can be found. Various fluid flow rates (0.2, 0.5, and 1 mm/sec) were utilized in order to conquer these challenges. According to the findings, the optimal parameters for mixing of PLA and ABS materials are good at a flow rate of 0.5 mm/sec and a simulation time of 50 s.

Understanding compressive viscoelastic properties of additively manufactured PLA for bone-mimetic scaffold design.

Bone tissue engineering has been recognized as a promising strategy to repair or replace damaged bone tissues. The mechanical properties of bone scaffolds play a critical role in successful bone regeneration, as it is essential to match the mechanical properties of the scaffold with the surrounding bone tissue. In this study, we investigated the effects of fused deposition modeling (FDM) process parameters, including printing speed, printing temperature, and layer thickness, on the compressive viscoelastic properties of polylactic acid (PLA) scaffolds. The compressive viscoelastic properties of bulk PLA specimens were characterized using a Zhu-Wang-Tang (ZWT) constitutive model under different compressive strain rates. A comprehensive statistical analysis comprising multivariate and univariate analysis of variance (MANOVA and ANOVA) and Tukey's post hoc analysis was utilized to quantify the effect of each FDM parameter on the viscoelastic mechanical properties of the PLA specimens. Subsequently, we fabricated modified face-centered cubic (MFCC) scaffolds using FDM and varied the FDM process parameters to achieve a compressive viscoelastic response that matched the natural trabecular bone tissue. The viscoelastic performance of the MFCC scaffolds was compared with traditional orthogonal cylindrical struts (OCS) scaffolds. Our methodology contributes to the design of bone-mimetic scaffolds with optimized mechanical properties by controlling FDM process parameters.

Wear prediction of 3D-printed acrylonitrile butadiene styrene-carbon nanotube nanocomposites at elevated temperatures

Abstract In this study, multi-wall carbon nanotube (MWCNT) reinforced acrylonitrile butadiene styrene (ABS) nanocomposite filaments are produced. Filaments are examined through thermogravimetric analysis (TGA) and definitive scanning calorimetry (DSC) analysis. Produced nanocomposite filaments are used in the fused deposition modeling (FDM) process to manufacture parts. Wear tests are conducted on 3D-printed parts using wear test apparatus with an attached heating module under different ambient temperatures. Hence, the influence of CNT reinforcement, along with different FDM process parameters and varying test conditions on the wear behavior of 3D-printed ABS-CNT parts, are examined. Worn surfaces of the specimens are examined by scanning electron microscopy (SEM). Nonlinear autoregressive exogenous (NARX) models are proposed for the prediction of the wear behavior of 3D-printed ABS-CNT nanocomposites. While wear rate is taken as output, ambient temperature and amount of nanofiller are accounted as input parameters along with the variation of coefficient of friction (COF) which is obtained from measured frictional force and three input-one output model structure is proposed for NARX. The use of multiple input-single output (MISO) model structure and examining the wear behavior of 3D-printed ABS-CNT samples under different wear test conditions with different FDM process parameters are the novelties in this work.