Fused Deposition Modeling Technology Research Articles

Research of Layer Thickness and Selected Thermoplastic Materials and their Influence on the Surface Roughness in the Process of Fused Deposition Modeling Technology

This paper focuses on the influence of layer thickness and five selected thermoplastic materials on the surface roughness of cuboidal sample in the process of manufacturing by Fused Deposition Modelling technology. The component, in this case, is a cuboidal specimen with the dimensions 15 mm by 15 mm by 30 mm. FDM or LPD/FFF is additive layer-based method of additive manufacturing, usually used for rapid prototyping of the prototypes and other fabricating applications which use thermoplastics materials. A geometric model is defined that takes into account the shape of the fibers of the material after application to define the theoretical roughness profile. The authors set four different layer thicknesses of the cuboid part: 0.29 mm, 0.19mm, 0.14 mm and 0.09 mm. In this experiment, authors also used five different thermoplastic filaments: ABS, ASA, HIPS, PCABS and PLA. The authors produced a total of 20 prints and the surface of each sample was measured three times in succession using a portable surface roughness tester Mitutoyo. SJ-210. The 3D printer used in the experiment was Zortrax M200. The surface roughness .in this paper is shown in .the .form of a scatter and bar graph.

3D printed orthopedic prostheses for domestic and wild birds—case reports

Regardless of the species, birds are exposed to injuries that lead to amputation of part of the body structure and often euthanasia. Based on the need for new technologies that improve the quality of life of birds with locomotor problems, the present case reports aimed to describe the development of custom-made three-dimensional (3D) prostheses for domestic and wild birds that suffered amputation or malformation of the hind limb. Using the measurements of the bird, a digital model was created for 3D printing using fused deposition modeling technology (FDM) by the Brazilian company 3D Medicine. In this study we report the use of 3D prosthesis for the rehabilitation of three birds with locomotor disorders in Brazil, the animals adapted to the custom-made prosthesis with an improvement in quality of life, better distribution of body weight, locomotion, and landing. This study describes the development of 3D prostheses for birds in Brazil, the first report of this technology for these species, and the pioneering development of socket prostheses for small birds. 3D prostheses offer a high-efficiency solution to improve the quality of life of animals with amputations and malformations of the hind limbs. In addition, 3D technology provides valuable tools for veterinary medicine, developing custom-made models for the most different anatomical demands of animal patients.

Optimasi Variasi Jumlah Blade Inlet Turbo dan Outlet Turbo Terhadap Gaya Dorong Pada Prototype Waterjet Thrusther Produk 3D Printing Menggunakan Metode Taguchi

 Efforts to improve Indonesia's maritime security continue to be increased by carrying out maritime security operations using a patrol fleet. The ability to maneuver well is needed by a ship to carry out encryption and security against enemies. This research aims to find a combination of Waterjet Thrusther ship propulsion system components that produces the most optimal thrust. The Waterjet Thrusther prototype was made using a 3D printing machine with FDM (Fused Deposition Modeling) technology using ST-PLA (Super Tough Polylactic Acid) filament. This research uses the Taguchi method to create an experimental design. The variables used are the number of turbo inlet blades, impeller type, and the number of turbo outlet blades. The test was carried out using tools in the form of a test vessel weighing 8.06 kg with an electric motor drive engine. The results of this test obtained the highest thrust force in the 2nd variation using a 3 blade type 2 impeller, 13 blade turbo inlet, and 13 blade turbo outlet with the lowest thrust force value of 2.231775 N. The 9th variation produced the lowest thrust force of 0,711225 N using Inlet Turbo 15 blades, Impeller 3 blade type 3, and Outlet Turbo 15 blades.

