Fused Deposition Modeling Research Articles

Simulation analysis and optimization of thermoelectric refrigeration and air conditioning

Abstract Thermoelectric refrigeration technology is mainly through the Peltier effect to achieve refrigeration, thermoelectric refrigeration air conditioning needs to be combined with a certain air flow rate to realize the separation of cold and heat, and make full use of the cold end to realize the refrigeration function, or else the refrigeration efficiency is seriously affected. Based on the ICEPAK simulation platform of ANSYS, we analyze the influence of structure and parameter settings on the conversion efficiency of thermoelectric refrigeration air conditioning fan under the established boundary conditions, establish the relationship between air flow rate and temperature drop value, and put forward the optimization of the product structure design scheme, and the results of the optimization scheme show that there is a peak in the operating current at a certain heat dissipation efficiency; and lengthening the length of the air ducts through the optimization of the structure can enhance the refrigeration effect of the air conditioner.

Fabrication and evaluation of a CMOS-based energy harvesting chip integrating photovoltaic and thermoelectric energy harvesters

This study explores the development of an energy harvesting chip (EHC) using a complementary metal oxide semiconductor (CMOS) process, addressing the need for efficient micro-scale energy harvesters in modern electronics. The EHC integrates a thermoelectric energy harvester (TEH) and a photovoltaic energy harvester (PEH) to maximize energy conversion efficiency. A key challenge in TEH design is enhancing power output, which is addressed by suspending the cold ends of 41 thermocouples within the TEH structure through post-processing. Experimental methods were employed to assess the performance of the TEH, revealing an output voltage of 21.4 mV and a maximum output power of 9.32 nW under a 3 K temperature difference. The TEH demonstrated a voltage factor of 8.9 mV/(mm2·K) and a power factor of 1.3 nW/(mm2·K2). The PEH was designed with novel patterned p-n junctions, integrating lightly doped n-type regions with interdigitated p-type doping to increase junction density, resulting in high conversion efficiency. The experimental results confirm the effectiveness of the EHC design, showcasing its potential in energy harvesting applications.

A high-performance all-day vertical thermoelectric generator based on a double-sided reflective structure

Harvesting environmental energy sources is crucial for achieving renewable energy generation and net-zero emissions. However, ensuring uninterrupted electricity generation from environmental energy sources remains challenging. In this study, we present a simple, compact, and expandable all-day vertical passive thermoelectric generator (V-TEG) with a double-sided reflective structure that simultaneously harnesses solar and space cold energy. Outdoor experimental measurements, combined with finite element simulation analysis, revealed that the optimal angles of the solar reflector relative to the TEG range from 30° to 50°. Additionally, the TEG placed in the north–south orientation was found to enhance its daytime performance. The use of low-cost black paint combined with the solar reflector achieved equivalent spectral selectivity, effectively minimizing the infrared heat loss of the hot end of the TEG. During a 48-h outdoor test, the V-TEG achieved an average daytime power of 112.00 mW/m2 and a peak of 363.42 mW/m2. Comparative experiments demonstrated that the V-TEG outperformed horizontally placed TEG during the daytime. Furthermore, scaling the system by connecting three TEGs in series significantly increased the daily power output. This compact V- TEG system offers a promising solution for long-term power generation in low-power sensors and off-grid communities, supporting renewable energy and carbon neutrality goals.

Evaluation of Fused Deposition Modelling process parameters influence on the porosity of printed parts

Fused Deposition Modelling (FDM) is an additive manufacturing technology that is rapidly gaining popularity due to its ability to produce complex shaped parts in a short time. However, parts produced by means of FDM have porosity that results from the printing process. The mechanical properties of printed parts depend on the FDM process parameters and porosity. This study investigates the effect of FDM process parameters on the porosity of FDM parts. The results of the study show that properly selected FDM process parameters can significantly minimize the percentage of part porosity. The effect of FDM process parameters on porosity was determined by analyzing nine process variables: layer height, extrusion temperature, printing speed, extrusion multiplier, bed temperature, infill pattern, deposited strand width, number of shells, number of solid top and bottom layers. The percentage of samples porosity was measured by means of the hydrostatic weighing method. Using the analysis of variance, statistically significant factors and their combinations affecting the percentage of parts porosity were determined. It was shown that the extrusion multiplier had the greatest influence on the percentage of parts porosity. A significant contribution to the formation of porosity was made by the infill pattern, layer heights, printing speed, number of shells, number of solid top and bottom layers and their interaction. A regression model has been developed that allows predicting the porosity of parts achieved by different combinations of FDM process parameters.

