Material Extrusion Additive Manufacturing Research Articles

Mechanical evaluation of elastomeric thermoplastic polyurethane additively manufactured triply periodic minimal surface area lattice structures for adjustable cushioning properties

Purpose Cushioning is a useful material property applicable for a range of applications from medical devices to personal protective equipment. The current ability to apply cushioning in a product context is limited by the appropriateness of available materials, with polyurethane foams being the current gold standard material. The purpose of this study is to investigate additively manufactured flexible printing of scaffold structures as an alternative. Design/methodology/approach In this study, this study investigates triply periodic minimal surface (TPMS) structures, including Gyroid, Diamond and Schwarz P formed in thermoplastic polyurethane (TPU), as a possible alternative. Each TPMS structure was fabricated using material extrusion additive manufacturing and evaluated to ASTM mechanical testing standard for polymers. This study focuses attention to TPMS structures fabricated for a fixed unit cell size of 10 mm and examine the compressive properties for changes in the scaffold porosity for samples fabricated in TPU with a shore hardness of 63A and 90A. Findings It was discovered that for increased porosity there was a measured reduction in the load required to deform the scaffold. Additionally, a complex relationship between the shore hardness and the stiffness of a structure. It was highlighted that through the adjustment of porosity, the compressive strength required to deform the scaffolds to a point of densification could be controlled and predicted with high repeatability. Originality/value The results indicate the ability to tailor the scaffold design parameters using both 63A and 90A TPU material, to mimic the loading properties of common polyurethane foams. The use of these structures indicates a next generation of tailored cushioning using additive manufacturing techniques by tailoring both geometry and porosity to loading and compressive strengths.

Optimization of the extrusion rate for different layer thicknesses to achieve controlled mechanical properties in MEX 3D printing of low-alloy steel

Composite extrusion modeling is an advanced material extrusion additive manufacturing process that requires fine-tuning of printing parameters for printing injection molding feedstocks. In order to achieve comparable high-quality parts at different layer thicknesses, the parameters must be optimized for the respective layer thicknesses. In this work, the printing parameters for AISI 8740 low-alloy steel injection molding material are optimized for four different layer thicknesses. The extrusion multiplier values for each layer thickness are tuned, allowing fine adjustment of the printer's screw rotation speed at every layer thickness, resulting in all final parts' maximum densities (≥ 98 %) with high accuracies. Scanning electron microscope images, surface roughness measurements, and printing precision tests proved the good and comparable high-quality of all optimized printed parts. Young's modulus, tensile and yield strengths also raised by ∼24 %, ∼16 % and ∼15 %, respectively, compared to the non-optimized printed sintered part. The achieved tensile strength range of (∼888–947) MPa and yield strength range of (∼574–586) MPa of all optimized printed sintered parts were also higher than those provided by the feedstock manufacturer. This promising approach significantly reduces printing time and manufacturing costs without compromising the printed final parts' quality and mechanical properties. The adjusting screw rotation speed methodology allows broader applicability across diverse material extrusion processes.

Improving a tool-path optimisation method in material extrusion additive manufacturing by data clustering and collapsing

Improving a tool-path optimisation method in material extrusion additive manufacturing by data clustering and collapsing

Material extrusion additive manufacturing of WC-9Co cemented carbide

Additive manufacturing (AM) cemented carbide is primarily challenged by critical issues of difficult-to-eliminate pores, cracks, deleterious phases, and non-uniform microstructure, which result in poor mechanical properties. This study utilizes material extrusion (MEX) AM technology to prepare a WC-9Co cemented carbide. The results show that green body printing and solvent debinding process significantly affect its stacked voids, interlayer bonding defects, and debound cracks. These green body defects are eliminated through liquid phase flow and WC particles flow-rearrangement during sintering, resulting in Co-rich regions or Co pools, abnormal growth of WC grains, and residual pores. A green body free of visible defects is prepared using a feedstock with a powder loading of 54 vol.%, a printing temperature of 150 ℃, a microfilament overlap ratio of 30%, and a printing-layer thickness of 0.1mm. Followed by a two-step solvent debinding and continuous thermal debinding-vacuum-pressure sintering, a nearly fully dense WC-9Co cemented carbide is fabricated, with a uniform microstructure of two phases and free of pores, cracks, and Co pools. Its Vickers hardness, transverse rupture strength, and fracture toughness reach 1525±3 HV30, 3492±45MPa, and 20.4±0.5MPa·m1/2, respectively, which are significantly better than those of similar reports and could be comparable to similar cemented carbides prepared by powder metallurgy. This study could provide a new technological path for developing high-performance cemented carbide complex-structured components.

