Fused Filament Fabrication Technology Research Articles

Application of the TOPSIS decision-making method for selecting a manufacturing technique for children’s furniture elements with therapeutic functions

AbstractMaking furniture or furniture elements that account for the needs of children at various stages of development or with psychomotor dysfunctions is very difficult. From the point of view of exploitation and production technology, it is difficult to select a specific material and manufacturing technique. In this article, the results of using the APEKS method, which is a type of Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method, are presented to select the best solution for the production of children’s furniture elements with surface structures similar to those of natural materials. Wood bark was selected as a material that, due to the sensory tactile sensations of dysfunctional children, could contribute to therapy and education. Comparative analysis was performed on the basis of the subtractive and additive methods used for manufacturing furniture products. Precise multiaxis milling of ash wood and 3D printing with fused filament fabrication technology using wood PLA filaments were carried out. The method used to select the best option considered quantitative and qualitative criteria in the assessment. Various parameters characterizing the surfaces were analyzed, such as geometric dimensions, hill heights, valley depths, and 3D surface parameters. The quality and surface roughness (Sa, Sz, Ssk, Sku, Sp, and Sv) parameters obtained based on 3D microscope measurements were determined. A scale of 1 to 10 was used to assess qualitative factors (i.e., usability and aesthetics). Based on the critical values obtained from the coefficient Kcri = 79.36, it was assumed that multiaxis wood milling was the best method for producing furniture elements with the required surface characteristics for use as therapeutic and educational tools for children with dysfunctions. The applied method allowed an effective evaluation of the compared variants of the production of furniture elements for customized applications.

4D printing and programming of continuous fibre-reinforced shape memory polymer composites

This study demonstrates the use of fused filament fabrication (FFF) 4D printing (4DP) to print programmable continuous fibre-reinforced composite (CFRC) structures with exceptional strength and eco-friendly features. This research focuses on bio-shape memory polymer composites (SMPCs) and employs experiments to fabricate lightweight CFRC parts using FFF technology. Different types of continuous fibres, including carbon fibre (CF), aramid fibre (AF), and fibreglass (FG), are incorporated into a biopolymer matrix made of biodegradable polylactic acid (PLA). The study evaluates microstructure, mechanical properties, and shape memory properties of SMPCs, employing techniques like cold and hot programming. Continuous fibres significantly enhance mechanical properties, increasing strength by over 1027.5 % in tensile tests and nearly 497.3 % in three-point bending tests. The research also addresses shape recovery and fixity ratios in 4D-printed SMPCs, finding a decrease when continuous fibres are incorporated into PLA. Notably, FGPLA specimens achieve the highest shape recovery ratio of approximately 95 ± 1 % after pure PLA. These findings highlight the potential of 4D-printed CFRCs in various applications, from human-material interaction to mechanical and biomedical fields. They contribute to sustainability by reducing material consumption and waste, demonstrated through the creation of reusable and lightweight items like hooks, lockers, finger splints, and meta-composites.

Progress in 3D printing of recycled PET

Filaments from blends of post-industrial, low-quality recycled poly(ethylene terephthalate) (RPET) and ethylene-butyl-acrylate-glycidyl-methacrylate (EBA-GMA) were extruded with different EBA-GMA contents, then specimens were 3D-printed by fused filament fabrication technology. It has been demonstrated that, when 0–90° layer order is applied, at 15 wt% EBA-GMA content the unnotched impact strength increases by two and a half times and the notched impact strength by nine times compared to samples printed from elastomer-free RPET. DSC and DMA measurements proved that EBA-GMA reactively bonds to PET molecules, which is indicated by the increment of rigid amorphous phase and glass transition temperature and the reduction of crystallinity. The co-polymer molecules formed in-situ during compounding create a Toughening Enhancer Interphase (TEI), which also remains after 3D printing and effectively enhances impact strength. The strain at break and tensile strength of the filaments are substantially higher than that of 3D-printed specimens due to the increasing shrinkage and the resulting increased porosity of the printed specimens with higher EBA-GMA content. However, the Young-modulus values are quite similar. The flexural strength of the 3D-printed specimens reaches 40–60% of the values of injection moulded samples. The proposed method enables the production of parts with arbitrary geometry and balanced mechanical properties from RPET, which may substitute acrylonitrile butadiene styrene.

