ArticlePDF Available

Abstract and Figures

One of the problems in Fused Deposition Modelling (FDM) 3D Printing process is that the extruded plastic filament tends to shrink and warp from the printing platform. The purpose of this research is to explore the warping deformation problem in four aspects i.e. curling, pincushion effect, trapezoid deformation and blocked shrinkage that usually occur in the process. Epoxy resin based adhesive was applied onto the printing platform to reduce and eliminate the warping deformation. Afterwards, by applying the adhesive, the 3D printed models were measured their curling, pincushion, trapezoid and blocked shrinkage using laser scanner and metrology software. The result shows that the pincushion and trapezoid has low deformation compared to curling and blocked shrinkage. Blocked shrinkage effect shows the highest warping deformation value. In comparison of materials, PLA shows the best geometry result with low warping deformation value and the best surface finish.
Content may be subject to copyright.
This content has been downloaded from IOPscience. Please scroll down to see the full text.
Download details:
IP Address: 1.9.209.50
This content was downloaded on 05/07/2017 at 10:30
Please note that terms and conditions apply.
An exploration of polymer adhesion on 3D printer bed
View the table of contents for this issue, or go to the journal homepage for more
2017 IOP Conf. Ser.: Mater. Sci. Eng. 210 012062
(http://iopscience.iop.org/1757-899X/210/1/012062)
Home Search Collections Journals About Contact us My IOPscience
You may also be interested in:
Organ Printing: Dispensing-based 3D printing
D-W Cho, J-S Lee, J Jang, J W Jung, J H Park and F Pati
A facile method for integrating direct-write devices into three-dimensional printed parts
Yung-Hang Chang, Kan Wang, Changsheng Wu et al.
CORRECTION OF PINCUSHION DISTORTION IN ELECTROSTATICALLY FOCUSED IMAGE TUBES
Gerald E. Kron and I. I. Papiashvili
Cryogenic 3D printing for producing hierarchical porous and rhBMP-2-loaded Ca-P/PLLA nanocomposite
scaffolds for bone tissue engineering
Chong Wang, Qilong Zhao and Min Wang
Development of three-dimensional printing system for magnetic elastomer with control of magnetic
anisotropy in the structure
Fujio Tsumori, Hidenori Kawanishi, Kentaro Kudo et al.
Inkjet 3D printing of microfluidic structures—on the selection of the printer towards printing your
own microfluidic chips
Rafa Walczak and Krzysztof Adamski
Thermal Characteristic Of Waste-Derived Hydroxyapatite (HA) Reinforced Ultra High Molecular Weight
Polyethylene (UHMWPE) Composites For Fused Deposition Modeling (FDM) Process
Mohamad Helmi Bin Md Ansari and Mohd Halim Irwan Bin Ibrahim
A molecular dynamics study of the failure modes of a glassy polymer
Udit Kulmi and Sumit Basu
1
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd
1234567890
International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012062 doi:10.1088/1757-899X/210/1/012062
An exploration of polymer adhesion on 3D printer bed
M A Nazan1*, F R Ramli1, 2*, M R Alkahari1, 2, M A Abdullah1, 2, M N Sudin1, 2
1Faculty of Mechanical Engineering, Universiti Teknikal Malaysia Melaka, Hang
Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
2Centre for Advanced Research on Energy, Universiti Teknikal Malaysia Melaka,
Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
E-mail: *muhd_afdhal@hotmail.com and faiz@utem.edu.my
Abstract. One of the problems in Fused Deposition Modelling (FDM) 3D Printing process is
that the extruded plastic filament tends to shrink and warp from the printing platform. The
purpose of this research is to explore the warping deformation problem in four aspects i.e.
curling, pincushion effect, trapezoid deformation and blocked shrinkage that usually occur in
the process. Epoxy resin based adhesive was applied onto the printing platform to reduce and
eliminate the warping deformation. Afterwards, by applying the adhesive, the 3D printed
models were measured their curling, pincushion, trapezoid and blocked shrinkage using laser
scanner and metrology software. The result shows that the pincushion and trapezoid has low
deformation compared to curling and blocked shrinkage. Blocked shrinkage effect shows the
highest warping deformation value. In comparison of materials, PLA shows the best geometry
result with low warping deformation value and the best surface finish.
1. Introduction
Fused deposition modeling (FDM) is one of the most widely used technique to produce object or part
in the field of 3D printer area [1-2]. 3D printer machine use three dimensional CAD data and form
layer by layer process to produce prototype part. 3D printer generally use thermoplastic plastic
materials such as Polylactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS) materials. These
materials are melt and extruded by the printer extrusion head and moves correspondingly to the
coordinate and position that been set in certain speed [1].
One of the problems in the 3D printing field especially FDM process is that the plastic filament
which is extruded from the machine nozzle tends to shrink and warp from the printing bed platform
[3]. This has been highlighted by several researchers that an adhesive layer between the first layer and
printing platform is required to counter the problem [4-6]. This problem can be reduced by applying
heat to the printing bed where the higher the bed temperature is, the less the deformed shape will be
[7]. Moreover, the warping deformation has also showing warping reduction when applying epoxy
resin based adhesive onto the printing bed [3].
