Material Extrusion of Multi-Polymer Structures Utilizing Design and Shrinkage Behaviors: A Design of Experiment Study

Al-Tamimi, Abdulsalam Abdulaziz; Tlija, Mehdi; Abidi, Mustufa Haider; Anis, Arfat; Elgawad, Abd Elatty E. Abd

doi:10.3390/polym15122683

Cited by 12 publications

(11 citation statements)

References 51 publications

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“…The parameters R t and R z are not strongly influenced by printing parameters, unlike R a which increases with layer thickness for both analyzed materials. This observation is in accordance with the literature findings [ 45 , 46 , 63 ], where it is specified that a high layer thickness results in an increased R a .…”

Section: Resultssupporting

confidence: 93%

“…Figure 15 , Figure 16 and Figure 17 also reveal that the most significant factor influencing the surface roughness is layer thickness. The same conclusion is presented in [ 46 ], where it was found that the layer thickness had a contribution percentage for R a of 51.56%, whereas layer composition contributed only 4.10%.…”

Section: Resultssupporting

confidence: 85%

“…Optimization techniques play a crucial role in identifying optimal parameters for enhanced performance. Subsequently, researchers [ 40 , 41 , 42 , 43 , 44 , 45 , 46 , 47 , 48 , 49 ] have applied various optimization techniques to refine the parameters directly affecting the mechanical performance of 3D-printed parts. Response surface methodology is a common method used in scientific papers [ 41 , 43 , 48 , 50 , 51 , 52 , 53 , 54 , 55 ] for optimization analysis.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of 3D Printing Parameters for Enhanced Surface Quality and Wear Resistance

et al. 2023

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In recent years, there has been a growing interest in the field of 3D printing technology. Among the various technologies available, fused deposition modeling (FDM) has emerged as the most popular and widely used method. However, achieving optimal results with FDM presents a significant challenge due to the selection of appropriate process parameters. Therefore, the objective of this research was to investigate the impact of process parameters on the tribological and frictional behavior of acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) 3D-printed parts. The design of experiments (DOE) technique was used considering the input design parameters (infill percentage and layer thickness) as variables. The friction coefficient values and the wear were determined by experimental testing of the polymers on a universal tribometer employing plane friction coupling. Multi-response optimization methodology and analysis of variance (ANOVA) were used to highlight the dependency between the coefficient of friction, surface roughness parameters, and wear on the process parameters. The optimization analysis revealed that the optimal 3D printing input parameters for achieving the minimum coefficient of friction and linear wear were found to be an infill percentage of 50% and layer thickness of 0.1 mm (for ABS material), and an infill percentage of 50%, layer thickness of 0.15 mm (for PLA material). The suggested optimization methodology (which involves minimizing the coefficient of friction and cumulative linear wear) through the optimized parameter obtained provides the opportunity to select the most favorable design conditions contributing to a more sustainable approach to manufacturing by reducing overall material consumption.

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Section: Resultssupporting

confidence: 93%

Section: Resultssupporting

confidence: 85%

Section: Introductionmentioning

confidence: 99%

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Optimization of 3D Printing Parameters for Enhanced Surface Quality and Wear Resistance

et al. 2023

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“…The build orientation is considered as one of the manufacturing factors of printing cost and time. Al-Tamimi et al conducted experimental investigations to assess the influence of printing parameters-specifically layer thickness, nozzle temperature, printing speed, raster angle, and layer composition (ABS-PLA)-on various aspects of the printed material [32]. These aspects include mechanical properties, such as bonding modulus, compression modulus, and strength, as well as surface roughness (Ra, Rz, Rku, and Rsk), and dimensional variations related to shrinkage.…”

Section: Related Workmentioning

confidence: 99%

Minimizing Dimensional Defects in FFF Using a Novel Adaptive Slicing Method Based on Local Shape Complexity

