Surface Roughness Quality and Dimensional Accuracy—A Comprehensive Analysis of 100% Infill Printed Parts Fabricated by a Personal/Desktop Cost-Effective FDM 3D Printer

Alsoufi, Mohammad S.; Elsayed, Abdulrhman E.

doi:10.4236/msa.2018.91002

Cited by 83 publications

(73 citation statements)

References 41 publications

(35 reference statements)

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“…The surface of the printed cylinders was smooth, with an average roughness of R a = 23.7 µm (SD = 35%) on vertical surfaces and R a = 12.4 µm (SD = 17%) on the top surfaces. This surface roughness is well within the range of reported values for standard plastic FDM parts [17][18][19][20]. The cylinder size and shape were very good, in accordance with the corresponding 3D model (on average 3.5% and 2% larger in diameter and height, respectively).…”

Section: Materials Characterizationsupporting

confidence: 87%

3D Printing of Functional Assemblies with Integrated Polymer-Bonded Magnets Demonstrated with a Prototype of a Rotary Blood Pump

et al. 2018

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Conventional magnet manufacturing is a significant bottleneck in the development processes of products that use magnets, because every design adaption requires production steps with long lead times. Additive manufacturing of magnetic components delivers the opportunity to shift to agile and test-driven development in early prototyping stages, as well as new possibilities for complex designs. In an effort to simplify integration of magnetic components, the current work presents a method to directly print polymer-bonded hard magnets of arbitrary shape into thermoplastic parts by fused deposition modeling. This method was applied to an early prototype design of a rotary blood pump with magnetic bearing and magnetic drive coupling. Thermoplastics were compounded with 56 vol.% isotropic NdFeB powder to manufacture printable filament. With a powder loading of 56 vol.%, remanences of 350 mT and adequate mechanical flexibility for robust processability were achieved. This compound allowed us to print a prototype of a turbodynamic pump with integrated magnets in the impeller and housing in one piece on a low-cost, end-user 3D printer. Then, the magnetic components in the printed pump were fully magnetized in a pulsed Bitter coil. The pump impeller is driven by magnetic coupling to non-printed permanent magnets rotated by a brushless DC motor, resulting in a flow rate of 3 L/min at 1000 rpm. For the first time, an application of combined multi-material and magnet printing by fused deposition modeling was shown. The presented process significantly simplifies the prototyping of products that use magnets, such as rotary blood pumps, and opens the door for more complex and innovative designs. It will also help postpone the shift to conventional manufacturing methods to later phases of the development process.

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Section: Materials Characterizationsupporting

confidence: 87%

3D Printing of Functional Assemblies with Integrated Polymer-Bonded Magnets Demonstrated with a Prototype of a Rotary Blood Pump

et al. 2018

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“…For more details about the basic technical details, see [14][15][16]. This is a fully customized personal 3D printer which allows lightweight, lowcost, and very rapid prototyping compared to conventional machining (as with, for example, a CNC machine).…”

Section: D Printermentioning

confidence: 99%

Quantitative analysis of 0% infill density surface profile of printed part fabricated by personal FDM 3D printer

