Analysis of printing parameters for metal additive manufactured parts through Direct Ink Writing process

Bonada, Jordi; Xuriguera, E.; Calvo, Laura; Poudelet, Louison; Cardona, Reinaldo; Padilla, José Antonio Samper; Niubó, M.; Fenollosa, F.

doi:10.1016/j.promfg.2019.09.056

Cited by 12 publications

(6 citation statements)

References 8 publications

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“…For example in DIW, parameters such as nozzle velocity, nozzle standoff height, infill flow rate, nozzle diameter, etc. significantly impact the final shape of the printed filament. ,, More specifically, it has been shown that increasing the nozzle velocity while keeping the infill flow rate constant decreases the amount of extruded material and results in filaments with a smaller basal radius. ,, Similarly, at fixed nozzle velocity and increasing infill flow rate, the basal radius increases. ,, Furthermore, the nozzle height can significantly influence the final bead shape by squeezing the fluid during deposition. , There are only a few studies on the effect of DIW operational parameters on the shape of the deposited filaments and almost all of them are limited to highly loaded pastes with minimized spreading. ,,− There is an important need for a quantitative relationship between printing parameters and the initial radius of the deposited filament and consequently its spreading dynamics, especially for the systems including medium to low-viscous fluids which undergo a considerable amount of spreading upon contact with the printing bed.…”

Section: Introductionmentioning

confidence: 99%

Predicting the Dynamics and Steady-State Shape of Cylindrical Newtonian Filaments on Solid Substrates

2023

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The spreading of liquid filaments on solid surfaces is of paramount importance to a wide range of applications including ink-jet printing, coating, and direct ink writing (DIW). However, there is a considerable lack of experimental, numerical, and theoretical studies on the spreading of filaments on solid substrates. In this work, we studied the dynamics of spreading of Newtonian filaments via experiment, numerical simulations, and theoretical analysis. More specifically, we used a novel experimental setup to validate a 2D moving mesh computational fluid dynamics (CFD) model. The CFD model is used to determine the effect of processing and fluid parameters on the dynamics of filament spreading. We experimentally showed that for a Newtonian filament, the same spreading dynamics and final shape are obtained when the initial radius is constant, independent of the magnitude in printing parameters. In other words, the only important parameter on the spreading of filaments is the initial filament radius. Using a numerical model, we showed that the initial filament radius manifests itself in two important dimensionless parameters, Bond number, Bo, and viscous timescale, τμ. Furthermore, the results clearly show that the dynamics of spreading are governed by the static advancing contact angle, θs. These three parameters determine a master spreading curve that can be used to predict the spreading of cylindrical filaments on flat substrates. Finally, we developed a theoretical model that was parameterized using experimental data to correlate the steady-state shape of filaments with Bo and θs. These results are particularly applicable for predicting and controlling the dynamics of filaments in DIW and other extrusion-based processes.

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Section: Introductionmentioning

confidence: 99%

Predicting the Dynamics and Steady-State Shape of Cylindrical Newtonian Filaments on Solid Substrates

2023

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“…Subsequent curing, often through processes like sintering, solidifies the metal particles, layer-by-layer, to form the desired 3D object. This technology enables the creation of intricate and customized metal components with a high level of precision, making it suitable for various applications, including prototyping and functional part production [48][49][50][51][52][53][54]. However, parts produced with this technology have high porosity and insufficient cohesion between layers [54].…”

Section: The Fff Process For Metallic Materialsmentioning

confidence: 99%

Fused Filament Fabrication for Metallic Materials: A Brief Review

Costa,

Sequeiros,

Vieira

2023

Materials

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Fused filament fabrication (FFF) is an extrusion-based additive manufacturing (AM) technology mostly used to produce thermoplastic parts. However, producing metallic or ceramic parts by FFF is also a sintered-based AM process. FFF for metallic parts can be divided into five steps: (1) raw material selection and feedstock mixture (including palletization), (2) filament production (extrusion), (3) production of AM components using the filament extrusion process, (4) debinding, and (5) sintering. These steps are interrelated, where the parameters interact with the others and have a key role in the integrity and quality of the final metallic parts. FFF can produce high-accuracy and complex metallic parts, potentially revolutionizing the manufacturing industry and taking AM components to a new level. In the FFF technology for metallic materials, material compatibility, production quality, and cost-effectiveness are the challenges to overcome to make it more competitive compared to other AM technologies, like the laser processes. This review provides a comprehensive overview of the recent developments in FFF for metallic materials, including the metals and binders used, the challenges faced, potential applications, and the impact of FFF on the manufacturing (prototyping and end parts), design freedom, customization, sustainability, supply chain, among others.

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“…Known for its cost-effectiveness and versatility, FFF is a popular choice for many applications [24,26,28,30,31]. Additionally, it is possible to use pellets as feedstocks (also a mixture of binders and powder metals) [4,5,[32][33][34], which avoids filament production using almost directly the materials from the mixture process [4][5][6] and Direct Ink Writing Processes where an ink with nanometric metal powder is used as feedstock [35][36][37][38]. This paper aims to provide a comprehensive overview of metallic materials FFF, including its principles, advantages, limitations, design considerations, advanced materials utilization, potential applications and prospects, and directions for research and development of metal FFF.…”

Section: Introductionmentioning

confidence: 99%

Fused Filament Fabrication for Metallic Materials: A Brief Review

Costa,

Sequeiros,

Vieira

2023

Preprint

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Extrusion-based additive manufacturing (AM) technologies (i.e., fused filament fabrication, FFF) mostly produce thermoplastic parts. However, producing metallic or ceramic parts by FFF is also a sintered-based AM process. FFF for metallic parts can be divided into five steps: (1) raw materials selection and feedstock mixture (including palletization), (2) filament production (extrusion), (3) production of AM components using the filament extrusion process, (4) debinding, and (5) sintering. These steps are interrelated, where the parameters interact with the other ones and have a key role in the integrity and quality of the final metallic parts. FFF can produce high-accuracy and complex metallic parts, potentially revolutionizing the manufacturing industry and taking AM components to a new level. In the FFF technology for metallic materials, material compatibility, production quality, and cost-effectiveness are the challenges to overcome to make it more competitive compared to other AM technologies, like the laser processes. This review provides a comprehensive overview of the recent developments in FFF for metallic materials, including the metals and binders used, the challenges faced, potential applications, and the impact of FFF on the manufacturing (prototyping and end parts), design freedom, customization, sustainability, supply chain, among others.

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Analysis of printing parameters for metal additive manufactured parts through Direct Ink Writing process

Cited by 12 publications

References 8 publications

Predicting the Dynamics and Steady-State Shape of Cylindrical Newtonian Filaments on Solid Substrates

Predicting the Dynamics and Steady-State Shape of Cylindrical Newtonian Filaments on Solid Substrates

Fused Filament Fabrication for Metallic Materials: A Brief Review

Fused Filament Fabrication for Metallic Materials: A Brief Review

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