scholarly journals A New Generation of Bio-Composite Thermoplastic Filaments for a More Sustainable Design of Parts Manufactured by FDM

2020 ◽  
Vol 10 (17) ◽  
pp. 5852
Author(s):  
Michele Calì ◽  
Giulia Pascoletti ◽  
Massimiliano Gaeta ◽  
Giovanni Milazzo ◽  
Rita Ambu
Keyword(s):  
Production Management ◽  
High Strength ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Aesthetic Appearance ◽  
Key Factor ◽  
Paper Fabrication ◽  
And Performance ◽  
Marine Engineering ◽  
By Products

The most recent developments of Fused Deposition Modelling (FDM) techniques are moving the application of Additive Manufacturing (AM) technologies toward new areas of investigation such as the biomedical, aerospace, and marine engineering in addition to the more consolidated industrial and civil fields. Some specific characteristics are required for the components designed for peculiar applications, such as complex geometries, lightweight, and high strength as well as breathability and aesthetic appearance specifically in the biomedical field. All these design specifications could be potentially satisfied by manufacturing with 3D printing techniques. Moreover, the development of purpose-dedicated filaments can be considered a key factor to successfully meet all the requirements. In this paper, fabrication and applications of five new thermoplastic materials with fillers are described and analyzed. They are organic bio-plastic compounds made of polylactic acid (PLA) and organic by-products. The growing interest in these new composite materials reinforced with organic by-products is due to the reduction of production management costs and their low environmental impact. In this study, the production workflow has been set up and described in detail. The main properties of these new thermoplastic materials have been analyzed with a major emphasis on strength, lightweight, and surface finish. The analysis showed that these materials can be particularly suitable for biomedical applications. Therefore, two different biomedical devices were selected and relative prototypes were manufactured with one of the analyzed thermoplastic materials. The feasibility, benefits, and performance of the thermoplastic material considered for these applications were successfully assessed.

scholarly journals Compression Behaviour of Bio-Inspired Honeycomb Reinforced Starfish Shape Structures Using 3D Printing Technology

Polymers ◽  
2021 ◽  
Vol 13 (24) ◽  
pp. 4388
Author(s):  
S. A. S. A. Saufi ◽  
M. Y. M. Zuhri ◽  
M. Lalegani Dezaki ◽  
S. M. Sapuan ◽  
R. A. Ilyas ◽  
...  
Keyword(s):  
Cell Size ◽  
Wall Thickness ◽  
Compression Strength ◽  
Peak Load ◽  
High Strength ◽  
Honeycomb Structure ◽  
Fused Deposition Modelling ◽  
Deformation And Failure ◽  
Fused Deposition ◽  
Load Increase

The bio-inspired structure (e.g., honeycomb) has been studied for its ability to absorb energy and its high strength. The cell size and wall thickness are the main elements that alter the structural ability to withstand load and pressure. Moreover, adding a secondary structure can increase the compressive strength and energy absorption (EA) capability. In this study, the bio-inspired structures are fabricated by fused deposition modelling (FDM) technology using polylactic acid (PLA) material. Samples are printed in the shape of a honeycomb structure, and a starfish shape is used as its reinforcement. Hence, this study focuses on the compression strength and EA of different cell sizes of 20 and 30 mm with different wall thicknesses ranging from 1.5 to 2.5 mm. Subsequently, the deformation and failure of the structures are determined under the compression loading. It is found that the smaller cell size with smaller wall thickness offered a crush efficiency of 69% as compared to their larger cell size with thicker wall thickness counterparts. It is observed that for a 20 mm cell size, the EA and maximum peak load increase, respectively, when the wall thickness increases. It can be concluded that the compression strength and EA capability increase gradually as the cell size and wall thickness increase.

Dynamic Response of FDM Made ABS Parts in Different Part Orientations

2013 ◽  
Vol 748 ◽  
pp. 291-294 ◽  
Author(s):  
Hesamodin Jami ◽  
Syed H. Masood ◽  
W.Q. Song
Keyword(s):  
Split Hopkinson Pressure Bar ◽  
Acrylonitrile Butadiene Styrene ◽  
High Strength ◽  
Fused Deposition Modelling ◽  
Compression Tests ◽  
Hopkinson Pressure Bar ◽  
Fused Deposition ◽  
Split Hopkinson ◽  
Pressure Bar ◽  
Static Behaviour

