Experimental Optimization of Fused Deposition Modelling Processing Parameters: A Design-for-Manufacturing Approach

Alafaghani, Ala’aldin; Qattawi, Ala; Alrawi, Buraaq; Guzman, Arturo

doi:10.1016/j.promfg.2017.07.079

Cited by 377 publications

(232 citation statements)

References 22 publications

Supporting

Mentioning

219

Contrasting

Unclassified

Order By: Relevance

“…It has to be pointed out that, in this research, only the polymer component (45% vol.) was melted during the FFF process; therefore, the effect of extrusion temperature on tensile properties was not as strong as in case of FFF of pure polymer material [46][47][48][49][50][51][52][53].…”

Section: Statistical Analysis Of Tensile Strengthmentioning

confidence: 99%

“…Several studies are available where the tensile properties of polymeric parts produced by MEAM were investigated. For example, Bayraktar et al [46], Alafaghani et al [47], Chacon et al [48], and Spoerk et al [49] investigated PLA (Polylactic Acid) parts; Ahn et al [50], Reddy et al [51], and Álvarez et al [52] investigated ABS parts; finally, Spoerk et al [53] investigated filled polypropylene. However, information of the optimization of the printing conditions to improve the tensile properties of feedstocks to obtain high-quality sintered metallic parts shaped by FFF is not available in the open literature.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

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

et al. 2020

View full text Add to dashboard Cite

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...

show abstract

Section: Statistical Analysis Of Tensile Strengthmentioning

confidence: 99%

Section: Introductionmentioning

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

View full text Add to dashboard Cite

show abstract

“…FDM technology has been applied for printing of cellulose reinforced PLA . Due to layer‐by‐layer process, the mechanical properties of the printed specimens are strongly influenced by the building direction, extrusion temperature, and height of the layers but less significantly on the infill shape and printing speed . In order to achieve good repeatability in terms of the physical properties of the materials, the samples have to be obtained under appropriate process parameters.…”

Section: Introductionmentioning

confidence: 99%

Nanoindentation analysis of 3D printed poly(lactic acid)‐based composites reinforced with graphene and multiwall carbon nanotubes

Batakliev

Georgiev²,

Ivanov

et al. 2018

J of Applied Polymer Sci

View full text Add to dashboard Cite

Influences of different nanocomposite loadings in poly(lactic acid) (PLA) matrix on resulting hardness and elasticity were examined in nanoindentation experiments. The following study was focused on the nanomechanical properties of PLA reinforced with graphene nanoplatelets (GNPs) and multiwall carbon nanotubes (MWCNTs) by using Berkovich type pyramidal nanoindenter. A masterbatch strategy was developed to disperse GNP and MWCNT into PLA by melt blending. Young's modulus and nanohardness of as‐prepared nanocomposites were characterized as a function of the graphene and carbon nanotubes loading. The nanoindentation analysis reveals that these carbon nanofillers improve the mechanical stability of the nanocomposites GNP/PLA, MWCNT/PLA, and GNP/MWCNT/PLA. That improvement of mechanical properties strongly depends on the fillers content. It was found that the best mechanical performance was achieved for the compound having 6 wt % graphene and 6 wt % MWCNTs in the PLA matrix. The received values for nanohardness and Young's modulus are among the highest reported for PLA‐based nanocomposites. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019, 136, 47260.

show abstract

“…The large decrease in strength of batch A compared to batch B is in line with expectations. A combination of a low temperature and high print speed is known to reduce stiffness and strength [24]. Reducing the fill percentage from 100% in batch B to 65% in batch C resulted in the same decrease of strength, using less material than in batch A.…”

Section: Discussionmentioning

confidence: 99%

“…When 3D printing, there is a wide choice of slicer settings that influence the quality of the printed product. Previous studies have shown that surface roughness, strength, stiffness, dimensional accuracy, and build time depend-among others-on layer thickness, print temperature, infill percentage, the number of shell perimeters, and print speed [23][24][25][26][27]. The perfect combination of settings depends on the desired properties of a product and is expected to vary for the wide range of medical tools that could be 3D printed.…”

Section: Introductionmentioning

confidence: 99%

The Effect of Chemical Cleaning on Mechanical Properties of Three-Dimensional Printed Polylactic Acid

Fleischer

Diehl

Wauben

et al. 2020

Journal of Medical Devices

View full text Add to dashboard Cite

Three-dimensional (3D) printing may be a solution to shortages of equipment and spare parts in the healthcare sector of low-and middle-income countries (LMICs). Polylactic acid (PLA) for 3D printing is widely available and biocompatible, but there is a gap in knowledge concerning its compatibility with chemical disinfectants. In this study, 3Dprinted PLA tensile samples were created with six different printer settings. Each of these six batches consisted of five sets with five or six samples. The first set remained untreated, the others were soaked in Cidex OPA or in a chlorine solution. These were applied for seven consecutive days or in 25 short cycles. All samples were weighed before and after treatment and subjected to a tensile test. Results showed that a third of the treatments led to an increase of the median weight with a maximum of 8.3%, however, the samples with the best surface quality did not change. The median strength increase was 12.5% and the largest decrease was 8.8%. The median stiffness decreased 3.6% in one set and increased in three others up to 13.6%. When 3D printing PLA medical tools, surface porosity must be minimized to prevent transfer of disinfectants to people. The wide variability of mechanical properties due to 3D printing itself and as a consequence of disinfection must be considered when designing medical tools by selecting appropriate printer settings. If these conditions are met, reusing 3D-printed PLA medical tools seems safe from a mechanical point of view.

show abstract

Experimental Optimization of Fused Deposition Modelling Processing Parameters: A Design-for-Manufacturing Approach

Cited by 377 publications

References 22 publications

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

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

Nanoindentation analysis of 3D printed poly(lactic acid)‐based composites reinforced with graphene and multiwall carbon nanotubes

The Effect of Chemical Cleaning on Mechanical Properties of Three-Dimensional Printed Polylactic Acid

Contact Info

Product

Resources

About