A study of parametric calibration for low cost 3D printing: Seeking improvement in dimensional quality

Santana, Leonardo; Alves, Jorge Lino; Netto, Aurélio da Costa Sabino

doi:10.1016/j.matdes.2017.09.020

Cited by 56 publications

(26 citation statements)

References 14 publications

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“…The combination of low values of layer thickness (0.16 mm) and high values of shell thickness (4 mm) showed higher cylindricity error (refer to Figure 4 a). Low values of infill density (20%) resulted in lower cylindricity error in fabricated parts (refer to Figure 4 b,d,f), analogous to earlier results reported by authors [ 54 ]. Lower infill density (quantity of material in the part) used less material.…”

Section: Resultssupporting

confidence: 88%

Analysis and Optimization of Dimensional Accuracy and Porosity of High Impact Polystyrene Material Printed by FDM Process: PSO, JAYA, Rao, and Bald Eagle Search Algorithms

et al. 2021

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High impact polystyrene (HIPS) material is widely used for low-strength structural applications. To ensure proper function, dimensional accuracy and porosity are at the forefront of industrial relevance. The dimensional accuracy cylindricity error (CE) and porosity of printed parts are influenced mainly by the control variables (layer thickness, shell thickness, infill density, print speed of the fused deposition modeling (FDM) process). In this study, a central composite design (CCD) matrix was used to perform experiments and analyze the complete insight information of the process (control variables influence on CE and porosity of FDM parts). Shell thickness for CE and infill density for porosity were identified as the most significant factors. Layer thickness interaction with shell thickness, infill density (except for CE), and print speed were found to be significant for both outputs. The interaction factors, i.e., shell thickness and infill density, were insignificant (negligible effect) for both outputs. The models developed produced a better fit for regression with an R2 equal to 94.56% for CE, and 99.10% for porosity, respectively. Four algorithms (bald eagle search optimization (BES), particle swarm optimization (PSO), RAO-3, and JAYA) were applied to determine optimal FDM conditions while examining six case studies (sets of weights assigned for porosity and CE) focused on minimizing both CE and porosity. BES and RAO-3 algorithms determined optimal conditions (layer thickness: 0.22 mm; shell thickness: 2 mm; infill density: 100%; print speed: 30 mm/s) at a reduced computation time equal to 0.007 s, differing from JAYA and PSO, which resulted in an experimental CE of 0.1215 mm and 2.5% of porosity in printed parts. Consequently, BES and RAO-3 algorithms are efficient tools for the optimization of FDM parts.

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Section: Resultssupporting

confidence: 88%

Analysis and Optimization of Dimensional Accuracy and Porosity of High Impact Polystyrene Material Printed by FDM Process: PSO, JAYA, Rao, and Bald Eagle Search Algorithms

et al. 2021

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“…The peak of elongation of the cyclohexane ring was observed at 974 cm − 1 [ 29 ]. Deflection was observed in the 1092 cm − 1 and 1015 cm − 1 bands, which could be caused by the stretching of C–O and the bending of the ether bonds present in the molecule [ 30 ].…”

Section: Resultsmentioning

confidence: 99%

Effects of Steam Heat and Dry Heat Sterilization Processes on 3D Printed Commercial Polymers Printed by Fused Deposition Modeling

et al. 2022

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Fused deposition modeling (FDM), the most widely used additive manufacturing (AM) technology, is gaining considerable interest in the surgical sector for the production of single-use surgical devices that can be tailor-made according to specific requirements (e.g., type of patient surgery, specific shapes, etc.) due to its low cost, ease of access to materials (3D-printing filament), and the relatively low complexity. However, surgical 3D-printing parts should resist sterilization treatments without losing structural, mechanical, and dimensional accuracy. Thus, in this work, 3D-filaments based on poly(lactic acid) (PLA), poly(ethylene glycol-co-1,4-cyclohexanedimethanol terephthalate) (PETG), and a modified PETG material (CPE) were used to produce 3D-printed parts and further subjected to moist heat (MH) and dry heat (DH) sterilization processes as affordable and widely used sterilization processes in the medical field. The effect of MH and DH was evaluated by performing a complete mechanical, structural, thermal, and morphological characterization before and after both treatments. In general, the moist heat treatment produced a higher degradation of the polymeric matrix of PETG and CPE due to hydrolytic and thermal degradation, particularly affecting the tensile test and flexural properties. For instance, the linear coefficient of thermal expansion (LCTE) before glass transition temperature (Tg) increased 47% and 31% in PETG samples due to the MH and DH, respectively, while it increased 31% in CPE due to MH and was mainly maintained after the DH process. Nevertheless, in PLA, the MH produced an increase of 20% in LCTE value and the DH showed an increase of 33%. Dry heat treatment resulted in being more suitable for medical applications in which dimensional accuracy is not a key factor and there are no great mechanical demands (e.g., surgical guides).

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“…Despite being one of the samples with the lowest degree of crystallinity, all of the mechanical properties displayed were among the highest with the exception of the notched Izod impact strength, which was similar to that of samples 3D printed at lower bed temperatures. 19,28…”

Section: Resultsmentioning

confidence: 99%

Improving the Impact Strength and Heat Resistance of 3D Printed Models: Structure, Property, and Processing Correlationships during Fused Deposition Modeling (FDM) of Poly(Lactic Acid)

et al. 2018

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A fused deposition modeling method was used in this research to investigate the possibility of improving the mechanical properties of poly(lactic acid) by changing the thermal conditions of the printing process. Sample models were prepared while varying a wide range of printing parameters, including bed temperature, melt temperature, and raster angle. Certain samples were also thermally treated by annealing. The prepared materials were subjected to a detailed thermomechanical analysis (differential scanning calorimetry, dynamic mechanical analysis, heat deflection temperature (HDT)), which allowed the formulation of several conclusions. For all prepared samples, the key changes in mechanical properties are related to the content of the poly(lactic acid) crystalline phase, which led to superior properties in annealed samples. The results also indicate the highly beneficial effect of increased bed temperature, where the best results were obtained for the samples printed at 105 °C. Compared to the reference samples printed at a bed temperature of 60 °C, these samples showed the impact strength increased by 80% (from 35 to 63 J/m), HDT increased by 20 °C (from 55 to 75 °C), and also a significant increase in strength and modulus. Scanning electron microscopy observations confirmed the increased level of diffusion between the individual layers of the printed filament.

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A study of parametric calibration for low cost 3D printing: Seeking improvement in dimensional quality

Cited by 56 publications

References 14 publications

Analysis and Optimization of Dimensional Accuracy and Porosity of High Impact Polystyrene Material Printed by FDM Process: PSO, JAYA, Rao, and Bald Eagle Search Algorithms

Analysis and Optimization of Dimensional Accuracy and Porosity of High Impact Polystyrene Material Printed by FDM Process: PSO, JAYA, Rao, and Bald Eagle Search Algorithms

Effects of Steam Heat and Dry Heat Sterilization Processes on 3D Printed Commercial Polymers Printed by Fused Deposition Modeling

Improving the Impact Strength and Heat Resistance of 3D Printed Models: Structure, Property, and Processing Correlationships during Fused Deposition Modeling (FDM) of Poly(Lactic Acid)

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