The mechanical properties of a product made in Fused Deposition Modelling (FDM) rapid prototyping are strongly dependant on process parameters selected during part fabrication. Acrylonitrile butadiene styrene (ABS) is a common material used in FDM systems. The advantages of ABS include high strength and rigidity with toughness and these properties make it one of the most common thermoplastics used in engineering applications. This paper describes an experimental investigation of dynamic stressstrain response of ABS parts made by fused deposition modelling for three different part build orientations. Currently there is limited research available for this aspect of ABS material processed by FDM systems. The high strain rate compression tests were performed using a Split Hopkinson Pressure Bar apparatus to determine the dynamic stress-strain response and results were compared with quasi-static behaviour of the same specimens.

Bioinspired structures for core sandwich composites produced by fused deposition modelling

2019 ◽  
Vol 234 (3) ◽  
pp. 379-393 ◽  
Author(s):  
J Bru ◽  
M Leite ◽  
AR Ribeiro ◽  
L Reis ◽  
AM Deus ◽  
...  
Keyword(s):  
Relative Density ◽  
Cell Shape ◽  
Sandwich Panel ◽  
Thickness Distribution ◽  
Sandwich Panels ◽  
High Strength ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Strength And Stiffness ◽  
Cell Thickness

Sandwich panels are widely used in many engineering applications where saving weight while maintaining high strength and stiffness is required. The most common core structure in sandwich panels is the two-dimensional regular hexagonal cell shape, denoted as Honeycomb. In recent times, bioinspired materials and structures have become increasingly attractive to researchers, as they provide adequate functional properties. The goal of the present work is to study two new bioinspired structures aimed at improving the performance of sandwich panel cores. Among all the large amount of structures that nature provides, two novel cores inspired in the structures of enamel and of bamboo were chosen. The compressive and flexural properties of these two innovative cellular structures were assessed and compared with the classic honeycomb. All the arrangements were numerically simulated for different relative densities. The fused deposition modelling technique enables to print selected samples in polylactic acid that were experimentally tested in compression and in bending. Results show that the mechanical properties depend strongly on the core geometry, on the relative density and on the cell thickness distribution. A satisfactory agreement was found between finite element results and experimental data. For the same relative density, the bioinspired natural structures proposed in the present study are potential competitors with the traditional core structures in what concerns strength, stiffness and energy absorption.

Evaluation of geometrical benchmark artifacts containing multiple overhang lengths fabricated using material extrusion technique

2020 ◽  
Vol 14 (3) ◽  
pp. 7296-7308
Author(s):  
Siti Nur Humaira Mazlan ◽  
Aini Zuhra Abdul Kadir ◽  
N. H. A. Ngadiman ◽  
M.R. Alkahari
Keyword(s):  
3D Model ◽  
Laser Scanner ◽  
Dimensional Accuracy ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Layer Technique ◽  
Subtractive Manufacturing ◽  
Manufacturing Features ◽  
Layer Problem

Fused deposition modelling (FDM) is a process of joining materials based on material entrusion technique to produce objects from 3D model using layer-by-layer technique as opposed to subtractive manufacturing. However, many challenges arise in the FDM-printed part such as warping, first layer problem and elephant food that was led to an error in dimensional accuracy of the printed parts especially for the overhanging parts. Hence, in order to investigate the manufacturability of the FDM printed part, various geometrical and manufacturing features were developed using the benchmarking artifacts. Therefore, in this study, new benchmarking artifacts containing multiple overhang lengths were proposed. After the benchmarking artifacts were developed, each of the features were inspected using 3D laser scanner to measure the dimensional accuracy and tolerances. Based on 3D scanned parts, 80% of the fabricated parts were fabricated within ±0.5 mm of dimensional accuracy as compared with the CAD data. In addition, the multiple overhang lengths were also successfully fabricated with a very significant of filament sagging observed.

scholarly journals Manufacturing and development of a bolted GFRP flange joint for oil and gas applications

2021 ◽  
pp. 095440542198951
Author(s):  
Muhsin Aljuboury ◽  
Md Jahir Rizvi ◽  
Stephen Grove ◽  
Richard Cullen
Keyword(s):  
Pressure Vessel ◽  
Oil And Gas ◽  
Polyester Resin ◽  
High Strength ◽  
Adhesively Bonded ◽  
Acceptable Quality ◽  
Composite Pipe ◽  
And Performance ◽  
Composite Pipes

