Multi-Material Additive Manufacturing of Sustainable Innovative Materials and Structures

Singh, Rupinder; Kumar, Ranvijay; Farina, Ilenia; Colangelo, Francesco; Feo, Luciano; Fraternali, Fernando

doi:10.3390/polym11010062

Cited by 141 publications

(70 citation statements)

References 49 publications

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“…However, with FFF printing, defects, By using printers with dual or multiple extrusion nozzles, multicolored or multiple material parts can be produced. Simultaneous 3D printing of multiple materials enables integration of different properties (e.g., flexibility, folding, deployment, shape memory, and electric conductivity) into intricate products in a single manufacturing process [15][16][17][18]. Additionally, a wide range of polymers used for FFF nowadays can be recycled, and the nonmelted material (metal and polymer) from different AM processes can be reused [3,19,20].…”

Section: Introductionmentioning

confidence: 99%

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

2020

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This article reports on the investigation of the effects of process parameters and their interactions on as-built part quality and resource-efficiency of the fused filament fabrication 3D printing process. In particular, the influence of five process parameters: infill percentage, layer thickness, printing speed, printing temperature, and surface inclination angle on dimensional accuracy, surface roughness of the built part, energy consumption, and productivity of the process was examined using Taguchi orthogonal array (L50) design of experiment. The experimental results were analyzed using ANOVA and statistical analysis, and the parameters for optimal responses were identified. Regression models were developed to predict different process responses in terms of the five process parameters experimentally examined in this study. It was found that dimensional accuracy is negatively influenced by high values of layer thickness and printing speed, since thick layers of printed material tend to spread out and high printing speeds hinder accurate deposition of the printed material. In addition, the printing temperature, which regulates the viscosity of the used material, plays a significant role and helps to minimize the dimensional error caused by thick layers and high printing speeds, whereas the surface roughness depends very much on surface inclination angle and layer thickness, which together determine the influence of the staircase effect. Energy consumption and productivity are primarily affected by printing speed and layer thickness, due to their high correlation with build time.

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Section: Introductionmentioning

confidence: 99%

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

2020

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“…Other concepts rely on filament deposition using various thermoplastic filaments including shape memory polymers, polylactic acid (PLA) or acrylonitrile butadiene styrene (ABS) [5,46]. Another additive manufacturing concept relies on stereo lithography using elastomers [47,48].…”

Section: Choice Of Materials Manufacturing Process and Manufacturingmentioning

confidence: 99%

Mechanical Metamaterials on the Way from Laboratory Scale to Industrial Applications: Challenges for Characterization and Scalability

2020

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Mechanical metamaterials promise a paradigm shift in materials design, as the classical processing-microstructure-property relationship is no longer exhaustively describing the material properties. The present review article provides an application-centered view on the research field and aims to highlight challenges and pitfalls for the introduction of mechanical metamaterials into technical applications. The main difference compared to classical materials is the addition of the mesoscopic scale into the materials design space. Geometrically designed unit cells, small enough that the metamaterial acts like a mechanical continuum, enabling the integration of a variety of properties and functionalities. This presents new challenges for the design of functional components, their manufacturing and characterization. This article provides an overview of the design space for metamaterials, with focus on critical factors for scaling of manufacturing in order to fulfill industrial standards. The role of experimental and simulation tools for characterization and scaling of metamaterial concepts are summarized and herewith limitations highlighted. Finally, the authors discuss key aspects in order to enable metamaterials for industrial applications and how the design approach has to change to include reliability and resilience.

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“…Singh used the FDM process to 3D print multi-material recycled composite using ABS, polylactic acid (PLA), and high impact polystyrene (HIPA). The tensile tests concluded that the multi-material composite offered better mechanical properties, while varying the laminar sequence of material could induce customization as well [ 19 ]. Li compared the interlaminar bonding strength (ILBS) for ABS and polyamide-12 (PA12).…”

Section: Introductionmentioning

confidence: 99%

On the Effects of Process Parameters and Optimization of Interlaminate Bond Strength in 3D Printed ABS/CF-PLA Composite

et al. 2020

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The scope of additive manufacturing, particularly fused deposition modelling (FDM), can indeed be explored with the fabrication of multi-material composite laminates using this technology. Laminar composite structures made up of two distinct materials, namely acrylonitrile butadiene styrene (ABS) and carbon fiber reinforced polylactic acid (CF-PLA), were produced using the FDM process. The current study analyzes the effect of various printing parameters on the interfacial bond strength (IFBS) of the ABS/CF-PLA laminar composite by employing response surface methodology. The physical examination of the tested specimens revealed two failure modes, where failure mode 1 possessed high IFBS owing to the phenomenon of material patch transfer. Contrarily, failure mode 2 yielded low IFBS, while no patch transfer was observed. The analysis of variance (ANOVA) revealed that printing parameters were highly interactive in nature. After extensive experimentation, it was revealed that good quality of IFBS is attributed to the medium range of printing speed, high infill density, and low layer height. At the same time, a maximum IFBS of 20.5 MPa was achieved. The study presented an empirical relation between printing parameters and IFBS that can help in forecasting IFBS at any given printing parameters. Finally, the optimized printing conditions were also determined with the aim to maximize IFBS.

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Multi-Material Additive Manufacturing of Sustainable Innovative Materials and Structures

Cited by 141 publications

References 49 publications

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

Mechanical Metamaterials on the Way from Laboratory Scale to Industrial Applications: Challenges for Characterization and Scalability

On the Effects of Process Parameters and Optimization of Interlaminate Bond Strength in 3D Printed ABS/CF-PLA Composite

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