A method for predicting geometric characteristics of polymer deposition during fused-filament-fabrication

Hebda, Michael; McIlroy, Claire; Whiteside, Ben; Caton‐Rose, Fin; Coates, Phil

doi:10.1016/j.addma.2019.02.013

Cited by 28 publications

(39 citation statements)

References 34 publications

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“…Based on the results obtained, low SA values are linked to the generation of rounded filament profiles (Figure 11a and Figure 14b). These profiles are obtained by modifying the road width (which is controlled by the flow rate (F) of material through the nozzle) [34,35]. Other types of profiles offer greater obstacles to the drop, which slides with difficulty (Figure 11b and Figure 14c).…”

Section: Discussionmentioning

confidence: 99%

Improvement of Surface Roughness and Hydrophobicity in PETG Parts Manufactured via Fused Deposition Modeling (FDM): An Application in 3D Printed Self–Cleaning Parts

Barrios

Romero

2019

Materials

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The fused deposition modeling (FDM) technique is used today by companies engaged in the fabrication of traffic signs for the manufacture of light-emitting diode LED spotlights. In this sector, the surface properties of the elements used (surface finish, hydrophobic features) are decisive because surfaces that retain little dirt and favor self–cleaning behavior are needed. A design of experiments (L27) with five factors and three levels has been carried out. The factors studied were: Layer height (LH), print temperature (T), print speed (PS), print acceleration (PA), and flow rate (F). Polyethylene terephthalate glycol (PETG) specimens of 25.0 × 25.0 × 2.4 mm have been printed and, in each of them, the surface roughness (Ra,0, Ra,90), sliding angle (SA0, SA90), and contact angle (CA0, CA90) in both perpendicular directions have been measured. Taguchi and ANOVA analysis shows that the most influential variables in this case are printing acceleration for Ra, 0 (p–value = 0.052) and for SA0 (p–value = 0.051) and flow rate for Ra, 90 (p–value = 0.001) and for SA90 (p–value = 0.012). Although the ANOVA results for the contact angle are not significant, specimen 8 (PA = 1500 mm/s2 and flow rate F = 110%) and specimen 10 (PA =1500 mm/s2 and F = 100%) have reached contact angle values above or near the limit value for hydrophobia, respectively.

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Section: Discussionmentioning

confidence: 99%

Improvement of Surface Roughness and Hydrophobicity in PETG Parts Manufactured via Fused Deposition Modeling (FDM): An Application in 3D Printed Self–Cleaning Parts

Barrios

Romero

2019

Materials

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“…12. Hebda et al [9] have presented a master curve to estimate the strand's width based on printing parameters U and V . Based on their study, the master curve is modified to fit our measurements defined as follows with α a pre-factor and C a constant determined by linear regression based on our experimental data.…”

Section: Geometrical Shape Area Rectanglementioning

confidence: 99%

“…H as a function of U/V for U ≤5 m min −1 . Comparison with H calculated using equations(9) and(7)for different strand geometry. The fitting parameters are α = 1.76 and C = −334.2 for the studied ABS polymer.…”

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confidence: 99%

Thermal analysis of the fused filament fabrication printing process: Experimental and numerical investigations

Zhang

Pigeonneau

2020

Int J Mater Form

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A 3d printing of a thin wall is achieved by a fused filament fabrication process. The influence of the printing velocities on the filament morphology is studied using optical microscopy. The strand morphology is approximated to different geometries and compared to experimental data. The oblong cross-section is a good approximation to estimate the strand's height and width. A local temperature is recorded by introducing a thermocouple during the printing of a thin wall. The polymer undergoes successive heating and cooling. Their magnitudes decrease with time while the filament deposition occurs farther from the thermocouple location. A steady-state cooling is observed after an extended period of time due to the surrounding air cooling. The influence of the strand's cross-section area on its cooling kinetics is investigated experimentally. The printing of a thin wall with the same geometry is also numerically computed by solving the heat transfer equation with a finite element method. The thermal conductivity takes into account the porosity of the printed wall. An estimation of the heat transfer coefficients between the wall and the surrounding air is done by comparison with a particular experiment. The numerical computation reproduces very well the amplitudes and the periods of heating and cooling observed experimentally. Moreover, the changes in the morphology of the melted filament show the reliability of the numerical tool to obtain a thermal history in agreement with experimental data. Keywords 3d printing • material extrusion • amorphous polymer • heat transfer • strand morphology • finite element analysis

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“…They have explored the effects of the speed ratio [ 14 , 15 ], viscosity [ 15 ], viscoelasticity [ 16 ], deposition flows [ 17 ], and interlayer contact pressures [ 18 ] on the dimensions of the deposited strands for particular combinations of processing parameters. As indicated in [ 19 ], a simple method is needed to calculate the geometries of the deposited filament for FFF. For this purpose, an empirical formula was proposed in [ 19 ] to predict the widths of the deposited strands.…”

Section: Introductionmentioning

confidence: 99%

“…As indicated in [ 19 ], a simple method is needed to calculate the geometries of the deposited filament for FFF. For this purpose, an empirical formula was proposed in [ 19 ] to predict the widths of the deposited strands. Naturally, a rigorously derived formula, which involves less empirical hypotheses, should give a better prediction.…”

Section: Introductionmentioning

confidence: 99%

Bonding widths of Deposited Polymer Strands in Additive Manufacturing

et al. 2021

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In this study, we explore the deformation of a polymer extrudate upon the deposition on a build platform, to determine the bonding widths between stacked strands in fused-filament fabrication. The considered polymer melt has an extremely high viscosity, which dominates in its deformation. Mainly considering the viscous effect, we derive analytical expressions of the flat width, compressed depth, bonding width and cross-sectional profile of the filament in four special cases, which have different combinations of extrusion speed, print speed and nozzle height. We further validate the derived relations, using our experimental results on acrylonitrile butadiene styrene (ABS), as well as existing experimental and numerical results on ABS and polylactic acid (PLA). Compared with existing theoretical and numerical results, our derived analytic relations are simple, which need less calculations. They can be used to quickly predict the geometries of the deposited strands, including the bonding widths.

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A method for predicting geometric characteristics of polymer deposition during fused-filament-fabrication

Cited by 28 publications

References 34 publications

Improvement of Surface Roughness and Hydrophobicity in PETG Parts Manufactured via Fused Deposition Modeling (FDM): An Application in 3D Printed Self–Cleaning Parts

Improvement of Surface Roughness and Hydrophobicity in PETG Parts Manufactured via Fused Deposition Modeling (FDM): An Application in 3D Printed Self–Cleaning Parts

Thermal analysis of the fused filament fabrication printing process: Experimental and numerical investigations

Bonding widths of Deposited Polymer Strands in Additive Manufacturing

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