The goal of this experimental study is to manufacture a bolted GFRP flange connection for composite pipes with high strength and performance. A mould was designed and manufactured, which ensures the quality of the composite materials and controls its surface grade. Based on the ASME Boiler and Pressure Vessel Code, Section X, this GFRP flange was fabricated using biaxial glass fibre braid and polyester resin in a vacuum infusion process. In addition, many experiments were carried out using another mould made of glass to solve process-related issues. Moreover, an investigation was conducted to compare the drilling of the GFRP flange using two types of tools; an Erbauer diamond tile drill bit and a Brad & Spur K10 drill. Six GFRP flanges were manufactured to reach the final product with acceptable quality and performance. The flange was adhesively bonded to a composite pipe after chamfering the end of the pipe. Another type of commercially-available composite flange was used to close the other end of the pipe. Finally, blind flanges were used to close both ends, making the pressure vessel that will be tested under the range of the bolt load and internal pressure.

scholarly journals Current State and Challenges of Natural Fibre-Reinforced Polymer Composites as Feeder in FDM-Based 3D Printing

Polymers ◽  
2021 ◽  
Vol 13 (14) ◽  
pp. 2289
Author(s):  
Nishata Royan Rajendran Royan ◽  
Jie Sheng Leong ◽  
Wai Nam Chan ◽  
Jie Ren Tan ◽  
Zainon Sharmila Binti Shamsuddin
Keyword(s):  
Mechanical Properties ◽  
Natural Fibre ◽  
Critical Discussion ◽  
Fused Deposition Modelling ◽  
Preparation Methods ◽  
Fused Deposition ◽  
Current State ◽  
Future Challenges ◽  
Raster Angle ◽  
Fibre Reinforced Polymer

As one of the fastest-growing additive manufacturing (AM) technologies, fused deposition modelling (FDM) shows great potential in printing natural fibre-reinforced composites (NFRC). However, several challenges, such as low mechanical properties and difficulty in printing, need to be overcome. Therefore, the effort to improve the NFRC for use in AM has been accelerating in recent years. This review attempts to summarise the current approaches of using NFRC as a feeder for AM. The effects of fibre treatments, composite preparation methods and addition of compatibilizer agents were analysed and discussed. Additionally, current methods of producing feeders from NFRCs were reviewed and discussed. Mechanical property of printed part was also dependent on the printing parameters, and thus the effects of printing temperature, layer height, infill and raster angle were discussed, and the best parameters reported by other researchers were identified. Following that, an overview of the mechanical properties of these composites as reported by various researchers was provided. Next, the use of optimisation techniques for NFRCs was discussed and analysed. Lastly, the review provided a critical discussion on the overall topic, identified all research gaps present in the use of NFRC for AM processes, and to overcome future challenges.

scholarly journals Are We Able to Print Components as Strong as Injection Molded?—Comparing the Properties of 3D Printed and Injection Molded Components Made from ABS Thermoplastic

2021 ◽  
Vol 11 (15) ◽  
pp. 6946
Author(s):  
Bartłomiej Podsiadły ◽  
Andrzej Skalski ◽  
Wiktor Rozpiórski ◽  
Marcin Słoma
Keyword(s):  
Tensile Strength ◽  
Injection Molding ◽  
Mechanical Strength ◽  
Cross Section ◽  
Fused Deposition Modeling ◽  
High Strength ◽  
Large Cross Section ◽  
Fused Deposition ◽  
Injection Molded ◽  
The Cross

In this paper, we are focusing on comparing results obtained for polymer elements manufactured with injection molding and additive manufacturing techniques. The analysis was performed for fused deposition modeling (FDM) and single screw injection molding with regards to the standards used in thermoplastics processing technology. We argue that the cross-section structure of the sample obtained via FDM is the key factor in the fabrication of high-strength components and that the dimensions of the samples have a strong influence on the mechanical properties. Large cross-section samples, 4 × 10 mm2, with three perimeter layers and 50% infill, have lower mechanical strength than injection molded reference samples—less than 60% of the strength. However, if we reduce the cross-section dimensions down to 2 × 4 mm2, the samples will be more durable, reaching up to 110% of the tensile strength observed for the injection molded samples. In the case of large cross-section samples, strength increases with the number of contour layers, leading to an increase of up to 97% of the tensile strength value for 11 perimeter layer samples. The mechanical strength of the printed components can also be improved by using lower values of the thickness of the deposited layers.

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