Effect of particle size on the properties of highly-filled polymers for fused filament fabrication

Kukla, Christian; González-Gutiérrez, Joamín; Đuretek, Ivica; Schuschnigg, Stephan; Holzer, Clemens

doi:10.1063/1.5016795

Cited by 49 publications

(48 citation statements)

References 5 publications

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“…Small powders were preferred for the use of smaller nozzles. In another study, Kukla et al [ 111 ] reported that increasing the average particle size (from 5.5. to 8.6 μm) of round steel particles (316L) used in the filament, while maintaining all parameters constant, can lead to unprintable filaments. The increase in the average particle size resulted in the decrease of apparent viscosity and secant modulus of the filaments by ca.…”

Section: Materials Extrusion Additive Manufacturing Of Highly-fillementioning

confidence: 99%

“…The decrease in secant modulus can be linked to a decrease in stiffness and thus it was responsible for the tendency to buckle at the feeding mechanism of conventional FFF machines, resulting in failure during printing. One possible solution to this problem could be to modify the proportion of backbone in the binder system, as discussed previously [ 111 ].…”

Section: Materials Extrusion Additive Manufacturing Of Highly-fillementioning

confidence: 99%

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Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives

et al. 2018

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Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented.

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Section: Materials Extrusion Additive Manufacturing Of Highly-fillementioning

confidence: 99%

Section: Materials Extrusion Additive Manufacturing Of Highly-fillementioning

confidence: 99%

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives

et al. 2018

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“…The particle size data measured by laser diffraction and the chemical composition as given by the producer are shown in Table 1. The particle size distribution is mentioned because it is a factor that greatly determines the FFF processability of the produced feedstocks [54]. Feedstock was prepared in a co-rotating twin-screw extruder (Leistritz ZSE 18 HP-48D, Leistritz Extrusionstechnik GmbH, Nuremberg, Germany).…”

Section: Feedstock Filamentsmentioning

confidence: 99%

Optimization of the 3D Printing Parameters for Tensile Properties of Specimens Produced by Fused Filament Fabrication of 17-4PH Stainless Steel

et al. 2020

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Fused filament fabrication (FFF) combined with debinding and sintering could be an economical process for three-dimensional (3D) printing of metal parts. In this paper, compounding, filament making, and FFF processing of feedstock material with 55% vol. of 17-4PH stainless steel powder in a multicomponent binder system are presented. The experimental part of the paper encompasses central composite design for optimization of the most significant 3D printing parameters (extrusion temperature, flow rate multiplier, and layer thickness) to obtain maximum tensile strength of the 3D-printed specimens. Here, only green specimens were examined in order to be able to determine the optimal parameters for 3D printing. The results show that the factor with the biggest influence on the tensile properties was flow rate multiplier, followed by the layer thickness and finally the extrusion temperature. Maximizing all three parameters led to the highest tensile properties of the green parts.One of the most commonly used AM technologies for the production of metal parts is PBF. In PBF, a laser or electron beam selectively fuses metal powder or metal powder covered with a binding agent by scanning cross-sectional layers generated from a CAD file of the part on the surface of a powder bed. After one cross-section is scanned, the powder bed is lowered and a new layer of powder is added on top of the previous one; the process repeats until the part is finished [6]. One of the biggest disadvantages of PBF is that it relies on high-power lasers or high-energy electron beams, which can be very costly. In addition, the powder must be free-flowing and, therefore, it requires a specific powder distribution, which adds to the price of the material. Therefore, MEAM shows great promise as a cost-effective alternative since the shaping equipment is orders of magnitude cheaper than PBF [6], and powders with a great range of particle size distributions can be processed. In the most common type of MEAM, the building material is supplied in the form of spooled filaments and, therefore, is also known as fused filament fabrication (FFF). In most FFF machines, the filament is fed into a heating unit with a nozzle using counter-rotating rollers as a feeding system. The extrusion head is controlled to move in the XY plane, and, as it moves, material is extruded through the nozzle on a flat platform that moves in the Z-direction [5]. However, there are also MEAM systems, where the extrusion system is fixed and the printing platform moves in three axes [7], and systems where the printed head moves in three axes and the building platform is fixed [8].FFF was first developed for polymeric materials; however, for the fabrication of metal or ceramic parts, a filament made of a polymeric blend filled with a large portion of metal or ceramic particles, known as feedstock, is used. After shaping the filament into what is referred to as the green parts, the binder system is removed from the part by thermal, catalytic, or solvent extraction and then sintered to ob...

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“…Additive manufacturing (AM) is extensively used in polymers for prototyping due to the flexibility in shaping [1][2][3][4][5]. Recently, interest has also been seen for 3D printing of ceramic and metals [6][7][8][9][10].…”

Section: Introductionmentioning

confidence: 99%

Effect of parameters on 3D printing of alumina ceramics and evaluation of properties of sintered parts

Mamatha

Biswas

Ramavath

et al. 2021

Journal of Asian Ceramic Societies

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Paste rheology and printing parameters contribute to a great extent to engineer the properties of ceramic parts produced through 3D printing process. Alumina paste, which showed shear thinning behavior, was prepared using optimum concentration of additives. Paste was 3D printed and effect of printing parameters such as printing speed, length to diameter (L/D) ratio of nozzle, self-standing distance of extrudate, filling pattern and filling angle have been studied. Additionally, effect of the substrate material on which the extrudate is printed was also elucidated. A printing speed of 5-6 mm/s, an L/D ratio of 25 mm and self-standing distance of 1.25 ± 0.25 mm are found to be optimum. Further, a filling pattern of rectilinear geometry along with filling angle of 90° is found to be desirable. Out of the substrates evaluated, polished metal surface is found to be relatively better to achieve close tolerances. The alumina samples printed under optimized conditions are found to possess integrity with respect to the structure and close to pre-designed dimensions. Sintered samples were found to be free of crack and exhibited a density of 3.88 g/cc (97.5% of theoretical density). Density and hardness (16.5 GPa) of printed part correlates well with the microstructure consisting of grains of average size of 9.68 μm.

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Effect of particle size on the properties of highly-filled polymers for fused filament fabrication

Cited by 49 publications

References 5 publications

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives

Optimization of the 3D Printing Parameters for Tensile Properties of Specimens Produced by Fused Filament Fabrication of 17-4PH Stainless Steel

Effect of parameters on 3D printing of alumina ceramics and evaluation of properties of sintered parts

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