Effects of TPU on the mechanical properties, fracture toughness, morphology, and thermal analysis of 3D‐printed ABS‐TPU blends by FDM

AbstractIn this paper, blends of ABS‐TPU with two different weight percentages of TPU were prepared using fused deposition modeling technology. The effect of adding TPU on the fracture toughness of ABS and mechanical properties was comprehensively studied. Tensile, compression, fracture toughness, and shear tests were conducted on the 3D‐printed samples. Thermal and microstructural analyses were performed using dynamic mechanical thermal analysis (DMTA), and scanning electron microscope (SEM). The DMTA results showed that adding TPU decreased the storage modulus and the glass transition temperature of ABS, as well as its peak intensity. The mechanical test results showed that adding TPU decreased the strength but increased the formability and elongation of the samples. Fracture tests showed that the addition of TPU decreased the maximum force needed for a crack to initiate. The force required for crack initiation decreased from 568.4 N for neat ABS to 335.3 N for ABS80 and 123.2 N for ABS60. The ABS60 blend exhibited the highest strength against crack growth, indicating that TPU can change the behavior of ABS from brittle to ductile. Shear test results and SEM images also showed good adhesion strength between the printed samples for all three specimens, indicating their good printability. Adding TPU resulted in a reduction in the size and number of voids and holes between the printed layers.Highlights Melt mixing, filament preparation, and 3D printing of ABS‐TPU blends. Investigation of mechanical properties, microstructure, and fracture toughness. Improved resistance to crack growth and elongation by adding TPU to ABS. Improving printability and reducing microholes in blends compared with ABS. Achieving a wide range of mechanical properties for various applications.

Evaluating and Comparing Flexure Strength of Dental Models Printed Using Fused Deposition Modelling, Digital Light Processing, and Stereolithography Apparatus Printers.

The introduction of three-dimensional (3D) printing in dentistry has mainly focused on applications such as surgical planning, computer-guided templates, and digital impression conversions. Additive manufacturing (AM), also known as 3D printing, involves layering resin material sequentially to construct objectsand is gaining recognition for its role in creating custom-made medical appliances. The field of orthodontics has also embraced this technological waveand with the advent of cost-effective printers and biocompatible resins, 3D printing has become increasingly feasible and popular in orthodontic clinics. The limitations of traditional plaster models may have prompted the emergence of 3D-printed models, but it led to enhancing treatment planning and device fabrication, particularly in orthodontics. Notable desktop printing technologies include fused deposition modelling (FDM), digital light processing (DLP), and stereolithography (SLA), each employing distinct methods and materials for fabricating appliances. Evaluating mechanical properties, like flexure strength, is crucial to determine the material's ability to withstand bending forces and thus prove useful in fabricating thermoformable appliances, surgical templates, etc. This study aims to assess the flexure strength of 3D-printed models using FDM, DLP, and SLA technology, providing insights into their suitability as replacements for conventional models and shedding some light on the durability and sustainability of 3D-printed models. Cuboids measuring 20 x 5 x 2 mm were cut from models, creating 10 samples per printer group. These samples underwent flexure strength testing using a three-point bending system in a universal testing machine. The FDM group exhibited the highest flexure strength at 69.36 ± 6.03 MPa, while the DLP group showed the lowest flexure strength at 67.47 ± 20.58 MPa. The results can be attributed to the differences in resin materials used for fabrication, with FDM using acrylonitrile butadiene styrene (ABS) polymer and SLA/DLP using polymethyl methacrylate (PMMA), and also to the variation in their printing mechanism. The findings affirm the suitability of FDM models for orthodontic applications, suggesting enhanced efficiency and reliability in clinical practices.

Creating a 3D-printed pelvic phantom to explore the impact of Magnetic Resonance (MR) scanner noise in radiomics analysis, a technical note.

Reproducibility of radiomics features necessitates that scanner noise be considered prior to feature extraction. Phantom research provides the opportunity for such ‘ground truth’ measurements, without the additional complication of patient-related factors. The aim of this technical note was to create a 3D printed Magnetic Resonance Imaging (MRI)-compatible pelvic phantom that can be used for subsequent analysis of the impact of scanner noise on the reproducibility of radiomics features.A 3D printed phantom of a male pelvis was created using fused deposition modelling technology. It was 3D printed using the high density MRI-compatible acrylonitrile butadiene styrene (ABS). The ‘negative’ mould created was then filled with silicone, and the prostate gland and femoral heads were also simulated.We successfully created an MRI-compatible 3D printed pelvic phantom, with a test scan. The phantom will subsequently be utilised to determine the impact of MRI scanner noise on radiomics feature reproducibility.

