Model analysis of feedstock behavior in fused filament fabrication: Enabling rapid materials screening

Gilmer, Eric L.; Miller, Darren A.; Chatham, Camden A.; Zawaski, Callie E.; Fallon, Jacob J.; Pekkanen, Allison M.; Long, Timothy Edward; Williams, Christopher B.; Bortner, Michael J.

doi:10.1016/j.polymer.2017.11.068

Cited by 87 publications

(71 citation statements)

References 25 publications

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“…The FFF process demands specific requirements to the new materials in order to avoid inherent problems of this technology, such as inaccurate filament diameter, backflow, and, in the case of flexible materials, buckling in particular [11,13]. Thus, a suitable feedstock material should provide an accurate balance between the physical properties in the solid state, mainly the compression modulus (K), and the rheological properties in the molten state.…”

Section: Rheological Analysismentioning

confidence: 99%

“…Materials 2020, 13, x FOR PEER REVIEW 5 of 14 flexible materials, buckling in particular [11,13]. Thus, a suitable feedstock material should provide an accurate balance between the physical properties in the solid state, mainly the compression modulus (K), and the rheological properties in the molten state.…”

Section: Rheological Analysismentioning

confidence: 99%

“…Various AM processes have considerably improved in last three decades, becoming established in the commercial market [1][2][3][4][5][6][7][8][9]. Each process depends on different phenomena, specific materials, and their physical and rheological characteristics [10][11][12][13][14][15]. Among the materials used for AM polymers have become a main center of interest for a wide range of applications, in addition to metals [16] and ceramics [17].…”

Section: Introductionmentioning

confidence: 99%

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Searching for Rheological Conditions for FFF 3D Printing with PVC Based Flexible Compounds

et al. 2020

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Rheology is proposed as a tool to explore plasticized poly(vinyl chloride) (PVC) formulations to be used in the fused filament fabrication (FFF) 3D printing process and so manufactures flexible and ductile objects by this technique. The viscoelastic origin of success/failure in FFF of these materials is investigated. The analysis of buckling of the filament is based on the ratio between compression modulus and viscosity, but for a correct approach the viscosity should be obtained under the conditions established in the nozzle. As demonstrated by small amplitude oscillatory shear (SAOS) measurements, PVC formulations have a crystallites network that provokes clogging in the nozzle. This network restricts printing conditions, because only vanishes at high temperatures, at which thermal degradation is triggered. It is observed that the analysis of the relaxation modulus G(t) is more performing than the G″/G′ ratio to get conclusions on the quality of layers welding. Models printed according to the established conditions show an excellent appearance and flexibility, marking a milestone in the route to obtain flexible objects by FFF.

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Section: Rheological Analysismentioning

confidence: 99%

Section: Rheological Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Searching for Rheological Conditions for FFF 3D Printing with PVC Based Flexible Compounds

et al. 2020

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“…The filament materials used in ME‐AM need to fulfill certain requirements in order to be flawlessly processable. The filament needs to be a thermoplastic that can be extruded within a certain diameter and ovality tolerance in order to be three‐dimensional (3D) printable at a constant flow rate over time . Moreover, the filament needs to be stiff yet flexible enough so that the filament can be spooled during filament production and despooled during printing .…”

Section: Introductionmentioning

confidence: 99%

Material extrusion‐based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage

Spoerk

Holzer

González-Gutiérrez

2019

J of Applied Polymer Sci

211

172

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Material extrusion-based additive manufacturing (ME-AM) is an emerging processing technique that is characterized by the selective deposition of thermoplastic filaments in a layer-by-layer manner based on digital part models. Recently, it has attracted considerable attention, as this technique offers manifold benefits over conventional manufacturing technologies. However, to meet the challenges of complex industrial applications, certain shortcomings of ME-AM still need to be overcome. A case in point is the limited amount of semicrystalline thermoplastics, which are still not established as reliable, commercial filament materials. Particularly, polypropylene (PP) offers attractive properties that are unique among the ME-AM material portfolio. This review describes the current approaches of fabricating PP components by ME-AM. Both commercial and scientific strategies to make PP 3D-printable are elaborated and compared. As dimensional issues are especially problematic for PP, a comprehensive section of this review focuses on the strategies developed for mitigating warpage for PP parts fabricated by ME-AM.

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“…Maintaining a consistent filament diameter is also critical for accurate, volumetric extrusion during printing. These properties are in addition to the thermal, rheological, and adhesive properties required during the liquefaction and solidification FFF process sub‐functions, as described by Gilmer, et al and Duty, et al…”

Section: Methodsmentioning

confidence: 99%

Semi‐Crystalline Polymer Blends for Material Extrusion Additive Manufacturing Printability: A Case Study with Poly(ethylene terephthalate) and Polypropylene

Chatham

Zawaski

Bobbitt³

et al. 2019

Macro Materials & Eng

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Semi‐crystalline polymers are an important class of materials for engineering applications due to their high modulus and barrier properties. Traditional manufacturing methods process semi‐crystalline polymers via rigid molds and well‐controlled temperature and pressure environments to handle the significant change in specific volume occurring during crystallization; however, material extrusion additive manufacturing does not use these features. This often leads to warpage‐induced build failure in fused filament fabrication (FFF). To enable FFF of semi‐crystalline polymers, this work investigates characteristics of immiscible polymer blends (e.g., disparate crystallization behavior and phase separation) to mitigate warping failure during printing. A series of poly(ethylene terephthalate)/polypropylene/polypropylene–graft–maleic anhydride blends are explored and the effect of thermal and morphological characteristics on printability is analyzed. It is shown that these blends can be extruded into filament and printed into a 3D structure. Extrapolations indicate that phase‐separated blends with increased total crystallization half‐time are beneficial for FFF printing.

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Model analysis of feedstock behavior in fused filament fabrication: Enabling rapid materials screening

Cited by 87 publications

References 25 publications

Searching for Rheological Conditions for FFF 3D Printing with PVC Based Flexible Compounds

Searching for Rheological Conditions for FFF 3D Printing with PVC Based Flexible Compounds

Material extrusion‐based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage

Semi‐Crystalline Polymer Blends for Material Extrusion Additive Manufacturing Printability: A Case Study with Poly(ethylene terephthalate) and Polypropylene

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