Material extrusion additive manufacturing of zirconia: from filament characterisation to Weibull statistics

PurposeThis study aims to investigate the performance of filament-based material extrusion additive manufacturing (MEX), combined with debinding and sintering, as a novel approach to manufacturing ceramic components.Design/methodology/approachA commercial ZrO2 filament was selected and analysed by infra-red (IR) spectroscopy, rheology and thermo-gravimetry. The influence of the print parameters (layer thickness, flow rate multiplier, printing speed) and sintering cycle were investigated to define a suitable printing and sintering strategy. Biaxial flexure tests were applied on sintered discs realised with optimised printing strategies, and the results were analysed via Weibull statistics to evaluate the mechanical properties of printed components. The hardness and thermal conductivity of sintered components were also tested.FindingsLayer thickness and flow rate multiplier of the printing process were proved to have significant effect on the density of as-printed parts. Optimised samples display a sintered density >99% of the theoretical density, 20% linear sintering shrinkage, a characteristic flexural strength of 871 MPa with a Weibull modulus of 4.9, a Vickers hardness of 12.90 ± 0.3 GPa and a thermal conductivity of 3.62 W/mK. Gyroids were printed for demonstration purposes.Originality/valueTo the best of the authors’ knowledge, this work is the first to apply biaxial flexure tests and Weibull statistics to additively manufactured MEX zirconia components, hence providing comparable results to other additive technologies. Moreover, fractography analysis builds the connection between printing defects and the fracture mechanism of bending. This study also provides guidelines for fabricating high-density zirconia components with MEX.

Water Diffusion in Additively Manufactured Polymers: Analysis of the Capillary Effect

Additive manufacturing (AM) is an advanced manufacturing method that produces objects by sequential layering. Material extrusion AM (MEAM) with continuous-fibre reinforcement is becoming more widely used in naval structures, which are exposed to the marine environment. However, the water diffusion process and the effect of water ageing on the mechanical performance of AM materials are not yet well understood because of their complex internal structure, caused by defects generated during manufacturing. Current research on diffusion is mostly based on experimental methods for conventionally manufactured materials without considering AM-induced defects. The objective of this study is to explore how the defects inherent to MEAM affect water diffusion in a composite material by the capillary effect. Results from a numerical study of capillary flow in MEAM polymer are applied as a boundary condition in the subsequent finite-element analysis. The study illustrates that flow in the capillary reaches the steady state quicker compared to the saturation time in the matrix, predicted by Fick’s diffusion equation. It is demonstrated that the capillary effect can significantly affect the water diffusion in MEAM parts and reduce the saturation time to one-third compared to the case without accounting for this effect.

A new design of star auxetic metastructure with enhanced energy-absorption under various loading rates: Experimental and numerical study

Cellular structures are widely used in various industrial applications due to their lightweight and high-strength properties. However, conventional cellular structures have some limitations in terms of energy absorption and load-bearing capacity. Therefore, novel cellular structures with enhanced performance are needed. This study introduces and evaluates two novel auxetic metastructures: Star Triangular Auxetic (STA) and Star Triangular Auxetic - Double Arrow (STA-DA). The metastructures are fabricated by material extrusion additive manufacturing and subjected to quasi-static axial crushing test at three loading rates. The tests are analyzed and validated by using digital image correlation and finite element modeling. The results show that the energy absorption of the STA structure is 19% higher than the STA-DA structure due to progressive damage and negative Poisson’s ratio. However, the STA-DA structure has higher load-bearing capacity than STA due to its stiffness which is 170% higher than the average stiffness of STA. The proposed auxetic metastructures show promising potential for industrial applications that require lightweight and high-strength structures with enhanced energy absorption.

Grain size prediction for stainless steel fabricated by material extrusion additive manufacturing

Most traditional powder melting-based additive manufacturing (AM) technologies generally yield high-performance parts at the expense of additional cost and energy consumption. As an economical and efficient alternative method, material extrusion (ME) that deploys polymer-based filaments with highly filled metal particles offers the possibility of scalable, low-cost fabrication of metal components. As a critical step, sintering governs the mechanical strength and geometry of the final parts. The grain growth behavior induced during sintering should be well controlled to achieve the parts with the desired mechanical performance. Due to the nature of AM, grain growth kinetics could also involve extremely complex grain boundary migration and atomic diffusion mechanisms caused by the heterogeneous pore distribution. In this work, an analytical model was developed to predict and understand the grain growth behavior of stainless steel (SS) 316L built by ME-based sintering-assisted AM. Such a model accounts for anisotropic viscosity parameters calibrated through a three-dimensional dilatometry test, enabling the prediction of grain size evolution during sintering. Grain growth kinetic parameters were further identified by the grain size data at the heating and holding stages. To validate and generalize the model, we also conducted the grain size evolution prediction under different sintering temperature profiles for as-built SS 316L specimens. This work will provide scientific insights into the grain growth behavior of metal parts built by this AM technique and its understanding can be readily transferred to other sintering-assisted AM processes like binder jetting and ink writing for metal structure creation.

