Minimizing warpage of ABS prototypes built with low-cost fused deposition modeling machine using developed closed-chamber and optimal process parameters

Kuo, Chil-Chyuan; Wu, Yuh-Renn; Li, Meng-Hong; Wu, Hao-Wei

doi:10.1007/s00170-018-2969-7

Cited by 46 publications

(35 citation statements)

References 35 publications

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“…Its contribution is about 83.6% Again, simulation results show the inverse monotonic correlation between warpage and layer thickness, which agrees with experimental results. Similar results were also observed in other works [13][14][15][16]. According to the optimization based on experimental results (Figure 11 and Table 7), layer thickness and bed temperature are the most significant factors affecting the warpage of the part.…”

Section: Taguchi Optimizationsupporting

confidence: 87%

Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method

et al. 2021

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Fused deposition modeling (FDM) is one of the most affordable and widespread additive manufacturing (AM) technologies. Despite its simplistic implementation, the physics behind this FDM process is very complex and involves rapid heating and cooling of the polymer feedstock. As a result, highly non-uniform internal stresses develop within the part, which can cause warpage deformation. The severity of the warpage is highly dependent on the process parameters involved, and therefore, currently extensive experimental studies are ongoing to assess their influence on the final accuracy of the part. In this study, a thermomechanical Finite Element model of the 3D printing process was developed using ANSYS. This model was compared against experimental results and several other analytical models available in the literature. The developed Finite Element Analysis (FEA) model demonstrated a good qualitative and quantitative correlation with the experimental results. An L9 orthogonal array, from Taguchi Design of Experiments, was used for the optimization of the warpage based on experimental results and numerical simulations. The optimum process parameters were identified for each objective and parts were printed using these process parameters. Both parts showed an approximately equal warpage value of 320 μm, which was the lowest among all 10 runs of the L9 array. Additionally, this model is extended to predict the warpage of FDM printed multi-material parts. The relative percentage error between the numerical and experimental warpage results for alternating and sandwich specimens are found to be 1.4% and 9.5%, respectively.

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Section: Taguchi Optimizationsupporting

confidence: 87%

Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method

et al. 2021

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“…For the bed temperature, for the PLA printed on a glass surface, a moderate adhesion force range based on previous studies is between 80 and 120 • C [46]. Other studies recommend that, for the ABS, the bed temperature should be set approximately 90-93 • C to minimize the warpage while printing [47]; therefore, a bed temperature of 90 • C for all materials was selected. Adding more parameters increases the complexity of the test, therefore for this particular study the air gap was established as zero (beads just touch).…”

Section: Methodsmentioning

confidence: 99%

Tensile Mechanical Behaviour of Multi-Polymer Sandwich Structures via Fused Deposition Modelling

Lopez

Ahmad

2020

Polymers

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The application of single homogeneous materials produced through the fused deposition modelling (FDM) technology restricts the production of high-level multi-material components. The fabrication of a sandwich-structured specimen with different material combinations using conventional thermoplastics such as poly (lactic acid) (PLA), acrylonitrile butadiene styrene (ABS) and high impact polystyrene (HIPS) through the filament-based extrusion process can demonstrate an improvement on its properties. This paper aims to assess among these materials, the best material sandwich-structured arrangement design, to enhance the mechanical properties of a part and to compare the results with the homogeneous materials selected. The samples were subjected to tensile testing to identify the tensile strength, elongation at break and Young’s modulus of each material combination. The experimental results demonstrate that applying the PLA-ABS-PLA sandwich arrangement leads to the best mechanical properties between these materials. This study enables users to consider sandwich structure designs as an alternative to manufacturing multi-material components using conventional and low-cost materials. Future work will consider the flexural tests to identify the maximum stresses and bending forces under pressure.

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“…Due to system characteristics, samples have lower mechanical properties compared to injection moulding. At negative temperature, thermoplastics have low impact resistance and FDM products may face warpage (Kuo et al, 2019;Alsoufi and El-Sayed, 2017), which happens when the material starts to cool after deposition (Armillotta et al, 2018). This issue causes poor accuracy and precision, as shown in Figure 23.…”

Section: Summary Challenges and Gapsmentioning

confidence: 99%

An overview of fused deposition modelling (FDM): research, development and process optimisation

Dezaki

Ariffin

Hatami

2021

RPJ

106

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Purpose The purpose of this paper is to review research studies on process optimisation and machine development that lead to the enhancement of final products in various aspects of the fused deposition modelling (FDM) process. Design/methodology/approach An overview of the literature, focussing on process parameters, machine developments and material characterisations. This study investigates recent research studies that studied FDM capabilities in printing a vast range of materials from thermoplastics to metal alloys. Findings FDM is one of the most common techniques in additive manufacturing (AM) processes. Many parameters in this technology have effects on three-dimensional printed products. Therefore, it is necessary to obtain the optimum elements, for example, build orientation, layer thickness, nozzle diameter, infill pattern and bed temperature. By selecting a proper variable range of parameters, the layers adhere strongly and building end-use products of high quality are achievable. A vast range of materials and their properties from polymers to composite-based polymers are presented. Novel techniques to print metal alloys and composites are examined to increase the productivity of the FDM process. Additionally, defects such as shrinkage and warpage are discussed to eliminate the system’s limitations and improve the quality of final products. Multi-axis and mobile machines brought enhancements throughout the process to eliminate obstacles such as staircase defects in the conventional FDM process. In brief, recent developments were identified and a summary of major improvements was discussed in this study for future research. Originality/value This paper is an overview that provides information about research and developments in FDM. This review focusses on process optimisation and obstacles in printing polymers, composites, geopolymers and novel materials. Therefore, machine characteristics were examined to find out the accessibility of printing novel materials for different applications.

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Minimizing warpage of ABS prototypes built with low-cost fused deposition modeling machine using developed closed-chamber and optimal process parameters

Cited by 46 publications

References 35 publications

Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method

Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method

Tensile Mechanical Behaviour of Multi-Polymer Sandwich Structures via Fused Deposition Modelling

An overview of fused deposition modelling (FDM): research, development and process optimisation

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