High-performance polymer 3D printing – Open-source liquid cooled scalable printer design

Birkelid, Andreas Hagerup; Eikevåg, S. W.; Elverum, Christer W.; Steinert, Martin

doi:10.1016/j.ohx.2022.e00265

Cited by 8 publications

(12 citation statements)

References 12 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

Section: Methodsmentioning

confidence: 99%

“…The process and environmental effect in additive manufacturing majorly impact material properties [12]. Therefore, a high-performance open-source liquid-cooled FFF printer with additional sensors for carefully monitoring the process was used while manufacturing [12]. The work by Birkelid et al [12] presents full build instructions in addition to performance benchmarking and results, including both PA6-CF and PEEK-CF.…”

Section: Methodsmentioning

confidence: 99%

“…Therefore, a high-performance open-source liquid-cooled FFF printer with additional sensors for carefully monitoring the process was used while manufacturing [12]. The work by Birkelid et al [12] presents full build instructions in addition to performance benchmarking and results, including both PA6-CF and PEEK-CF. The printer used in this study uses a SuperVolcano HotEnd [13], the top modification available, and a heated chamber that can be adjusted up to 135 • C. Multiple sensors monitor the chamber temperature and important components of the hardware.…”

Section: Methodsmentioning

confidence: 99%

“…In addition, essential components, such as the nozzle, are calibrated by external sensors and continuously measured by double thermistors. The setup is made for scientific use, and the result presented by Birkelid et al [12] shows that PA6-CF from Polymaker [14] samples on an open-source printer outperforms the Prusa Mk3 by 25% and the datasheet by 15% in the UTS.…”

Section: Methodsmentioning

confidence: 99%

“…As more hardware with which to deposit high-performance polymers becomes available, such as the open-source machine used in this study [12] as well as commercial alternatives, TLD will become more relevant for high-end polymer components. By properly calibrating the manufacturing process, continuous monitoring, and manufacturing control [12], tensile testing specimens of PA6-CF can even outperform the material datasheet. The new open-source design also allows for investigating individual parameters with higher accuracy due to the controlled setup.…”

Section: Introductionmentioning

confidence: 99%

See 4 more Smart Citations

Thermal Layer Design in Fused Filament Fabrication

et al. 2022

Self Cite

View full text Add to dashboard Cite

The current limitations of design for additive manufacturing (DfAM) are the state of knowledge on materials and the effects of production parameters. As more engineering-grade polymers become available for fused filament fabrication (FFF), the designs and processes must be adapted to fully utilize the structural properties of such materials. By studying and comparing the production parameters of a material test specimen and a component, the effects of layer temperature on the strength, surface roughness, and dimensional accuracy of PA6-CF were found. As the cross-section increases in component manufacturing, maintaining the layer temperature becomes a major challenge. From the findings, the concept of thermal layer design (TLD) was introduced as a way of increasing strength via temperature in selected regions after presenting the effect of layer temperature. TLD proved to have a major effect on layer temperature and heat distribution. Depending on the investigated layer temperature, from 147 °C to 193 °C the UTS of PA6-CF increased from 42 MPa to 73 MPa. Implementing TLD in DfAM represents a big leap for designing high-performance polymer components.

show abstract

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Thermal Layer Design in Fused Filament Fabrication

et al. 2022

Self Cite

View full text Add to dashboard Cite

show abstract

Creating an Open-Source, Low-Cost Composite Feeder Design to Improve Filament Quality of High-Performance Materials to Be Used in Fused Filament Fabrication (Fff)

Øvrebø,

Koldre,

Nesheim

et al. 2023

Proc. Des. Soc.

Self Cite

View full text Add to dashboard Cite

Composite filaments are getting increased attention in additive manufacturing (AM). More and better solutions for filament production are needed to assist researchers in discovering new materials capable of producing AM-made high-performance parts. This article presents a method for producing composite filament, including an open-source, low-cost automatic composite feeder designed to increase the accuracy and quality of the filament. The feeder includes a fibre screw designed through an iterative prototyping process to accurately control the filament's fibre percentage while reducing lumps' occurrence in a single step. An experiment evaluating the quality of filament made of Polylactic Acid (PLA) and carbon fibre (CF) tested the use of the feeder compared to manual mixing. Filament with a nominal diameter of 2.85mm with 4.5%, 7.9%, 11.2% and 14.5% CF was made. The results suggest that the composite feeder improved the filament quality. The filament diameter RMSE value was reduced from 0.08 to 0.06 and 0.15 to 0.13 for both 4.5% and 11.2%, respectively. The article concludes that the feeder design may help researchers develop and discover new materials while improving the quality of the filament.

show abstract

Sensing in-Situ Temperatures by Coordinates in Fused Filament Fabrication for Identifying Interlayer Anisotropic Mechanical Properties and Enabling Post-Fem Analysis

Amlie,

Fylling,

Eikevåg

et al. 2023

Proc. Des. Soc.

Self Cite

View full text Add to dashboard Cite

In Additive Manufacturing (AM), new generations of polymer composites presented as engineering- grade materials provide high-end mechanical properties with the design freedom AM provides. Interlayer anisotropy is the main challenge in both in-situ optimization and post-analysis in transitioning from prototypes to high-performance components in fused filament fabrication (FFF). Recent studies show a direct correlation between layer fusion temperature and mechanical properties. In this paper, we present synchronized position and temperature data and study how a component changes based on layer height and geometry. An IR sensor transfers data while printing a G-code generated by FullControllGcode, printing in a single direction and recording temperature in front of the nozzle. Results show that within each layer, a Δt of 20°C at thinner geometries, the heat loss will provide a reduction in mechanical properties and further heat loss occurs when moving away from the heated bed. By using the presented temperature mesh in further studies, post- printed anisotropic components can be analyzed by FEM, and the FFF process can be adaptively optimized based on location, size and geometry.

show abstract

High-performance polymer 3D printing – Open-source liquid cooled scalable printer design

Cited by 8 publications

References 12 publications

Thermal Layer Design in Fused Filament Fabrication

Thermal Layer Design in Fused Filament Fabrication

Creating an Open-Source, Low-Cost Composite Feeder Design to Improve Filament Quality of High-Performance Materials to Be Used in Fused Filament Fabrication (Fff)

Sensing in-Situ Temperatures by Coordinates in Fused Filament Fabrication for Identifying Interlayer Anisotropic Mechanical Properties and Enabling Post-Fem Analysis

Contact Info

Product

Resources

About