Fabrication of Polypill Pharmaceutical Dosage Forms Using Fused Deposition Modeling 3D Printing: A Systematic Review

Background/Objectives: The pharmacy profession has undergone significant changes driven by advancements in patient care and healthcare systems. The FDA approval of Spritam® (levetiracetam), the first 3D-printed drug, has sparked increased interest in the use of Fused Deposition Modeling (FDM) 3D printing for pharmaceutical applications, particularly in the production of polypills. Methods: This review provides an overview of FDM 3D printing in the development of pharmaceutical dosage forms, focusing on its operation, printing parameters, materials, additives, advantages, and limitations. Key aspects, such as the ability to personalize medication and the challenges associated with the technique, including drug stability at high temperatures, are discussed. Results: Fourteen studies relevant to FDM 3D-printed polypills were analyzed from an initial pool of 60. The increasing number of publications highlights the growing global interest in this technology, with the UK contributing the highest number of studies. Conclusions: FDM 3D printing offers significant potential for personalized medicine by enabling precise control over dosage forms and tailoring treatments to individual patient needs. However, limitations such as high printing temperatures and the lack of standardized GMP guidelines for large-scale production must be addressed to fully realize its potential in pharmaceutical manufacturing.

Comparison of the Torsional Strength of Material Samples Made Using Selected Rapid Prototyping Methods

In recent years, there has been a marked increase in the use of rapid prototyping techniques that support industrial processes. The analysis of studies on strength tests of parts manufactured using additive techniques from model materials and hybrid composites usually includes tests of material and strength parameters based on uniaxial tension, bending, and compression tests. For elements manufactured from polymeric materials using traditional methods (e.g. injection moulding), data obtained from these tests are sufficient to determine the strength of the material and to apply the results in the product design process. In the case of the layered extrusion method, due to the model construction process, strength data based on standard samples do not have a direct transposition on the strength of machine parts operating under various load ranges, especially torsional loads. The publication presents the results of tests on the torsional strength of cylindrical samples with splines produced by layered extrusion, vacuum casting technology, and hybrid technology, which combines both technologies. The test samples were made using a Prusa i3 MK3 3D printer and the plasticised plastic modelling (fused filament fabrication, FFF) method, while PolyJet technology was used to create a reference model. The findings indicate that hybrid technology, in which a thin-walled mould is filled with a chemically hardened polymer, achieves the desired strength for the manufactured parts while maintaining dimensional accuracy and shape. The research results show that producing rotating elements using the hybrid technology reduces the sample core’s ability to undergo plastic deformation due to the adhesion between the materials and the occurrence of notches resulting from the model production process using the layered extrusion method.

Technological and Mechanical Studies on Additively Manufactured Cellular Structures Made of the Ultrafuse 316L Composite Filament

Regular cellular materials produced using additive manufacturing (AM) techniques represent a significant development trend in modern engineering materials. Depending on the applied elementary unit cell of topology, it is possible to define the course of the structure deformation process in order to obtain the highest possible energy absorption effectiveness. This feature makes regular cellular structural materials particularly attractive for a number of industrial branches. This paper presents the results of technological trials and the results of experimental studies on the mechanical properties of regular cellular structures made using 3D printing technology under compression test loading conditions. The material used for their production was the Ultrafuse 316L filament and the fused filament fabrication (FFF) technique. The proposed material is a polymer-metal composite with a manufacturing process similar to metal injection moulding (MIM). The adopted research methodology included a feasibility study aimed at achieving material homogeneity and compression tests of the developed and manufactured regular cellular structures under quasi-static loading conditions. Several structural topologies were analysed. Experimental results indicated that regular cellular structures made from 316L steel exhibit high mechanical strength and extensive plastic deformation capabilities. The utilized in this work manufacturing technology used combines the advantages of 3D printing process with the potential of powder metallurgy. The proposed technique of structure manufacturing process is much cheaper than other based on melting metallic powders.

