Mechanical characterization of parts fabricated using fused deposition modeling

Abstract

Layered manufacturing is an evolution of rapid prototyping (RP) techniques where the part is built in layers. While most of the previous applications focused on building “prototypes”, recent developments in this field enabled some of the prototyping methods to achieve an agile fabrication technology to produce the final product directly. A shift from prototyping to manufacturing of the final product necessitates broadening of the material choice, improvement of the surface quality, dimensional stability, and achieving the necessary mechanical properties to meet the performance criteria. The current study is part of an ongoing project to adapt fused deposition modeling to fabrication of ceramic and multi‐functional components. This paper presents a methodology of the mechanical characterization of products fabricated using fused deposition modeling.

Mechanical Characterization of Additively Manufactured Parts by FE Modeling of Mesostructure

“…Therefore, it is important to estimate the final properties of a material for effective analysis of the part. Studies are available on experimental work to find the elastic moduli of the material of an FDM processed part [2][3][4][5]. The effect of process parameters and building strategies on the mechanical properties of a part have been the main focus in research so far.…”

“…The bond formation among the roads is driven by thermal energy of the extruded material [9]. Researchers [2][3][4][5][6][7][8][9][10][11][12][13] discussed the various process parameters of FDM such as raster orientation, air gap, bead width and temperature effect on the mechanical properties of the final fabricated part. The raster angle was observed to have more influence on the mechanical properties than other parameters.…”

“…The building strategy has a pronounced effect on the properties and ultimately performance of the product. Bellini and Guceri [4] carried out experimental work to find the stiffness matrix of an anisotropy behavioral FDM processed parts. Tymrak et al [14] compared the mechanical properties of the parts processed with an open source 3D printer and commercial available printers.…”

“…The elastic moduli for FDM processed layers (orthotropic material) are found experimentally by Casavola et al [27] and then classical laminate theory is employed to characterize the mechanical behavior of the FDM processed parts. So far, most studies [2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18] presented experimental work. However, there has been relatively little literature available on numerical modeling to find the elastic moduli of a material of the FDM processed part.…”

Integration of physically-based and data-driven approaches for thermal field prediction in additive manufacturing

“…Based on the phase change mechanism, the laser-based processes can be grouped into two sub-categories: laser melting [10], where the powders are melt by a laser beam; and laser polymerization [11], where the material is a photosensitive resin. In the extrusion-based processes, a heated extrusion nozzle is used to soften plastic material, including two typical methods: FDM process [12], which applies a moveable head to deposit a thread of molten thermoplastic material onto a substrate; and robocasting processes [13], which is a layer-wise deposition for colloidal slurries freeform fabrication technology. In the material jetting processes, an adhesive binder is used to bind the powder in a solid object, which includes inkjet printing processes [14], multijet modeling [15], ballistic particle manufacturing [16].…”