A strategy to eliminate interbead defects and improve dimensional accuracy in material extrusion 3D printing of highly filled polymer

Côté, Raphaël; Demers, Vincent; Demarquette, Nicole R.; Charlon, S.; Soulestin, J.

doi:10.1016/j.addma.2023.103509

Cited by 7 publications

(4 citation statements)

References 30 publications

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“…Therefore, unidirectional hexagonal stacking with an additional overlap between the extruded fibers was adopted in the present work to take advantage of the highest possible packing as shown in Figure 4. A similar strategy of employing overlap of the fibers with a novel approach was proposed by Côté et al demonstrating it to be more effective than the commonly employed overextrusion or flow multiplier approach to eliminate interbead defects and obtain dense green parts [29]. In this study, the impact of scan spacing and layer thickness on the final density has been investigated whilst leaving other printing parameters unchanged.…”

Section: Printingmentioning

confidence: 95%

“…Research on extrusion-based printing has been performed by employing various printing strategies, i.e. cross-printing [21], [23], unidirectional [29] and unidirectional (0-0°) hexagonal layer stacking [30]. Feilden et al employed a hexagonal layer stacking which is anticipated to result in a closed-packed stacking of filaments along with an overlap of the fibers [30].…”

Section: Printingmentioning

confidence: 99%

See 1 more Smart Citation

Process optimization and characterization of dense pure copper parts produced by paste-based 3D micro-extrusion

Beretta

Kolli

Selema

et al. 2023

Additive Manufacturing

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Section: Printingmentioning

confidence: 95%

Section: Printingmentioning

confidence: 99%

Process optimization and characterization of dense pure copper parts produced by paste-based 3D micro-extrusion

Beretta

Kolli

Selema

et al. 2023

Additive Manufacturing

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“…, 2023), printing strategy optimization (Afsharkohan et al. , 2023; Côté et al. , 2023; Jiang et al.…”

Section: Introductionmentioning

confidence: 99%

Additive manufactured parts surface treatment through impinged hot air jet technique the theoretical and experimental evaluation

Barzegar,

Farahani,

Gomroki

2024

RPJ

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Purpose Material extrusion-based additive manufacturing is a prominent manufacturing technique to fabricate complex geometrical three-dimensional (3D) parts. Despite the indisputable advantages of material extrusion-based technique, the poor surface and subsurface integrity hinder the industrial application of this technology. The purpose of this study is introducing the hot air jet treatment (HAJ) technique for surface treatment of additive manufactured parts. Design/methodology/approach In the presented research, novel theoretical formulation and finite element models are developed to study and model the polishing mechanism of printed parts surface through the HAJ technique. The model correlates reflow material volume, layer width and layer height. The reflow material volume is a function of treatment temperature, treatment velocity and HAJ velocity. The values of reflow material volume are obtained through the finite element modeling model due to the complexity of the interactions between thermal and mechanical phenomena. The theoretical model presumptions are validated through experiments, and the results show that the treatment parameters have a significant impact on the surface characteristics, hardness and dimensional variations of the treated surface. Findings The results demonstrate that the average value of error between the calculated theoretical results and experimental results is 14.3%. Meanwhile, the 3D plots of Ra and Rq revealed that the maximum values of Ra and Rq reduction percentages at 255°C, 270°C, 285°C and 300°C treatment temperatures are (35.9%, 33.9%), (77.6%,76.4%), (94%, 93.8%) and (85.1%, 84%), respectively. The scanning electron microscope results illustrate three different treatment zones and the treatment-induced and manufacturing-induced entrapped air relief phenomenon. The measured results of hardness variation percentages and dimensional deviation percentages at different regimes are (8.33%, 0.19%), (10.55%, 0.31%) and (−0.27%, 0.34%), respectively. Originality/value While some studies have investigated the effect of the HAJ process on the structural integrity of manufactured items, there is a dearth of research on the underlying treatment mechanism, the integrity of the treated surface and the subsurface characteristics of the treated surface.

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“…In the case of the screw-based approach, the disadvantage is the maximum extrusion flow rate given by the need for a certain dwell time in a heated printing head dedicated to melting similar to a filament-based approach. Meanwhile, the plunger-based approaches tend to be less precise in the start/stop stages of the printing, and there are also issues connected to the flow control due to feedstock compressibility (Miclette et al , 2022; Côté et al , 2023).…”

Section: Introductionmentioning

confidence: 99%

On the possibilities of merging additive manufacturing and powder injection molding in the production of metal parts

Novák,

Hausnerova,

Pata

et al. 2024

RPJ

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Purpose This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS). Design/methodology/approach PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools. Findings Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route. Originality/value This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.

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A strategy to eliminate interbead defects and improve dimensional accuracy in material extrusion 3D printing of highly filled polymer

Cited by 7 publications

References 30 publications

Process optimization and characterization of dense pure copper parts produced by paste-based 3D micro-extrusion

Process optimization and characterization of dense pure copper parts produced by paste-based 3D micro-extrusion

Additive manufactured parts surface treatment through impinged hot air jet technique the theoretical and experimental evaluation

On the possibilities of merging additive manufacturing and powder injection molding in the production of metal parts

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