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Assessment of the mechanical properties of PC/ABS blends for functional prototyping by FFF 3D printing

RAPID PROTOTYPING JOURNAL 2024年第2期30卷 214-227页

作者： De Assis, Cleiton Lazaro Fazolo Rampazo, Cleber Augusto Fed Inst Educ Sci & Technol Sao Paulo Dept Ind Votuporanga Brazil 3DX Filamentos Ltda Sao Caetano do Sul Brazil

PurposeThis paper aims to evaluate the mechanical behaviour of polycarbonate/acrylonitrile butadiene styrene (PC/ABS) filaments for fusion filament fabrication (FFF). PC/ABS have emerged as a promising material for FFF due to their excellent mechanical properties. However, the optimal processing conditions and the effect of the blending ratio on the mechanical properties of the resulting workpieces are still ***/methodology/approachA statistical factorial matrix was designed, including infill pattern, printing speed, nozzle size, layer height and printing temperature as factors (with three levels). A total of 810 workpieces were printed using PC/ABS blends filament with the FFF. The workpieces' finishing and mass were evaluated. Tensile tests were performed. Analysis of variance was performed to determine the main effects of the processing conditions on the mechanical *** results showed that the PC/ABS (70/30) exhibited higher tensile. Tensile rupture corresponded to 30% of the tensile strength. The infill pattern showed the highest contribution to the responses. The concentric pattern showed higher tensile strength. Tensile strength and mass ratio demonstrated the influence of mass on tensile strength. The influence of printing parameters on deformation depended on the blend proportions. Higher printing speed and lower layer height provided better quality ***/valueThis study has implications for the design and manufacturing of three-dimensional printed parts using PC/ABS filaments. An extensive experimental matrix was applied, aiming at a complete understanding of mechanical behavior, considering the main printing parameters and combinations not explored by literature.

关键词： Additive manufacturing Polymer printing parameters Mechanical behavior Mass Finishing

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Yttrium-Stabilized Zirconia Ceramics Fabrication through Material Extrusion 3D printing

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JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE 2024年第9期34卷 1-8页

作者： Guo, Xiuhu Li, Chuanyong Li, Lu Yuan, Zhentao Wang, Xiao Zhang, Weichen Liu, Junnan Chen, Gang Cui, Xiaoying Xu, Yaoping Kunming Univ Sci & Technol Fac Mat Sci & Engn Kunming 650093 Peoples R China Kunming Univ Sci & Technol City Coll Kunming 650051 Peoples R China Univ Sci & Technol Beijing Inst Adv Mat & Technol Beijing 100083 Peoples R China Kunming Univ Sci & Technol Res Ctr Anal & Measurement Kunming 650093 Peoples R China Yunnan Titanium Ind Co Chuxiong 651200 Peoples R China

In this study, the authors refined and molded 8 wt.% yttrium-stabilized zirconia (8YSZ) ceramic powders by using extrusion 3D printing to obtain green bodies. The green bodies were then subjected to degreasing and sintering to obtain the final parts. It used two printing nozzles, with diameters of 0.8 and 0.6 mm, for 3D molding, and examined the macroscopic and microscopic characteristics of the green, brown, and sintered parts. The parts printed by using both nozzles exhibited smooth surfaces and satisfactory layer-to-layer bonding. However, there were differences in the densities of the sintered parts obtained by using the two nozzles. The sintered part printed by using the nozzle with a diameter of 0.6 mm had a higher density of 5.37 g/cm3, while that printed by using the nozzle with a diameter of 0.8 mm had a density of 4.59 g/cm3. The bending strengths of the sintered bodies manufactured by using nozzles with diameters of 0.8 and 0.6 mm were 114.4 and 261.9 MPa, respectively.

关键词： 8YSZ 3D printing agglomerant mechanical properties printing parameters

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Parameter impact on 3D concrete printing from single to multi-layer stacking

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AUTOMATION IN CONSTRUCTION 2024年 164卷

作者： Wei, Ying Han, Song Yu, Shiwei Chen, Ziwei Li, Ziang Wang, Hailong Cheng, Wenbo An, Mingzhe Beijing Jiaotong Univ Sch Civil Engn Beijing 100044 Peoples R China Hong Kong Polytech Univ Dept Civil & Environm Engn Hong Kong 999077 Peoples R China Zhejiang Univ Coll Civil Engn & Architecture Hangzhou 310058 Peoples R China