Convolutional Neural Network-Based Defect Detection Technique in FDM Technology

This research focuses on developing a Convolutional Neural Network (CNN)-based machine learning algorithm for detecting anomalies in Fused Deposition Modelling (FDM) 3D printers. To develop the CNN algorithm, the training data was obtained from the experiments. Therefore, process parameters such as; material flow, printing speed, and vibration of the print bed were adjusted to create infill pattern defects such as over-extrusion and layer shift (misalignment). A high-resolution camera was used to take the images during the printing. The developed CNN-based machine learning algorithm is capable of detecting and distinguishing types of defects providing a systematic quality assessment of a product. The main advantage is that it can be used to detect different types of defects related to infill patterns, and it can reduce the calibration error. Therefore, the application of machine learning in defect detection in 3D printing illustrates the prospects of integrating machine learning algorithms into manufacturing processes.

Using Scanner and Algorithm to Improve the Accuracy of Fused Deposition Modeling Printer

This essay explores the application of laser sensors and algorithms to enhance the accuracy of Fused Deposition Modeling (FDM) Three dimensions (3D) printers. Laser sensors, combined with advanced algorithms, provide a promising solution for improving the accuracy of FDM printers. The essay discusses the limitations of traditional FDM printers in achieving high precision and outlines the significance of accuracy improvement in 3D printing. It then explores the principles and functioning of laser sensors. By analyzing real-time sensor measurements, algorithms can identify errors, compensate for mechanical inaccuracies, and adjust the printer's motion to ensure precise printing. Additionally, the essay discusses the advantages and challenges of incorporating laser sensors and algorithms into FDM printers. The benefits include improved print quality, enhanced compatibility with complex geometries, and reduced dependency on manual calibration. However, challenges such as cost, sensor integration, and algorithm optimization must be addressed for specific adoption or further development. The integration of laser sensors with advanced algorithms offers a promising pathway for achieving high precision and detail in printed objects, ultimately advancing the capabilities and applications of FDM technology.

A NEW BIO-INSPIRED WING DESIGN WITH 3D ADDITIVE MANUFACTURING SCANNING AND PRINTING METHOD: MJF TECHNOLOGY

In this study, unlike many wing profiles currently available, a new wing design has been carried out with bio-inspiration, which has attracted the attention of many scientists. There are many traditional methods in 3d additive manufacturing technologies. There are several types of 3D printing method. The four most preferred 3d printing methods are as follows. Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS), Multi Jet Fusion (MJF). MJF technology, one-to-one prototype production of wings with very small dimensions and aerodynamic structure has been achieved. In contrast to FDM and other additive printing technologies, it is possible to eliminate highly sensitive and high surface quality products.

Design and Optimization of 4D Printed Carbon Fiber Reinforced Poly Lactic Acid Parts Using Fused Deposition Modeling for Shape Memory Applications: A Taguchi Approach

The manufacturing industry has witnessed substantial interest in the advancement of 4D printing technology in recent years. This technology has enabled the production of complex structures with enhanced functionality and adaptability. Fused Deposition Modeling (FDM) has become a preferred technique for 4D printing due to its ease of use, affordability, and versatile nature. To achieve efficient and effective 4D printing, the process parameters must be optimised to ensure the desired shape recovery behaviour of the printed parts. The main objective of this study is to optimize the process parameters for the production of 4D printed components using FDM technology and Carbon Fiber reinforced Poly Lactic Acid (CF/PLA) Shape Memory Polymer Composites (SMPCs). This study examines the shape recovery properties of the printed components by modifying the process parameters, including Infill Density (ID), Geometrical Thickness (GT), and Bending Angle (BA), through the implementation of Design of Experiments (DOE) L9 Orthogonal Array (OA). Utilizing Analysis of Variance (ANOVA) to determine the significant factors and their optimum levels, the process parameters are statistically analysed. The results indicate that ID and GT are the statistically significant parameters, and the optimum levels for parameters includes 20% ID, 1.5mm GT, and 300 BA led to faster shape recovery. This study demonstrates the effectiveness of the Taguchi approach in the design and optimization of the process parameters for 4D printed parts using FDM.

