Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented.
A major challenge in extrusion‐based additive manufacturing is the lack of commercially available materials compared to those in well‐established processes like injection molding or extrusion. This study aims at expanding the material database by evaluating the feasibility of polypropylene, which is one of the most common and technologically relevant semicrystalline polymers. Expanded‐perlite‐filled polypropylene and ternary blends with amorphous polyolefins are evaluated to establish an understanding of their processability and their printability. A detailed study on the shrinkage behavior, as well as on the thermal, mechanical, morphological, and warpage properties is performed. It is found that smaller sized fillers result in a tremendous warpage and shrinkage reduction and concurrently improved mechanical properties than compounds filled with bigger sized fillers. Based on the optimal properties profile, a ternary blend that can overcome the shrinkage and warpage of printed parts is suggested.
For parts produced by fused filament fabrication (FFF) the adhesion between the first printed layer and the printing bed is crucial, since it provides the foundation to the subsequent layers. Inadequate adhesion can result in poor printing quality or destroyed bed surfaces. This study aims at understanding and optimising the adhesion process for parts produced by FFF. The consequences of varying printing bed temperatures on the adhesion of two commonly used printing materials on two standard bed surfaces were investigated by means of an in-house built adhesion measurement device and complemented by contact angle measurements. This study shows a significant increase in adhesion forces, when printing parts at a bed temperature slightly above the glass transition temperature of the printing material.
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