Extrusion-based additive manufacturing of forming and molding tools

Strano, Matteo; Rane, Kedarnath; Farid, Muhammad Asad; Mussi, Valerio; Zaragoza, Veronica Geraldine; Monno, Michele

doi:10.1007/s00170-021-07162-8

Cited by 26 publications

(12 citation statements)

References 36 publications

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“…They concluded that polymer tools give similar UTS with respect to aluminum tools but lower elongation and brittle fracture. Strano and his coworkers [39] reviewed different types of rapid tools produced by material extrusion, both for sheet deformation and injection molding, including metal tools made by extrusion, debinding and sintering. Farioli and his colleagues [10] studied the effectivity, through DSC, DMA, compression tests, and simulations, of an injection mold produced by filament FDM with PEI 1010.…”

Section: Applicationsmentioning

confidence: 99%

Extrusion Additive Manufacturing of PEI Pellets

Fabrizio

Strano

Farioli

et al. 2022

JMMP

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The simplest, most cost-efficient, and most widespread Additive Manufacturing (AM) technology is Extrusion Additive Manufacturing (EAM). Usually, EAM is performed with filament feedstock, but using pellets instead of filaments yields many benefits, including significantly lower cost and a wider choice of materials. High-performance polymers offer high strength even when produced with AM technique, allowing to produce near-net-shape functional parts. The production of these materials in filament form is still limited and expensive; therefore, in this paper, the possibility of producing AM components with engineering polymers from pellets will be thoroughly investigated. In this work, the effectiveness of a specially designed AM machine for printing high-performance materials in pellet form was tested. The material chosen for the investigation is PEI 1000 which offers outstanding mechanical and thermal properties, giving the possibility to produce with EAM functional components. Sensitivity analyses have been carried out to define a process window in terms of thermal process parameters by observing different response variables. Using the process parameters in the specified range, the additive manufactured material has been mechanically tested, and its microstructure has been investigated, both in dried and undried conditions. Finally, a rapid tool for sheet metal forming has been produced.

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Section: Applicationsmentioning

confidence: 99%

Extrusion Additive Manufacturing of PEI Pellets

Fabrizio

Strano

Farioli

et al. 2022

JMMP

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“…These tools can be manufactured from metal alloys or polymers using the AM technology. The existing research has focused on evaluating their flexibility, feasibility and mechanical performance (Strano et al. , 2021).…”

Section: Introductionmentioning

confidence: 99%

Experimental and numerical investigations on the thermoforming of 3D-printed polylactic acid parts

Alexandru,

Popescu,

Constantin

et al. 2024

RPJ

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Purpose The purpose of this study is to investigate the thermoforming process of 3D-printed parts made from polylactic acid (PLA) and explore its application in producing wrist-hand orthoses. These orthoses were 3D printed flat, heated and molded to fit the patient’s hand. The advantages of such an approach include reduced production time and cost. Design/methodology/approach The study used both experimental and numerical methods to analyze the thermoforming process of PLA parts. Thermal and mechanical characteristics were determined at different temperatures and infill densities. An equivalent material model that considers infill within a print is proposed. Its practical use was proven using a coupled finite-element analysis model. The simulation strategy enabled a comparative analysis of the thermoforming behavior of orthoses with two designs by considering the combined impact of natural convection cooling and imposed structural loads. Findings The experimental results indicated that at 27°C and 35°C, the tensile specimens exhibited brittle failure irrespective of the infill density, whereas ductile behavior was observed at 45°C, 50°C and 55°C. The thermal conductivity of the material was found to be linearly related to the temperature of the specimen. Orthoses with circular open pockets required more time to complete the thermoforming process than those with hexagonal pockets. Hexagonal cutouts have a lower peak stress owing to the reduced reaction forces, resulting in a smoother thermoforming process. Originality/value This study contributes to the existing literature by specifically focusing on the thermoforming process of 3D-printed parts made from PLA. Experimental tests were conducted to gather thermal and mechanical data on specimens with two infill densities, and a finite-element model was developed to address the thermoforming process. These findings were applied to a comparative analysis of 3D-printed thermoformed wrist-hand orthoses that included open pockets with different designs, demonstrating the practical implications of this study’s outcomes.

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“…For example, research has shown that The compressive strength and surface finish in fused filament fabrication (FFF) parts play critical roles in various demanding applications. Notably, FFF finds application in metal forming and molding tools [8][9][10], jigs and fixtures [11,12], full-scale molds for wind turbine blades [13], packaging products [14,15], bone scaffolds [2], and medical implants [16], where compressive strength is essential to withstand compressive stresses. The surface finish is equally crucial in such applications.…”

Section: Introductionmentioning

confidence: 99%

Influence of Three-Dimensional Printing Parameters on Compressive Properties and Surface Smoothness of Polylactic Acid Specimens

Bakhtiari,

Nikzad,

Tolouei-Rad

2023

Polymers

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While the mechanical performance of fused filament fabrication (FFF) parts has been extensively studied in terms of the tensile and bending strength, limited research accounts for their compressive performance. This study investigates the effect of four process parameters (layer height, extrusion width, nozzle temperature, and printing speed) on the compressive properties and surface smoothness of FFF parts made of Polylactic Acid (PLA). The orthogonal Taguchi method was employed for designing the experiments. The surface roughness and compressive properties of the specimens were then measured and optimized using the analysis of variance (ANOVA). A microscopic analysis was also performed to identify the failure mechanism under static compression. The results indicated that the layer height had the most significant influence on all studied properties, followed by the print speed in the case of compressive modulus, hysteresis loss, and residual strain; extrusion width in the case of compressive strength and specific strength; and nozzle temperature in the case of toughness and failure strain. The optimal design for both high compressive properties and surface smoothness were determined as a 0.05 mm layer height, 0.65 mm extrusion width, 205 °C nozzle temperature, and 70 mm/s print speed. The main failure mechanism observed by SEM analysis was delamination between layers, occurring at highly stressed points near the stitch line of the PLA prints.

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Extrusion-based additive manufacturing of forming and molding tools

Cited by 26 publications

References 36 publications

Extrusion Additive Manufacturing of PEI Pellets

Extrusion Additive Manufacturing of PEI Pellets

Experimental and numerical investigations on the thermoforming of 3D-printed polylactic acid parts

Influence of Three-Dimensional Printing Parameters on Compressive Properties and Surface Smoothness of Polylactic Acid Specimens

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