Fused Deposition Modeling Machine Research Articles

Process capability analysis of fused deposition modelling for plastic components

Purpose – The purpose of the present study is process capability analysis of fused deposition modelling (FDM) process as rapid pattern making (RDPM) solutions for plastic components. Design/methodology/approach – Starting from the identification of component, prototypes with ABS plastic material were produced and dimensional measurements were made with coordinate measuring machine (CMM). Some important mechanical properties were also compared to verify the suitability of the components. Findings – The study highlighted the best settings of orientation, support material quantity for the selected component as a case study on FDM machine from dimensional accuracy and economic point of view as RDPM solution for plastic components. Practical implications – This process ensures rapid production of statistically controlled pre-series technological prototypes and proof of concept at less production cost and time. Final components produced are acceptable as per ISO standard UNI EN 20286-I and DIN16901. Originality/value – The results of the study suggest that FDM process lies in ±4.5 sigma (σ) limit in regard to dimensional accuracy of plastic component is concerned and may be gainfully employed as RDPM solution for bio-medical applications.

Metallization on FDM Processed Parts Using Electroless Procedure

Metallization has been studied on flat ABS (acrylonitrile-butadiene-styrene) parts. These parts were fabricated on fused deposition modelling machine using layer by layer deposition principle using ABS as part material. Electroless copper deposition has been performed on these parts using three different surface preparation processes namely aluminium paste (Al paste) coated ABS parts, surface prepared using chromic acid for etching and ABS parts prepared using H2SO4/H2O2 for etching. Surface preparation is followed by Cu (copper) deposition by electroless procedure using four different acidic baths. The acidic baths used are 5 wt% CuSO4 (copper sulphate) with 15 wt% of individual HF (hydrofluoric acid), H2SO4 (sulphuric acid), H3PO4 (phosphoric acid) and CH3COOH (acetic acid) acids. Cu deposition is presented and compared based on their electrical performance, scanning electron microscopy (SEM) and energy dispersive X-ray spectrometry (EDS). The results shows that Al pasted samples demonstrated better electrical performance and more uniform Cu deposition.

Fabrication of biodegradable, porous scaffolds using a low-cost 3D printer

A low–cost 3D printer was used to generate porous biopolymer scaffolds. Scaffolds with various interconnected pores were designed and built on an open–source fused deposition modelling (FDM) system 'RepRap Mendel'. The scaffolds were analysed in accordance with feasibility, geometrical accuracy, and quality. REM images were taken for visual investigation and the results were qualitatively compared with industrial FDM systems. The results have shown that highly porous scaffolds with different pore geometries and sizes can be achieved with a low–cost printer. This paper also describes the potential application for the manufacture of scaffolds with a low–cost FDM machine and its limitations.

Manufacturing of patient‐specific optically accessible airway models by fused deposition modeling

PurposeThe purpose of this paper is to use rapid prototyping technology, in this case fused deposition modeling (FDM), to manufacture 2D and 3D particle image velocimetry (PIV) compatible patient‐specific airway models.Design/methodology/approachThis research has been performed through a case study where patient‐specific airway geometry was used to manufacture a PIV compatible model. The sacrificial kernel of the airways was printed in waterworks™ which is a support material used by Stratasys Maxum FDM devices. Transparent silicone with known refractive index was vacuum casted around the kernel and after curing out, the kernel was removed by washing out in sodium hydroxide.FindingsThe resulting PIV model was tested in an experimental PIV setup to check the PIV compatibility. The results showed that the model performs quite well when the refractive index (RI) of the silicone and the fluid are matched.Research limitations/implicationsDrawbacks such as the surface roughness, due to the size of the printing layers, and the yellowing of the silicone, due to the wash out of the kernel, need to be overcome.Originality/valueThe paper presents the manufacturing process for making complex thick walled patient‐specific PIV models starting from a strong workable sacrificial kernel. This removable kernel is obtained by switching the building and the support materials of the FDM machine. In this way, the kernel was printed in support material while the building material was used to support the kernel during printing. The model was tested in a PIV setup and the results show that the airway model is suitable for performing particle image velocimetry.

English

The purpose of this paper is to examine the suitability of fused deposition modelling (FDM), for the production of a pattern that can be used in direct manufacturing applications. In this work, the benchmark was identified and its best part orientation in a FDM machine was located through experimentation. Control charts and process capability histogram were drawn to assess the process capability of the FDM process. The micro hardness of the prepared sample was measured to check the suitability of the process for investment casting applications. Further dimensional accuracy of patterns was established by IT grades as per the ISO standard UNI EN 20286-I (1995). It was observed that the performance indices for all the dimensions in the present study are greater than 1. The study of photo micrographs using SEM gave an insight into the properties of the component (produced by FDM). This study highlights that the tolerance grades for ABS plastics are consistent with the permissible range of tolerance grades as per the ISO standard UNI EN 20286-I (1995) and DIN16901 standard.

