Bead parameterization of desktop and room-scale material extrusion additive manufacturing: How print speed and thermal properties affect heat transfer

D’Amico, Tone; Peterson, Amy M.

doi:10.1016/j.addma.2020.101239

Cited by 27 publications

(21 citation statements)

References 26 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Typically, the welding quality relies on polymer diffusion across the interface to form bridging entanglements, which depends on the geometry of adjacent printed roads [ 50 , 51 ] and the build (layer) orientation [ 52 ]. The overall print layout can affect the local thermal history, which determines the effective diffusion time [ 53 ]. Thus, printing multiple parts simultaneously can lead to changes in the mechanical properties as increased cooling between printed layers (interlayer time) leads to less effective polymer diffusion across interlayer to deteriorate mechanical properties [ 54 ].…”

Section: Introductionmentioning

confidence: 99%

Size and print path effects on mechanical properties of material extrusion 3D printed plastics

Vogt

2022

Prog Addit Manuf

View full text Add to dashboard Cite

Print conditions for thermoplastics by filament-based material extrusion (MatEx) are commonly optimized to maximize the elastic modulus. However, these optimizations tend to ignore the impact of thermal history that depends on the specimen size and print path selection. Here, we investigate the effect of size print path (raster angle and build orientation) and print sequence on the mechanical properties of polycarbonate (PC) and polypropylene (PP). Examination of parallel and series printing of flat ( XY ) and stand-on ( YZ ) orientation of Type V specimens demonstrated that to observe statistical differences in the mechanical response that the interlayer time between printed roads should be approximately 5 s or less. The print time for a single layer in XY orientation is much longer than that for a single layer in YZ orientation, so print sequence only impacts the mechanical response in the YZ orientation. However, the specimen size and raster angle did influence the mechanical properties in XY orientation due to the differences in thermal history associated with intralayer time between adjacent roads. Moreover, all of these effects are significantly larger when printing PC than PP. These differences between PP and PC are mostly attributed to the mechanism of interface consolidation (crystallization vs. glass formation), which changes the requirements for a strong interface between roads (crystals vs. entanglements). These results illustrate how the print times dictated by the print path layout impact observed mechanical properties. This work also demonstrated that the options available in some standards developed for traditional manufacturing will change the quantitative results when applied to 3D printed parts. Supplementary Information The online version contains supplementary material available at 10.1007/s40964-022-00275-w.

show abstract

Section: Introductionmentioning

confidence: 99%

Size and print path effects on mechanical properties of material extrusion 3D printed plastics

Vogt

2022

Prog Addit Manuf

View full text Add to dashboard Cite

show abstract

“…Zhou et al [ 12 ] optimized FFF processing parameters to reduce the warpage of printed ABS parts through a voxel-based finite element simulation and showed that the print chamber temperature has a significant effect on thermal deformation. D’Amico and Peterson presented an adaptive finite element method to evaluate heat transfer in polymer deposition additive manufacturing [ 13 , 14 ]. They found that large volume deposition processes retain more heat than desktop size printers which improved the interlayer diffusion, but promoted slumping or sagging.…”

Section: Introductionmentioning

confidence: 99%

A Fully Coupled Simulation of Planar Deposition Flow and Fiber Orientation in Polymer Composites Additive Manufacturing

Wang

Smith

2021

Materials

View full text Add to dashboard Cite

Numerical studies for polymer composites deposition additive manufacturing have provided significant insight promoting the rapid development of the technology. However, little of existing literature addresses the complex yet important polymer composite melt flow–fiber orientation coupling during deposition. This paper explores the effect of flow–fiber interaction for polymer deposition of 13 wt.% Carbon Fiber filled Acrylonitrile Butadiene Styrene (CF/ABS) composites through a finite-element-based numerical approach. The molten composite flow in the extrusion die plus a strand of the deposited bead contacting the deposition substrate is modelled using a 2D isothermal and incompressible Newtonian planar flow model, where the material deposition rate is ~110 mm/s simulating a large scale additive manufacturing process. The Folgar–Tucker model associated with the Advani–Tucker orientation tensor approach is adopted for the evaluation of the fiber orientation state, where the orthotropic fitted closure is applied. By comparing the computed results between the uncoupled and fully coupled solutions, it is found that the flow-orientation effects are mostly seen in the nozzle convergence zone and the extrusion-deposition transition zone of the flow domain. Further, the fully coupled fiber orientation solution is highly sensitive to the choice of the fiber–fiber interaction coefficient , e.g., assigning as 0.01 and 0.001 results in a 23% partial relative difference in the predicted elastic modulus along deposition direction. In addition, Structural properties of deposited CF/ABS beads based on our predicted fiber orientation results show favorable agreements with related experimental studies.

show abstract

“…These results indicate that the effect of print speed can be well accounted for from layer time. Layer time was first presented as important within large scale material extrusion (big area additive manufacturing, or BAAM) 30 , 36 , 37 and has also been acknowledged as important to the desktop scale material extrusion represented by FFF 2 , 38 , 39 . Since increasing layer time leads to lower tear energy in this system, efforts should be made when planning an ABS print to shorten the layer time when practical.…”

Section: Resultsmentioning

confidence: 99%

“…Structures fabricated using FFF are commonly used industrially for functional prototyping and tooling, with broader adoption often limited by inferior mechanical properties. In FFF in particular 2 , molten polymer rapidly cools below the glass transition temperature (T g ) after extrusion 3 leading to poor interlayer adhesion as well as warping.…”

Section: Introductionmentioning

confidence: 99%

Predicting mechanical properties of material extrusion additive manufacturing-fabricated structures with limited information

Peterson

Kazmer

2022

Sci Rep

Self Cite

View full text Add to dashboard Cite

Mechanical properties of additively manufactured structures fabricated using material extrusion additive manufacturing are predicted through combining thermal modeling with entanglement theory and molecular dynamics approaches. A one-dimensional model of heat transfer in a single road width wall is created and validated against both thermography and mechanical testing results. Various model modifications are investigated to determine which heat transfer considerations are important to predicting properties. This approach was able to predict tear energies on reasonable scales with minimal information about the polymer. Such an approach is likely to be applicable to a wide range of amorphous and low crystallinity thermoplastics.

show abstract

Bead parameterization of desktop and room-scale material extrusion additive manufacturing: How print speed and thermal properties affect heat transfer

Cited by 27 publications

References 26 publications

Size and print path effects on mechanical properties of material extrusion 3D printed plastics

Size and print path effects on mechanical properties of material extrusion 3D printed plastics

A Fully Coupled Simulation of Planar Deposition Flow and Fiber Orientation in Polymer Composites Additive Manufacturing

Predicting mechanical properties of material extrusion additive manufacturing-fabricated structures with limited information

Contact Info

Product

Resources

About