Solvent/non-solvent treatment as a method for surface coating of poly(ε-caprolactone) 3D-printed scaffolds with hydroxyapatite

Introduction Over the last decades numerous new materials and techniques for bone tissue engineering have been developed. The use of bioresorbable polymeric scaffolds is one of the most promising techniques for surgical management of bone defects. However, the lack of bioactive properties of biodegradable polymers restricts the area of their application for bone tissue engineering.The aim of study was to apply solvent/non-solvent treatment to coat the surface of 3D-printed bioresorbable poly(ε-caprolactone) scaffolds with bioactive hydroxyapatite particles and report on the physicochemical properties of the resulting materials.Material and Methods In the present study, biomimetic poly(ε-caprolactone) scaffolds were 3D-printed via fused deposition modeling technology and their surface was treated with the solvent/non-solvent method for coating with bioactive particles of hydroxyapatite.Results It has been found that treatment in the mixture of toluene and ethanol is suitable for the coating of poly(ε-caprolactone) scaffolds with hydroxyapatite. The scaffolds maintain porous structure after treatment while hydroxyapatite particles form homogeneous coating. The amount of hydroxyapatite on the treated scaffolds was 5.7 ± 0.8 wt. %.Discussion The proposed method ensures a homogeneous coating of outer and inner surfaces of the poly(ε-caprolactone) scaffolds with hydroxyapatite without a significant impact on the structure of a scaffold. Fourier-transform infrared spectroscopy confirmed that the solvent/non-solvent treatment has no effect on the chemical structure of PCL scaffolds.Conclusion Coating of biomimetic 3D-printed PCL scaffolds with bioactive hydroxyapatite by the solvent/non-solvent treatment has been successfully carried out. Upon coating, scaffolds retained their shape and interconnected porous structure and adsorbed hydroxyapatite particles that were uniformly distributed on the surface of the scaffold.

Implementation and evaluation of curved layer fused deposition modeling

Fused Deposition Modeling (FDM) is an extrusion-based additive manufacturing (AM) process in which a thermoplastic material is extruded through a nozzle. Although it was initially developed for rapid prototyping, advances in the FDM technology have rapidly increased its range of applications. However, the FDM process has inherent disadvantages, such as poor surface finish, severe anisotropic mechanical properties, and increased build time for high-resolution parts. This is the result of the layer-by-layer manufacturing process. To remedy these issues, Curved Layer Fused Deposition Modeling (CLFDM) offers a new building paradigm for FDM in which the material is deposited in curved nonplanar layers. The purpose of this study is to implement a curved-layer toolpath generation algorithm and quantify the benefits of the curved layered methodology over traditional planar layers in printing thin-contoured parts.

Integration of FDM and self-healing technology: evaluation of crack sealing by durability and mechanical strength

