Papers by Keyword: Fused Deposition Modeling (FDM)

Abstract: The development of physiological detection is advancing rapidly, driven largely by the increase in the awareness of sport, healthcare, and biomedical knowledge. Wearable electronics have been integrated into real-world physiological sensing applications, with many recent studies aimed at enhancing their capabilities from both material selection and fabrication perspectives. To create the best fit for specific wearers, three-dimensional (3D) printing is an excellent candidate because of its potential to create structures ranging from simple to highly complex. This work investigates the effect of infill densities (20%, 40%, and 60%) on the electromechanical properties of 3D-printed thermoplastic polyurethane (TPU) using fused deposition modeling (FDM). The printing conditions were consistently controlled throughout the study, specifically using a honeycomb infill pattern. The flexible TPU substrates were successfully 3D-printed, and 1% w/v of multiwalled carbon nanotubes (MWCNTs) were embedded in the 3D-printed samples using an ultrasonic cavitation-enabled treatment and thermal-assisted method. This process aims to prevent CNT fallout while maintaining the compression load-bearing capacity. A compressive load of 10 kN was applied to the samples during electromechanical testing. The results show that a 20% infill density provides the optimum sensitivity of 11.32 MPa^-1 at 2V applied voltage due to its appropriate current path, which is confirmed by scanning electron microscope (SEM). The dimension accuracy of the 3D-printed TPU samples tend to increase with higher infill densities and application of the double treatment.

Abstract: PEEK is a polyaromatic semi-crystalline thermoplastic polymer with good mechanical characteristics for biomedical applications. The medical field has been applying its mechanical properties to make bone implants and modeling for surgical planning using 3D printing, more formally called Additive Manufacturing (AM). This paper provides a concise discussion about PEEK and its development for orthopedic applications. Some of the designs used to fix specific issues are shown in this review paper including the mechanical properties development for PEEK to be applicable in the medical field. Challenges and prospects when 3D printing using this material on improving PEEK’s biocompatibility and ease of printing are also discussed.

Abstract: Self-healing capable of storing two or more solutions is proposed to heal cracks by manufacturing capsules with a 3D printer to enable structural design, repeatable fabrication, and strength analysis. The Fusion Deposition Modeling (FDM) method was used to design, analyze, and produce new, widely used self-healing capsules at low cost. However, since the PLA extruded from FDM has low interlayer adhesion energy, the strength varies depending on the load angle applied to the laminated surface and concrete structure, which degrades the performance of the self-healing capsule. Therefore, this paper designed a structure with isotropic strength by controlling the direction and number of solution injection ports of capsules manufactured by the FDM PLA method. In addition, the intensity isotropy of the load applied through the compression test and ANSYS in the x, y, and z directions were verified. As a result, as the arrangement and number of holes were different, the standard deviation of strength according to the direction decreased by 24%.

Abstract: Polypropylene (PP) is a promising material for extrusion-based additive manufacturing due to its low cost, chemical resistance, good mechanical properties, versatile, and can be applied in various industrial applications. Recent research has focused on addressing the warpage issue in 3D printing of PP filaments. The effect of environmental conditions and loading of nanoprecipitated calcium carbonate (NPCC) in the pristine polypropylene to decrease warpage using the Fused Deposition Modelling (FDM) printing technology was studied. PP-NPCC composite filaments containing 5, 10, and 15 NPCC (wt%) were prepared using the twin-screw extruder. The printability, physicochemical, and mechanical properties of the PP-NPCC blends were determined. Based on the results, the incorporation of NPCC has contributed to the improvement of 3D printability and warpage in the PP-NPCC composite. At controlled environmental conditions, the filament was printable and the warpage was decreased by 44% at 10% NPCC loading. At the same concentration, there was a 30% increase in compressive strength and 43% increase in elastic modulus of the 3D printed parts.

Abstract: Among all additive manufacturing techniques, fused deposition modeling (FDM) has been used the most extensively to fabricate continuous fiber reinforced polymers. Onyx, a short carbon fiber reinforced PA6 composite material developed by Markforged, has received widespread attention, and been employed as matrix in FDM-fabricated composites. This study investigates the tensile properties of continuous glass fiber (GF) reinforced Onyx (CGFRO) composites under quasi-static loading. CGFRO contains three different components, which are short carbon fiber in micrometer scale, continuous glass fiber and polyamide-d thermoplastic. The synergistic reinforcing behavior of these three components was evaluated experimentally by testing Onyx material, and CGFRO with different volume fractions of fibers (Vf). It was found that the failure mode of Onyx was different from that of GF/Onyx and the deformation modes of GF/Onyx varied with the volume fraction of glass fiber. The tensile properties of CGFRO increased with glass fiber volume fractions, where 42% Vf specimens exhibited the highest tensile modulus and strength of 10 GPa and 383 MPa, respectively, which are approximately nine times higher than that of Onyx parent material.