Previous studies have revealed that the design of printing parameters influences the filament shape, while the similarity degree between filament shape and modeled slice directly determines the precision of multi-layer stacking structures. This paper experimentally investigates the influence of printing parameters on filament shape and pressure along the printing path. Computational Fluid Dynamic simulation is employed to verify the experimental findings from the aspect of internal stress distribution. The results highlight the crucial role of printing pressure in connecting these parameters with filament shape. A settlement theory of the multi-layer structure is proposed and tested based the filament shape analysis. In practice, guaranteeing filament shape and adjusting printing progress can be achieved through proportional changes in nozzle travel speed and screw rotation speed. Controlling structure settlement is possible by adjusting nozzle height and time interval. These findings provide a solid foundation for the precise manufacturing of 3D printed structures.

关键词： 3D concrete printing Computational fluid dynamic printing parameters printing pressure Filaments shape Structural settlement

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Understanding 3D food printing through computer simulation and extrusion force analysis

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JOURNAL OF FOOD ENGINEERING 2024年 370卷

作者： Ning, Xinzhe Devahastin, Sakamon Wang, Xuejiao Wu, Nan Liu, Zhenbin Gong, Yunyi Zhou, Linpeng Huo, Liu Ding, Weiheng Yi, Junjie Guo, Chaofan Hu, Xiaosong Kunming Univ Sci & Technol Fac Food Sci & Engn Kunming 650500 Peoples R China Yunnan Engn Res Ctr Fruit & Vegetable Prod Kunming 650500 Peoples R China Int Green Food Proc Res & Dev Ctr Kunming City Kunming 650500 Peoples R China King Mongkuts Univ Technol Thonburi Fac Engn Dept Food Engn Adv Food Proc Res Lab Tungkru 10140 Bangkok Thailand Shaanxi Univ Sci & Technol Sch Food & Biol Engn Xian 710021 Peoples R China China Agr Univ Coll Food Sci & Nutr Engn Beijing 100083 Peoples R China

Extrusion force is an important indicator of the effectiveness of a printing material for extrusion-based 3D printing. Finite element method was therefore used to first analyze flow field distribution of selected gels (pumpkin, potato and purple sweet potato gels) undergoing 3D printing and then predict the extrusion force of such gels. Experimental extrusion force was correlated with simulated extrusion force;adequate agreement was noted (R2 = 0.98). Pressure suitable for 3D printing of the gels was determined, being lower than 200 kPa for the tested gels. The extrusion curves indicate that there exists a buffer time after which each gel would start to flow. An increase in the gel water content and a decrease in the nozzle diameter increase the extrusion force and the buffer time. The results of this study may serve as a benchmark for printing materials development and printing parameters selection for successful extrusion-based 3D printing.

关键词： Extrusion force printing parameters Shear rate Starch gels Structural collapse Viscosity

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Effect of Filament Material and printing Temperature on 3D printing Extrusion Force

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APPLIED SCIENCES-BASEL 2025年第4期15卷 2046-2046页

作者： Krapez, Dasa Jusufagic, Muhammed Obucina, Murco Kuzman, Manja Kitek Kariz, Mirko Univ Ljubljana Biotech Fac Jamnikarjeva 101 Ljubljana 1000 Slovenia Univ Sarajevo Fac Mech Engn Dept Wood Technol Sarajevo 71000 Bosnia & Herceg

Featured Application The results of this study demonstrate a practical application for improving the performance and reliability of 3D printing systems. By integrating a load cell-based force measurement system into the 3D printer, this approach can be used to dynamically monitor and optimize printing parameters. This is particularly beneficial for preventing nozzle clogging and ensuring the uniform extrusion of composite filaments containing, for example, wood particles. The proposed system could be used as part of an effective tool for real-time quality control in additive manufacturing, especially for materials with a variable *** In this study, a modified 3D printer hotend equipped with a load cell, attached to the feeding system, was used to evaluate the effects of filament material composition and printing parameters on the extrusion force required. Four different materials (commercial PLA, pure PLA, wood-PLA with different ratios of wood particles, and wood-PLA with different ratios of thermally modified wood particles) were used for 3D printing, and the feeding resistance was measured. The filament feeder was connected to the extruder hotend via a load cell, which measured the forces required to push the filament through the extruder and the nozzle. Three printing nozzle temperatures of 200, 210, and 220 degrees C were used. The results show that the printing temperature and the material influence the required extrusion forces, which varied between 1 and 8 N, but the variation was high. With proper optimization and integration into the printer firmware, this setup could also be used to detect nozzle clogging during printing, modify printing parameters during the process, and prevent the uneven extrusion of composite filaments.

