Additive manufacturing of an automotive brake pedal by metal fused deposition modelling

Sargini, M.I.M.; Masood, Syed H.; Palanisamy, Suresh; Jayamani, Elammaran; Kapoor, Ajay

doi:10.1016/j.matpr.2021.01.010

Cited by 35 publications

(25 citation statements)

References 9 publications

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“…It is known by many terms, such as "fused deposition modelling" (FDM), first developed by Stratasys, Ltd. (Eden Prairie, MN, USA and Rehovot, Israel) for polymer [139]; "fused filament fabrication" (FFF) or "atomic diffusion additive manufacturing" (ADAM) proposed by Markforged, Inc., Watertown, MA, USA [140]. At the beginning, this process was usually used for rapid prototyping; however, it can currently be used for tooling and end-user part fabrication [50,140,141]. The filament of metal MEX composed of the metal powder and polymeric binder is fed by the filament transport system to the heating element and heated nozzle so that the filament will be softened and extruded to the printing bed layer-by-layer following the CAD design as illustrated in Figure 3c.…”

Section: Filament-based Mex (Fb)mentioning

confidence: 99%

“…The rapid prototype of high wear resistance M2 steel can be fabricated with the in-house built filament, which can be an alternative for establishing a method for MIM part prototyping [96]. In addition, several end-user engineering parts have been commercially fabricated by the user-friendly closed metal MEX system [83,141]. The example of the end-user brake pedal 316L part is presented in Figure 25a.…”

Section: Current Prospective Applications and Future Direction Of Met...mentioning

confidence: 99%

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A Review on Material Extrusion Additive Manufacturing of Metal and How It Compares with Metal Injection Moulding

Suwanpreecha¹,

Manonukul²

2022

Metals

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Material extrusion additive manufacturing of metal (metal MEX), which is one of the 3D printing processes, has gained more interests because of its simplicity and economics. Metal MEX process is similar to the conventional metal injection moulding (MIM) process, consisting of feedstock preparation of metal powder and polymer binders, layer-by-layer 3D printing (metal MEX) or injection (MIM) to create green parts, debinding to remove the binders and sintering to create the consolidated metallic parts. Due to the recent rapid development of metal MEX, it is important to review current research work on this topic to further understand the critical process parameters and the related physical and mechanical properties of metal MEX parts relevant to further studies and real applications. In this review, the available literature is systematically summarised and concluded in terms of feedstock, printing, debinding and sintering. The processing-related physical and mechanical properties, i.e., solid loading vs. dimensional shrinkage maps, sintering temperature vs. relative sintered density maps, stress vs. elongation maps for the three main alloys (316L stainless steel, 17-4PH stainless steel and Ti-6Al-4V), are also discussed and compared with well-established MIM properties and MIM international standards to assess the current stage of metal MEX development.

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Section: Filament-based Mex (Fb)mentioning

confidence: 99%

Section: Current Prospective Applications and Future Direction Of Met...mentioning

confidence: 99%

A Review on Material Extrusion Additive Manufacturing of Metal and How It Compares with Metal Injection Moulding

Suwanpreecha¹,

Manonukul²

2022

Metals

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“…The automotive industry is confronted with new challenges where new design trends and technological deployments from research push companies to develop new models and facelifts in the short term, necessitating the development of new tools or the reshaping of existing tools. In the automotive industry, additive manufacturing has been used to tool up a stamping process for the production of body panels and brake pedals [ 161 ]. The findings led to the conclusion that metal additive manufacturing provided stamping tools with excellent performance and a significant reduction in time-to-tooling [ 162 ].…”

Section: Novel Materials Used In 3d Printing Applicationsmentioning

confidence: 99%

3D Printing and Shaping Polymers, Composites, and Nanocomposites: A Review

et al. 2022

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Sustainable technologies are vital due to the efforts of researchers and investors who have allocated significant amounts of money and time to their development. Nowadays, 3D printing has been accepted by the main industry players, since its first establishment almost 30 years ago. It is obvious that almost every industry is related to technology, which proves that technology has a bright future. Many studies have shown that technologies have changed the methods for developing particular products. Three-dimensional printing has evolved tremendously, and currently, many new types of 3D printing machines have been introduced. In this paper, we describe the historical development of 3D printing technology including its process, types of printing, and applications on polymer materials.

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“…Other examples also employ polymer filaments filled with metal or ceramic powders that are intended to be printed using a conventional Fused Filament Fabrication (FFF) printer. We can name the Ultrafuse 316L produced by BASF [25] , or the alumina filament produced by Zetamix 1 . However, few materials are currently available for this process, mainly because of the difficulties encountered when creating a powder highly filled filament [26] and when handling it.…”

Section: Hardware In Contextmentioning

confidence: 99%