The Fused Filament Fabrication is a revolutionary method for the manufacturing industry. However, there are still numerous challenges need to be tackled in order to standardize the procedure of printing process. In this study, the process parameters of line width, shell thickness, infill orientation and infill overlap, have been experimentally investigated over their affect on tensile strength properties and the mass of the produced samples. Design of experiments has been planned, conducted and evaluated using the Taguchi approach. A total of 25 combinations of the four printing parameters with five different settings have been set according to the L 25 Orthogonal Array table. The sample parts have been printed via widely used type lowcost and open-source 3D printer. Afterwards, the printed samples are tested for their tensile strength. The best combinations of the parameters with relevant settings have been revealed by S/N Ratio analysis. In order to validate the statistical results, the sample with newly found combination has been manufactured. Then, the ANOVA has been applied in order to reveal the percentage contributions of parameters to the tensile behaviour. It has been concluded that infill overlap and orientation parameters are dominant factors over the ultimate tensile strength of the samples. As a widespread effect, generalized equations have been established and presented in order to calculate the occupied area by an overlap. By implementing the equations, the users will be able to configure their input parameters in behalf of increasing the tensile strength while controlling the material consumption.
The need for Fused Filament Fabrication (FFF) type 3D printers in additive manufacturing family is increasing day by day. In parallel to the accelerating developments in these devices, the technical difficulties and the cost of operation have started to decrease in time. There are numerous studies available in the way to enhance the mechanical properties of parts printed with these devices. However, the energy and the time management in the printing processes have also become a new focus of today's research for more eco-friendly operations. In this study, the amount of energy and the time consumed during the printing period are examined in detail. The experiments are planned in accordance with the Taguchi method for Design of Experiments. Signal-to-Noise Ratio and ANOVA analysis, which are widely accepted and powerful statistical tools in the field of experimental engineering, are used to interpret the results. It is observed that the parameters of platform temperature, the layer thickness, the printing speed and the nozzle temperature are the most influential process parameters on the required power and time respectively. The percentage contributions of these parameters to the process performance is also presented. Furthermore, the optimal combination of parameters with suitable levels were obtained in order to minimize both the power and the time requirement for printing processes. The statistical hypothesis are verified by the confirmatory experiments. As a result, the parameters that significantly reduce the amount of energy and processing time for the production of a part applicable to most printing processes are revealed.
In this study, a metal droplet generator developed with an open-source concept is presented. The continuous droplet generation process was achieved without inert gas assistance. Owing to this desktop device, which is proposed as an alternative to high-cost metal printing devices, users can achieve stable droplets continuously at low costs. Taking into account the pressure balance inside the melting region, the necessary amount of a metal wire feed was first revealed. The droplets generated which are in good agreement with the theoretical calculations were then ejected via mechanically restricted vibrational impacts. The reproducibility of the system was also tested. The droplet formation stages were classified, and the stable parameter groups were revealed in accordance with the measurements. Moreover, the wire type material feeding issue in metal droplet generators, which were insufficiently studied so far, has also been examined. A dynamic feeder mechanism was introduced in detail. In conclusion, Ball Grid Array deposition and functional circuit printing have been successfully achieved. This study on a continuous metal droplet formation is also important for future studies because the structure of the device is easily accessible and modifiable.
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