Surface Quality Enhancement of Fused Deposition Modeling (FDM) Printed Samples Based on the Selection of Critical Printing Parameters

Pérez, Mercedes López; Medina-Sánchez, G.; García-Collado, Alberto; Gupta, Munish Kumar; Carou, Diego

doi:10.3390/ma11081382

Cited by 163 publications

(107 citation statements)

References 32 publications

(39 reference statements)

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“…The opposite is observed at low temperatures, thin layers, and slow speeds, because the filament creates blobs due to its high viscosity, the slow speed does not stretch the filament, and thin layers cool rapidly. The investigations of Peng et al [27], Pérez et al [28],Yang et al [32], and Huang et al [33] confirm the results of this study that layer thickness greatly influences the surface quality. Raju et al [29] also ascribe this result to the staircase effect.…”

Section: Surface Roughnesssupporting

confidence: 82%

“…Therefore, layer thickness is a conflicting factor, but the energy consumption can be reduced by increasing printing speed while maintaining a good surface quality. Pérez et al [28] inspected the effect of layer thickness, printing speed, temperature, and wall thickness (contour thickness) on the surface roughness. Using analysis of variance, layer thickness and wall thickness were identified as critical factors, while printing speed and temperature seemed to have less influence.…”

Section: Introductionmentioning

confidence: 99%

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Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

2020

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This article reports on the investigation of the effects of process parameters and their interactions on as-built part quality and resource-efficiency of the fused filament fabrication 3D printing process. In particular, the influence of five process parameters: infill percentage, layer thickness, printing speed, printing temperature, and surface inclination angle on dimensional accuracy, surface roughness of the built part, energy consumption, and productivity of the process was examined using Taguchi orthogonal array (L50) design of experiment. The experimental results were analyzed using ANOVA and statistical analysis, and the parameters for optimal responses were identified. Regression models were developed to predict different process responses in terms of the five process parameters experimentally examined in this study. It was found that dimensional accuracy is negatively influenced by high values of layer thickness and printing speed, since thick layers of printed material tend to spread out and high printing speeds hinder accurate deposition of the printed material. In addition, the printing temperature, which regulates the viscosity of the used material, plays a significant role and helps to minimize the dimensional error caused by thick layers and high printing speeds, whereas the surface roughness depends very much on surface inclination angle and layer thickness, which together determine the influence of the staircase effect. Energy consumption and productivity are primarily affected by printing speed and layer thickness, due to their high correlation with build time.

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Section: Surface Roughnesssupporting

confidence: 82%

Section: Introductionmentioning

confidence: 99%

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

2020

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“…They drew a conclusion that a lack of pigmentation and a low extrusion temperature were preferable for better surface quality. Unlike most of the previously mentioned research, Pérez et al [63] used a cylindrical-shaped specimen instead of a cuboid-shaped specimen. In their study, layer thickness, print speed, extrusion temperature, and shell thickness were the analyzed parameters.…”

Section: Surface Roughnessmentioning

confidence: 99%

A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics

Dey

Yodo

2019

JMMP

335

257

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Fused deposition modeling (FDM) is an additive manufacturing (AM) process that is often used to fabricate geometrically complex shaped prototypes and parts. It is gaining popularity as it reduces cycle time for product development without the need for expensive tools. However, the commercialization of FDM technology in various industrial applications is currently limited due to several shortcomings, such as insufficient mechanical properties, poor surface quality, and low dimensional accuracy. The qualities of FDM-produced products are affected by various process parameters, for example, layer thickness, build orientation, raster width, or print speed. The setting of process parameters and their range depends on the section of FDM machines. Filament materials, nozzle dimensions, and the type of machine determine the range of various parameters. The optimum setting of parameters is deemed to improve the qualities of three-dimensional (3D) printed parts and may reduce post-production work. This paper intensively reviews state-of-the-art literature on the influence of parameters on part qualities and the existing work on process parameter optimization. Additionally, the shortcomings of existing works are identified, challenges and opportunities to work in this field are evaluated, and directions for future research in this field are suggested.

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“…Raju et al optimized the FDM process parameters by using the hybrid particle swarm and bacterial foraging optimization (PSO‐BFO) evolutionary algorithm. Pérez et al experimentally studied the effect of printing parameters on the surface roughness of FDM parts. They found that layer height and wall thickness were the most important factors for controlling surface roughness.…”

Section: Introductionmentioning

confidence: 99%

“…They found that layer height and wall thickness were the most important factors for controlling surface roughness. The main advantages of this technology include: wide variety of materials, low maintenance costs, cheap printing equipment, less pollution, and facile manipulation …”

Section: Introductionmentioning

confidence: 99%

Laser polishing of Cu/PLA composite parts fabricated by fused deposition modeling: Analysis of surface finish and mechanical properties

et al. 2019

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Fused deposition modeling (FDM) technology decreases production time and cost in engineering industry, but with typical low surface quality. In this study, laser polishing was employed to improve surface quality of copper fiber/polylactide acid (Cu/PLA) composite parts fabricated by FDM. Surface roughness, surface morphology, dynamic mechanical analysis (DMA), and tensile properties were studied. The results showed that after laser polishing, the surface roughness was reduced by more than 91% (from 10.52 to 0.87 μm Sa) at the optimized parameters (the laser power of 5 W and the laser beam diameter of 200 μm). Laser polishing can effectively remove surface defects formed during FDM. DMA showed that the storage modulus, loss modulus, and glass transition temperature of Cu/PLA composites were significantly improved, because the Cu fibers and PLA matrix formed a strong interfacial adhesion after treatment. Moreover, the tensile strength and Young's modulus of the Cu/PLA composites sample also improved by laser polishing. The fracture morphologies were observed, and the possible strengthening mechanism was also discussed.

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Surface Quality Enhancement of Fused Deposition Modeling (FDM) Printed Samples Based on the Selection of Critical Printing Parameters

Cited by 163 publications

References 32 publications

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics

Laser polishing of Cu/PLA composite parts fabricated by fused deposition modeling: Analysis of surface finish and mechanical properties

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