In-situ monitoring of strain and temperature distributions during fused deposition modeling process

Kousiatza, Charoula; Karalekas, D.

doi:10.1016/j.matdes.2016.02.099

Cited by 163 publications

(103 citation statements)

References 30 publications

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“…3D printer manufacturers tend to utilize different nozzle and heater designs and thermocouple placements, which is expected to result in different amounts of error in measuring the actual temperature of the polymer exiting the nozzle . Furthermore, even the location of the sample on the printing bed has been reported to result in variations in the specimen temperature . In our data, the ductility abruptly diminishes as nominal nozzle temperature is decreased from 200 °C to 190 °C, which can potentially explain the observed discrepancy.…”

Section: Resultsmentioning

confidence: 64%

Improving the ductility of polylactic acid parts produced by fused deposition modeling through polyhydroxyalkanoate additions

Kaygusuz

Özerinç

2019

J of Applied Polymer Sci

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Polylactic acid (PLA) is one of the most commonly used materials for fused deposition modeling (FDM) due to its low cost, biocompatibility, and desirable printing characteristics. However, its low ductility is a major disadvantage for engineering applications where high damage tolerance is needed. This study investigates the feasibility of polyhydroxyalkanoate (PHA) additions to PLA for improving the ductility of parts produced by FDM. Thermal and mechanical behavior of PLA/PHA specimens containing 12 wt % PHA is investigated for a range of printing nozzle temperatures. All PLA/PHA specimens exhibit amorphous PLA phase with semicrystalline PHA and possess outstanding ductility exceeding 160% for nozzle temperatures in the range of 200 C-240 C. Lower and higher nozzle temperatures result in low ductility, similar to that of pure PLA. Overall, PLA/PHA is a very promising polymer blend for FDM processes, providing a combination of sufficient strength with excellent damage tolerance.

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Section: Resultsmentioning

confidence: 64%

Improving the ductility of polylactic acid parts produced by fused deposition modeling through polyhydroxyalkanoate additions

Kaygusuz

Özerinç

2019

J of Applied Polymer Sci

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“…At present, the lack of relevant studies necessitates the undertaking of such research activities important in this area of interest. Recently, a methodology has been presented by Kousiatza et al [16] for monitoring the temperature profiles generated during the building process of rectangular cross section thick specimens. The experimental results of that study indicate that the in-process induced temperature fluctuations influence the magnitude of the measured residual strains.…”

Section: Introductionmentioning

confidence: 99%

Temperature Mapping of 3D Printed Polymer Plates: Experimental and Numerical Study

Kousiatza

Chatzidai

Karalekas

2017

Sensors

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In Fused Deposition Modeling (FDM), which is a common thermoplastic Additive Manufacturing (AM) method, the polymer model material that is in the form of a flexible filament is heated above its glass transition temperature (Tg) to a semi-molten state in the head’s liquefier. The heated material is extruded in a rastering configuration onto the building platform where it rapidly cools and solidifies with the adjoining material. The heating and rapid cooling cycles of the work materials exhibited during the FDM process provoke non-uniform thermal gradients and cause stress build-up that consequently result in part distortions, dimensional inaccuracy and even possible part fabrication failure. Within the purpose of optimizing the FDM technique by eliminating the presence of such undesirable effects, real-time monitoring is essential for the evaluation and control of the final parts’ quality. The present work investigates the temperature distributions developed during the FDM building process of multilayered thin plates and on this basis a numerical study is also presented. The recordings of temperature changes were achieved by embedding temperature measuring sensors at various locations into the middle-plane of the printed structures. The experimental results, mapping the temperature variations within the samples, were compared to the corresponding ones obtained by finite element modeling, exhibiting good correlation.

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“…However, the use of wider infill benefits from the reheating and remelting process to improve bonding between layers, which is favorable for dimensions on the z axis direction or in this case, the milliprojection height. In material extrusion 3D printing, the thermal energy from the high temperature molten material drives the bond formation via diffusion bonding mechanism between layers and lines …”

Section: Resultsmentioning

confidence: 92%

“…38 In 3D printing, thermal elastic stresses dominate and are generated from the repeated expansion and contraction of the materials caused by the remelting and cooling cycle of the 3D printing process resulting in nonuniform thermal gradients. [39][40][41] The residual stresses in the 3D printed parts lead to distortions, deterioration of mechanical properties, and poor dimensional accuracy. [42][43][44] This is largely experienced along the x and y axis, that is, the length and the width of the 3D printed part 13 and thus will affect both the milliprojection base diameter and tip diameter more than the height.…”

Section: Influence Of Extrusion Width and Infill Width On Print Qualitymentioning

confidence: 99%

Design and fabrication of transdermal drug delivery patch with milliprojections using material extrusion 3D printing

Tang

Wong-Holmes

Dean

et al. 2019

J of Applied Polymer Sci

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This paper investigates the effect of various 3D printing parameters on a transdermal drug delivery system with milliprojections printed using poly(lactic acid) (PLA). The parameters studied involve printing temperature, layer thickness, extrusion width, infill width, and nozzle orifice diameter. Their effects on the final print quality were evaluated based on the surface finish and dimensional accuracy of the milliprojections. The change in the molecular weights of the polymers after extrusion and printing suggests thermal degradation. Further thermal analysis also showed that 3D printing decreases polymer crystallinity. The parameters studied showed varying effects on print quality with respect to PLA types and the dimensions involved. In general, it is sensible to process at temperature close to the melting point of a semicrystalline polymer or at the lowest temperature for which the polymer flows for an amorphous polymer. Although the layer thickness and extrusion width affect each dimension differently, it was found to be a reasonable approach to choose a thinner layer for a more accurate tip, and a thinner infill width for more accurate part diameters. Lastly, it was found that the smaller nozzle orifice and increased spacing between milliprojections produced better surface finish but had no significant effect on part accuracy. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020, 137, 48777.

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In-situ monitoring of strain and temperature distributions during fused deposition modeling process

Cited by 163 publications

References 30 publications

Improving the ductility of polylactic acid parts produced by fused deposition modeling through polyhydroxyalkanoate additions

Improving the ductility of polylactic acid parts produced by fused deposition modeling through polyhydroxyalkanoate additions

Temperature Mapping of 3D Printed Polymer Plates: Experimental and Numerical Study

Design and fabrication of transdermal drug delivery patch with milliprojections using material extrusion 3D printing

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