3D-printed poly(p-dioxanone)/graphene oxide composite bioresorbable stents for congenital heart disease treatment

Bioresorbable stents (BRSs) offer significant advantages in treating congenital heart disease-related vascular stenoses, especially for pediatric patients. However, the insufficient mechanical performance of polymeric BRSs remains a critical challenge. In this study, Poly(p-dioxanone) (PPDO) was incorporated with graphene oxide (GO) for the first time to improve both mechanical properties and biocompatibility. PPDO/GO composites with varying GO contents were fabricated via solution mixing and solvent casting, and tensile tests revealed that lower GO content levels (0.2% and 0.5%) significantly improved the Young’s modulus, tensile strength, and elongation at break of PPDO due to hydrogen bonding and increased degree of crystallinity. 3D-printed PPDO/GO sliding-lock stents with optimal GO contents were fabricated by fused deposition modeling and demonstrated superior compression force compared to pristine PPDO stents. In vitro hemocompatibility and cytocompatibility assessments showed that 3D-printed PPDO/GO stents exhibited low hemolysis rate, reduced platelet adhesion, and enhanced adhesion and proliferation of endothelial cells. In vivo evaluation further demonstrated improved endothelialization in rat abdominal aortas implanted with 3D-printed PPDO/GO filaments for 4 weeks. Overall, PPDO/0.5%GO exhibited superior performance in compression force, hemocompatibility, cytocompatibility, and in vivo endothelialization. This study, for the first time, combines PPDO with GO and explains the mechanism of the enhanced mechanical properties of PPDO/GO composite material. Using 3D printing, PPDO/GO BRS with improved compression performance and biocompatibility were developed, highlighting its potential value for treating pediatric patients with CHD-related vascular stenoses.

A Critical Review on Polymer Composites Reinforced with Artificial Fibers using Fused Deposition Modelling

The practical application of Additive Manufacturing (AM) technology expands constantly in the automotive, aerospace, and biomedical sectors, among others. Additive manufacturing technology has been categorized by ASTM into seven groups according to the type of material and process used to fabricate the parts. Intellectual property rights of manufacturer restrict the users to process few materials in a machine. Nevertheless, compared to extrusion or injection molding, the mechanical strength and robustness of three dimensional (3D) printed items are significantly lower. First, some researchers have looked into optimizing process factors such build orientation, layer height, infill density, and air gap with the purpose of enhancing the mechanical properties. Secondly, altering the material with reinforcement improves mechanical properties compared with un-reinforced material. Fusion Deposition Modelling (FDM) technology based on 3D printer retains a market share of 40% globally. This article reviews the mechanical performance of FDM feed stock filament of thermo-plastic polymers ABS/PLA/PP with a reinforcement of CF/CNF/CNT/JFRT/CPT. The researchers reported improvements in mechanical characteristics such as strength, strain failure rate, and Young's modulus.

The Influence of Printing Speed and Temperature on the Mechanical, Absorptive, and Morphological Properties of PLA-Based Hybrid Materials Produced with an FDM-Type 3D Printer.

Composite materials are used in many engineering applications and industrial fields due to their superior properties, such as high strength, lightweight, and stiffness. These outstanding properties have made these materials an alternative to metallic materials. The vital need for new lightweight and inexpensive materials with superior strength properties has led to research on "hybridisation". Hybrid composites with more than one type of polymer in the same structure are needed to achieve a better balance of properties and to combine many desired properties in a single material. Many researchers have studied the hybrid effect and contributed to the understanding and modelling of the subject. Studies to explain the primary mechanism of the hybrid effect are limited and insufficient to explain the complex interaction. In this study, a three-dimensional printer using fused deposition modelling technique was used to produce hybrid materials, and the influence of printing parameters on the mechanical, absorptive, and morphological properties of poly (lactic acid) (PLA), Tough PLA, and PLA/Tough PLA hybrid materials were investigated. The hybrid material form exhibited superior properties when selecting specific production parameters from individual raw elements. It can be said that the mechanical properties of the PLA/Tough PLA hybrid material increased with the increase in production temperature.

