Integration of Additive Manufacturing, Parametric Design, and Optimization of Parts Obtained by Fused Deposition Modeling (FDM). A Methodological Approach

García-Domínguez, Amabel; Gil, Juan Claver; Pérez, Miguel Ángel Sebastián

doi:10.3390/polym12091993

Cited by 17 publications

(6 citation statements)

References 90 publications

(108 reference statements)

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“…The procedure can be further refined to make the selection of the optimal values of key PPs more objective (e.g., by measuring the profiles of the grooves with a profilometer or implementing an image recognition system, etc.) or to include geometry- and toolpath-specific parameters [ 21 ]. The procedure itself can become a useful add-on feature in a toolpath-generation software or 3D printers.…”

Section: Resultsmentioning

confidence: 99%

On the Heuristic Procedure to Determine Processing Parameters in Additive Manufacturing Based on Materials Extrusion

Bakradze

Arājs²,

Gaidukovs

et al. 2020

Polymers

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We present a heuristic procedure for determining key processing parameters (PPs) in materials-extrusion-based additive manufacturing processes. The concept relies on a design-of-experiment approach and consists of eleven “test objects” to determine the optimal combinations of key PPs values, starting with the PPs for printing the first layer and progressing to more complex geometric features, e.g., “bridges”. In each of the test objects, several combinations of the known PPs’ values are used, and only the values resulting in the best printed-part quality are selected for the following tests. The concept is intrinsically insensitive to different artefacts of the additive manufacturing machine (e.g., discrepancies between the nominal and actual nozzle diameters, and improper calibration of the feeding screws) and the optimal values of key PPs for manufacturing defect-free parts under the actual processing conditions can be determined. We validated the proposed procedure for two common commercial polymer feedstock materials, and we show that, by using the proposed procedure, it is possible to reduce the optimization time down to several hours, as well as to reduce the amount of consumed feedstock material. Tensile tests revealed a strong effect of amorphous and semi-crystalline nature of the polymer on the results of optimization. To the best of our knowledge, this is the first attempt to describe a systematic approach for optimizing PPs for materials extrusion-based additive manufacturing processes without relying on statistical data analysis or virtual simulations. The concept was implemented as a web-tool 3DOptimizer®.

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Section: Resultsmentioning

confidence: 99%

On the Heuristic Procedure to Determine Processing Parameters in Additive Manufacturing Based on Materials Extrusion

Bakradze

Arājs²,

Gaidukovs

et al. 2020

Polymers

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show abstract

“…The material moves along the section contour and filling track of the part after being heated and melted by the extrusion head. Then, the melted material is superimposed layer by layer with a certain layer thickness [6][7][8]. After the material is cooled and solidified, the supporting structure is removed to obtain the finished part.…”

Section: Introductionmentioning

confidence: 99%

Adaptive Layering Algorithm for FDM-3D Printing Based on Optimal Volume Error

Ouyang

Qiao

2022

Micromachines

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The characteristics of fused deposition 3D printing lead to the inevitable step effect of surface contour in the process of forming and manufacturing, which affects molding accuracy. Traditional layering algorithms cannot take into account both printing time and molding accuracy. In this paper, an adaptive layering algorithm based on the optimal volume error is proposed. The angle between the normal vector and the layering direction is used for data optimization. The layer thickness is determined by calculating the volume error, and based on the principle of the optimal volume error, the unequal thickness adaptive layering of each printing layer of the model is realized. The experimental results show that the self-adaptive layering algorithm based on the optimal volume error has a better layering effect, greatly improves the forming efficiency and surface forming accuracy, and has a good adaptability to models with complex surfaces.

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“…[12,13] The phenomenon related to the occurrence of lower fatigue strength of AM parts could be compensated by adjusting the geometry of the parts to the so-called ''Design for Additive Manufacturing.'' [14,15] Additionally, it is possible to affect (within a certain range) the process parameters which could significantly improve the fatigue performance of the AM parts.…”

Section: Introductionmentioning

confidence: 99%

The Influence of Process Parameters on the Low-Cycle Fatigue Properties of 316L Steel Parts Produced by Powder Bed Fusion

Kluczyński

Śnieżek

Grzelak

et al. 2022

Metall Mater Trans A

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In this paper, the influence of the additive manufacturing (AM), powder bed fusion (PBF) process parameters on the low-cycle fatigue (LCF) properties of 316L steel samples is shown. Based on the previous research, five parameter groups were selected. To make this analysis broader, research results of AM parts have been compared to the conventionally made counterparts. Such an approach allowed analyzing the manner different parameters affect the tensile and LCF behavior. The preliminary tests indicated that AM specimens are characterized by 65 pct of the total LCF strength in comparison to the conventionally made material. Further LCF tests indicated differences in the dissipated energy of some samples, which was visible in the hysteresis loops generated during testing in the total strain amplitude range from 0.30 to 0.45 pct. Based on the Morrow approach, it was possible to register an increased share of the plastic component during the fracture process in the Additive Manufacturing (AM) parts in the LCF tests with the total strain amplitude above 0.45 pct. The final microscopical investigation of parts’ fractures surfaces indicated the influence of the layered structure, and internal imperfections (such as unmelted powder particles and lack of fusion) of the as-built AM parts on the cracking process, which caused an increased number of multiplanar cracks and generation of the complex fracture morphology characterized by the layered structure of AM parts and share of imperfections—mostly porosity caused by unmelted powder particles which potentially was a base of secondary stage cracks.

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Integration of Additive Manufacturing, Parametric Design, and Optimization of Parts Obtained by Fused Deposition Modeling (FDM). A Methodological Approach

Cited by 17 publications

References 90 publications

On the Heuristic Procedure to Determine Processing Parameters in Additive Manufacturing Based on Materials Extrusion

On the Heuristic Procedure to Determine Processing Parameters in Additive Manufacturing Based on Materials Extrusion

Adaptive Layering Algorithm for FDM-3D Printing Based on Optimal Volume Error

The Influence of Process Parameters on the Low-Cycle Fatigue Properties of 316L Steel Parts Produced by Powder Bed Fusion

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