Abstract: This paper intended to measure the material's rigidity according to the orientation of the PLA specimen produced by the FDM method. To measure the change of strength and stiffness according to the direction of stacking of FDM PLA, the specimen was manufactured and tested not only in the direction of stacking but also infill using line pattern and concentric pattern. The intensity of each direction was 38.11MPa with a 0 degree tensile in the line pattern, 3.45 times higher than 11.9MPa with a 90 degree tensile, and 2.15 times higher shear strength with 28.05MPa and 13.88MPa. In concentric pattern, 0 degree tensile was 50.62MPa, 6.25 times higher than 8.46MPa, and 2.23 times higher in shear strength at 13.52MPa compared to 29.56MPa. The biggest difference in zero-degree concentric pattern tensile was the 37% difference in the 0 degree concentric pattern factor. This shows that the difference in intensity according to direction is more pronounced in concentric patterns than line patterns, and the behavior under load will be similar until the breaking point regardless of the direction.

Abstract: The paper is devoted to the assessment of the possibility to use a new design of a stretch die made of plastics used for fused deposition modeling (FDM) 3 D printing. Studies were conducted to assess the stress-strain state of a stretch die, from the normal pressure of a deforming sheet blank in a NASTRAN solver, using the finite element method. The convergence assessment of the simulation results was carried out for different quantities and corresponding sizes of finite elements. The optimal thicknesses of the hollow structure of the stretch die were determined by step-by-step calculations of its stress-strain state for acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate glycol (PETG). On the basis of the conducted studies, a general algorithm was developed for the structural design of stretch dies made of plastics used for fused deposition modeling (FDM) printing.

Abstract: 3D printing is a promising digital manufacturing technique that manufactures product parts in a layer fashion. Fused deposition modeling (FDM) is a widely used 3D printing technique that produces components by heating, extruding, and depositing the filaments of thermoplastic polymers. Meanwhile, the properties of FDM-produced parts are significantly influenced by process parameters. These process parameters have different advantages that need to be investigated. This paper examines the effect of some process parameters on the tensile properties of some components produced using FDM technique. The study is performed on polylactic acid (PLA) material, using full factorial experimental design. Furthermore, three process parameter—material, infill density, and infill pattern—are considered. The results indicate that only the infill pattern significantly influences the tensile properties of the model.

Abstract: Additive manufacturing (3D printing) is a hopeful technique that is used to produce complex geometry parts in a layer-by-layer method. Fused deposition modeling (FDM) is a popular 3D printing technology for producing components of thermoplastic polymers. In FDM process, the part quality is influenced strongly by the printing parameters. Until now, these parameters stil need to be investigated. Therefore, in this study, the influence of FDM 3D printing parameters on the tensile strength of product will be investigated. By experiment, three parameters, that is, layer height, solid layer top, and first-layer height, were studied. The investigation shows that the layer height is the only parameter impacted the tensile strength of the product.

Abstract: This scientific paper consists of the analysis of the grasshopper jumping mechanism through literature studies, manufacturing, analysis and experimentation to enhance the knowledge to the manufacturing and analyzing of the artificially developed grasshopper-like robots. The first step involved the understanding of the actual grasshopper mechanisms which was carried out by the dissection of actual grasshopper bodies to analyze the hind leg movements, actuating muscles and structured sizes of the involved organs. The next step involved the development structural of the prototype consisted of design of the grasshopper jumping robot and the durability of the structure was checked at the critical locations. The results indicated that the strains produced in the tibia (immediately before and immediately after the jump) and femur of the designed structure was 2.5.10^-5, 3.2.10^-5 and 634.10^-5 respectively. Whereas, the maximum allowable strain of the material during elastic deformation is 660.10^-5, so the design of the structure could satisfy the strength requirements. The structural strength of the tibia and femur with the vertical printing were also in line with the stress requirements. Fabrication and jumping test was carried out which indicated 5 times higher jumps for the designed and fabricated grasshopper like jumping robot. This result is very helpful in robotic industry for the smooth movements of the robots for carrying out the intended function on rough terrains.