Experimental investigation and optimization of printing parameters of3Dprinted polyphenylene sulfide through response surface methodology

Abstract

Today fused filament fabrication is one of the most widely used additive manufacturing techniques to manufacture high performance materials. This method entails a complexity associated with the selection of their appropriate manufacturing parameters. Due to the potential to replace poly-ether-etherketone in many engineering components, polyphenylene sulfide (PPS) was selected in this study as a base material for 3D printing. Using central composite design and response surface methodology (RSM), nozzle temperature (T), printing speed (S), and layer thickness (L) were systematically studied to optimize the output responses namely Young's modulus, tensile strength, and degree of crystallinity. The results showed that the layer thickness was the most influential printing parameter on Young's modulus and degree of crystallinity. According to RSM, the optimum factor levels were achieved at 338 C nozzle temperature, 30 mm/s printing speed, and 0.17 mm layer thickness. The optimized post printed PPS parts were then annealed at various temperatures to erase thermal residual stress generated during the printing process and to improve the degree of crystallinity of printed PPS's parts. Results showed that annealing parts at 200 C for 1 hr improved significantly the thermal, structural, and tensile properties of printed PPS's parts. K E Y W O R D S crystallization, glass transition, mechanical properties, thermal properties 1 | INTRODUCTION Fused deposition modeling (FDM), also called fused filament fabrication (FFF), is a very popular additive manufacturing (AM) technology for its simplicity and low investment costs. [1] It relies on the deposition of a liquefied thermoplastic polymer filament in a layer upon layer manner. The precise control of the extruder head enables direct fabrication of three-dimensional complex geometries from a computer-aided design (CAD) system. FFF often considers as a simple and efficient process to print commodity polymers, such as polylactic acid (PLA), acrylonitrile butadiene styrene, polycarbonate, and highdensity polyethylene due to their low cost and simple operation. [2-7] However, when applied to manufacture high performance thermoplastics (HPT), the FFF equipment faces a number of challenges to achieve optimized results for both material properties and part quality. Among these challenges, high melting temperature, large thermal expansion, and large temperature gradient are

Influence of fused filament fabrication parameters on tensile properties of polylactide/layered silicate nanocomposite using response surface methodology

“…The poor filament adhesion would increase the anisotropy of the printed part by lowering the mechanical properties in the building direction 21 . Other phenomena might also influence the effect of temperature on mechanical properties, such as crystallinity 10,22 or matrix degradation, 23 and cause a more difficult understanding of this thermal behavior. Printing speed and temperature are thought to interact, since printing speed can modify the time between two adjacent depositions, which is the time allowed for a filament to weld before the temperature falls below the glass transition 24 .…”

An overview on the influence of process parameters through the characteristic of 3D-printed PEEK and PEI parts

“…A recent review of the literature on this matter found that the layer thickness of deposited material through a nozzle has a direct impact on the adhesion between layers, printing speed, porosity, and on the resulting mechanical properties. 13,25–28 As mentioned by Anitha et al 29 the layer height contributes to 51% in the variance of surface roughness. They suggested that optimal surface roughness can be achieved with a reduced extrusion width and increased layer height.…”

“…31 More literature studies have revealed that nozzle temperature has a direct effect on polymer fluidity and viscosity that will, in turn, influence the resulting properties during the cooling phases such as interlayer bonding and surface quality. 13,32–34 El Magri et al 26 studied the effect of nozzle temperature on the tensile properties and crystallinity of printed Polyphenylene sulfide (PPS) using FFF process. Results show that printing samples at 340°C nozzle temperature yield the highest values of tensile properties and degree of crystallinity.…”

An Investigation to Study the Effect of Process Parameters on the Strength and Fatigue Behavior of 3D-Printed PLA-Graphene

“…In this method, the thermoplastic filament is fed into a heated nozzle, melted, and subsequently extruded and deposited layer by layer onto a build plate forming the desired 3D part [ 9 , 10 ]. Various thermoplastics and composites are currently used to produce 3D parts satisfactorily by the FFF process [ 11 , 12 , 13 ]. In the latter, multiple controllable printing parameters, such as liquefier and platform temperature, print speed, raster angle, and layer thickness, are accounted to produce highly qualified 3D-printed parts.…”

“…In another study, researchers found that the liquefier temperature, print speed, raster angle, and layer thickness parameters need to be taken into serious consideration. They found that these printing parameters impact directly the tensile properties and crystallinity of FFF printed materials [ 2 , 8 , 11 ]. Another study performed to determine the tensile properties and surface roughness of ABS to optimize the process parameters of FFF [ 24 ].…”