A layer thickness algorithm for additive/subtractive rapid pattern manufacturing

Luo, Xiaoming; Frank, Matthew C.

doi:10.1108/13552541011025825

Cited by 11 publications

(1 citation statement)

References 22 publications

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“…The layer thickness algorithm was implemented and tested using an additive/subtractive manufacturing system developed in the laboratory, which is proved to be effective in determining appropriate layer heights for thick slab machining, taking into account a variety of geometries. Several sand casting patterns have been successfully created using the proposed system, and a significant improvement from traditional manufacturing method has been observed (Luo et al , 2010). The factors which influence the surface quality of FDM parts are (Armillotta, 2006): stair-stepping effect; accuracy of machine; material flow rate; shrinkage and residual stresses due to resign solidification and cooling; and support material marks on parts. …”

Section: Post-processing Techniquesmentioning

confidence: 99%

Development of rapid tooling using fused deposition modeling: a review

Boparai

Singh

2016

RPJ

189

100

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Purpose The purpose of this study is to highlight the direct fabrication of rapid tooling (RT) with desired mechanical, tribological and thermal properties using fused deposition modelling (FDM) process. Further, the review paper demonstrated development procedure of alternative feedstock filament of low-cost composite material for FDM to extend the range of RT applications. Design/methodology/approach The alternative materials for FDM and their processing requirements for fabrication in filament form as reported by various researchers have been summarized. The literature demonstrates the role of various post-processing techniques on surface finish of FDM prints. Further, low-cost materials for feedstock filament have been investigated experimentally to check their adaptability/suitability for commercial FDM setup. The approach was to realize the requirements of FDM (melt flow rate, flexibility, stiffness, glass transition temperature and mechanical strength), necessary for the successful run of an alternative filament. The effect of constituents (additives, plasticizers, surfactants and fillers) in polymeric matrix on mechanical, tribological and thermal properties has been investigated. Findings It is possible to develop composite material feedstock as filament for commercial FDM setup without changing its hardware and software. Surface finish of the parts can further be improved by applying various post-processing techniques. Most of the composite parts have high mechanical strength, hardness, thermal stability, wear resistant and better bond formation than standard material parts. Research limitations/implications Future research may be focused on improving the surface quality of parts fabricated with composite feedstock, solving issues related to the uniform distribution of filled materials during the fabrication of feedstock filament which in turns further increases mechanical strength, high dimensional stability of composite filament and transferring the technology from laboratory scale to various industrial applications. Practical implications Potential applications of direct fabrication with RT includes rapid manufacturing (RM) of metal-filled parts and ceramic-filled parts (which have complex shape and cannot be rapidly made by any other manufacturing techniques) in the field of biomedical and dentistry. Originality/value This new manufacturing methodology is based on the proper selection and processing of various materials and additives to form high-performance, low-cost composite material feedstock filament (which fulfil the necessary requirements of FDM process). Finally, newly developed feedstock filament material has both quantitative and qualitative advantage in RT and RM applications as compared to standard material filament.

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