Polymer-based fused deposition modeling of gas diffusion layer with conductive coating for proton exchange membrane fuel cell

Polymer-based fused deposition modeling of gas diffusion layer with conductive coating for proton exchange membrane fuel cell

Artificial Intelligence‐Augmented Additive Manufacturing: Insights on Closed‐Loop 3D Printing

The advent of 3D printing has transformed manufacturing. However, extending the library of materials to improve 3D printing quality remains a challenge. Defects can occur when printing parameters like print speed and temperature are chosen incorrectly. These can cause structural or dimensional issues in the final product. This review investigates closed‐loop artificial intelligence‐augmented additive manufacturing (AI2AM) technology that integrates AI‐based monitoring, automation, and optimization of printing parameters and processes. AI2AM uses AI to improve defect detection and prevention, improving additive manufacturing quality and efficiency. This article explores generic 3D printing processes and issues using existing research and developments. Next, it focuses on fused deposition modeling (FDM) printers and reviews their parameters and issues. The current remedies developed for defect detection and monitoring in FDM 3D printers are presented. Then, the article investigates AI‐based 3D printing monitoring, closed‐loop feedback systems, and parameter optimization development. Finally, closed‐loop 3D printing challenges and future directions are discussed. AI‐based systems detect and correct 3D printing failures, enabling current printers to operate within optimal conditions and minimizing the risk of defects or failures, which in turn leads to more sustainable manufacturing with minimum waste and extending the library of materials.

Assessment of Thermal Management Using a Phase-Change Material Heat Sink under Cyclic Thermal Loads

Phase-change materials (PCMs) are widely used in the thermal management of electronic devices by effectively lowering the hot end temperature and increasing the energy conversion efficiency. In this article, numerical studies were performed to understand how temperature instability during the periodic utilization of electronic devices affects the heat-dissipation effectiveness of a phase-change material heat sink embedded in an electronic device. Firstly, three amplitudes of 10 °C, 15 °C, and 20 °C for fixed periods of time, namely, 10 min, 20 min, and 40 min, respectively, were performed to investigate the specific effect of amplitude on the PCM melting rate. Next, the amplitude was fixed, and the impact of the period on heat sink performance was evaluated. The results indicate that under the 40 min time period, the averaged melting rate of PCMs with amplitudes of 20 °C, 15 °C, and 10 °C reaches the highest at 19 min, which saves 14 min, 10 min, and 8 min, respectively, compared with the constant input of the same melting rate. At a fixed amplitude of 20 °C, the PCM with a period of 40 min, 20 min, and 10 min has the highest averaged melting rate at 6 min, 11 min, and 19 min, saving the heat dissipation time of 3 min, 8 min, and 14 min, respectively. Overall, it was observed that under identical amplitude conditions, the peak melting rate remains consistent, with longer periods resulting in a longer promotion of melting. On the other hand, under similar conditions, larger amplitude values result in faster melting rates. This is attributed to the fact that the period increases the heat flux output by extending the temperature rise, while the amplitude affects the heat flux by adjusting the temperature.