An overview of fused filament fabrication technology and the advancement in PLA-biocomposites

An overview of fused filament fabrication technology and the advancement in PLA-biocomposites

Dielectric and viscoelastic properties of 3D-printed biobased materials

This study aimed to develop new biobased materials containing plasticized cellulose acetate (CA) by Fused Filament Fabrication (FFF). We investigated the influence of CA on the viscoelastic/dielectric properties and the influence of 3D printing on the dielectric properties of the polymer blends. A microstructural analysis showed that the blends had a strong heterogeneous morphology, as the two phases formed a fibrillar and lamellar structure. CA strongly increased the blend viscosity at 175 °C, multiplying by 100 times the complex viscosity between neat PLA and the blend containing 40% of CA by weight (CA-40). The addition of CA to the blends increased the dielectric constant (ε') and dielectric loss (ε''), as well as the alternative current electrical conductivity (σAC). The dielectric constant of CA (ε'CA) was proportional to its percentage in the blend, showing a behavior analogous to a rule of mixture. Moreover, the activation energy of the electrical conductivity (σDC) measured at T > 124 °C decreased with increasing CA content and was associated with the enhancement of the ionic conductivity provided by the CA and its plasticizer. A decrease in the α-relaxation temperature and the associated activation energy of the PLA was also linked to the presence of the CA plasticizer. Finally, 3D printing greatly decreased both ε', ε'' and σAC due to the internal voids induced by the 3D printing process. The porosity was measured at 12% for neat PLA and between 20% and 25% for the blends. These results showed the advantage provided by FFF technology in the production of PLA:CA blends with controlled dielectric properties, thereby favoring the use of these new materials in key dielectric areas.

Polymer materials to produce wrist-hand orthoses using the additive method

Wrist-hand orthosis was developed using PolyJet Matrix (PJM) and Fused Filament Fabrication (FFF) additive technologies. MED610 and PLACTIVE were used as the filament. The orthosis was divided into parts A and B. The accuracy of both parts was checked using an optical scanner. The PJM method was more accurate. The compressive strength and stress relaxation of the orthosis were also tested. Greater strength was achieved for part A made using PJM technology, and for part B made using FFF technology.

Effect of Core Material Thickness on the Shore Hardness of the Sandwich-Structured Multi-Material 3D-Printed Parts

Fused Filament Fabrication (FFF) continues to experience improvements in terms of its flexibility and functionality, therefore it attracts public attention to use this technology. Multi-Material Additive Manufacturing (MMAM) is an approach in the FFF technology that allows the manufacturing of 3D-printed products composed of two or more materials in a single printing process. MMAM enables the user to apply various configurations to obtain a 3D-printed material with adjustable properties. This study aims to determine the effect of core material on the Shore hardness of the FFF printed parts with the MMAM approach. There were two types of materials combined with the MMAM approach in this work, namely polylactic-acid (PLA) and thermoplastic elastomer (TPE). The Shore hardness test was conducted according to the ASTM D2240-15 standard. The results showed that the thickness of the core material inserted into the printed material had a significant effect on the hardness value of printed multi-material parts. In addition, the hardness value was highly dependent on the modulus of elasticity of the material. Therefore, the hardness value changed following the proportion of the printed material.

Investigation of 3D Printed Underwater Thruster Propellers Using CFD and Structural Simulations