Investigation of Optimal Parameters for Tensile Strength Property of ABS in Rapid Prototyping

This paper presents the investigation of the effect of fused deposition modeling (FDM) parametric processes on the tensile strength of the developed acrylonitrile butadiene styrene (ABS) compliant prototype. The prototype is produced using prodigy plus FDM machine with Insight 7.2 software. Four essential process parameters include layer thickness, part interior style, raster width, and raster angle are considered. The effect of these parameters on the tensile strength of ABS prototype is studied. Experiments are conducted in accordance with Taguchi’s design of experiment with three levels for each factor. The tensile strength of the models is tested using universal testing machine (UTM). The results are statistically analyzed using analysis of variance (ANOVA) in order to determine the optimal parameter which affects the tensile strength characteristic significantly. From the analysis, it was found that the part interior style parameter affects the tensile strength performance more greatly than others.

Optimization of positioning system of FDM machine design using analytical approach

PurposeThe purpose of this paper is to analyse the conception of the positioning system of fused deposition modeling (FDM) machines, optimising design parameter and components accuracy to decrease mechanical errors of equipment, which, consequently, results in the increase of parts accuracy. This paper also reports studies related to analytical estimation of machine errors, describing a theoretical model which was used for the multivariable study. Additionally, an alternative conception is proposed, according with the result of this study.Design/methodology/approachFor elaboration of the numerical model of equipment, the authors have focused on conception of first generation of FDM, specifying as design parameters, timing belt stiffness, linear bearing clearance, and accuracy grade of ball screw housing, support and pulley. In order to identify the main effect of each design parameter for the final error of machine, the authors have applied a multivariable method in addition to identifying the error budget of model. Also indicated are the two factors that promote more errors, undergoing a proposal of conception which consists in replacing one component of machine.FindingsWith reference to the evaluation of the numerical model, equivalency was found between the resultant error of model and the current FDM accuracy. The result of multivariable study identified the main causes of errors in machine, implying on an optimized solution which decreases the initial error in 69 μm. Similarly, the evaluation of the proposed conception resulted in the reduction of general error in almost 20 μm, even though the worst case was studied for this comparison.Originality/valueAlthough the number of applications for additive manufacturing has been growing in recent years, implying an increase of demand for high precision parts, there are still several challenges to be overcome, such as the improvement of equipment. For that reason, the motivation of this work concerns the contribution for development of new equipment, as well the improvement of current technologies. Furthermore, the authors' focus was the reduction of mechanical errors through an analytical approach.

Moisture and Humidity Effects on the ABS Used in Fused Deposition Modeling Machine

The environment seems to have an effect on Acrylonitrile-Butadiene-Styrene (ABS) which consequently causes physical, morphological and thermal stability changes to the polymer. Not only that, these changes may have caused nozzle blockage on the liquefier of the Fused Deposition Modeling (FDM) rapid prototyping machine. Experiments are conducted to support and verify whether ABS does affect the blockage. It has been observed that physical changes may have not caused nozzle clogging.

Exploring the Links between CAD Model and Build Strategy for Inexpensive FDM

Additive Manufacturing (AM) represents a maturing collection of production technologies also known as rapid prototyping, rapid manufacturing or three-dimensional (3D) printing. One of the most promising aspects of AM is the possibility to create complex geometries. Despite a growing body of knowledge concerning the technological challenges, there is a lack of methods and tools that allow designers to effectively deal with the new possibilities of AM.Recently, several sub 5000 AM printers have come to the market. Initiatives from the open-source community contribute to this development. These inexpensive machines are based on the Fused Deposition Modeling (FDM) technology.In order to investigate the relationship of the FDM process and the built structures, this paper presents experiments to model and build FDM-specific structures that hold unique mechanical and visual properties.The findings show that inexpensive FDM machines are able to manufacture complex shapes and patterns in order to achieve unique mechanical and visual properties. However, for a designer to control these phenomena, solid-modeling must be combined with tool path generation. Unfortunately adequate tools and methods that integrate these two approaches are nonexistent.

