Influence of processing parameters tuning and rheological characterization on improvement of mechanical properties and fabrication accuracy of 3D printed models

Abstract

Purpose Fabrication settings such as printing speed and nozzle temperature in fused deposition modeling undeniably influence the quality and strength of fabricated parts. As available market filaments do not contain any exact information report for printing settings, manufacturers are incapable of achieving desirable predefined print accuracy and mechanical properties for the final parts. The purpose of this study is to determine the importance of selecting suitable print parameters by understanding the intrinsic behavior of the material to achieve high-performance parts. Design/methodology/approach Two common commercial polylactic acid filaments were selected as the investigated samples. To study the specimens’ printing quality, an appropriate scaffold geometry as a delicate printing sample was printed according to a variety of speeds and nozzle temperatures, selected in the filament manufacturer’s proposed temperature range. Dimensional accuracy and qualitative surface roughness of the specimens made by one of the filaments were evaluated and the best processing parameters were selected. The scaffolds were fabricated again by both filaments according to the selected proper processing parameters. Material characterization tests were accomplished to study the reason for different filament behaviors in the printing process. Moreover, the correlations between the polymer structure, thermo-rheological behavior and printing parameters were denoted. Findings Compression tests revealed that precise printing of the characterized filament results in more accurate structure and subsequent improvement of the final printed sample elastic modulus. Originality/value The importance of material characterization to achieve desired properties for any purpose was emphasized. Obtained results from the rheological characterizations would help other users to benefit from the highest performance of their specific filament.

Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective

“…These materials have a structure consisting of a matrix, which can be solid or flexible, and voids called pores. These porous structures can have different sizes, shapes, and arrangements, giving them different properties and applications [44]. The matrix, which is the solid part of the structure, surrounds and holds the pores.…”

Mechanical properties of additively manufactured polymeric composites using sheet lamination technique and fused deposition modeling: A review

“…Apart from the usual factors such as stacking sequence, fiber volume, and fiber orientation, the mechanical performance of printed parts was influenced by printing speed, nozzle diameter, and temperature, build orientation, and layer thickness. [29][30][31][32][33] In the present review, the authors revealed the recent developments in the AM technique, especially the sheet lamination method and FDM. Moreover, process parameters for obtaining the optimized performance of the manufactured 3-D printed products have been discussed.…”

“…The ability to alter process parameters becomes useful when manufacturing printed components for structural applications. Apart from the usual factors such as stacking sequence, fiber volume, and fiber orientation, the mechanical performance of printed parts was influenced by printing speed, nozzle diameter, and temperature, build orientation, and layer thickness 29–33 …”

Additive manufactured parts surface treatment through impinged hot air jet technique the theoretical and experimental evaluation

“…The current issue and full text archive of this journal is available on Emerald Insight at: https://www.emerald.com/insight/1355-2546.htm developed as secondary processes to ameliorate the surface integrity and dimensional accuracy of the printed parts (Hashmi et al, 2023a;Tiwary et al, 2022a). The preprocessing techniques are divided into the optimization of printing machine structure (Chu et al, 2021;Marion et al, 2023;Xu et al, 2022) and feedstock filament (Dontsov et al, 2020;Ginoux et al, 2023;Yan et al, 2023), printing strategy optimization (Afsharkohan et al, 2023;Côt e et al, 2023;Jiang et al, 2022;Wang et al, 2021) including printing path, printing speed, build orientation and layer thicknessand slicing optimization methods (Mosleh et al, 2023;Nayyeri et al, 2022;Vinoth Babu et al, 2021).…”