Elayeb,

Tlija,

Eltaief

et al. 2024

JMMP

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Additive Manufacturing (AM) has emerged as an innovative technology that gives designers several advantages, such as geometric freedom of design and less waste. However, the quality of the parts produced is affected by different design and manufacturing parameters, such as the part orientation, the nozzle temperature and speed, the support material, and the layer thickness. In this context, the layer thickness is considered an important AM parameter affecting the part quality and accuracy. Thus, in this paper, a new adaptative slicing method based on the cusp vector and the surface deviation is proposed with the aim of minimizing the dimensional defects of FFF printed parts and investigate the impact on the dimensional part tolerancing. An algorithm is developed to automatically extract data from the STL file, select the build orientation, and detect intersection points between the initial slicing and the STL mesh. The innovation of this algorithm is exhibited via adapting the slicing according to the surface curvature based on two factors: the cusp vector and the surface deviation. The suggested slicing technique guarantees dimensional accuracy, especially for complex feature shapes that are challenging to achieve using a uniform slicing approach. Finally, a preview of the slicing is displayed, and the G-code is generated to be used by the FFF machine. The case study consists of the dimensional tolerance inspection of prototypes manufactured using the conventional and adaptive slicing processes. The proposed method’s effectiveness is investigated using RE and CMM processes. The method demonstrates its reliability through the observed potential for accuracy improvements exceeding 0.6% and cost savings of up to 4.3% in specific scenarios. This reliability is substantiated by comparing the resulting dimensional tolerances and manufacturing costs.

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“…Over the years, MEX has been adopted in numerous sectors, including composites [ 4 ], scaffolds [ 5 ], energy harvesting [ 6 ], pharmaceuticals [ 7 ], and home applications [ 8 ]. Moreover, MEX is playing a significant role in the recycling and recovery of different thermoplastic composites [ 9 , 10 , 11 ].…”

Section: Introductionmentioning

confidence: 99%

Material Extrusion of Wool Waste/Polycaprolactone with Improved Tensile Strength and Biodegradation

Haque,

Naebe

2023

Polymers

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Additive manufacturing (AM) through material extrusion (MEX) is becoming increasingly popular worldwide due to its simple, sustainable and safe technique of material preparation, with minimal waste generation. This user-friendly technique is currently extensively used in diverse industries and household applications. Recently, there has been increasing attention on polycaprolactone (PCL)-based composites in MEX due to their improved biodegradability. These composites can be printed at a lower temperature, making them more energy efficient compared to commercial filaments such as acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA). Although wool is the leading protein fibre in the world and can be more compatible with PCL due to its inherent hydrophobicity, the suitability of MEX using a wool/PCL combination has not been reported previously. In the current study, waste wool/PCL composite parts were printed using the MEX technique, and rheology, thermal and tensile properties, and morphology were analysed. The impact of wool loading (10% and 20%) was investigated in relation to different filling patterns (concentric, rectilinear and gyroid). Furthermore, the impact of fibre fineness on the final material produced through MEX was investigated for the first time using two types of wool fibres with diameters of 16 µm and 24 µm. The yield strength and modulus of PCL increased with the inclusion of 10% wool, although the elongation was reduced. The crystallinity of the composites was found to be reduced with wool inclusion, though the melting point of PCL remained mostly unchanged with 10% wool inclusion, indicating better compatibility. Good miscibility and uniform structure were observed with the inclusion of 10% wool, as evidenced by rheology and morphology analysis. The impact of fibre fineness was mostly minor, though wool/PCL composites showed improved thermal stability with finer diameter of wool fibres. The printed specimens exhibited an increasing rate of biodegradation in marine water, which was correlated to the amount of wool present. Overall, the results demonstrate the practical applicability of the wool/PCL composition in MEX for the preparation of varied objects, such as containers, toys and other household and industrial items. Using wool/PCL combinations as regular plastics would provide a significant environmental advantage over the non-degradable polymers that are currently used for these purposes.

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Material Extrusion of Multi-Polymer Structures Utilizing Design and Shrinkage Behaviors: A Design of Experiment Study

Cited by 12 publications

References 51 publications

Optimization of 3D Printing Parameters for Enhanced Surface Quality and Wear Resistance

Optimization of 3D Printing Parameters for Enhanced Surface Quality and Wear Resistance

Minimizing Dimensional Defects in FFF Using a Novel Adaptive Slicing Method Based on Local Shape Complexity

Material Extrusion of Wool Waste/Polycaprolactone with Improved Tensile Strength and Biodegradation

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