Optimization of process parameters in fused deposition modelling of thermoplastics: A review

Nyiranzeyimana, Gaudence; Mutua, James; Mose, Bruno R.; Mbuya, Thomas Ochuku

doi:10.1002/mawe.202000193

Cited by 25 publications

(14 citation statements)

References 53 publications

(51 reference statements)

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“…In the research carried out so far, one to five process parameters have been varied. Statistical methods, such as design of experiments (DOE), the Taguchi method, and analysis of variance (ANOVA) were used to determine the influence of the different parameters on the mechanical characteristics [ 15 , 16 ].…”

Section: Introductionmentioning

confidence: 99%

The Influence of the Process Parameters on the Mechanical Properties of PLA Specimens Produced by Fused Filament Fabrication—A Review

et al. 2022

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Polylactic acid (PLA) is produced from renewable materials, has a low melting temperature and has a low carbon footprint. These advantages have led to the extensive use of polylactic acid in additive manufacturing, particularly by fused filament fabrication (FFF). PLA parts that are 3D printed for industrial applications require stable mechanical properties and predictability regarding their dependence on the process parameters. Therefore, the development of the FFF process has been continuously accompanied by the development of software packages that generate CNC codes for the printers. A large number of user-controllable process parameters have been introduced in these software packages. In this respect, a lot of articles in the specialized literature address the issue of the influence of the process parameters on the mechanical properties of 3D-printed specimens. A systematic review of the research targeting the influence of process parameters on the mechanical properties of PLA specimens additively manufactured by fused filament fabrication was carried out by the authors of this paper. Six process parameters (layer thickness, printing speed, printing temperature, build plate temperature, build orientation and raster angle) were followed. The mechanical behavior was evaluated by tensile, compressive and bending properties.

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Section: Introductionmentioning

confidence: 99%

The Influence of the Process Parameters on the Mechanical Properties of PLA Specimens Produced by Fused Filament Fabrication—A Review

et al. 2022

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“…The development and optimization of the process parameters, in order to obtain FDM prints with good surface quality, dimensional accuracy, and predictable properties, is a topic that has been addressed over many years by an impressive number of researchers. Experimental investigations, as well as statistical methods, such as the design of experiments (DOE), the Taguchi method, and an analysis of variance (ANOVA), were applied, aiming to define the optimal combinations of the printing variables that could ensure the best quality and the desired properties of the FFF-printed samples [ 10 , 14 ].…”

Section: Introductionmentioning

confidence: 99%

The Influence of the Printing Temperature and the Filament Color on the Dimensional Accuracy, Tensile Strength, and Friction Performance of FFF-Printed PLA Specimens

et al. 2022

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The printing variable least addressed in previous research aiming to reveal the effect of the FFF process parameters on the printed PLA part’s quality and properties is the filament color. Moreover, the color of the PLA, as well as its manufacturer, are rarely mentioned when the experimental conditions for the printing of the samples are described, although current existing data reveal that their influence on the final characteristics of the print should not be neglected. In order to point out the importance of this influential parameter, a natural and a black-colored PLA filament, produced by the same manufacturer, were selected. The dimensional accuracy, tensile strength, and friction properties of the samples were analyzed and compared for printing temperatures ranging from 200 °C up to 240 °C. The experimental results clearly showed different characteristics depending on the polymer color of samples printed under the same conditions. Therefore, the optimization of the FFF process parameters for the 3D-printing of PLA should always start with the proper selection of the type of the PLA material, regarding both its color and the fabricant.

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“…The bonding process in fused deposition modelling involves the local remelting of the previously deposited material and fusing it with the new layer. Remelting and fast cooling may induce non‐uniform thermal gradient and result in residual stresses developing within the part [19, 20]. These stresses are increased due to the suboptimal setting of fused deposition modelling process parameters provided by the user [21].…”

Section: Introductionmentioning

confidence: 99%

Fused deposition modelling (FDM) process parameter optimization to minimize residual stresses of 3 d printed carbon fiber nylon 12 hip joint implant

Nyiranzeyimana

Mutua

Mbuya

et al. 2022

Materialwissenschaft Werkst

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Residual stresses induced during the layer-by-layer fabrication process affect mechanical properties and dimensional accuracy of additively manufactured components. Some of these effects cannot be corrected by post processing like heat treatment. This work aims at optimizing fused deposition modelling process parameters for the least residual stresses during 3D printing of carbon fiber reinforced nylon 12 hip implant. Taguchi design of experiment was used to study the effect of printing temperature, layer thickness and print speed on the residual stresses using the Digimat-additive manufacturing software. The results show that the optimal factor setting levels for minimizing part residual stresses were printing temperature of 255 °C, layer thickness of 0.3 mm, and a print speed of 50 mm/s. Printing temperature has the most significant influence on the residual stresses. The combination of the optimum parameter levels yielded the least simulation residual stresses of (41.75�6.53) MPa while the experimental residual stress results were (40.7�7.7) MPa. The simulated and experimental results agreed with minimal percentage difference of (2.51�0.04) %. Tensile and compressive properties of 3D printed carbon fiber nylon 12 composite hip implant matched those of cortical bone. The fracture surface of failed tensile specimens revealed that failure occurred through fiber pull-out and matrix fracture Keywords: Carbon fiber nylon 12 composite / fused deposition modelling (FDM) / hip joint implant / mechanical properties / residual stresses Schlüsselwörter: Kohlefaser-Nylon 12-Verbundwerkstoff / Schmelzschichtung (FDM) / Hüftimplantat / mechanische Eigenschaften / Eigenspannungen

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Optimization of process parameters in fused deposition modelling of thermoplastics: A review

Cited by 25 publications

References 53 publications

The Influence of the Process Parameters on the Mechanical Properties of PLA Specimens Produced by Fused Filament Fabrication—A Review

The Influence of the Process Parameters on the Mechanical Properties of PLA Specimens Produced by Fused Filament Fabrication—A Review

The Influence of the Printing Temperature and the Filament Color on the Dimensional Accuracy, Tensile Strength, and Friction Performance of FFF-Printed PLA Specimens

Fused deposition modelling (FDM) process parameter optimization to minimize residual stresses of 3 d printed carbon fiber nylon 12 hip joint implant

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