Fused filament fabrication: A state-of-the-art review of the technology, materials, properties and defects

Yadav, Aniket; Rohru, Piyush; Babbar, Atul; Ranjan, Nishant; Chohan, Jasgurpreet Singh; Kumar, Raman; Gupta, Manish

doi:10.1007/s12008-022-01026-5

Cited by 34 publications

(26 citation statements)

References 218 publications

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“…Fused filament fabrication (FFF) is one of the additive manufacturing processes that is extensively used to produce polymeric parts [ 10 ]. In fused filament technology, the mastering of the rheological behaviour of the feedstock material is the key to achieving rapid rigidification after the cooling down of a filament heated above its glass transition temperature [ 11 ]. Filament solutions based on biosourced material have been considered in fused filament technology [ 12 ].…”

Section: Introductionmentioning

confidence: 99%

The Thermal and Mechanical Behaviour of Wood-PLA Composites Processed by Additive Manufacturing for Building Insulation

et al. 2023

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This study was aimed at considering the potential of wood-based composites processed using additive manufacturing as insulators in the building sector. A polylactic acid blend with 30% wood particles was used as a feedstock material in fused filament technology. Its thermal and mechanical properties were determined for various processing conditions, including printing temperature and infill rate. The results showed a minor contraction in its tensile performance as a result of the printing process. The printing temperature had a negligible effect on its stiffness and a limited influence on the other engineering constants, such as the tensile strength and ultimate stress. The thermal properties of printed structures have been found to significantly depend on the infill rate. Although the tested 3D printed wood-PLA material exhibited good thermal properties, which were tuneable using the printing conditions, its performance was still 38% to 57% lower compared to insulators such as the glass wool of the synthetic foams used in the building sector.

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Section: Introductionmentioning

confidence: 99%

The Thermal and Mechanical Behaviour of Wood-PLA Composites Processed by Additive Manufacturing for Building Insulation

et al. 2023

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“…The porosity values for 100% infill programming in the slicer software must be 9%, as demonstrated in the simulations and experiments by Brackett et al 54 The high porosity in some mixtures may be related to the increase in printing speed for internal filling (Geng et al 55 apud Yadav et al 56 ). All parts were printed with a fixed speed of 50 mm/s, and…”

Section: Composite Printed Modelsmentioning

confidence: 99%

Acrylonitrile‐butadiene‐styrene‐based composites for the manufacture of anthropomorphic simulators

Thomazi,

Roman,

Vanni

et al. 2024

Polymer Composites

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The development of functional compounds for extrusion applied in the additive manufacturing of anthropomorphic simulators is interesting, as it guarantees the manufacture of a 3D model similar to the patient. These simulators find applications in therapies or laboratory tests involving x‐rays. In order to replicate human conditions in these tests, it is essential to create materials that closely match the properties of human tissue, including the smoothness of soft tissues and the hardness of the bone tissue. This study developed ceramic‐polymeric composites, where the tomography intensity of each mixture was measured experimentally. Combinations of acrylonitrile butadiene styrene (ABS) with zirconium oxide and basic bismuth carbonate allowed imitation of bone tissue. The samples containing zirconium oxide and basic bismuth carbonate presented results that exceeded the minimum limit and reached a value close to 2000 Hounsfield units (HU) with 12% basic bismuth carbonate content. Combinations of ABS with hydroxyapatite and aluminum oxide can imitate soft tissues. The use of a surfactant facilitated the mixing of ceramic filler with polymer. Finally, 3D printing of a physical model was performed using a dual extruder printer, allowing simultaneous printing of bone and soft tissue components.Highlights Material mimicking x‐ray attenuation similar to bone tissue. Relation between 3D printing porosity and intensity in Hounsfield unit. Computed tomography tests on a 3D printed anthropomorphic phantom. Creating a 3D model from a Computed Tomography scan. Double extruder for 3D printing of two tissue simultaneously.

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“…Additive manufacturing (AM) or 3D printing (3DP) is an emerging technology poised to revolutionize the way products are fabricated from plastics, metals, concrete, ceramics, composites, and many others. − Using one of the seven ASTM 52900 recognized types of AM, material is typically added in a layer-by-layer fashion exactly where needed to form the desired geometry developed by using 3D modeling software. It has long been recognized that the fusing of materials in AM-derived objects leads to an inherent mechanical inferiority in traditionally manufactured objects, the extent of which depends on the AM technique, processing parameters, material, and postprint processing steps.…”

Section: Introductionmentioning

confidence: 99%

Plasticization of a Diels–Alder Covalent Adaptable Network for Fused Filament Fabrication

Bischoff,

Mackay

2024

ACS Appl. Polym. Mater.

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Fused filament fabrication (FFF) is a 3D printing technique used to manufacture thermoplastic objects that offers users nearly unlimited design freedom compared with traditional subtractive and formative methodologies. The most significant barriers prohibiting its more widespread adoption are the reduced mechanical properties compared to injection or compressionmolded counterparts and the large degree of mechanical anisotropy due to the layer-by-layer additive process, where strength between layers is developed through the reptation and entanglement of polymer chains. Herein, a highly cross-linked covalent adaptable network (CAN) based on the Diels−Alder reaction between furan and maleimide functionalities is blended with flexible and tough polycaprolactone (PCL) to afford a dynamic semi-interpenetrating polymer network (semi-IPN) that can be spooled for use on an unmodified, commercially available desktop FFF 3D printer. By leveraging the thermoreversible nature of the Diels−Alder adducts, strong covalent bonds can form across the interfaces between deposited tracks. Tensile testing is performed on specimens fabricated using 0 and 90°raster angles, causing stress to be transferred either along the tracks or across the interlayer welds, respectively. The semi-IPN exhibits a degree of mechanical anisotropy of 11% without requiring specialized hardware or postprint processing steps, a marked improvement over about 60% in the typical polylactic acid used in FFF. The addition of the PCL makes the toughness of the blend 100× that of pure CAN, and the 3D-printed objects do not contain void space between tracks, making them fully dense.

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Fused filament fabrication: A state-of-the-art review of the technology, materials, properties and defects

Cited by 34 publications

References 218 publications

The Thermal and Mechanical Behaviour of Wood-PLA Composites Processed by Additive Manufacturing for Building Insulation

The Thermal and Mechanical Behaviour of Wood-PLA Composites Processed by Additive Manufacturing for Building Insulation

Acrylonitrile‐butadiene‐styrene‐based composites for the manufacture of anthropomorphic simulators

Plasticization of a Diels–Alder Covalent Adaptable Network for Fused Filament Fabrication

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