Alsoufi

Elsayed

2018

IJET

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Fused deposition modeling or FDM technology is an additive manufacturing (AM) technology commonly used for prototyping applications which suffer seriously from low levels of fluctuated surface finish quality, demanding some hand finishing tool for even the necessary levels of 3D printed parts. This paper, therefore, aims at giving close attention to the variation in the surface roughness profile between the inner and the outer faces of FDM 3D printed parts based on advanced polylactic acid (PLA+) thermoplastic filament material. The surface roughness is quantitatively analyzed using a contact-type test-rig with a 90° angle measurement on each face along with each zone and sub-zone. The obtained results revealed that the surface finish of the inner faces is rougher than those of the outer faces as regards nozzle temperature, nozzle diameter, infill density and layer height is 220°C, 0.5 mm, 0% and 0.3 mm, respectively. The personal FDM 3D printer is thus confirmed to be an excellent platform, flexible, straightforward and cost-effective. Keywords: Additive Manufacturing (AM), Fused Deposition Modeling (FDM), Surface Profile, 3D Printer.1. Background Rapid Prototyping and 3D PrintingRapid prototyping (RP) refers to a collection of new technologies, such as fused deposition modeling (FDM), direct metal deposition (DMD), selective laser sintering (SLS), inject modeling (IJM) and stereolithography (SLA), which can be used to create any desired 3D physical model of a printed part, element, device or artefact faster than before without machining or tooling [1] by layer manufacturing from computer aided design (CAD) data [2] and without a significant increase in time or cost [3]. This rapid growth of the market has placed 3D printers not just in enormously varied industrial settings but also in schools, universities, and homes, and it is therefore often preferable to call these devices a 'personal 3D printer' or 'desktop 3D printer' [4,5]. The range of applications where FDM 3D printer technology can be used is widespread in different fields, ranging from medical [6] to automotive [7] and aeronautics applications [8]. Currently, as RP is moving towards rapid manufacturing, there is an increasing demand for obtaining good surface quality printed parts as this has more influence on how customers assess the quality of the 3D printed parts. FDM TechnologyOpen source fused deposition modeling (FDM) is one of several RP technologies available that is currently attracting attention [9]. The FDM process was established commercially and sold to international trade in the early 1990s in the USA as a form of concept modeling by Stratasys Inc. [10]. Figure 1 shows the schematic concept of the FDM 3D printer process. It begins with a 3D model (or three-dimensional modeling) in a computer aided design (CAD) file in order to calculate the horizontal cross-sections at sufficiently small increments of the layer height of the printed part before converting it to an STL (Stereo-Lithography) format file [11]. The STL (Stereo-Lithog...

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“…Fused deposition modeling (FDM, developed in the 1980s [6] and commercialized in 1990 [7]) is additive manufacturing (AM) technologies that build automatically three-dimensional (3D) physical parts by heating up and extruding down the thermoplastic filaments materials through a small nozzle, without any tooling or machining [8,9,10] and also by eliminating the need for human interventions [11]. They are not only used to fabricate prototypes, but final products are also manufactured with these types of machines [12] with a dimensional tolerance equal to ±1 mm overall [13].…”

Section: Introductionmentioning

confidence: 99%

Experimental Characterization of the Influence of Nozzle Temperature in FDM 3D Printed Pure PLA and Advanced PLA+

Alsoufi¹,

Alhazmi²,

Suker³

et al. 2019

AJME

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This paper experimentally observed at a small level the influence of nozzle temperature change on warping deformation (WD), dimensional Accuracy (DA) and density. The materials chosen are pure PLA and advanced PLA+ specimens of rectangular shape of 63.5 mm × 9.53 mm × 3.2 mm produced by the end-user 3D printer based on fused deposition modeling (FDM). During the printing work, the nozzle temperature was conducted at twelve different values 195°C to 250°C with 5°C increments. Additionally, the infill density was set at 20% along with infill line direction of 0°, 90°, 45° and ±45°. After the fabrication, the FDM 3D printed parts naturally cooled down to room temperature at T = 23±2°C. As a result, the higher the nozzle temperature, the lower the deformed shape errors (with low uncertainty) of the specimens were. Experimental results show that the measured dimensions are always more than the original CAD file dimension along the height but less than the original CAD file dimensions along the width and length. The density measurements of both materials at 90° infill line direction have higher values compared with other directions (0°, 45°, ±45°), which have very similar results. The data and knowledge obtained from this investigation can be helpful for both an academic and an industrial perspective to set optimum nozzle temperature at small scale level and also it can be used to fabricate low-cost functional objects. Furthermore, it will also allow us to redesign the original CAD file in order to compensate the warping deformation encountered when using end-user FDM 3D additive manufacturing.

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Surface Roughness Quality and Dimensional Accuracy—A Comprehensive Analysis of 100% Infill Printed Parts Fabricated by a Personal/Desktop Cost-Effective FDM 3D Printer

Cited by 83 publications

References 41 publications

3D Printing of Functional Assemblies with Integrated Polymer-Bonded Magnets Demonstrated with a Prototype of a Rotary Blood Pump

3D Printing of Functional Assemblies with Integrated Polymer-Bonded Magnets Demonstrated with a Prototype of a Rotary Blood Pump

Quantitative analysis of 0% infill density surface profile of printed part fabricated by personal FDM 3D printer

Experimental Characterization of the Influence of Nozzle Temperature in FDM 3D Printed Pure PLA and Advanced PLA+

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