Extruded polymer instability study of the polylactic acid in fused filament fabrication process: Printing speed effects on tensile strength

Abstract

In recent years, additive manufacturing (AM) processes have allowed the building of complex parts and objects with favorable geometric shapes without the need for fabricating special tools. In AM, objects are built layer by layer. Advantages include the possibility of forming complex shapes, reduced waste, no special requirements, and so forth. A critical parameter to consider in AM technologies is the processing (printing) speed, which, if increased, can reduce production (printing) time and expenses. Thus, speeding up the production time in AM has always been paramount. In recent years, fused filament fabrication (FFF) has been extensively developed due to straightforward processing, reliability, and ability to build complex objects and parts from thermoplastic materials. In addition to simplicity, this method has some shortcomings, including low printing speed and instability during the rasters deposition when speeding up the printing process, which is investigated in this study. The results showed that the nozzle height from the work‐piece surface and nozzle diameter play a critical role in the process instability. Additionally, there is a critical limit in the formation of molten instability independent of the printing speed. Furthermore, the effect of printing speed on tensile strength was investigated. The results showed that optimizing the nozzle temperature and the extra extrusion multiplier allows printing a high‐quality part having optimum tensile and mechanical properties by the maximum printing speed.

Novel advancements in additive manufacturing of PLA: A review

“…Meanwhile, PNCs have been fabricated with enhanced thermal and electrical conductivity, improved mechanical and thermal expansion, and increased fire retardancy for automotive, oil and gas, and other versatile applications 137–207 . Finally, it is emphasized that 3‐DPT and 4‐DPT are innovative processing technologies, presenting the future route of the manufacturing sector 208–244 …”

Optimization of polylactic acid 3D printing parameters based on support vector regression and cuckoo search

“…Among them, FDM has the advantages of high production efficiency, simple operation, and can greatly reduce material loss in the production process, is widely used in aerospace, wind power generation, automobile, medical, sports, and other fields. 4 Nonetheless, the lack of reasonable process parameters selection, which often leads to warping and sagging of the part, is a bottleneck for the widespread application of polymer 3D printing in industry. Therefore, how to determine the optimal process parameter combination, so as to reduce the warping and sagging of the workpiece, and improve the shape accuracy, must be properly studied and understood.…”

“…Common types of 3D printing include fused deposition molding (FDM), stereo lithography apparatus (SLA), selective laser sintering (SLS), selective laser melting (SLM), and so forth. Among them, FDM has the advantages of high production efficiency, simple operation, and can greatly reduce material loss in the production process, is widely used in aerospace, wind power generation, automobile, medical, sports, and other fields 4 . Nonetheless, the lack of reasonable process parameters selection, which often leads to warping and sagging of the part, is a bottleneck for the widespread application of polymer 3D printing in industry.…”

Direct ink writing‐based additive manufacturing of styrene‐isoprene‐styrene block copolymer

“…6,7 Depending on the type of material, different AM techniques are used to process it, such as stereolithography, material jetting (such as in direct inkjet), material extrusion, powder-based fusion (such as in selective laser sintering (SLS)), etc. [8][9][10][11][12] The most efficient AM process for solid thermoplastics is material extrusion additive manufacturing, which is based on fused deposition modeling (FDM). 13 Amorphous thermoplastics, such as polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS), are compatible with FDM 3D printer.…”