A post-processing laser polishing method to improve process performance of 3D printed new Industrial Nylon-6 polymer

Mushtaq, Ray Tahir; Wang, Yanen; Khan, Aqib Mashood; Rehman, Mudassar; Li, Xinpei; Sharma, Shubham

doi:10.1016/j.jmapro.2023.06.019

Cited by 28 publications

(5 citation statements)

References 38 publications

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“…Parts subjected to meticulous post-processing exhibit superior mechanical integrity, dimensional accuracy, and surface quality, translating into heightened functionality and reliability across diverse applications. Whether in aerospace, automotive, medical, or consumer goods industries, the comprehensive impact of post-processing on mechanical properties, aesthetics, and performance underpins its indispensable role in achieving the desired standards for additively manufactured parts [46]. Table 1 depicts the detailed aspects of post-processing techniques in additive manufacturing.…”

Section: The Categories Of Post-processing In Ammentioning

confidence: 99%

Post-Production Finishing Processes Utilized in 3D Printing Technologies

Kantaros,

Ganetsos,

Petrescu

et al. 2024

Processes

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Additivе manufacturing (AM) has rеvolutionizеd production across industriеs, yеt challеngеs pеrsist in achiеving optimal part quality. This papеr studies thе еnhancеmеnt of post-procеssing tеchniquеs to еlеvatе thе ovеrall quality of AM-producеd componеnts. This study focuses on optimizing various post-procеssing mеthodologiеs to addrеss prеvalеnt issuеs such as surfacе roughnеss, dimеnsional accuracy, and matеrial propеrtiеs. Through an еxtеnsivе rеviеw, this article idеntifiеs and еvaluatеs a spеctrum of post-procеssing mеthods, еncompassing thеrmal, chеmical, and mеchanical trеatmеnts. Spеcial attеntion is givеn to thеir еffеcts on diffеrеnt typеs of additivе manufacturing tеchnologiеs, including sеlеctivе lasеr sintеring (SLS), fusеd dеposition modеling (FDM), and stеrеolithography (SLA) and their dedicated raw materials. Thе findings highlight thе significancе of tailorеd post-procеssing approachеs in mitigating inhеrеnt dеfеcts, optimizing surfacе finish, and еnhancing mеchanical propеrtiеs. Additionally, this study proposеs novеl post-procеssing procedures to achiеvе supеrior quality whilе minimizing fabrication timе and infrastructure and material costs. Thе intеgration of post-procеssing techniques such as cleaning, surface finishing, heat treatment, support structure removal, surface coating, electropolishing, ultrasonic finishing, and hot isostatic pressing (HIP), as stеps dirеctly within thе additivе manufacturing workflow can immensely contribute toward this direction. The outcomes displayed in this article not only make a valuable contribution to the progression of knowledge regarding post-processing methods but also offer practical implications for manufacturers and researchers who are interested in improving the quality standards of additive manufacturing processes.

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Section: The Categories Of Post-processing In Ammentioning

confidence: 99%

Post-Production Finishing Processes Utilized in 3D Printing Technologies

Kantaros,

Ganetsos,

Petrescu

et al. 2024

Processes

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“…The coefficient of determination, R 2 [80], is an essential metric to evaluate the performance of established models [81]. A value nearing one signifies a strong correlation between the dependent and independent variables [82,83]. The models were evaluated with the provided summaries:…”

Section: Mathematical Modelingmentioning

confidence: 99%

Parametric Investigation of the Effects of Electrical Discharge Machining on Plain D2 Steel

Hassan,

Mushtaq,

Mashood Khan

et al. 2023

Metals

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Electrical discharge machining (EDM) has emerged as a pivotal non-conventional production technique due to its unique capability to machine without the cutting tool’s physical contact with the workpiece, making it apt for brittle, delicate, and complex materials. This research delved into the influence of operational parameters—pulse duration (Ton), peak current (Ip), duty cycle (T), and gap voltage (Vg)—on machining attributes, namely material removal rate (MRR), electrode wear rate (EWR), and radial overcut (ROC) for AISI D2 steel. Utilizing the Taguchi L9 orthogonal array for experimental design, nine experiments were conducted, followed by signal-to-noise ratio (S/N ratio) computations. Key findings highlighted a 4.02 dB improvement in the S/N ratio for MRR, leading to a 29.13% improvement; a 10.35 dB enhancement in the S/N ratio for EWR, resulting in a 33.33% reduction; and a 2.20 dB increase in the S/N ratio for ROC, leading to a 28.57% increment. ANOVA analyses further underscored the predominant influence of all four parameters. The significance of these findings lies in optimizing the EDM process for increased efficiency, reduced tool wear, and enhanced precision, potentially leading to cost savings and improved production quality in industrial applications.

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“…The first technique involves filling biocompatible polymers such as poly-L-lactic acid, polycaprolactone and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with HA (Eosoly et al , 2010; Hao et al , 2007). Laser irradiation melts the polymer in the powder feedstock (Mushtaq et al , 2023), creating polymer/ceramic composite scaffolds (Duan et al , 2010; Xia, 2013). Since these polymers are not eliminated following SLS, implantation might influence their characteristics or tissue regeneration (Donate et al , 2020).…”

Section: Introductionmentioning

confidence: 99%

Understanding the consolidation mechanism of selective laser sintering/powder bed selective laser process of ceramics: Hydroxyapatite case

Ur Rehman,

Navarrete-Segado,

Salamci

et al. 2024

RPJ

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Purpose The consolidation process and morphology evolution in ceramics-based additive manufacturing (AM) are still not well-understood. As a way to better understand the ceramic selective laser sintering (SLS), a dynamic three-dimensional computational model was developed to forecast thermal behavior of hydroxyapatite (HA) bioceramic. Design/methodology/approach AM has revolutionized automotive, biomedical and aerospace industries, among many others. AM provides design and geometric freedom, rapid product customization and manufacturing flexibility through its layer-by-layer technique. However, a very limited number of materials are printable because of rapid melting and solidification hysteresis. Melting-solidification dynamics in powder bed fusion are usually correlated with welding, often ignoring the intrinsic properties of the laser irradiation; unsurprisingly, the printable materials are mostly the well-known weldable materials. Findings The consolidation mechanism of HA was identified during its processing in a ceramic SLS device, then the effect of the laser energy density was studied to see how it affects the processing window. Premature sintering and sintering regimes were revealed and elaborated in detail. The full consolidation beyond sintering was also revealed along with its interaction to baseplate. Originality/value These findings provide important insight into the consolidation mechanism of HA ceramics, which will be the cornerstone for extending the range of materials in laser powder bed fusion of ceramics.

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A post-processing laser polishing method to improve process performance of 3D printed new Industrial Nylon-6 polymer

Cited by 28 publications

References 38 publications

Post-Production Finishing Processes Utilized in 3D Printing Technologies

Post-Production Finishing Processes Utilized in 3D Printing Technologies

Parametric Investigation of the Effects of Electrical Discharge Machining on Plain D2 Steel

Understanding the consolidation mechanism of selective laser sintering/powder bed selective laser process of ceramics: Hydroxyapatite case

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