Effects of infill patterns on part performances and energy consumption in acrylonitrile butadiene styrene fused filament fabrication via industrial-grade machine

Bernárdez, L.S. De; Campana, Giampaolo; Mele, Mattia; Sanguineti, Juan José; Sandre, Cristian; Mur, Sebastián Matías

doi:10.1007/s40964-022-00316-4

Cited by 7 publications

(5 citation statements)

References 61 publications

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“…Therefore, during the redesign of parts, close attention must be paid to the building time of the new part. This is due to the predominant role of energy consumption, in line with findings by [46].…”

Section: Extendability Of the Findingssupporting

confidence: 88%

See 1 more Smart Citation

Environmental drawbacks of lightweight design algorithms in material extrusion additive manufacturing: a case study

Mele,

Pisaneschi,

Ciotti

et al. 2023

J Braz. Soc. Mech. Sci. Eng.

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Lightweight design is often assumed to be the leading strategy to improve the sustainability of parts produced by additive manufacturing. The present study confutes such an assumption by a cradle-to-gate life cycle assessment of different lightweight strategies applied to a specific case study in the medical field. In particular, a patient-specific finger splint made of polyamide is redesigned by means of generative design, topology optimization and lattice structures. The analysis investigates two markedly different deposition processes, namely Arburg plastic freeforming and fused filament fabrication. The former is carried out on an industrial-grade machine, while a desktop printer is used for the latter. This allows for observing the impact of the redesign in two quite distinct scenarios. Findings demonstrate that, since environmental impacts are mainly driven by building time, the adoption of automated design algorithms can be detrimental to the sustainability of the process. On the other hand, relevant benefits on environmental impacts were achieved by reducing the infill percentage of parts. The results of this work highlight the most relevant aspects which must be considered to limit environmental impacts when designing parts for deposition-based additive manufacturing. This information can be used by designers to drive weight reduction towards sustainability.

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Section: Extendability Of the Findingssupporting

confidence: 88%

“…This can be explained if considering that the APF-2X 300K uses a heated building chamber. As discussed by [46], the build chamber heating is responsible for most of the energy demand of industrialgrade 3D printers.…”

Section: Slicingmentioning

confidence: 99%

Environmental drawbacks of lightweight design algorithms in material extrusion additive manufacturing: a case study

Mele,

Pisaneschi,

Ciotti

et al. 2023

J Braz. Soc. Mech. Sci. Eng.

Self Cite

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show abstract

“…[ 68 ] 3D printing exhibits highly attractive characteristics, primarily stemming from its FFF approach, which leads to minimal waste generation during the manufacturing process or analysis, using these devices. [ 69 ]…”

Section: Miniaturization Of Systemsmentioning

confidence: 99%

How to Improve Sustainability in Fused Filament Fabrication (3D Printing) Research?

Kalinke,

Crapnell,

de Oliveira

et al. 2024

Global Challenges

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This review aims to provide an overview of sustainable approaches that can be incorporated into well‐known procedures for the development of materials, pre‐ and post‐treatments, modifications, and applications of 3D‐printed objects, especially for fused filament fabrication (FFF). Different examples of conductive and non‐conductive bespoke filaments using renewable biopolymers, bioplasticizers, and recycled materials are presented and discussed. The main final characteristics of the polymeric materials achieved according to the feedstock, preparation, extrusion, and treatments are also covered. In addition to recycling and remanufacturing, this review also explores other alternative approaches that can be adopted to enhance the sustainability of methods, aiming to produce efficient and environmentally friendly 3D printed products. Adjusting printing parameters and miniaturizing systems are also highlighted in this regard. All these recommended strategies are employed to minimize environmental damage, while also enabling the production of high‐quality, economical materials and 3D printed systems. These efforts align with the principles of Green Chemistry, Sustainable Development Goals (SDGs), 3Rs (Reduce, Reuse, Recycle), and Circular Economy concepts.

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“…However, the simplest method that is capable of generating complex geometries, producing less waste and using the relatively cheapest equipment and raw material is fused deposition modelling (FDM) [12], or fused filament fabrication (FFF). Thermoplastic materials, including acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS), nylon, polycarbonate (PC), polyethylene (PE), polyether ether ketone (PEEK), polyethylene terephthalate glycol-modified (PETG), polylactide (PLA), polyoxymethylene (POM), polypropylene (PP), and polyvinyl alcohol (PVA), can be used in conjunction with the FDM method to obtain parts with different mechanical properties [9,[13][14][15]. Figure 1 shows a schematic of the typical FDM process.…”

Section: Introductionmentioning

confidence: 99%

“…Meanwhile, the low nozzle temperature was claimed to affect the fluidity of the deposited materials, weakening the interlayer bonding strength. Since the variation in distinct 3D printing process parameters like layer thickness, raster angle, nozzle temperature [16], infill pattern [17], and infill density can strongly modify the parts' properties, understanding their influence is a crucial step to guarantee high-quality 3D-printed products. In a study, layer thickness, infill density, and raster angle were found to have significant influences on the mechanical properties of ABS FDMprinted parts.…”

Section: Introductionmentioning

confidence: 99%

Evaluation on Material Anisotropy of Acrylonitrile Butadiene Styrene Printed via Fused Deposition Modelling

Zohdi,

Nguyen,

Yang

2024

Applied Sciences

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Thermoplastic polymers are widely used in industry to generate parts with reasonable production costs, lightweight, chemical stability, sustainability, and recyclability compared to other materials such as metals, metalloids, or even thermoset polymers. The innovative additive manufacturing (AM) techniques, e.g., fused deposition modelling (FDM), can be used to fabricate thermoplastic products with complex geometries and specific properties. However, the mechanical integrity of those FDM-printed plastic parts can be greatly impacted by a phenomenon named material anisotropy. In this study, an experimental study on a popular 3D printing polymer material—acrylonitrile butadiene styrene (ABS)—is performed to determine how FDM process parameters affect the mechanical properties of the printed ABS parts. This study uniquely concentrates on investigating mechanical anisotropy in FDM-printed ABS, delving into a combination of key printing parameters for a comprehensive exploration. Meanwhile, a finite-element-based numerical analysis is also utilised to numerically evaluate the influences of infill percentage and build orientations on the mechanical properties of the 3D-printed ABS materials for comparison. It generates a better understanding of material anisotropy and helps to find the optimal FDM process parameters to print high-quality ABS parts and may attract industrial interests in transitioning from traditional ABS part production methods such as injection moulding or hot pressing to additive manufacturing.

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Effects of infill patterns on part performances and energy consumption in acrylonitrile butadiene styrene fused filament fabrication via industrial-grade machine

Cited by 7 publications

References 61 publications

Environmental drawbacks of lightweight design algorithms in material extrusion additive manufacturing: a case study

Environmental drawbacks of lightweight design algorithms in material extrusion additive manufacturing: a case study

How to Improve Sustainability in Fused Filament Fabrication (3D Printing) Research?

Evaluation on Material Anisotropy of Acrylonitrile Butadiene Styrene Printed via Fused Deposition Modelling

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