Box-Behnken modeling to optimize the engineering response and the energy expenditure in material extrusion additive manufacturing of short carbon fiber reinforced polyamide 6

Box-Behnken modeling to optimize the engineering response and the energy expenditure in material extrusion additive manufacturing of short carbon fiber reinforced polyamide 6

Investigation on the forming process of polylactic acid in material extrusion additive manufacturing technique

Investigation on the forming process of polylactic acid in material extrusion additive manufacturing technique

Effects of aging and shot peening on surface quality and fatigue properties of material extrusion additive manufactured 17-4PH stainless steel

Material extrusion additive manufacturing (MEX) gains increasing interest due to its cost-effectiveness. However, concerns arise regarding inherent MEX characteristics potentially affecting mechanical properties. This study investigates the effects of shot peening and heat treatment on MEX 17-4PH stainless steel. After shot peening, surface nanocrystalline and compressive residual stress are induced. Aging results in higher hardness and tensile strength with lower elongation, while shot peening results in higher surface hardness with minimal change in elongation. For fatigue properties of as-sintered specimens, Al2O3 particle contamination dominates at high cycle regimes, while other MEX surface inhomogeneities dominate at low cycle regimes. Furthermore, as-aged properties are dominated by all surface inhomogeneities, resulting in the non-improvement of fatigue performance compared to the as-sintered specimens. However, shot peening on the as-sintered specimens significantly enhances fatigue properties through the formation of surface nanocrystalline structures and the induction of compressive residual stress, albeit with the occurrence of wrapped corners acting as fatigue crack initiation sites. Remarkably, the combination of aging and shot peening yields the most improvement in fatigue performance, exhibiting behaviours akin to as-sintered specimens with shot peening but without the generation of wrapped corners. Instead, fatigue crack initiation sites shift to subsurface region’s inhomogeneities.

A Review on Process Parameter Optimization in Material Extrusion Additive Manufacturing using Thermoplastic

Material extrusion is one of the most commonly used additive manufacturing techniques which utilizes thermoplastics as the building material. The quality and performance of parts produced via material extrusion depends highly on the process parameters selected. This paper reviews the work done by various researchers on optimizing key process parameters like extrusion temperature, layer thickness, infill percentage, infill pattern etc. in material extrusion 3D printing using thermoplastics like PLA, ABS and nylon. The effects of these parameters on properties like surface roughness, dimensional accuracy, mechanical strength are discussed. Statistical tools like Taguchi method and response surface methodology that have been applied for parameter optimization are also reviewed. The review highlights the need for further process optimization studies considering part design, build orientation and post processing to unleash the full potential of material extrusion 3D printing..

Quantitative Insight into the Compressive Strain Rate Sensitivity of Polylactic Acid, Acrylonitrile Butadiene Styrene, Polyamide 12, and Polypropylene in Material Extrusion Additive Manufacturing

AbstractHerein, a research and engineering gap, i.e., the quantitative determination of the effects of the compressive loading rate on the engineering response of the most popular polymers in Material Extrusion (MEX) Additive Manufacturing (AM) is successfully filled out. PLA (Polylactic Acid), ABS (Acrylonitrile Butadiene Styrene), PP (Polypropylene), and PA12 (Polyamide 12) raw powders were evaluated and melt-extruded to produce fully documented filaments for 3D printing. Compressive specimens after the ASTM-D695 standard were then fabricated with MEX AM. The compressive tests were carried out in pure quasi-static conditions of the test standard (1.3 mm/min) and in accelerated loading rates of 50, 100, 150, and 200 mm/min respectively per polymer. The experimental and evaluation course proved differences in engineering responses among different polymers, in terms of compressive strength, elasticity modulus, toughness, and strain rate sensitivity index. A common finding was that the increase in the strain rate increased the mechanical response of the polymeric parts. The increase in the compressive strength reached 25% between the lowest and the highest strain rates the parts were tested for most polymers. Remarkable variations of deformation and fracture modes were also observed and documented. The current research yielded results with valuable predictive capacity for modeling and engineering modeling, which hold engineering and industrial merit.

