Investigation on the Scale Factor applicable to ABS based FDM Additive Manufacturing

Rahman, Habibur; John, Thompson; Sivadasan, M.; Singh, Narinder

doi:10.1016/j.matpr.2017.11.258

Cited by 33 publications

(27 citation statements)

References 8 publications

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“…These results were in accordance with our results for length at lower layer thicknesses, and for width at higher layer thicknesses. In the study with ABS material by Rahman et al [18] a positive deviation in the Z-axis and shrinkage in the X-axis, and Y-axis were found, which is in opposition to our results. Galantuchi et al [21] found that dimensional precision improved with reduced path speed, which is again in opposition to our results, where speed had no significant effect on dimensional accuracy.…”

Section: Resultscontrasting

confidence: 99%

“…Kaveh et al [17] examined the effects of the 3D printing parameters (extruded temperature, feed rate, flow rate, and raster width) on HIPS material. Rahman et al [18] used the bed temperature, number of loops, nozzle temperature, print speed, layer thickness, and infill to evaluate dimensional precision, Noriega et al [19] proposed a method for improving dimensional precision between parallel faces using ABS.…”

Section: Introductionmentioning

confidence: 99%

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Analysis of PLA Geometric Properties Processed by FFF Additive Manufacturing: Effects of Process Parameters and Plate-Extruder Precision Motion

et al. 2019

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The evolution of fused filament fabrication (FFF) technology, initially restricted to the manufacturing of prototypes, has led to its application in the manufacture of finished functional products with excellent mechanical properties. However, FFF technology entails drawbacks in aspects, such as dimensional and geometric precision, and surface finish. These aspects are crucial for the assembly and service life of functional parts, with geometric qualities lagging far behind the optimum levels obtained by conventional manufacturing processes. A further shortcoming is the proliferation of low cost FFF 3D printers with low quality mechanical components, and malfunctions that have a critical impact on the quality of finished products. FFF product quality is directly influenced by printer settings, material properties in terms of cured layers, and the functional mechanical efficiency of the 3D printer. This paper analyzes the effect of the build orientation (Bo), layer thickness (Lt), feed rate (Fr) parameters, and plate-extruder movements on the dimensional accuracy, flatness error, and surface texture of polylactic acid (PLA) using a low cost open-source FFF 3D printer. The mathematical modelling of geometric properties was performed using artificial neural networks (ANN). The results showed that thinner layer thickness generated lower dimensional deviations, and feed rate had a minor influence on dimensional accuracy. The flatness error and surface texture showed a quasi-linear behavior correlated to layer thickness and feed rate, with alterations produced by 3D printer malfunctions. The mathematical models provide a comprehensive analysis of the geometric behavior of PLA processing by FFF, in order to identify optimum print settings for the processing of functional components.

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Section: Resultscontrasting

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Analysis of PLA Geometric Properties Processed by FFF Additive Manufacturing: Effects of Process Parameters and Plate-Extruder Precision Motion

et al. 2019

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“…The adhesion of the desired final coating meets the applicable values for wood and wood-based products, polymers, and WPCs alike [7,[36][37][38]. Therefore, it is assumed that it will meet the practical considerations of the desired setting in marine tool composite manufacturing.…”

Section: Pull-off Strength/dolly Testmentioning

confidence: 99%

“…The first two production steps have their own challenges to overcome. For example, warping and cracking of large-scale prints [6,7]. However, a crucial part of the production process for composite tooling manufacture is the final coating application.…”

Section: Introductionmentioning

confidence: 99%

Surface Preparation and Treatment for Large-Scale 3D-Printed Composite Tooling Coating Adhesion

