Interlayer bonding has bulk-material strength in extrusion additive manufacturing: New understanding of anisotropy

Allum, James; Moetazedian, Amirpasha; Gleadall, Andrew; Silberschmidt, Vadim V.

doi:10.1016/j.addma.2020.101297

Cited by 38 publications

(92 citation statements)

References 41 publications

(114 reference statements)

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“…With FullControl, the band required no post-processing because it was printed with a single pass of the nozzle, extruding 250% of the nozzle diameter (aspect ratio of 5 for width:layer-height). This was found to achieve a solid structure with good mechanical integrity, as expected based on recent understanding that a wider aspect ratio for filament cross-sections improves mechanical performance [37] (discussed in Section 4.1). Due to improved mechanical integrity, it was possible to reduce weight by 20% whilst maintaining equivalent or improved performance.…”

Section: Industrial Manufacturingsupporting

confidence: 73%

“…That study investigated hundreds of different combinations of speed, acceleration, jerk, retraction, extrusion width, and other parameters. By enabling design geometric tolerances an order of magnitude smaller than the nozzle diameter,, a new micro-tensile-testing specimen was designed with extrusion-widths of filaments carefully controlled to achieve a dog-bone geometry (Figure 4A) [36,37]. This demonstrates the potential to design at completely new scales if process limitations are considered.…”

Section: Process Calibration Characterisation and Hardware Developmentmentioning

confidence: 99%

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FullControl GCode Designer: Open-source software for unconstrained design in additive manufacturing

Gleadall

2021

Additive Manufacturing

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Section: Industrial Manufacturingsupporting

confidence: 73%

Section: Process Calibration Characterisation and Hardware Developmentmentioning

confidence: 99%

FullControl GCode Designer: Open-source software for unconstrained design in additive manufacturing

Gleadall

2021

Additive Manufacturing

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“…With FullControl, the band required no post-processing because it was printed with a single pass of the nozzle, extruding 250% of the nozzle diameter (aspect ratio of 5 for width:layer-height). This was found to achieve a solid structure with good mechanical integrity, as expected based on recent understanding that a wider aspect ratio for filament cross-sections improves mechanical performance [36] (discussed further in Section 4.1 for micro-tensile-testing specimens). Due to improved mechanical integrity, it was possible to reduce weight by 20% whilst maintaining equivalent or improved performance.…”

supporting

confidence: 70%

“…In other process characterisation research, a new micro-tensile-testing specimen was designed with extrusion-widths of filaments carefully controlled to achieve a dog-bone geometry (Figure 4A) [35,36]. Structures were designed with geometric tolerances an order of magnitude smaller than the nozzle diameter, demonstrating the potential to design at completely new scales if process limitations are considered.…”

Section: Process Calibration Characterisation and Hardware Developmentmentioning

confidence: 99%

FullControl GCode Designer: open-source software for unconstrained design in additive manufacturing

Gleadall¹

2021

Preprint

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A new concept is presented for the design of additive manufacturing procedures, which is implemented in open-source software called FullControl GCode Designer. In this new design approach, the user defines every segment of the print-path along with all printing parameters, which may be related to geometric and non-geometric factors, at all points along the print-path. Machine control code (GCode) is directly generated by the software, without the need for any programming skills and without using computer-aided design (CAD), STL-files or slicing software. Case studies are used to demonstrate the broad range of structures that can be designed using the software, including: precisely controlled specimens for printer calibration, parametric specimens for hardware characterisation utilising hundreds of unique parameter combinations, novel mathematically defined lattice structures, and previously inconceivable 3D geometries that are impossible for traditional slicing software to achieve. FullControl GCode Designer enables unconstrained freedom to create nonplanar 3D print-paths and break free from traditional restrictions of layerwise print-path planning. It also allows nozzle movements to be carefully designed - both during extrusion and while travelling between disconnected extrusion volumes - to overcome inherent limitations of the printing process or to improve capabilities for challenging materials. An industrial case study shows how explicit print-path design improved printer reliability, production time, and print quality for a production run of over 1,000 parts. FullControl GCode Designer offers a general framework for unconstrained design and is not limited to a particular type of structure or hardware; transferability to lasers and other manufacturing processes is discussed. Parametric design files use a few bytes or kilobytes of data to describe all details that are sent to the printer, which greatly improves shareability by eliminating any risk of errors being introduced during STL file conversion or due to different users having inconsistent slicer settings. Adjustable parameters allow GCode for revised designs to be produced instantly, instead of the laborious traditional routine using multiple software packages and file conversions. The FullControl design concept offers new opportunities for creative and high-precision use of additive manufacturing systems. It facilitates design for additive manufacturing (DfAM) at the smallest possible scale based on the fundamental nature of the process (i.e. assembly of individual extrusions). The software and source code are provided as supplementary data and ongoing updates will be available at www.fullcontrolgcode.com.

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“…We performed preliminary mechanical testing on the films produced here and demonstrated that the results are consistent with those obtained from similar films produced using other methods and are also consistent with the anticipated structure and properties of the films. In addition, since the slot die process is an example of a polymer extrusion process, some of which are known to influence the structure and properties of the resulting polymer [ 17 , 18 , 19 ], we performed a very preliminary assessment of the chitosan-only films in terms of direction of extrusion and found no evidence for any such effects.…”

Section: Introductionmentioning

confidence: 99%

A Slot-Die Technique for the Preparation of Continuous, High-Area, Chitosan-Based Thin Films

et al. 2021

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Chitosan-based films have a diverse range of potential applications but are currently limited in terms of commercial use due to a lack of methods specifically designed to produce thin films in high volumes. To address this limitation directly, hydrogels prepared from chitosan, chitosan-tetraethoxy silane, also known as tetraethyl orthosilicate (TEOS) and chitosan-glutaraldehyde have been used to prepare continuous thin films using a slot-die technique which is described in detail. By way of preliminary analysis of the resulting films for comparison purposes with films made by other methods, the mechanical strength of the films produced was assessed. It was found that as expected, the hybrid films made with TEOS and glutaraldehyde both show a higher yield strength than the films made with chitosan alone. In all cases, the mechanical properties of the films were found to compare very favorably with similar measurements reported in the literature. In order to assess the possible influence of the direction in which the hydrogel passes through the slot-die on the mechanical properties of the films, testing was performed on plain chitosan samples cut in a direction parallel to the direction of travel and perpendicular to this direction. It was found that there was no evidence of any mechanical anisotropy induced by the slot die process. The examples presented here serve to illustrate how the slot-die approach may be used to create high-volume, high-area chitosan-based films cheaply and rapidly. It is suggested that an approach of the type described here may facilitate the use of chitosan-based films for a wide range of important applications.

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Interlayer bonding has bulk-material strength in extrusion additive manufacturing: New understanding of anisotropy

Cited by 38 publications

References 41 publications

FullControl GCode Designer: Open-source software for unconstrained design in additive manufacturing

FullControl GCode Designer: Open-source software for unconstrained design in additive manufacturing

FullControl GCode Designer: open-source software for unconstrained design in additive manufacturing

A Slot-Die Technique for the Preparation of Continuous, High-Area, Chitosan-Based Thin Films

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