The tensile zone of concrete is prone to cracking due to its limited ability to withstand tension. To address this issue, steel reinforcement is used in these specific regions. The occurrence of little cracks might potentially facilitate the ingress of liquids and gases into the reinforcing material, hence inducing corrosion. Self-healing concrete can repair and seal minuscule cracks, thus impeding the formation of corrosion. This study investigates the potential application of fused deposition modeling (FDM) for generating novel vascular networks and tubes using polylactic acid (PLA) as the material. Poly (lactic acid) (PLA) was fabricated using three-dimensional (3D) printing techniques, and its properties were compared to those of one-dimensional (1D) and two-dimensional (2D) networks. The external diameter measured 5.6 mm, while the internal diameter measured 4 mm. utilized a 10 ml volume to apply healing agents, specifically organic polyethylene glycol liquid and nano-powder (fly ash) derived from recycled materials, to all vascular structures (1D, 2D, and 3D). This application was carried out using a planetary ball mill. Following this, the prepared tubes were incorporated into a concrete beam to introduce self-healing capabilities. The water-to-cement ratio (W/C) utilized for all concrete mixtures was 0.6%, while the definite mixture proportions were 1:2.16:2.98. The quantification of the self-healing phenomenon was conducted by evaluating the restoration of load-carrying capacity following the application of a repaired specimen to a four-point bending test. Furthermore, these enhancements resulted in improved durability, increased compressive strength, and enhanced other physical characteristics. The pipes that are manufactured can be utilized to produce innovative concrete that possesses the ability to undergo self-healing processes by combining low-viscosity healing solutions (PEG) with powders (nano fly ash) that are appropriate for this application by injection into the vascular network , making it well-suited for various self-healing applications.

The 3D Printing in Military Applications: FDM Technology, Materials, and Implications

The article describes the 3D printing technology using the Fused Deposition Modelling (FDM) method and the materials used in this technology in the context of military applications. The author presents the potential that this technology carries and discusses the use of 3D prints in the contemporary conflict in Ukraine. The article lists currently used materials and filaments, including a fiber technology that allows for printing of composites. Then the author presents a SWOT analysis of this technology in the context of national defense and its citizens who have 3D printers and can use them to produce so called “war gadgetsˮ. The article contains many examples of the application of this technology in the defense sector and also discusses potential threats associated with it.

A review of the performance of polymer parts printed on fused deposition modelling under cyclic loading

Fused deposition modelling (FDM) is one of the most promising and widely used additive manufacturing (AM) technologies. FDM is commonly used to fabricate simple to complex 3D parts from polymeric materials. Different 3D-printed polymeric components manufactured using FDM technology exhibit various mechanical and load-bearing properties. They are utilized in various industries, particularly the medical industry, for load-bearing applications in bio-implants. Therefore, it is crucial to understand the mechanical characteristics, especially the fatigue behaviour, of these 3D-printed parts under cyclic loadings. This paper focuses on the dynamic behaviour of 3D-printed polymeric parts produced through the FDM process and under different loading modes. First, the FDM mechanism, the various polymeric materials used in FDM, and the effective FDM parameters are briefly introduced. Then, the paper comprehensively covers one of the most important mechanical characteristics of 3D-printed parts for load-bearing applications: their fatigue life under different printing conditions and cyclic loadings. The most influential factors on the fatigue behaviour of polymers include the type of polymeric material, surrounding environmental conditions, cyclic loading conditions, the type of testing specimen, and the FDM printing parameters (such as raster angle, infill density, nozzle diameter, and nozzle temperature). In addition to the anisotropic behaviour reported by various studies on 3D-printed parts using FDM, it has been concluded that the layered structure (with a large number of interfaces between the raster) and the presence of microholes are two factors that weaken the fatigue strength of 3D-printed structures compared to other fabrication processes. These conditions can be exacerbated by choosing inappropriate printing parameters, and often, the failure mechanism in 3D-printed parts fabricated with FDM is delamination.

Biodegradable materials with FDM technology under the aging effect of solar and saltwater exposure

The durability and degradation of polymers is very important for product design in terms of material choice. The degradation behavior of two biodegradable thermoplastic materials manufactured by 3D printing, Enviro ABS and PLA, was studied. The action of the sun and seawater was simulated to find out how they affect the properties of these materials over a period of 8 weeks. The yield strength, maximum elongation, ultimate tensile strength, and microscopy were analyzed, as well as dimensions and mass changes. These biodegradable materials were studied to conclude whether there is an environmentally friendly alternative to traditional ABS, being one of the most widely used petroleum-based plastics in industry and in fused deposition modeling (FDM) or fused filament fabrication (FFF). PLA showed a weight loss and increase in ultimate tensile stress on degradation by sunlight and a prolonged decrease in ultimate tensile stress on degradation by seawater due to humidity absorption. In contrast, Enviro ABS does not show a noticeable difference between the beginning and the end of the test, which leads to the conclusion that Enviro ABS is a good alternative to conventional ABS without forgetting the environmental effects that are currently involved in the manufacture, recycling and composting of this type of material.

