Additive manufacturing is a process wherein a three-dimensional object is created layer-by-layer. It offers adaptability to the geometrical complexity and customizability of the design, which is difficult to manufacture using conventional manufacturing. The aerospace industry is one of the sectors that first adopted additive manufacturing, particularly three-dimensional printing (3D printing) in the production of aircraft parts such as rocket engine components, oil fuel tanks, environmental control system ducting, combustor liner, custom cosmetic aircraft interior components, and unmanned aerial vehicle (UAV) components. The aircraft's most common materials used in the 3D printing prototype parts are acrylonitrile butadiene styrene (ABS) thermoplastic, carbon-fiber and thermoplastic composite, and nylon 12 using selective laser sintering, fused deposition modeling, or composite filament co-extrusion technology. One of the aerospace industry's challenges is ensuring the efficiency and quality of aircraft structural parts that typically require complicated manufacturing due to their complexity and variability of function. Additive manufacturing is seen to respond to this challenge by developing and prototyping 3D printed parts and exploring practical 3D printing technologies.
Fused Deposition Modelling (FDM) technology is one of most common technique used in 3D printing as of today for several reasons such as it is low cost and high speed printing capacity. However, common characteristic of FDM 3D printed materials are poor layer adhesion strength and rough surface finish which requires post-processing to improve it. Heat treatment and vapor-polishing are post-processing techniques used to address the poor layer adhesion and rough surface finish of 3D printed materials, respectively. This study will combine these two post-processing techniques and investigate its effect on the mechanical properties of 3D printed materials. The present study describes the effect of acetone vapor-polishing to facture behavior of ABS 3D printed material at higher operating temperatures. The study will compare the fracture behavior of ABS 3D-printed material when polished using acetone vapor bath and tested at high operating temperature to unpolished material. Five replications for each test condition were conducted. All experiment was carried out using ASTM Izod Type E tests with a 2.75J pendulum. The results showed that acetone vapor polishing strongly affects the fracture behavior of ABS 3D printed materials when operating at high temperature.
The adoption of Additive Manufacturing (AM) is continuously growing due to its capability to produce complex shapes which leads to the dependence of manufacturers on AM to replace conventional manufacturing processes. One important focus of research now is on the accuracy of 3D printed products produced via the Fused Deposition Modeling (FDM). These products have great potential to be applied to tooling and other rapid prototyping applications. The aim of this study is to assess the accuracy of 3D printed Acrylonitrile Butadiene Styrene (ABS) through manual measurements of dimensions. Several sets of samples with cubic shapes were printed and measured using a digital micrometer to evaluate the dimensional accuracy of the 3d-printed parts. A 22 full factorial design was employed to investigate the effects of infill density and layer thickness on the dimensional accuracy of ABS parts.
Stereolithography (SLA) is an Additive Manufacturing technology which converts liquid resins to solid parts layer-by-layer by selectively curing the liquid resin using a (laser) light source. The mechanical properties SLA 3D printed parts are not yet determined or estimated before printing. Thus, this study aims to identify the optimum 3D printing configuration based on the indentation hardness properties of SLA-printed polymer parts. Taguchi approach was used in identifying the optimum 3D printing configuration wherein different factors were considered to meet the requirements of the orthogonal arrays. Five pieces of 3D printed test blocks with 9 indentation points on the surface were prepared for each factor. The tests followed ASTM D785 – 03 using Rockwell Scale B. The result for the optimum 3D printing configuration of SLA 3D printed material were concluded as the values with the highest Rockwell Hardness Number.
This paper discusses some basic metrology considerations when 3D printing. The importance of ensuring correct measurements is highlighted especially for practical applications. The last part of the paper presents sample dimensional measurements of 3D-printed parts with varying sizes, infill density and layer thickness. Different cube sizes of 10 mm3, 15 mm3, and 20 mm3 has been produced using a commercially-available 3D printer. Acrylonitrile butadiene styrene (ABS) has been used for the experiments. Important observations and insights are presented.
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