A review on advancements in applications of fused deposition modelling process

Abstract

Purpose Fabrication of customized products in low volume through conventional manufacturing incurs a high cost, longer processing time and huge material waste. Hence, the concept of additive manufacturing (AM) comes into existence and fused deposition modelling (FDM), is at the forefront of researches related to polymer-based additive manufacturing. The purpose of this paper is to summarize the research works carried on the applications of FDM. Design/methodology/approach In the present paper, an extensive review has been performed related to major application areas (such as a sensor, shielding, scaffolding, drug delivery devices, microfluidic devices, rapid tooling, four-dimensional printing, automotive and aerospace, prosthetics and orthosis, fashion and architecture) where FDM has been tested. Finally, a roadmap for future research work in the FDM application has been discussed. As an example for future research scope, a case study on the usage of FDM printed ABS-carbon black composite for solvent sensing is demonstrated. Findings The printability of composite filament through FDM enhanced its application range. Sensors developed using FDM incurs a low cost and produces a result comparable to those conventional techniques. EMI shielding manufactured by FDM is light and non-oxidative. Biodegradable and biocompatible scaffolds of complex shapes are possible to manufacture by FDM. Further, FDM enables the fabrication of on-demand and customized prosthetics and orthosis. Tooling time and cost involved in the manufacturing of low volume customized products are reduced by FDM based rapid tooling technique. Results of the solvent sensing case study indicate that three-dimensional printed conductive polymer composites can sense different solvents. The sensors with a lower thickness (0.6 mm) exhibit better sensitivity. Originality/value This paper outlines the capabilities of FDM and provides information to the user about the different applications possible with FDM.

Establishing a Framework for Fused Filament Fabrication Process Optimization: A Case Study with PLA Filaments

“…FFF is particularly versatile regarding material compatibility, spanning many polymer types and filament colors, with the principal requirement being that filaments must be extrudable through a heated nozzle. The most common filaments used in FFF are acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) due to material availability and relative ease of printability; however, several other filament types are also used, including nylon, polycarbonate (PC), polyethylene terephthalate glycol (PETG), thermoplastic polyurethane (TPU), and polyether ether ketone (PEEK) [13][14][15][16]. Composite blends are also utilized as FFF filaments, with reinforcement phases ranging from carbon fibers to wood fillers, for a variety of functional and esthetic applications [17][18][19][20].…”

Fused Deposition Modelling (FDM) and Selective Laser Sintering (SLS) as Indisputable Machines in Additive Manufacturing: A Review

“…As a result, the concept of additive manufacturing (AM) emerges, and fused deposition modelling (FDM) is at the forefront of technological innovation in polymer-based additive manufacturing (Sathies, 2020). AM based on selective laser sintering (SLS) is a relatively common technique for producing complex shape parts out of metallic alloys, ceramics, and polymers (Kozak et al, 2021).…”

Biodegradable Materials Used in FDM 3D Printing Technology: A Critical Review

“…The fabrication of tissues and organs, customization of prostheses, orthopedic transplants, and anatomical replicas, as well as distribution of medications and drug screening, are among the current and upcoming research priorities of 3D printing in the biomedical and pharmaceutical areas [97]. The ideal characteristics of materials that are regarded suitable for printing for biomedical applications include printability, superior mechanical, thermal, and structural qualities [98].…”