Getting Rid of the Wires: Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

Diegel, Olaf; Singamneni, Sarat; Huang, Bin; Gibson, Ian

doi:10.4028/www.scientific.net/kem.467-469.662

Cited by 18 publications

(10 citation statements)

References 9 publications

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“…Alayoldi, et al (2020) [68] investigated the effect of the infill pattern on the compressive strength of the part. It was found that triangular, grid and hexagonal infilled parts resulted in similar ultimate tensile strength (56)(57)(58)(59)(60)(61)(62)(63)(64)(65)(66)(67)(68)(69)(70)(71)(72), while the quarter cubic infill exhibited a significantly lower strength of 27 MPa. It was also found that the grid pattern had the highest tensile strength due to its special layer arrangement in which the infill layers are crisscrossed one above the other as shown in Figure 5.…”

Section: Effect Of Infill Patternsmentioning

confidence: 99%

Optimisation of Strength Properties of FDM Printed Parts—A Critical Review

et al. 2021

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Additive Manufacturing is currently growing fast, especially fused deposition modeling (FDM), also known as fused filament fabrication (FFF). When manufacturing parts use FDM, there are two key parameters—strength of the part and dimensional accuracy—that need to be considered. Although FDM is a popular technology for fabricating prototypes with complex geometry and other part product with reduced cycle time, it is also limited by several drawbacks including inadequate mechanical properties and reduced dimensional accuracy. It is evident that part qualities are greatly influenced by the various process parameters, therefore an extensive review of the effects of the following process parameters was carried out: infill density, infill patterns, extrusion temperature, layer thickness, nozzle diameter, raster angle and build orientation on the mechanical properties. It was found from the literature that layer thickness is the most important factor among the studied ones. Although manipulation of process parameters makes significant differences in the quality and mechanical properties of the printed part, the ideal combination of parameters is challenging to achieve. Hence, this study also includes the influence of pre-processing of the printed part to improve the part strength and new research trends such as, vacuum-assisted FDM that has shown to improve the quality of the printing due to improved bonding between the layers. Advances in materials and technologies that are currently under development are presented. For example, the pre-deposition heating method, using an IR lamp of other technologies, shows a positive impact on the mechanical properties of the printed parts.

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Section: Effect Of Infill Patternsmentioning

confidence: 99%

Optimisation of Strength Properties of FDM Printed Parts—A Critical Review

et al. 2021

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“…Additive manufacturing generally involves extruding or deposition of material onto a flat horizontal surface and building up an object from numerous stacked planar layers. Relatively few papers have been published on the topic of Conformal Printing-examples include Curved Fused Deposition Modeling [1][2][3][4] or Direct Ink Writing onto curvilinear surfaces with a priori knowledge of substrate shape. 5 Recent publications describe deposition systems that can measure the shape and size of an unknown curved substrate and then immediately print on it in a repeatable accurate manner.…”

Section: Introductionmentioning

confidence: 99%

Production Techniques for 3D Printed Inflatable Elastomer Structures: Part II—Four-Axis Direct Ink Writing on Irregular Double-Curved and Inflatable Surfaces

Coulter

Papastavrou

et al. 2018

3D Printing and Additive Manufacturing

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This article is the second in a two-part series describing a process for conformal 3D printing onto inflated substrates. The article describes the design and build of a custom-built four-axis 3D printer with the ability to measure the shape of any uneven substrate, and to then accurately extrude a thixotropic silicone onto the substrate by using Direct Ink Writing techniques. Details of strategies for 3D scanning a double-curved tubular inflated substrate using an industrial triangulation laser measurement device are given. Methods to import scan data and create a digital representation of the surface within the parametric design software Grasshopper 3D are explained. Geodesic print paths are created over the surface of the computed substrate, and these are the basis for calculating 3D printer toolpaths. A constant surface linear velocity strategy is developed, allowing the printer to move the print nozzle at a varying speed over the substrate surface. The change in speed is correlated with changes in the surface linear velocity of a fourth axis rotation of the variable radius balloon substrate. This ensures that the extruded bead maintains a constant thickness, even while using a constant flow rate deposition. The process is achieved by adapting cartographic techniques to re-project to the desired print paths. The efficacy of this technique is analyzed by 3D scanning a printed patterned balloon, then measuring and comparing multiple cross-sections of the extruded beading.

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“…In recent years, the electronics industry has been searching for new methods for manufacturing conductive lines in order to meet the requirements of smaller feature size, less environmental impact, less weight and volume, flexible electronics, embedded electronics, etc. Many new techniques have been developed during the past decade, such as Curved Layer Fused Deposition Modeling (CLFDM) [2], Laser-based Direct Write (LDW) [3], Laser Micro-cladding Electronic Pastes (LMCEP) [4], screen printing [5], offset lithography [6], aerosol jet [7,8], and inkjet deposition [9][10][11][12][13][14]. CLFDM is limited by the conductivity.…”

Section: Introductionmentioning

confidence: 99%

“…Fused deposition modeling (FDM) has become a prominent form of additive manufacturing and has been used to build mechanical structures for many commercial products. Although conductive polymers can be used in FDM to build conductive lines [2], the resistance is nonetheless too high for most of the applications. D. Espalin et al demonstrated a multi 3D system that can produce 3D, multi-material and multifunctional devices based on a combination of FDM process, direct printing technology, and a novel thermal embedding technology.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of conductive paths on a fused deposition modeling substrate using inkjet deposition

Zhou

List

Duty

et al. 2016

Rapid Prototyping Journal

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Inkjet deposition is one of the most attractive fabrication techniques for producing cost efficient and lightweight electronic devices on various substrates with low environmental impact. Fused Deposition Modeling (FDM) is one of the most used and reliable additive manufacturing processes by extrusion of wire-shaped thermoplastic materials, which provides an opportunity for embedding printed electronics into mechanical structures during the building process and enables the design of compact smart structures that can sense and adapt to their own state and the environment. This paper represents one of the first explorations of integrating inkjet deposition of silver nanoparticle inks with the FDM process for making compact electro-mechanical structures. Three challenges have been identified and investigated, including the discontinuity of the printed lines resulting from the irregular surface of the FDM substrate, the non-conductivity of the printed lines due to the particle segregation during the droplet drying process, and the slow drying process caused by the "skinning effect". Two different techniques are developed in this paper to address the issue of continuity of the printed lines, including surface ironing and a novel "thermal plow" technique that plows a channel in the FDM substrate to seal off the pores in the substrate and contain the deposited inks. Two solutions are also found for obtaining conductivity from the continuous printed lines, including porous surface coating and using a more viscous ink with larger nanoparticle size. Then the effects of the printing and post-processing parameters on the conductivity are examined. It is found that post-processing is a dominant factor in determining the conductivity of the printed lines.

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Getting Rid of the Wires: Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

Cited by 18 publications

References 9 publications

Optimisation of Strength Properties of FDM Printed Parts—A Critical Review

Optimisation of Strength Properties of FDM Printed Parts—A Critical Review

Production Techniques for 3D Printed Inflatable Elastomer Structures: Part II—Four-Axis Direct Ink Writing on Irregular Double-Curved and Inflatable Surfaces

Fabrication of conductive paths on a fused deposition modeling substrate using inkjet deposition

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