Variable Fused Deposition Modelling – analysis of benefits, concept design and tool path generation

Brooks, Hadley Laurence; Rennie, Allan; Abram, Thomas; McGovern, Jim; Caron, François

doi:10.1201/b11341-83

Cited by 29 publications

(11 citation statements)

References 1 publication

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“…These 3D printed composite samples exhibited a reduction in ΔD x of 74% and ΔD y of 58%, compared with samples manufactured with the ∅ N = 0.8 mm nozzle diameter. These results were in accordance with previous studies (Sukindar et al , 2016), and can be explained by considering that the geometric error increases linearly with nozzle diameter (Brooks et al , 2012). In addition, the use of a smaller nozzle diameter was essential for reproducing fine details, as can be seen in the corner details of the 3D printed composite specimens in Figure 12, where the extruded line rounded the corners instead of reproducing exactly the sharp edges of the CAD model.…”

Section: Resultssupporting

confidence: 93%

“…In general, the pressure drop along the nozzle was higher for small nozzle diameters, causing a reduction in geometrical accuracy. However, according to Brooks et al (2012), geometrical errors increased as nozzle diameter increased, and, hence, a compromise solution between printing time and geometrical quality must be achieved. Thus, further research is required to examine the influence of nozzle diameter on the mechanical and quality performance of 3D printed composites, in particular using short carbon fibre reinforcements.…”

Section: Introductionmentioning

confidence: 99%

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Effect of nozzle diameter on mechanical and geometric performance of 3D printed carbon fibre-reinforced composites manufactured by fused filament fabrication

Chacón

Caminero

Núñez

et al. 2021

RPJ

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Purpose Fused filament fabrication (FFF) is one of the most popular additive manufacturing (AM) technologies due to its ability to build thermoplastic parts with complex geometries at low cost. The FFF technique has been mainly used for rapid prototyping owing to the poor mechanical and geometrical properties of pure thermoplastic parts. However, both the development of new fibre-reinforced filaments with improved mechanical properties, and more accurate composite 3D printers have broadened the scope of FFF applications to functional components. FFF is a complex process with a large number of parameters influencing product quality and mechanical properties, and the effects of the combined parameters are usually difficult to evaluate. An array of parameter combinations has been analysed for improving the mechanical performance of thermoplastic parts such as layer thickness, build orientation, raster angle, raster width, air gap, infill density and pattern, fibre volume fraction, fibre layer location, fibre orientation and feed rate. This study aims to assess the effects of nozzle diameter on the mechanical performance and the geometric properties of 3D printed short carbon fibre-reinforced composites processed by the FFF technique. Design methodology approach Tensile and three-point bending tests were performed to characterise the mechanical response of the 3D printed composite samples. The dimensional accuracy, the flatness error and surface roughness of the printed specimens were also evaluated. Moreover, manufacturing costs, which are related to printing time, were evaluated. Finally, scanning electron microscopy images of the printed samples were analysed to estimate the porosity as a function of the nozzle diameter and to justify the effect of nozzle diameter on dimensional accuracy and surface roughness. Findings The effect of nozzle diameter on the mechanical and geometric quality of 3D printed composite samples was significant. In addition, large nozzle diameters tended to increase mechanical performance and enhance surface roughness, with a reduction in manufacturing costs. In contrast, 3D printed composite samples with small nozzle diameter exhibited higher geometric accuracy. However, the effect of nozzle diameter on the flatness error and surface roughness was of slight significance. Finally, some print guidelines are included. Originality value The effect of nozzle diameter, which is directly related to product quality and manufacturing costs, has not been extensively studied. The presented study provides more information regarding the dependence of the mechanical, microstructural and geometric properties of short carbon fibre-reinforced nylon composite components on nozzle diameter.

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Section: Resultssupporting

confidence: 93%

Section: Introductionmentioning

confidence: 99%

Effect of nozzle diameter on mechanical and geometric performance of 3D printed carbon fibre-reinforced composites manufactured by fused filament fabrication

Chacón

Caminero

Núñez

et al. 2021

RPJ

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“…These extruders quickly traverse resolution-insensitive portions of the build while shrinking and slowing to provide additional detail in complex regions. 4 This method allows part surface quality to be maintained while increasing overall throughput. However, uniformly high-resolution parts will still face the same rate limit as in the fixed aperture extruder case.…”

Section: Related Workmentioning

confidence: 99%

Local Viscosity Control Printing for High-Throughput Additive Manufacturing of Polymers

SiegelJoshua

ErbDylan

EhrenbergIsaac

et al. 2016

3D Printing and Additive Manufacturing

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Fused deposition modeling's (FDM) throughput is limited by process physics as well as practical considerations favoring single-head polymer extrusion. To expedite the thermoplastic additive manufacturing process, we propose a parallelized material deposition process called local viscosity control (LVC) additive manufacturing. LVC prints an entire layer in one step by selectively modulating the viscosity of polymer feedstock in contact with a heated wire mesh. Layers of molten polymer are contact printed, with the relative motion between the wire mechanism and a build plate allowing wetting and surface tension to transfer selectively heated, lower viscosity regions of polymer to a fixed substrate. Experiments demonstrate the viability of this process using a single cell depositing layered polycarbonate pixels. Theoretical analysis shows this process may offer similar capabilities in resolution to conventional FDM with a significantly higher production rate for commonly available input power.

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“…Therefore it makes sense to provide solutions to this limitation first. One suggested method of overcoming the road width limits is to use variable diameter nozzles (Brooks et al, 2011). These nozzles may be continuously variable, allowing tapered roads, or discretely variable.…”

Section: Variable Volumetric Deposition Extrudersmentioning

confidence: 99%

Research towards high speed extrusion freeforming

2013

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Abstract:Additive manufacturing (AM) methods are currently utilised for the manufacture of prototypes and low volume, high cost parts. This is because in most cases the high material costs and low volumetric deposition rates of AM parts result in higher per part cost than traditional manufacturing methods. This paper brings together recent research aimed at improving the economics of AM, in particular Extrusion Freeforming (EF).A new class of machine is described called High Speed Additive Manufacturing (HSAM) in which software, hardware and materials advances are aggregated. HSAM could be cost competitive with injection moulding for medium sized medium quantity parts. A general outline for a HSAM machine and supply chain is provided along with future required research.

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Variable Fused Deposition Modelling – analysis of benefits, concept design and tool path generation

Cited by 29 publications

References 1 publication

Effect of nozzle diameter on mechanical and geometric performance of 3D printed carbon fibre-reinforced composites manufactured by fused filament fabrication

Effect of nozzle diameter on mechanical and geometric performance of 3D printed carbon fibre-reinforced composites manufactured by fused filament fabrication

Local Viscosity Control Printing for High-Throughput Additive Manufacturing of Polymers

Research towards high speed extrusion freeforming

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