Investigation of the Effectiveness of Silicon Nitride as a Reinforcement Agent for Polyethylene Terephthalate Glycol in Material Extrusion 3D Printing.

Polyethylene terephthalate glycol (PETG) and silicon nitride (Si3N4) were combined to create five composite materials with Si3N4 loadings ranging from 2.0 wt.% to 10.0 wt.%. The goal was to improve the mechanical properties of PETG in material extrusion (MEX) additive manufacturing (AM) and assess the effectiveness of Si3N4 as a reinforcing agent for this particular polymer. The process began with the production of filaments, which were subsequently fed into a 3D printer to create various specimens. The specimens were manufactured according to international standards to ensure their suitability for various tests. The thermal, rheological, mechanical, electrical, and morphological properties of the prepared samples were evaluated. The mechanical performance investigations performed included tensile, flexural, Charpy impact, and microhardness tests. Scanning electron microscopy and energy-dispersive X-ray spectroscopy mapping were performed to investigate the structures and morphologies of the samples, respectively. Among all the composites tested, the PETG/6.0 wt.% Si3N4 showed the greatest improvement in mechanical properties (with a 24.5% increase in tensile strength compared to unfilled PETG polymer), indicating its potential for use in MEX 3D printing when enhanced mechanical performance is required from the PETG polymer.

Soft Chemiresistive Sensing Shields Soft Robotic Actuators from Mechanical Degradation due to Critical Solvent Exposure

Thermoplastic elastomers (TPEs) are popular for fabricating soft actuators thanks to their compatibility with thermoplastic processing methods, like material extrusion additive manufacturing. However, these TPEs are susceptible to nonpolar solvents, and upon exposure, the mechanical properties can diminish significantly. Herein, soft chemiresistive sensing elements based on thermoplastic elastomers and carbon black (CB) are developed for detecting the presence of nonpolar solvents. A low CB concentration (20% w/w) leads to a faster response for detecting the presence of nonpolar solvents. A threshold value of the electrical current is defined by tensile testing, based on exposure time that does not diminish the mechanical properties. Exposure to solvent vapor above 150 s decreases the elongation at fracture significantly (450%). To achieve nociceptive behavior for a sensorized soft actuator and shield the actuator from structural damage, this threshold value is used for programming a closed‐loop control motion system. When the threshold value is reached, the actuator withdraws from the solvent surface autonomously. However, this threshold decreases with parameters like the solvent temperature and sensor distance from the solvent surface. Overall, adding soft chemiresistive elements into elastomer‐based soft robots extends their lifetime, by preventing damage in harsh chemical atmospheres.

Coupling μ-computed tomography and multi-scale modelling to assess the mechanical performance of material extrusion metal components

The porosity defects arising in objects produced by metal Material Extrusion (MEX) additive manufacturing affect the macroscopic mechanical behaviour. This paper presents a new approach integrating μ-computed tomography (μXCT) and multi-scale finite element analysis to evaluate the mechanical performance of components fabricated by metal MEX. The porosity information from μXCT is mapped into the finite element model, allowing to define the volume fraction of porosity to each finite mesh element. Then, the Mori-Tanaka homogenization technique is used to estimate the effective mechanical properties in each integration point, assuming a representative volume element composed by a metal matrix with a void. The reliability of the proposed approach was assessed using tensile specimens of stainless steel 316L produced by metal MEX. The numerical predictions were compared with experimental measurements, namely the strain field evolution measured by digital image correlation (DIC). The results highlight the detrimental influence of the porosity distribution, evaluated in the specimen using μXCT, on the strain distribution during the loading stage. The numerical predictions are in agreement with the experimental measurements, i.e. the difference is lower than 11%. Therefore, the proposed approach offers valuable insights for evaluating the mechanical performance of components produced by metal MEX, focusing on the detrimental effects of porosity defects.