Unmanned Surface Vehicles (USV) and Autonomous or Remotely Operated Underwater vehicles (AUV, ROV) are developing and spreading rapidly in various industries. A common feature of these vehicles is that they are propelled by small plastic (or metal) propellers in most cases. Additive manufacturing can offer an excellent opportunity for rapid prototyping and the development of new models. This paper aims to investigate the fundamental aspects to be considered in the geometric design and manufacturing of small (diameter less than 100 mm) PLA (Polylactic acid) propellers 3D-printed using Fused Filament Fabrication (FFF) technology. In-service deformation of 3D-printed PLA ducted propellers with average geometry was investigated to determine the effect on the thrust and torque on the blades. For this purpose, one-directional FSI (Fluid Solid Interaction) simulations were performed using CFD (Computational Fluid Dynamics) and structural simulations. The propeller CAD geometries were generated using an in-house MATLAB script. The variable parameters of each version are the thickness, skew, and rake of the propeller blades. For the structural simulations, it was considered that the material properties of PLA parts printed with FFF technology depend on the print orientation. The results of the simulations show that except for extreme geometries (e.g., thin blades, skew, or rake more than 10°), the deformation of small PLA ducted propellers is not significant. CFD studies of the deformed geometries have shown that the resulting deformation has no significant effect on the thrust and torque of the propeller and thruster.

Development of approaches for forming complex profile parts from Al–Cu alloys using the metal fused filament fabrication technology

Development of approaches for forming complex profile parts from Al–Cu alloys using the metal fused filament fabrication technology

Analysis of the Effect of the Surface Inclination Angle on the Roughness of Polymeric Parts Obtained with Fused Filament Fabrication Technology

Analysis of the Effect of the Surface Inclination Angle on the Roughness of Polymeric Parts Obtained with Fused Filament Fabrication Technology

Fused Filament Fabrication for Metallic Materials: A Brief Review.

Fused filament fabrication (FFF) is an extrusion-based additive manufacturing (AM) technology mostly used to produce thermoplastic parts. However, producing metallic or ceramic parts by FFF is also a sintered-based AM process. FFF for metallic parts can be divided into five steps: (1) raw material selection and feedstock mixture (including palletization), (2) filament production (extrusion), (3) production of AM components using the filament extrusion process, (4) debinding, and (5) sintering. These steps are interrelated, where the parameters interact with the others and have a key role in the integrity and quality of the final metallic parts. FFF can produce high-accuracy and complex metallic parts, potentially revolutionizing the manufacturing industry and taking AM components to a new level. In the FFF technology for metallic materials, material compatibility, production quality, and cost-effectiveness are the challenges to overcome to make it more competitive compared to other AM technologies, like the laser processes. This review provides a comprehensive overview of the recent developments in FFF for metallic materials, including the metals and binders used, the challenges faced, potential applications, and the impact of FFF on the manufacturing (prototyping and end parts), design freedom, customization, sustainability, supply chain, among others.

Filament extrusion state monitoring in fused filament fabrication using Bhattacharyya distance and K-nearest neighbor

Fused filament fabrication (FFF) is one of the most popular techniques of additive manufacturing. However, product quality issues still limit the further application of FFF technology. Filament extrusion state has a great influence on the quality of FFF fabricated products, since both under-extrusion and over-extrusion can lead to the deterioration of product quality. Therefore, monitoring the filament extrusion states is vital and essential. This paper aims to monitor the filament extrusion state by acoustic emission (AE). To achieve this goal, experiments are conducted on a desktop FFF machine, where the states of under-extrusion and over-extrusion are induced by different extrusion speeds. Original AE signals are collected during the experiments. Confronted with the challenge posed by the susceptibility of AE signals to noise during the complex extrusion process and different conditions, one calculates the statistical distribution of the features defined on the raw AE signals, without the need for noise reduction steps. The k-nearest neighbor algorithm is then adopted to identify the different extrusion states, where the Bhattacharyya distance is employed to measure the distances or similarities of the calculated distributions. The findings demonstrate the successful identification of various extrusion states induced by different extrusion speeds through the presented method. The outcomes of this study pave the way for the development of an affordable in-situ FFF monitoring system with comprehensive capabilities.

Structural and Dimensional Analysis by Computed Tomography of a Multi Geometric Template Manufactured by Fused Deposition Modeling.

