3D printing of low melting temperature alloys by fused deposition modeling

Hsieh, Patrick C.H.; Tsai, Chia-Hung Dylan; Liu, Bernard Haochih; Wang, Wei; Wang, A. B.; Luo, Ren C.

doi:10.1109/icit.2016.7474915

Cited by 14 publications

(8 citation statements)

References 4 publications

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“…In addition, FDM is used in biomedical applications, whereby the material used to create scaffolds are polycaprolactone (PCL), poly lactic-co-glycolic acid (PLGA) and PLA (Chia and Wu, 2015;Ortega et al, 2016). Furthermore, research was done on the low-temperature melting alloys Sn60pb40 to find out the effect and capability of FDM on metal alloys (Hsieh et al, 2016). One of the advantages of the FDM process over SLA is that the printed samples have high hardness and are more durable (Novakova-Marcincinova and Kuric, 2012).…”

Section: Introductionmentioning

confidence: 99%

An overview of fused deposition modelling (FDM): research, development and process optimisation

Dezaki

Ariffin

Hatami

2021

RPJ

108

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Purpose The purpose of this paper is to review research studies on process optimisation and machine development that lead to the enhancement of final products in various aspects of the fused deposition modelling (FDM) process. Design/methodology/approach An overview of the literature, focussing on process parameters, machine developments and material characterisations. This study investigates recent research studies that studied FDM capabilities in printing a vast range of materials from thermoplastics to metal alloys. Findings FDM is one of the most common techniques in additive manufacturing (AM) processes. Many parameters in this technology have effects on three-dimensional printed products. Therefore, it is necessary to obtain the optimum elements, for example, build orientation, layer thickness, nozzle diameter, infill pattern and bed temperature. By selecting a proper variable range of parameters, the layers adhere strongly and building end-use products of high quality are achievable. A vast range of materials and their properties from polymers to composite-based polymers are presented. Novel techniques to print metal alloys and composites are examined to increase the productivity of the FDM process. Additionally, defects such as shrinkage and warpage are discussed to eliminate the system’s limitations and improve the quality of final products. Multi-axis and mobile machines brought enhancements throughout the process to eliminate obstacles such as staircase defects in the conventional FDM process. In brief, recent developments were identified and a summary of major improvements was discussed in this study for future research. Originality/value This paper is an overview that provides information about research and developments in FDM. This review focusses on process optimisation and obstacles in printing polymers, composites, geopolymers and novel materials. Therefore, machine characteristics were examined to find out the accessibility of printing novel materials for different applications.

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Section: Introductionmentioning

confidence: 99%

An overview of fused deposition modelling (FDM): research, development and process optimisation

Dezaki

Ariffin

Hatami

2021

RPJ

108

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“…For example, Panda et al [19] evaluated the FDM process and its parameters to find out the strengths and limitations such as warping in printing various samples. Furthermore, it should be noted that FDM is a capable process for building composite based materials [20][21][22], geopolymers [23], metal alloys [24,25], and biocomposites [26]. This method consists of processing a Stereolithography (.STL) file, which will then mathematically slice the designed model to initiate the process.…”

Section: Introductionmentioning

confidence: 99%

Effects of CNC Machining on Surface Roughness in Fused Deposition Modelling (FDM) Products

2020

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Fused deposition modelling (FDM) opens new ways across the industries and helps to produce complex products, yielding a prototype or finished product. However, it should be noted that the final products need high surface quality due to their better mechanical properties. The main purpose of this research was to determine the influence of computer numerical control (CNC) machining on the surface quality and identify the average surface roughness (Ra) and average peak to valley height (Rz) when the specimens were printed and machined in various build orientations. In this study, the study samples were printed and machined to investigate the effects of machining on FDM products and generate a surface comparison between the two processes. In particular, the block and complex specimens were printed in different build orientations, whereby other parameters were kept constant to understand the effects of orientation on surface smoothness. As a result, wide-ranging values of Ra and Rz were found in both processes for each profile due to their different features. The Ra values for the block samples, printed samples, and machined samples were 21, 91, and 52, respectively, whereas the Rz values were identical to Ra values in all samples. These results indicated that the horizontal surface roughness yielded the best quality compared to the perpendicular and vertical specimens. Moreover, machining was found to show a great influence on thermoplastics in which the surfaces became smooth in the machined samples. In brief, this research showed that build orientation had a great effect on the surface texture for both processes.

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“…Laser-driven printing uses laser to melt thin metal layer to produce droplets [12]. Most of the current metal printing methods [7][8][9][10][11][12][13][14] are limited in resolution and the setup of the printing system is relatively complicated and expensive. New printing technology needs to be developed for high-resolution metal printing.…”

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confidence: 99%

High-resolution direct printing of molten-metal using electrohydrodynamic jet plotting

Han

Dong

2017

Manufacturing Letters

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In this paper, a high-resolution direct printing process was developed for molten metal using Elctrohydrodynamic (EHD) printing technology. The effect of the critical printing conditions, such as voltage and printing speed, on the printing process was characterized. Compared with direct extrusion using pneumatic pressure, the EHD printing can effectively reduce the dimension of the printed filament down to less than 50μm with better quality of the printed features. We successfully applied EHD printing to print high-resolution 2D patterns and some high aspect-to-ratio 3D structures, which demonstrated the potential capabilities of EHD printing process in producing fine metal structures.Additive manufacturing [1-5] has a capability of rapid prototyping and small volume production of parts for many different industries (e.g. medical device, aerospace, automotive, etc.). The resolution of tradition additive manufacturing, such as 3D printing, stereolithography, fused deposition modeling (FDM) and selective laser sintering [1-2], is approximately no better than 50μm, and the improvement of the resolution from these processes is very difficult. For extrusion based printing processes, the nozzle size is the primary limitation for achieveing high printing resolution. Adopting the nozzle with too small size will result in impractically high extrusion pressure, because the extrusion pressure scales up much faster when the nozzle size is scaled down.High-resolution metal printing is vital for many engineering areas, ranging from additive manufacturing to electronics fabrication [6][7], since high precision manufacturing of metal patterns enables the production of complex structures with reduced cost and time. A few research groups studied drop-on-demand metal printing [7][8][9][10][11][12]. The common methods for the generation of the droplet are the pneumatic-driven, piezoelectric-driven, electromagnetism-driven and laser-driven printing processes.Pneumatic driven printing uses pneumatic pressure to generate droplets [8]. Piezoelectric-driven printing

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3D printing of low melting temperature alloys by fused deposition modeling

Cited by 14 publications

References 4 publications

An overview of fused deposition modelling (FDM): research, development and process optimisation

An overview of fused deposition modelling (FDM): research, development and process optimisation

Effects of CNC Machining on Surface Roughness in Fused Deposition Modelling (FDM) Products

High-resolution direct printing of molten-metal using electrohydrodynamic jet plotting

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