关键词： FFF wood-PLA filament wood content extrusion force printing parameters

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Correlation between filament deposition path, microstructural and mechanical properties of dense alumina parts printed by robocasting

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JOURNAL OF THE EUROPEAN CERAMIC SOCIETY 2024年第2期44卷 1027-1035页

作者： Gourdonnaud, Delphine Pateloup, Vincent Junger, Anna Bourret, Julie Chartier, Thierry Geffroy, Pierre -Marie Univ Limoges Inst Res Ceram IRCER CNRS UMR 7315 F-87000 Limoges France Wroclaw Univ Sci & Technol PL-50370 Wroclaw Poland

Robocasting is an extrusion-based additive manufacturing (AM) process widely used to produce porous structures. It enables to build three-dimensional (3D) ceramic parts, thanks to computer numerical control of the filament deposition path onto a fabrication substrate. Despite its high potential, robocasting is much less explored than other AM techniques for producing dense parts. This work focused on the robocasting of dense alumina parts by varying the filament deposition path of an environmentally friendly paste. Taguchi method was used to establish a correlation between the printing parameters and the microstructural and mechanical properties of the sintered parts. Closed pores located between adjacent filaments were found to dictate crack propagation mechanisms, depending on the infill pattern. The optimal printing strategy led to 93% dense alumina samples having a flexural strength of 140 MPa, a Young's modulus of 355 GPa and a Poisson's ratio of 0.23.

关键词： printing parameters Additive manufacturing Porosity Young 's modulus Flexural strength

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Influence of selected sheet-fed offset printing conditions on primary mottling

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NORDIC PULP & PAPER RESEARCH JOURNAL 2024年第3期39卷 425-434页

作者： Kowalczyk, Jan Warsaw Univ Technol Inst Mech & Printing Fac Mech & Ind Engn Dept Printing Technol Konwiktorska 2 PL-00217 Warsaw Poland

The key parameter in the printing process is the evenness of applying the ink layer on the printing substrate. It determines the quality of the produced prints. One of the many factors affecting the final evenness of the ink layer on the print is the phenomenon of mottling, which is caused by the non-uniform internal structure of the paper. The aim of this work was to analyze the influence of basic printing parameters on the value of the mottling index. The research showed a significant effect of the pressure in the printing unit of the offset machine and the thickness of the ink layer on the printing substrate on the value of the primary mottling index. In addition, the research revealed that the properties of the printing substrate have a significant impact on the value and nature of changes in the mottling index. In this work, using the Fourier analysis, the frequency of optical density fluctuations in solid tone area related to the mottling phenomenon was also studied. No influence of pressure changes in the Nip of the printing unit on this print parameter was found.

关键词： offset printing primary mottling printing parameters printing pressure properties of the printing paper

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Manufacturing-induced stochastic constitutive behaviors of additive manufactured specimens: testing, data-driven modeling, and optimization

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RAPID PROTOTYPING JOURNAL 2024年第4期30卷 662-676页

作者： Chen, Baixi Mao, Weining Lin, Yangsheng Ma, Wenqian Hu, Nan Univ Wisconsin Madison Dept Mech Engn Madison WI USA Nanyang Technol Univ Sch Mech & Aerosp Engn Singapore Singapore South China Univ Technol Sch Civil Engn & Transportat Guangzhou Peoples R China

PurposeFused deposition modeling (FDM) is an extensively used additive manufacturing method with the capacity to build complex functional components. Due to the machinery and environmental factors during manufacturing, the FDM parts inevitably demonstrated uncertainty in properties and performance. This study aims to identify the stochastic constitutive behaviors of FDM-fabricated polylactic acid (PLA) tensile specimens induced by the manufacturing ***/methodology/approachBy conducting the tensile test, the effects of the printing machine selection and three major manufacturing parameters (i.e., printing speed S, nozzle temperature T and layer thickness t) on the stochastic constitutive behaviors were investigated. The influence of the loading rate was also explained. In addition, the data-driven models were established to quantify and optimize the uncertain mechanical behaviors of FDM-based tensile specimens under various printing *** indicated by the results, the uncertain behaviors of the stiffness and strength of the PLA tensile specimens were dominated by the printing speed and nozzle temperature, respectively. The manufacturing-induced stochastic constitutive behaviors could be accurately captured by the developed data-driven model with the R2 over 0.98 on the testing dataset. The optimal parameters obtained from the data-driven framework were T = 231.3595 degrees C, S = 40.3179 mm/min and t = 0.2343 mm, which were in good agreement with the *** implicationsThe developed data-driven models can also be integrated into the design and characterization of parts fabricated by extrusion and other additive manufacturing ***/valueStochastic behaviors of additively manufactured products were revealed by considering extensive manufacturing factors. The data-driven models were proposed to facilitate the description and optimization of the FDM products and control their quality.

