Design of a hybrid high-throughput fused deposition modeling system for circular economy applications

Kuclourya, Tanay; Monroy, Roberto; Castillo, Miguel; Bača, D.

doi:10.3934/ctr.2022010

Cited by 7 publications

(3 citation statements)

References 60 publications

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“…The reason for this large nozzle size is that this printer was designed as a hybrid system where recycled material will be used as pellets for the infill through direct deposition and for better finishing of the filament system on the visible faces of the part (outer walls, and top and bottom layers). In order to guarantee a high throughput and slicing compatibility between both deposition systems, a nozzle size of a similar diameter to the pellet nozzle was used; more information can be found in [ 41 ].…”

Section: Cyber Physical Production System and Design Of Experimentsmentioning

confidence: 99%

Design of Experiments to Compare the Mechanical Properties of Polylactic Acid Using Material Extrusion Three-Dimensional-Printing Thermal Parameters Based on a Cyber–Physical Production System

Castillo,

Monroy,

Ahmad

2023

Sensors

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The material extrusion 3D printing process known as fused deposition modeling (FDM) has recently gained relevance in the additive manufacturing industry for large-scale part production. However, improving the real-time monitoring of the process in terms of its mechanical properties remains important to extend the lifespan of numerous critical applications. To enhance the monitoring of mechanical properties during printing, it is necessary to understand the relationship between temperature profiles and ultimate tensile strength (UTS). This study uses a cyber–physical production system (CPPS) to analyze the impact of four key thermal parameters on the tensile properties of polylactic acid (PLA). Layer thickness, printing speed, and extrusion temperature are the most influential factors, while bed temperature has less impact. The Taguchi L-9 array and the full factorial design of experiments were implemented along with the deposited line’s local fused temperature profile analysis. Furthermore, correlations between temperature profiles with the bonding strength during layer adhesion and part solidification can be stated. The results showed that layer thickness is the most important factor, followed by printing speed and extrusion temperature, with very close influence between each other. The lowest impact is attributed to bed temperature. In the experiments, the UTS values varied from 46.38 MPa to 56.19 MPa. This represents an increase in the UTS of around 17% from the same material and printing design conditions but different temperature profiles. Additionally, it was possible to observe that the influence of the parameter variations was not linear in terms of the UTS value or temperature profiles. For example, the increase in the UTS at the 0.6 mm layer thickness was around four times greater than the increase at 0.4 mm. Finally, even when it was found that an increase in the layer temperature led to an increase in the value of the UTS, for some of the parameters, it could be observed that it was not the main factor that caused the UTS to increase. From the monitoring conditions analyzed, it was concluded that the material requires an optimal thermal transition between deposition, adhesion, and layer solidification in order to result in part components with good mechanical properties. A tracking or monitoring system, such as the one designed, can serve as a potential tool for reducing the anisotropy in part production in 3D printing systems.

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Section: Cyber Physical Production System and Design Of Experimentsmentioning

confidence: 99%

Design of Experiments to Compare the Mechanical Properties of Polylactic Acid Using Material Extrusion Three-Dimensional-Printing Thermal Parameters Based on a Cyber–Physical Production System

Castillo,

Monroy,

Ahmad

2023

Sensors

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“…As shown in Supplemental Table 14, researcher established the relationships between screw rotation and the various types of flow rate in the extruder based on different theories. [122][123][124][125] Data obtained during tool path generation is then converted to G and M codes as shown in Supplemental Figure 34(a). This G and M codes have been used along with 3-axis CNC milling machines (Okuma, Japan) for the printing of AM objects.…”

Section: Tool Path Generation For Pellets Extrusion 118mentioning

confidence: 99%

Extrusion strategies in fused deposition additive manufacturing: A review

Krishnanand

Singh

Mittal

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part E:

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Fused deposition or fused layer additive manufacturing is a technique in which a part is fabricated layer by layer using filament or pellets-form input material. The extruder is the central part of the fused deposition additive manufacturing (FDAM) system. The extrusion mechanism is unique to the geometry and form of the feedstock material. Extrusion of filament-form material through the nozzle needs to design of a material feeding mechanism based on various filament extrusion parameters. At the same time if the material is in the form of pellets, then the design of the feeding mechanism is very different due to the shape and size of the pellets. These two different design strategies for material extrusion namely the design of the feeding mechanism of filament and pellets form materials have been a major concern to avoid unwanted deformation of extruded materials in FDAM. These two design strategies for filament and pellet-form materials have led to the development of several material extrusion strategies. The present paper reviews various material extrusion strategies developed for FDAM of filament or pellets form input material. This article presents the review of design, development, performance evaluation, and process planning for each extrusion strategy. Based on the literature review authors have suggested a possible extrusion method that can accept both forms of materials to fulfill the need for the filament as well as pellets-based additive manufacturing.

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“…Fused deposited modelling (FDM) appears to be a promising technology to employ in 2023, as research in this area has advanced since open-source printers became available on the market. Previous studies have indicated that having successfully printed composites may bring about industrial advantages due to their ability to broaden the economic impact whilst increasing the recyclability of polymeric composite materials [1]. Achieving a proper understanding and functional capability of polymeric composite samples or products through FDM printing will allow greater versatility, especially in metal-composite materials [2].…”

Section: Introductionmentioning

confidence: 99%

Mechanical Analysis of 3D Printed Polyamide Composites under Different Filler Loadings

et al. 2023

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The production of fabricated filaments for fused deposited modelling printing is critical, especially when higher loading filler (>20 wt.%) is involved. At higher loadings, printed samples tend to experience delamination, poor adhesion or even warping, causing their mechanical performance to deteriorate considerably. Hence, this study highlights the behaviour of the mechanical properties of printed polyamide-reinforced carbon fibre at a maximum of 40 wt.%, which can be improved via a post-drying process. The 20 wt.% samples also demonstrate improvements of 500% and 50% in impact strength and shear strength performance, respectively. These excellent performance levels are attributed to the maximum layup sequence during the printing process, which reduces the fibre breakage. Consequently, this enables better adhesion between layers and, ultimately, stronger samples.

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Design of a hybrid high-throughput fused deposition modeling system for circular economy applications

Cited by 7 publications

References 60 publications

Design of Experiments to Compare the Mechanical Properties of Polylactic Acid Using Material Extrusion Three-Dimensional-Printing Thermal Parameters Based on a Cyber–Physical Production System

Design of Experiments to Compare the Mechanical Properties of Polylactic Acid Using Material Extrusion Three-Dimensional-Printing Thermal Parameters Based on a Cyber–Physical Production System

Extrusion strategies in fused deposition additive manufacturing: A review

Mechanical Analysis of 3D Printed Polyamide Composites under Different Filler Loadings

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