2018

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Recent advances in large-scale thermoplastic additive manufacturing (AM), using fused deposition modelling (FDM), have shown that the technology can effectively produce large aerospace tools with common feed stocks, costing 2.3 $/kg, such as a 20% carbon-filled acrylonitrile butadiene styrene (ABS). Large-scale additive manufacturing machines have build-volumes in the range of cubic meters and use commercially available pellet feedstock thermoplastics, which are significantly cheaper (5–10 $/kg) than the filament feedstocks for desktop 3D printers (20–50 $/kg). Additionally, large-scale AM machines have a higher material throughput on the order of 50 kg/h. This enables the cost-efficient tool production for several industries. Large-scale 3D-printed tooling will be computerized numerical control (CNC)-machined and -coated, to provide a surface suitable for demolding the composite parts. This paper outlines research undertaken to review and improve the adhesion of the coating systems to large, low-cost AM composite tooling, for marine or infrastructure composite applications. Lower cost tooling systems typically have a lower dimensional accuracy and thermal operating requirements than might be required for aerospace tooling. As such, they can use lower cost commodity grade thermoplastics. The polymer systems explored in the study included polypropylene (PP), styrene-maleic anhydride (SMA), and polylactic acid (PLA). Bio-based filler materials were used to reduce cost and increase the strength and stiffness of the material. Fillers used in the study included wood flour, at 30% by weight and spray-dried cellulose nano-fibrils, at 20% by weight. Applicable adhesion of the coating was achieved with PP, after surface treatment, and untreated SMA and PLA showed desirable coating adhesion results. PLA wood-filled composites offered the best properties for the desired application and, furthermore, they have environment-friendly advantages.

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“…As a kind of AM, fused deposition modelling (FDM) is a rapid prototype technology characterized by a facile approach, easy operation, low cost, and low production time that is capable of manufacturing functional structural parts with complex geometries . Currently, the need for FDM has grown substantially because FDM has attractive advantages, which include the ability to easily make molds; therefore, FDM is used for many applications, such as automobiles, aerospace vehicles, medical implants, and household appliances . In the forming process, the printing feedstock is generally plastic and made into a filament bundle, which is partially melted and then extruded from a printing nozzle controlled by an xyz motor system (the main components of the printing nozzle are shown in Figure ).…”

Section: Introductionmentioning

confidence: 99%

Preparation and Rheological and Mechanical Properties of Poly(butylene succinate)/Talc Composites for Material Extrusion Additive Manufacturing

Zhou

Xia²,

Liu

et al. 2019

Macro Materials & Eng

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In this paper, poly(butylene succinate) (PBS) with a low melting point and a similar performance to polyethylene is employed as a printing material; talc is introduced into the matrix to enhance the melt strength of pure PBS during printing. The PBS/talc composite 3D printing filament is prepared by melt extrusion, and the thermal, mechanical, morphological, and rheological properties of the composites are investigated. The results show that the addition of talc to PBS leads to an increase in crystallization temperature. In addition, the tensile and flexural strengths of the injection‐molded specimens increase when the talc concentration increases. However, the mechanical properties of the printed specimens exhibit an opposite variation trend due to their distinct forming process. The printing temperature is 135 °C, which is far lower than those of commercial grade polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) printing filaments. Scanning electron microscopy (SEM) images show that increasing the talc concentration creates better printed formability and well‐organized fracture surface structures. By comparing printed fishbones, the results suggest that the presence of talc leads to a good printing performance with the composite. Furthermore, the rheological results reveal that η*, G′, and G″ are enhanced by the addition of talc.

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Investigation on the Scale Factor applicable to ABS based FDM Additive Manufacturing

Cited by 33 publications

References 8 publications

Analysis of PLA Geometric Properties Processed by FFF Additive Manufacturing: Effects of Process Parameters and Plate-Extruder Precision Motion

Analysis of PLA Geometric Properties Processed by FFF Additive Manufacturing: Effects of Process Parameters and Plate-Extruder Precision Motion

Surface Preparation and Treatment for Large-Scale 3D-Printed Composite Tooling Coating Adhesion

Preparation and Rheological and Mechanical Properties of Poly(butylene succinate)/Talc Composites for Material Extrusion Additive Manufacturing

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