A Study of Melt Flow Analysis of an ABS-Iron Composite in Fused Deposition Modelling Process

Fused deposition modelling (FDM) is a filament based rapid prototyping system which offers the possibility of introducing new composite material for the FDM process as long as the new material can be made in feedstock filament form. Swinburne has been undertaking extensive research in development of new composite materials involving acrylonitrile-butadiene-styrene (ABS) and other materials including metals. In order to predict the behaviour of new ABS based composite materials in the course of FDM process, it is necessary to investigate the flow of the composite material in liquefier head. No such study is available considering the geometry of the liquefier head. This paper presents 2-D and 3-D numerical analysis of melt flow behaviour of a representative ABS-iron composite through the 90-degree bent tube of the liquefier head of the fused deposition modelling process using ANSYS FLOTRAN and CFX finite element packages. Main flow parameters including temperature, velocity, and pressure drop have been investigated. Filaments of the filled ABS have been fabricated and characterized to verify the possibility of prototyping using the new material on the current FDM machine. Results provide promising information in developing the melt flow modelling of metal-plastic composites and in optimising the FDM parameters for better part quality with such composites.

Filament geometrical model and nozzle trajectory analysis in the fused deposition modeling process

The geometrical model of the filament during the fused deposition modeling (FDM) process was firstly proposed based on three different models, tractrix, parabola, and catenary. Comparing with the actual measured filament curves on the Stratasys 1600 FDM machine, it is indicated that the tractrix model had the best agreement with the actual measured curves. With the analytical simulation, the nozzle trajectories in the straight-line deposition road, circle road, and arbitrary continuous curve road were deduced, according to the traxtric based geometrical model of the filament.

An Experimental–Numerical Methodology for a Rapid Prototyped Application Combined with Finite Element Models in Vertebral Trabecular Bone

In the present study, a novel evaluation method involving rapid prototyped (RP) technology and finite element (FE) analysis was used to study the elastic mechanical characteristics of human vertebral trabecular bone. Three-dimensional (3D) geometries of the RP and FE models were obtained from the central area of vertebral bones of female cadavers, age 70 and 85. RP and FE models were generated from the same high-resolution micro-computed tomography (μCT) scan data. We utilized RP technology along with FE analysis based on μCT for high-resolution vertebral trabecular bone specimens. RP models were used to fabricate complex 3D objects of vertebral trabecular bone that were created in a fused deposition modeling machine. RP models of vertebral trabecular bone are advantageous, particularly considering the repetition, risks, and ethical issues involved in using real bone from cadaveric specimens. A cubic specimen with a side length of 6.5 mm or a cylindrical specimen with a 7 mm diameter and 5 mm length proved better than a universal cubic specimen with a side length of 4 mm for the evaluation of elastic mechanical characteristics of vertebral trabecular bones through experimental and simulated compression tests. The results from the experimental compression tests of RP models closely matched those predicted by the FE models, and thus provided substantive corroboration of all three approaches (experimental tests using RP models and simulated tests using FE models with ABS and trabecular bone material properties). The RP technique combined with FE analysis has potential for widespread biomechanical use, such as the fabrication of dummy human skeleton systems for the investigation of elastic mechanical characteristics of various bones.

A CASD/CASM method for prosthetic socket fabrication using the FDM technology

As an application of the computer aided design and computer aided manufacturing (CAD/CAM) technology in prosthetics, computer aided socket design and computer aided socket manufacturing (CASD/CASM) is becoming an active field in the prosthetics research. In this paper, a CASD/CASM method for prosthetic socket fabrication is described in detail. This is different from other fabrication methods in its novel combination of the CAD/CAM technology with fused deposition modeling (FDM) technology. Prosthetic sockets for volunteer amputees have been designed and fabricated in a FDM machine. In order to test the fabrication result, a final product was used to perform a clinical trial and some results are reported. In addition, the deficiency of the long fabrication time is addressed and some feasible solutions are discussed.

Short fiber reinforced composites for fused deposition modeling

Addressed in this paper are critical material property issues related to the short fiber reinforced composite used in rapid prototyping and manufacturing (RP&M). Acrylonitrile–butadiene–styrene (ABS) copolymer has been a popular choice of material used in fused deposition modeling (FDM), a commonly used RP&M process. However, conventional ABS polymers in the filamentary form for FDM are known to be of low strength and hardness. In order to overcome this deficiency, ABS was modified by incorporating several different property modifiers including the short glass fiber, plasticizer, and compatibilizer. Glass fibers were found to significantly improve the strength of an ABS filament at the expense of reduced flexibility and handleability. The latter two properties of glass fiber reinforced ABS filaments were improved by adding a small amount of plasticizer and compatibilizer. The resulting composite filament, prepared by extrusion, was found to work well with a FDM machine.