Pattern optimization for 3D printing of composite filament materials with natural fibers and polylactic acid

Composite fiber materials developed through Fused Deposit Modeling (FDM) in high demand in fabricating automotive, machinery components such as bearings, sleeves, bumpers, windshields, etc. In this article, a new composite filament with natural fiber (Flax) and polylactic acid was prepared and their mechanical properties were analyzed. Taguchi approaches L27 orthogonal array was used to optimize the process parameters layer thickness (0.15, 0.25, 0.35 mm) for 0.4 mm nozzle with filling structure (L1—lines, L2—triangles, L3—octet), speed of nozzle movement (80,100,120 mm/s) and occupancy ratios (20%, 40%, 60%) were chosen as process parameters. Tensile and Impacts test have been carried with American Society of Testing and Materials Standard (ASTM D638 and ASTM D256) to evaluate the tensile strength, percentage of elongation and impacts strength of the fabricated specimens. The results emphasized that layer thickness significant influences the tensile characteristics as compared to better process parameters. The occupancy ratio at 20% and 40% with triangle and octet filling structure, nozzle speed of 100 mm/s at constant extruder temperature of 200°C have been found to optimize 3D printing parameters in this work. They were calculated as tensile strength 61.13 MPa, percentage of elongation is 4.43% and Izod impact test is 12.77 kJ/m2.

Uncertainty propagation in fused filament fabrication process: a multiscale approach

Uncertainty propagation in fused filament fabrication process: a multiscale approach

Investigation on the Coalescence of Filaments in Fused Filament Fabrication Process for Amorphous Polyether Ketone Ketone for Varying Nozzle Diameters and Chamber Temperatures.

The use of Fused Filament Fabrication (FFF) of high-performance polymers is becoming increasingly prevalent, leading to the exploration of new applications. The use of such materials in critical cases for aerospace applications necessitates the verification of industry standards, particularly with regard to the requirements for part porosity. The authors investigate the effect of nozzle diameter and cooling temperature printing parameters on the porosity of the part by using existing modelling methods based on the sintering of cylinders and spheres and comparing the results to microscope snapshots of sections of parts. The models are able to be used as limits for predicting the longitudinal neck growth of the part. The authors show through experiments that the value of the cooling temperature of the deposited filament has a minimal effect on the outcome, while nozzle diameter has a strong impact on the resulting porosity. The modelling results show that there is a significant impact of both the nozzle diameter and cooling temperature on the porosity of the part. This implies that further refinement of the models is needed for the resulting parts to be applied in critical structures.

Wide-angle broadband metamaterial absorber with carbon black-carbonyl iron/polylactic acid composites fabricated by fused filament fabrication

Wide-angle broadband metamaterial absorber with carbon black-carbonyl iron/polylactic acid composites fabricated by fused filament fabrication

Monitoring of fused filament fabrication (FFF): An infrared imaging and machine learning approach

Monitoring of fused filament fabrication (<scp>FFF</scp>): An infrared imaging and machine learning approach

Investigating the Influence of Additive Manufacturing and Ultrasonic Coating Parameters on Biopolymeric Scaffold Performance Using Response Surface Methodology.

Triply periodic minimal surface (TPMS) scaffolds have gained attention in additive manufacturing due to their unique porous structures, which are useful in biomedical applications. Unlike metallic implants that can cause stress shielding, polymeric scaffolds offer a safer alternative. This study is focused on enhancing the compressive strength of additive-manufactured polylactic acid (PLA) scaffolds with a diamond structure. The response surface methodology (RSM)-based experimental design was developed to study the influence of printing parameters. The fused deposition modeling (FDM) process parameters were optimized, achieving a compressive strength of 56.2 MPa. Subsequently, the scaffolds were fabricated at optimized parameters and underwent ultrasonic-assisted polydopamine coating. With the utilization of the RSM approach, the study examined the effects of ultrasonic vibration power, coating solution concentration, and submersion time on compressive strength. The optimal coating conditions led to a maximum compressive strength of 92.77 MPa-a 65.1% improvement over the uncoated scaffold. This enhancement is attributed to the scaffold's porous structure, which enables uniform coating deposition. Energy-dispersive x-ray spectroscopy confirmed the successful polydopamine coating, with 10.64 wt% nitrogen content. These findings demonstrate the potential of ultrasonic-assisted coating in improving the mechanical properties of PLA scaffolds, making them suitable for biomedical applications.

Effects of fused filament fabrication (FFF) process parameters on tensile and flexural properties of ABS/PLA multi-material

Effects of fused filament fabrication (FFF) process parameters on tensile and flexural properties of ABS/PLA multi-material