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Building end-use functional metal parts by metal fused filament fabrication (MF 3 ) is an emerging topic in additive manufacturing. MF 3 involves extrusion of polymer filaments that are highly filled with metal powder to print three-dimensional parts, followed by debinding and sintering to eliminate the polymer binder and get a fully dense metal part, respectively. Material properties, part design and processing conditions have a significant influence on the quality of MF 3 printed parts. Part distortion and dimensional variations are significant quality challenges that hinder the acceptance of printed parts in potential functional applications. Trial-and-error experiments to find the best conditions are commonly used for defect avoidance, though they are time-consuming and expensive. Hence, computational simulation and design solutions are required for MF 3 to enable a virtual analysis of the process outcome and reduce dependency on experimental methods. This paper investigates the applicability of a thermo-mechanical model for finite element simulation of the MF 3 printing process. The quantitative influence of material properties on MF 3 printed part quality was estimated using a simulation platform. The simulation results of two materials, a Ti-6Al-4V filled polymer and an unfilled ABS copolymer, were compared to experiments. It was determined that the unfilled polymer showed greater shrinkage and warpage than the Ti-6Al-4V filled polymer in simulations and experiments. Further, the trend in the distribution of warpage was consistent between experiments and simulation results for both materials. Finally, warpage compensation algorithms showed improvement in dimensional control for both materials in simulations and were consistent with experimental results.

Purpose This paper aims to investigate the feasibility of supportless printing of lattice structures by metal fused filament fabrication (MF3) of Ti-6Al-4V. Additionally, an empirical method was presented for the estimation of extrudate deflection in unsupported regions of lattice cells for different geometric configurations. Design/methodology/approach Metal-polymer feedstock with a solids-loading of 59 Vol.% compounded and extruded into a filament was used for three-dimensional printing of lattice structures. A unit cell was used as a starting point, which was then extended to multi-stacked lattice structures. Feasible MF3 processing conditions were identified to fabricate defect-free lattice structures. The effects of lattice geometry parameters on part deflection and relative density were investigated at the unit cell level. Computational simulations were used to predict the part quality and results were verified by experimental printing. Finally, using the identified processing and geometry parameters, multi-stacked lattice structures were successfully printed and sintered. Findings Lattice geometry required considerable changes in MF3 printing parameters as compared to printing bulk parts. Lattice cell dimensions showed a considerable effect on dimensional variations and relative density due to varying aspect ratios. The experimental printing of lattice showed large deflection/sagging in unsupported regions due to gravity, whereas simulation was unable to estimate such deflection. Hence, an analytical model was presented to estimate extrudate deflections and verified with experimental results. Lack of diffusion between beads was observed in the bottom facing surface of unsupported geometry of sintered unit cells as an effect of extrudate sagging in the green part stage. This study proves that MF3 can fabricate fully dense Ti-6Al-4V lattice structures that appear to be a promising candidate for applications where mechanical performance, light-weighting and design customization are required. Originality/value Supportless printing of lattice structures having tiny cross-sectional areas and unsupported geometries is highly challenging for an extrusion-based additive manufacturing (AM) process. This study investigated the AM of Ti-6Al-4V supportless lattice structures using the MF3 process for the first time.

Metal fused filament fabrication (MF 3 ) combines fused filament fabrication and sintering processes to fabricate complex metal components. To design for MF 3 , an understanding of part geometry, printing parameters and material properties' effects on processability, part quality and ensuing properties is required. However, such investigation is a complex problem having several linked geometry, process and material variables to be considered that influence the process outcome. Moreover, such investigations through the experimental trial-and-error approach are costly and time-consuming, and sometimes not even feasible due to so many input variables involved. This study investigated the sensitivity of key output parameters toward each of the input parameters in MF 3 . FEA-based thermomechanical process simulations were used to estimate the process outcome in response to variable inputs, and a systematic procedure for sensitivity analysis has been successfully developed for the printing phase of the MF 3 process. Dimensionless sensitivity values for all output parameters were calculated in the response of each input parameter, which allows parameters with different units to be compared quantitatively with a single yardstick. Moreover, three different part geometries were studied to identify how the process sensitivity varies with part geometry. For each output parameter, the most influential input parameters were identified from the whole set of input parameters and their influence trends were evaluated for different part geometries. The present sensitivity analysis procedure is expected to be an invaluable tool not only for process parameters optimization but also for the development of material and part geometry for MF 3 , hence enabling design for MF 3 (DfMF 3 ).

Additive manufacturing (AM) and related digital technologies have enabled several advanced solutions in medicine and dentistry, in particular, the design and fabrication of patient-specific implants. In this study, the feasibility of metal fused filament fabrication (MF3) to manufacture patient-specific maxillofacial implants is investigated. Here, the design and fabrication of a maxillofacial implant prototype in Ti-6Al-4V using MF3 is reported for the first time. The cone-beam computed tomography (CBCT) image data of the patient’s oral anatomy was digitally processed to design a 3D CAD model of the hard tissue and fabricate a physical model by stereolithography (SLA). Using the digital and physical models, bone loss condition was analyzed, and a maxillofacial implant initial design was identified. Three-dimensional (3D) CAD models of the implant prototypes were designed that match the patient’s anatomy and dental implant requirement. In this preliminary stage, the CAD models of the prototypes were designed in a simplified form. MF3 printing of the prototypes was simulated to investigate potential deformation and residual stresses. The patient-specific implant prototypes were fabricated by MF3 printing followed by debinding and sintering using a support structure for the first time. MF3 printed green part dimensions fairly matched with simulation prediction. Sintered parts were characterized for surface integrity after cutting the support structures off. An overall 18 ± 2% shrinkage was observed in the sintered parts relative to the green parts. A relative density of 81 ± 4% indicated 19% total porosity including 11% open interconnected porosity in the sintered parts, which would favor bone healing and high osteointegration in the metallic implants. The surface roughness of Ra: 18 ± 5 µm and a Rockwell hardness of 6.5 ± 0.8 HRC were observed. The outcome of the work can be leveraged to further investigate the potential of MF3 to manufacture patient-specific custom implants out of Ti-6Al-4V.