Reinforced HDPE with optimized biochar content for material extrusion additive manufacturing: morphological, rheological, electrical, and thermomechanical insights

The development of efficient and sustainable composites remains a primary objective of both research and industry. In this study, the use of biochar, an eco-friendly reinforcing material, in additive manufacturing (AM) is investigated. A high-density Polyethylene (HDPE) thermoplastic was used as the matrix, and the material extrusion (MEX) technique was applied for composite production. Biochar was produced from olive tree prunings via conventional pyrolysis at 500 °C. Composite samples were created using biochar loadings in the range of 2.0–10.0 wt. %. The 3D-printed samples were mechanically tested in accordance with international standards. Thermogravimetric analysis (TGA) and Raman spectroscopy were used to evaluate the thermal and structural properties of the composites. Scanning electron microscopy was used to examine the fractographic and morphological characteristics of the materials. The electrical/dielectric properties of HDPE/biochar composites were studied over a broad frequency range (10–2 Hz–4 MHz) at room temperature. Overall, a laborious effort with 12 different tests was implemented to fully characterize the developed composites and investigate the correlations between the different qualities. This investigation demonstrated that biochar in the MEX process can be a satisfactory reinforcement agent. Notably, compared to the control samples of pure HDPE, biochar increased the tensile strength by over 20% and flexural strength by 35.9% when added at a loading of 4.0 wt. %. The impact strength and microhardness were also significantly improved. Furthermore, the Direct current (DC) conductivity of insulating HDPE increased by five orders of magnitude at 8.0 wt. % of biochar content, suggesting a percolation threshold. These results highlight the potential of C-based composites for the use in additive manufacturing to further exploit their applicability by providing parts with improved mechanical performance and eco-friendly profiles.Graphical

Effect of oxide nanoparticles in aqueous alumina inks for material extrusion additive manufacturing

The effects of the addition of nanoparticles (NPs) of alumina (NA) and silica (NS) on the rheological properties of aqueous-based ceramic inks for material extrusion-based additive manufacturing (ME-AM) and sinterability of printed ceramic components were investigated. The inks were first designed using bimodal particle sizes of NPs with micro-alumina, and their solids fraction in printable inks was found to be dependent on the functionalization properties of NPs. NAs create a lubricating effect in the ink system and improve solids-loading in the ink. Meanwhile, NSs form silanol bonds in aqueous-based inks that increase viscosity and reduce solids-loading for a printable ME-AM ink. The inks containing NPs with higher solids-loading and optimized rheology were printed using ME-AM, and the printed components were sintered at 1400–1550 ºC. Adding NPs in the ink significantly improved the sinterability of printed shapes by enhancing sintering kinetics and filling-effects, with NS having a more significant effect than NA.

Unraveling the main issues of direct sample printing and sample cutting from a sheet of tensile test samples for characterization of Material Extrusion components

AbstractThis research investigates the influence of varied sample manufacturing strategies on the mechanical properties of Material Extrusion (MatExt) Additive Manufacturing components. Two procedures were investigated: direct sample printing and sample cutting from a sheet. The thickness of the samples was also varied to determine possible differences in the measurements performed. Through a comprehensive analysis involving mechanical testing, optical microscopy, and IR thermography during deposition, the study revealed significant implications of the manufacturing strategy on the thermal history and polymer chain entanglement. The results indicated that Young’s modulus and the tensile strength produced through direct printing differed from that measured on the samples made through sample cutting. At the same time, the elongation at rupture was less influenced by the manufacturing strategy. The sample thickness also influenced the fracture strength; the thicker samples were characterized by a strength of 27.9 MPa, which was higher by 23% than that of the extracted samples.The observed differences in mechanical behavior underscore the critical role of sample manufacturing strategy in determining the final mechanical properties of upright samples. Results shed light on the complex interplay between manufacturing protocols and component performance in MatExt applications.

A shape-predictive model for the spreading of photo-curable polymers in material extrusion additive manufacturing

Recently, there is a growing interest in material extrusion to print thermoset resins to manufacture large format and high-performance parts. However, the fidelity and mechanical integrity of the printed parts are limited by challenges such as uncontrolled spreading of individual beads (filament/droplet) after deposition and during cure. There is a considerable lack of experimental and theoretical studies on the spreading of reactive beads on solid substrates. In this work, we studied the simultaneous spreading and photo-curing of the photopolymerizable thermoset beads via experiment and numerical simulations. We used a novel experimental setup to track the spreading of droplets and filaments during photopolymerization and validate a moving mesh computational fluid dynamics (CFD) model. The CFD model was used to develop an approach (predictive model) to accurately predict the final spreading coefficient of cured resin beads without the need for full numerical simulations. The predictive model combines the generalized theory of a Newtonian spreading filament with a characteristic viscosity μave and time to gelation, τgel. Interestingly, μave is shown to be a material parameter that does not depend on processing conditions, but only on the material’s chemorheology. The predictive model is tested against a wide range of chemorheology and cure kinetic parameters and found to be in excellent agreement with the full numerical CFD simulations. This work will be very useful in estimating the final shape of beads during the material extrusion printing process, as well as a model to successfully parameterize extrusion-based 3D printers to control the shape of printed beads a-priori.