Quality of 3D Printed Objects Using Fused Deposition Modeling (FDM) Technology in Terms of Dimensional Accuracy

3D printers are known for providing parts with relatively good accuracy. However, the level of accuracy in the dimensions of printed objects may not matter if they do not have a mechanical purpose. When multiple 3D-printed parts are intended to be integrated with each other to create a larger system, even a fraction of a millimeter can have a significant impact on the entire system. This study aims to investigate the variation in dimension when a single print file is replicated using the same slicing settings. The findings are then analyzed using quality control tools and compared to the designed measurements. Fused deposition modeling (FDM) technology or fused filament fabrication (FFF) technology was chosen for this study due to its availability to the common user, its relatively low cost, and its increasing popularity in different applications and industries. The material used in this study is polylactic acid (PLA) which is a thermoplastic and the most widely used plastic filament in 3D printing. It has a low melting point, high strength, low thermal expansion, and is relatively cheap. The dimensional accuracy of FDM-produced parts was evaluated by comparing the dimensions of the fabricated specimens with their computer-aided design (CAD) models. Statistical analysis revealed that the mean dimensional deviations were within the specified tolerance limits for most of the tested parts. This suggests that FDM technology is reliable in terms of achieving dimensional accuracy.

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.

Mechanical properties of 3D printed specimen using FDM (Fused deposition modelling) and SLA (Stereolithography) technologies

In this competitive world, grabbing the market and achieving the deadlines is one of the deciding factors for the industry. So, develop a scope of new manufacturing methods for high quality and cost-efficient products to maintain in the competitive world. Thus, the utilization of Rapid Prototyping Techniques (RPT) has become essential in the rapid product development cycle for complex products. Mechanical properties are the one focusing area of rapid prototyping (RP) end product, which may help for proper strength in the structure. Furthermore, fused deposition modelling (FDM) and Stereolithography (SLA) are the two major 3D printing technologies for building parts. This study investigates the mechanical properties of 3D-printed end products of these methods (FDM and SLA). Initially, numerical analysis (Structural) of acrylonitrile butadiene styrene (ABS) 3D model has been created using ANSYS 3D. Furthermore, printed specimens using said 3D printing method to identify the tensile, compressive, flexural and hardness tests. Lastly, the data are used to compare and identify the optimum result of ABS printed specimens.

Aging effects on the viscoelastic behaviour of products by fused deposition modelling (FDM) made from recycled and wood-filled polymer resins

In this work, we analyse the thermal aging effects on the thermo-mechanical properties of bio-based specimens realized using fused deposition modelling technology. For the investigations, three commercial filaments made of polylactide acid (PLA) were used. The first filament was a pure virgin PLA (B-PLA); the second one was made from recycled waste production, PLA (R-PLA), and the third one was wood-filled PLA (W-PLA). Such materials were extruded under pre-optimized conditions and thermally aged in an oven at 70 °C. The as-prepared specimens were subjected to dynamic mechanical analysis (DMA) and infrared spectroscopy (IR). The experimental results are presented in terms of storage modulus (E'), loss modulus (E"), tan delta, and absorption spectra at different aging periods (0, 50, 70, 130, 175 days). For B-PLA and R-PLA, the thermal aging results in a decrease in both storage and loss moduli and in an increase in the glass transition temperature (Tg). On the contrary, for the W-PLA the storage modulus increases with the aging time, while the Tg remains constant. The IR spectra support the hypothesis of a degradation mechanism involving hydrolysis and/or hydrogen atom transfer. Based on these observations, we conclude that heat treatments always lead, through polymer degradation and structural changes, to more stable structures. The presence of wood particles slows down the aging process and makes the final products more durable.