As a consequence of the development of AM, strategies have been developed to optimize the printing process, which focuses on reducing manufacturing time, such as using genetic algorithms (GAs), among others. The effect caused by the modification of path patterns is an effect of interest in two aspects: dimensional assurance focused on the compliance of the dimensions of the components in comparison with the digital design of the components, and the structural composition and resistance that the printing process itself can generate. This paper aims to present the effect of optimizing the path of fused filament fabrication (FFF) equipment on the dimensional finish and structural quality of a multi-geometric component using computed tomography. For this purpose, a template composed of 23 geometric elements, printed using FFF technology and PLA as the base material, is used. The results show an 11% reduction in the total process time required to print the component. The effect on the dimensional precision of different geometric elements was identified. In addition, it was possible to ensure that the structural quality of the multi-geometric component was not affected by the modification of the path required by the printing process.

Parametric Study of Functional Components Obtained by Additive Manufacturing Fused Filament Fabrication

Fused Filament Fabrication (FFF) is a growing additive manufacturing technology for various applications in the engineering field. The mechanical properties of 3D printed materials in FFF technology depends on various parameters and the literature suggests that infill pattern and infill density are the parameters that most affect the mechanical properties of 3D printed parts.These factors have direct influence on the time of production and amount of material used. In this work it was analyzed the influence of infill parameter on stiffness of the final parts, considering the printing time and amount material used. For this purpose, the Taguchi method was used and then the statistical method of ANOVA to calculate the influence of each parameter.Test specimens were printed according to ASTM Standard D790 dimensions, in Polyethylene terephthalate glycol (PETG). The specimens were printed in the same position on the printing bed to reduce as much as possible the influence of external factors on the results. A visual and dimensional inspection of the specimens was carried out for further analysis. The best combination between production and stiffness, with 350 MPa/mm, was obtained with 15% infill density, concentric pattern, 45º orientation, with 4 perimeters path, layer thickness of 0.1 mm and speed of 45 mm/s. The results obtained allow us a broader view of how to save 3D printing time and the amount of material consumed during the production of a part.

Use of Digital Image Correlation in Predicting Mechanical Properties of Parts Made by Additive Manufacturing

Abstract The publication is focused on the anisotropic properties of products of additive manufacturing using a Fused Filament Fabrication technology (FFF). Five different materials used in technical practice were tested. These materials are PLA (polylactic acid), PETG/CF (polyethylene terephthalate-glycol with carbon fibre, composite material), PETG (polyethylene terephthalate-glycol), ABS (acrylonitrile butadiene styrene), and ASA (acrylic styrene acrylonitrile). Mechanical properties are verified by tensile testing according to ASTM D638. Testing is complemented by a digital image correlation method to locate the areas with the highest load transfer. The results have shown clear anisotropic properties of the test specimens. Anisotropic mechanical properties were also confirmed by digital image correlation (DIC).

Analysis of the Changes in the Mechanical Properties of the 3D Printed Polymer rPET-G with Different Types of Post-Processing Treatments

The paper deals with the actual topic of mechanical properties of 3D prints made from the polymer material rPET-G and its changes. Using this material in additive technology has great potential in the automotive industry. The research evaluates five different post-processing modifications of 3D prints from rPET-G (recycled polyethylene terephthalate-glycol) material produced by the Fused Filament Fabrication technology. The post-processing included the chemical smoothing of the samples using dichloromethane vapors and heat treatment in an annealing furnace. An epoxy resin, a synthetic coating, and a water-based coating were also applied. The standard was represented by samples without post-processing modifications, both in the form of recycled material and in the form of virgin PET-G. The texture of the samples was evaluated according to EN ISO 4287. Furthermore, the moisture absorption of the samples was evaluated using the gravimetric method according to EN ISO 62. The mechanical testing of the samples was carried out using a tensile test (EN ISO 527-2), a three-point bending test (EN ISO 178), impact strength (EN ISO 179-2), and a cupping test (EN ISO 1520). Degradation of the coatings took place using cyclic tests, which used a combination of exposure in a salt fog environment and in a climate chamber. The results of the experiments indicate that heat treatment appears to be a universal post-processing technology, as this method statistically improves not only the mechanical properties but also significantly reduces moisture absorption.