关键词： Fused deposition modelling (FDM) Polylactic acid (PLA) printing parameters Stochastic constitutive behaviors Data-driven modeling

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Interaction between material and process parameters during 3D concrete extrusion process

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STRUCTURES 2024年 70卷

作者： Fasihi, Ali Libre, Nicolas A. Missouri Univ Sci & Technol Dept Civil Architectural & Environm Engn Rolla MO 65409 USA

Extrusion of cement-based materials in additive manufacturing is influenced by a complex interaction of various material and process parameters. This study aims to investigate the impact of rheological properties and printing parameters on the extrudability of cement-based materials as well as the interaction between rheological properties of print materials and extrusion speed, as a key printing process parameter. 20 different print materials with diverse rheological properties were extruded at 10 different extrusion speeds. The effect of material parameters (i.e. rheological properties) and process parameters (i.e., extrusion speed) and their interaction during the extrusion process were evaluated using filament continuity, conformity and consistency. At a constant printing speed, a higher yield stress adversely impacted filament continuity in mixtures with a yield stress of over 260 Pa, whereas viscosity showed minimal influence on filament quality within the tested range of the rheological properties. The results of this study highlighted a significant correlation between material and process parameters and that adapting process parameters to variations in material properties is crucial for meeting printing criteria. The filament consistency of the mixtures with high yield stress was more sensitive to change in the extrusion speed than that of mixtures with low yield stress. An opposite trend, however, was observed for filament conformity where low yield stress mixtures showed a higher sensitivity to the extrusion speed. A procedure was suggested and applied to determine the optimum extrusion speed. Optimal extrusion speeds enabled printing mixtures with a broader spectrum of rheological properties with an acceptable visual quality, filament conformity and consistency requirements. With extrusion speed adjustment, the extrudability window was expanded from dynamic yield stress of 108-126 Pa to 108-263 Pa and plastic viscosity of 8.2-12.3 Pa.s to 5.1-16.4 Pa.s.

关键词： 3D concrete printing Rheological properties printing parameters Extrusion Filament inspection

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Cost Model Framework for Pieces Additively Manufactured in Fused Deposition Modeling for Low to Medium Batches

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3D printing AND ADDITIVE MANUFACTURING 2024年第1期11卷 287-298页

作者： Korner, Mario Enrique Hernandez Lamban, Maria Pilar Albajez, Jose Antonio Santolaria, Jorge Corrales, Lisbeth del Carmen Ng Royo, Jesus Univ Zaragoza Design & Mfg Engn Dept Zaragoza 50018 Spain Univ Tecnol Panama Dept Ind Engn Ciudad De Panama Panama

The cost impact of implementing additive manufacturing (AM) in the fabrication process is nowadays an issue. The scope of this research is to establish a cost model framework that can predict the cost of a piece in a low to medium batch considering fused deposition modeling (FDM) printing parameters. Every enterprise wants to increase its internal capabilities for tools, prototypes, and the production of pieces for maintenance purposes. FDM is an AM technology increasingly used in aerospace, automotive, and many other sectors. The research methodology consists of developing a cost model based on the extrusion-type AM process for any given machine characteristics and comparing the cost per piece based on diverse lot sizes and raw materials. Two test cases were simulated to show the usefulness of the cost model, one with a conventional polymer material (acrylonitrile butadiene styrene) and another with a high-performance material (polyetheretherketone);materials with very different costs, machine technical requirements, and energy consumption. The framework could be used to predict the best machine size and material type that could be suitable for a certain situation. The strength of our approach lies in the energy cost calculus, which is dependent on machine capabilities and size.

关键词： cost model framework fused deposition modeling printing parameters high-performance materials energy consumption additive manufacturing

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