Purpose Increasing use of 3D printing techniques to manufacture consumer products and open-source designs raises the question of “What is the mechanical reliability of 3D printed parts?” Therefore, the purpose of this paper is to investigate the impacts of build orientation on the mechanical reliability of acrylonitrile butadiene styrene (ABS) produced using 3D printing. Design/methodology/approach Tensile tests on ABS specimens were performed with and without a hole in the center, which were produced by fused deposition modeling (FDM). Seven sets of approximately 30 specimens were printed in XY, XZ and C+45 orientations to obtain reliable fracture statistics. Weibull analysis was performed to quantify the variation in the tensile strength. Findings The Weibull analysis showed that the reliability of FDM produced ABS can be as low as advanced ceramics. Weibull moduli of specimens without a hole were between 26 and 69, and specimens with a hole had Weibull moduli between 30 and 41. P-type deviations from the Weibull statistics were observed. The XZ orientation resulted in the highest average fracture strength for specimens with and without a hole, and C+45 orientation resulted in the lowest strength. Practical implications As the Weibull distribution relates the applied stress to probability of failure, the Weibull analysis provides a practical design criterion to achieve specific reliability levels for additively manufactured parts. Originality/value This study, for the first time, provides Weibull statistics for FDM-produced ABS parts, which can be used to predict mechanical reliability.
Incorporation of nanoparticles into polymer resins has recently attracted a significant amount of attention from researchers for the nanoparticles’ ability to alter the properties of the resin. Whereas graphene-based structures possess a two-dimensional honeycomb arrangement of carbon atoms that makes them desirable for engineering composite materials, quantum dot formulations have been primarily used in optoelectronic applications that take advantage of quantum confinement and size-tunable properties. Graphene and quantum dots (GQDs) are ubiquitous in the current research literature; however, the impact of GQD on the physical properties of polymer resins like epoxy remains unclear. Here, we show that infusing GQD into an epoxy polymer matrix results in (1) a 2.6-fold increase in the toughness of the polymer resins, (2) a 2.25-fold increase in the tensile strength of the polymer resins compared to its original tensile strength, (3) uniform loading at weight percentages as high as 10% of the polymer resin, (4) an 18% change to the max % increase in tensile strain compared to that of the neat polymer resin without GQDs, even though there is an increase in tensile strength, and (5) a 2.5-times increase in Young’s modulus compared to that of the neat polymer resin, all while maintaining excellent optical properties of the composite formulation. Our results demonstrate that GQDs with dual acid and alcohol functional groups can enable high loading percentages, which, in turn, give rise to composite materials that are simultaneously stronger and tougher. We believe that these GQDs, created from an abundant source, are a starting point for new and more sophisticated composite materials with potential in mechanical, electrical, and photosensitive applications.
Purpose Mechanical reliability (variations in mechanical properties) of fused deposition modeled (FDMed) short-fiber-reinforced composites are unknown, which limits wider and safer use of these composites. Accordingly, this paper aims to investigate the mechanical reliability of FDMed model material short-carbon-fiber-reinforced acrylonitrile butadiene styrene (SCFR-ABS). A new vibration-assisted FDM (VA-FDM) process was used to reduce porosity. Design/methodology/approach Tensile tests were performed on FDMed SCFR-ABS produced with and without vibrations. Weibull analysis was performed to quantify the variation in fracture strength, tensile strength, strain at break and strain at tensile strength. Findings Introduction of vibrations to the extrusion head during FDM decreased the inter-bead porosity in SCFR-ABS and thus improved elastic modulus, toughness, fracture strength, tensile strength and strain at break. Weibull modulus of fracture strength increased from 25 to 57 with vibrations. Practical implications The reported Weibull analysis offers a practical design guideline to predict failure rates at specific service stresses. Originality/value A detailed Weibull analysis of the variations in the mechanical properties of FDMed SCFR-ABS was performed for the first time. A new vibration-assisted FDM process was reported to reduce inter-bead porosity in FDMed composites.
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