Abstract:One of the most essential components of the fused deposition modeling (FDM) additive manufacturing (AM) process is the build plate, the surface upon which the part is constructed. These are typically made from aluminum or glass, but there are clear disadvantages to both and restrictions on which materials can be processed on them successfully. This study examined the suitability of heated aluminum-polycarbonate (AL-PC) composite print beds for FDM, looking particularly at the mechanical properties, thermal behavior, deformation behavior, bonding strength with deposited material, printing quality, and range of material usability. Theoretical examination and physical experiments were performed for each of these areas; the results were compared to similar experiments done using heated aluminum and aluminum-glass print beds. Ten distinct materials (ABS, PLA, PET, HIPS, PC, TPU, PVA, nylon, metal PLA, and carbon-fiber PLA) were tested for printing performance. The use of a heated AL-PC print bed was found to be a practical option for most of the materials, particularly ABS and TPU, which are often challenging to process using traditional print bed types. Generally, the results were found to be equivalent to or superior to tempered glass and superior to standard aluminum build plates in terms of printing capability.
One of the fundamental characteristics of additively processed materials is that they are naturally anisotropic; this variance in mechanical properties is primarily generated through the formulation of patterned shell and in-filled regions within the material during processing. This paper describes the formulation and results of a study to ascertain the impact strength of various full–infill polymer-based materials processed in various orientations and angles via fused deposition modeling. Ten different materials were tested using seven different hatch angles and three print orientations. Seven different pure materials were tested, as well as three composites; these were acrylonitrile butadiene styrene, standard polylactic acid, high-temperature polylactic acid, high-impact polystyrene, nylon, polyethylene terephthalate + glycol, polycarbonate, aluminum polylactic acid, wood polylactic acid, and carbon–fiber polylactic acid. All experiments were carried out using ASTM IZOD Type E tests with a 2.7J pendulum. Five replications of each test combination were collected, for a total of 1050 tests. The results showed that the shell orientation and raster angle were primary drivers in determining impact properties, as they strongly influenced the crack length and path though the material during fracture. This was especially clear for the polycarbonate, nylon, and polyethylene terephthalate + glycol which underwent large plastic deformation during the tests. It was further observed that the impact toughness was inversely correlated with test repeatability, with the toughest materials having the highest variability between test replications.
This paper describes the collection of a large dataset (6930 measurements) on dimensional error in the fused deposition modeling (FDM) additive manufacturing process for full-density parts. Three different print orientations were studied, as well as seven raster angles ( 0 ∘ , 15 ∘ , 30 ∘ , 45 ∘ , 60 ∘ , 75 ∘ , and 90 ∘ ) for the rectilinear infill pattern. All measurements were replicated ten times on ten different samples to ensure a comprehensive dataset. Eleven polymer materials were considered: acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), high-temperature PLA, wood-composite PLA, carbon-fiber-composite PLA, copper-composite PLA, aluminum-composite PLA, high-impact polystyrene (HIPS), polyethylene terephthalate glycol-enhanced (PETG), polycarbonate, and synthetic polyamide (nylon). The samples were ASTM-standard impact-testing samples, since this geometry allows the measurement of error on three different scales; the nominal dimensions were 3 . 25 mm thick, 63 . 5 mm long, and 12 . 7 mm wide. This dataset is intended to give engineers and product designers a basis for judging the accuracy and repeatability of the FDM process for use in manufacturing of end-user products.
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