Aluminium deep drawing with additive manufacturing polymer punches: analysis of performance in small batch production

In this research the authors tested the performance of polymer punches, filled with short carbon fibres, produced with fused filament fabrication technology for aluminium sheet deep drawing. An experimental campaign was designed to investigate the geometry accuracy of 99th produced cup and the punches wear mechanism. Results demonstrated that polymer punches are subjected to elastic and plastic deformation that affects cup radius and depth. However, the tolerance comparison with cup produced by conventional steel tools is in a range of tenth of micron; consequently, these punches can withstand the small batch or customised production of one hundred parts.

Rheological and mechanical assessment for formulating hybrid feedstock to be used in MIM & FFF

Processes involving additive manufacturing (AM) and Powder Injection Moulding (PIM) in industry show great potential in producing parts with complex shapes, covering both short series of customed components and high production volumes. A deep study into the fundamentals of the material flow behaviour according to both processing methods requirements, not previously described, is carried out and the synergy of PIM and AM based on Fused Filament Fabrication (FFF) is confirmed. The significance of having a robust material, defined as “hybrid feedstock”, carefully designed to enable the FFF and PIM process, including the debinding and sintering stages, is discussed. The mechanical properties of the 17-4 PH filaments, such as shear strength and maximum force, are analysed, and it is concluded that the choice of an appropriate binder system is crucial for achievement optimal performance during the printing process. The rheological properties of the materials (fluidity and shear thinning behaviour) are also examined and the importance of considering printing speed and temperature to control nozzle pressure and ensure successful printing is emphasized. Furthermore, the mechanical properties of the filaments with different metallic powder loadings are discussed, The need to stablish limits for material suitability in terms of shear stress and activation energy is also mentioned. Overall, the scientific discussion addresses various relevant aspects related to the mechanical and rheological properties of the materials used in 3D printing of metals using FFF technology. Conclusions based on experimental results are provided and key parameters to consider for successful printed parts are highlighted.

Research of the Pre-Processing Strategy Influence on the Tribological Properties of PEI Processed by Fused Filament Fabrication Technology

The aim of this study was to investigate the effect of Fused Filament Fabrication (FFF) layer generation strategies on abrasive wear resistance and compare the material loss of PEI (polyetherimide) plastic specimens based on different specimen building strategies. The study also compares a newly proposed path generation strategy (parallel paths in layers with 0.25 mm displacement of alternate layers) with samples from a previous study where samples were printed without displacement of alternate layers, i.e., layers stacked perpendicularly to each other. The primary focus was on the weight loss due to abrasive wear before and after the test. The tests were conducted on a tribometer constructed according to ASTM G65/16 standards using dry sand. Two printing directions were examined: X (longitudinal) and Z (portrait) orientations. For X construction, three orientations of deposition path generation were utilized, resulting in three samples for each orientation (nine samples in total for X construction). The same approach was applied to Z construction, resulting in another nine samples. In total, 18 samples were produced and tested. The deposited infill path width was 0.5 mm, and the layer thickness used in printing was 0.254 mm. Garnet abrasive Fe3Al2(SiO4)3 was employed in this test. Analysis of the experimental data revealed a relationship between the construction method (X and Z orientations) and the variation in different orientations (1X–3X and 1Z–3Z). The research results can be categorized as overall and partial. The overall results indicate poorer wear resistance for 1X–3X and 1Z–3Z specimens, while the partial results illustrate the findings within each individual specimen.

A review of fused filament fabrication of continuous natural fiber reinforced thermoplastic composites: Techniques and materials

AbstractThe combination of continuous natural fiber and fused filament fabrication (FFF) 3D printing enables the manufacturing of low carbon emitting, environment friendly, lightweight, and high strength biomass composites with designated geometry characteristics. In current literature, reviews associated with continuous fiber 3D printing primarily cover synthetic fibers, such as carbon fiber, Kevlar, and glass fiber. Very few pieces of literature on the FFF printing of continuous natural fibers are available. Techniques/methodologies for incorporating continuous natural fiber reinforcements in FFF is an emerging field of research. A comprehensive review and discussion on current progress and the future prospects of continuous natural fiber 3D printing would be beneficial to its development. This article summarizes the current research status of continuous natural fiber 3D printing, including information on printing techniques, materials, and the influence of printing parameters on composite properties, so as to provide reference for the future development of FFF technology using continuous natural fiber and thermoplastic composites.