The printing process involved printing onto the printing platform for the first layer of the formation
until the last layer. Each of the layer from the molten plastic is solidified either naturally or by the help
of external cooling process. Due to the cooling effect, the warpage problems are sometimes occur
where it definitely affecting the printed part especially in the geometry size and manufacturing quality.
The warpage problem happens because of the first layer is not stick well and peeled away from the
printing platform due to the adhesion of the first layer with the printing platform such in figure 1 and
2. Young et al [7] has stated that in 3D printer it is an undesirable shape error which is occured in the
2
1234567890
International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012062 doi:10.1088/1757-899X/210/1/012062
product due to the heat shrinkage phenomenon. The paper also stated that the main reason for
inhomogeneous shrinkage of the parts in the 3D printing process are due to time delayed for the
solidification of the layers. Moreover, the problem is caused by force transmission between the layers
since phase of change from molten plastic to solid during building process. Some of examples of
warpage problems occur in the FDM process are pincushion, trapezoid, curling and blocked
shrinkages [5].
Figure 1. Fused deposition modeling
process [2]
Figure 2. Warpage affect during printing
process
Epoxy resin adhesive is an adhesive that has been used widely all over the world. The adhesive is
proven to be suitable for the repair and restoration of the glass substance in several problem [8-9]. The
epoxy has declared containing 5.0% of organic solvents and 56.5% water based that soluble inside the
water and have non-toxicity effect to the human and environment [10]. By referring to the safety data
sheet, epoxy resin has zero hazard and has harmful effect if it used and handled accordingly to
necessary regulation. The epoxy resin based adhesive used in this experiment is shown as in figure 3
[11].
Thus, the purpose of this paper is to study the relation and the performance of the epoxy resin
based adhesive through the surface preparation for the printing platform during the process. In
addition, this research also study the warping deformation that occur through pincushion, curling,
trapezoid, and blocked shrinkage effects using PLA and ABS material either printing with and without
applying heat on bed.
3
1234567890
International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012062 doi:10.1088/1757-899X/210/1/012062
2. Experiment characteristics
2.1. Sample Preparation
Figure 4. Dimensioned isometric view with angle
45º of specimen
The experiment was started by sketching the solid model of specimens using solid modelling software,
CATIA V5 with its dimension shows in figure 4. The solid model was sketched with three different
angles of 30º, 45º and 60º, to investigate the warping deformation effect in various angle. Next, the
solid model was sliced by using 3D printer slicer software, Repetier Host that was built with Slic3r
engines to create machine language, G-Code for 3D printer path direction. This slicing process was
required to set up the 3D printer specifications where the infill density, layer temperature, printing
speed and layer height need to be defined. Thus, table 1 shows the printing settings that being used for
this experiment.
Table 1. Printing setting
Preferences
Materials
PLA
ABS
Infill density (%)
13
13
First layer temperature, T (ºC)
235
235
Other layer temperature, T (ºC)
193
230
Printing Speed (mm/s)
40
40
Layer Height (mm)
0.2
0.2
The printing experiment was conducted by using a FDM 3D printer machine, Pursa i3 model 3D
printer machine that has printing area of 180mmx180mmx150mm with glass as the material of
printing platform. Before the printing process began, the printing platform was prepared by applying
the epoxy resin based adhesive and spreading onto the printing area of printing platform. Four
specimens type i.e. ABS without the use of heat bed printing platform, ABS with use of heat bed, PLA
without heat bed, and PLA with heat bed has been print by using 3D Printer for each angles of 30º, 45º
and 60º . Table 2 shows the label for type of specimens used on the experiment.
Table 2. Labelled type of specimens based on material and heat bed
Specimens
Material
Heat bed
1
ABS
Without
2
ABS
With
3
PLA
Without
4
PLA
with
4
1234567890
International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012062 doi:10.1088/1757-899X/210/1/012062
In addition, the printing setting for the layer temperature was set differently between PLA and ABS
material. This is because of the different melting point and different material properties. The bed
temperature setting has been set for ABS and PLA are100ºC and 60ºC respectively.
2.2. Warping Deformation Preparation
Figure 5. Scanning process by Solutionix Rexscan CS2+ laser scanner
After the printing process completed, the next process was scanning the geometry shape that been
printed using the 3D printer. The specimens was scanned using laser scanning and metrology
software; Solutionix Rexscan CS2+ 3D scanner machine and Geomagic Quality 2013 tools software to
compare with the sketched theoretical geometry from drawing. The warping deformation that was
measured are shown in figure 6. The geometry of the sample was compared using 3D and 2D compare
tools that available in the Geomagic software. Moreover, the result also has been figured using
coordinate method which is similar to the conventional method of Coordinate Measuring Machine
(CMM).
Pincushion
Trapezoid
Curling
Blocked shrinkage
Figure 6. Description of warpage deformation [5]
3. Results and discussions
All the sample of specimen is completely printed using the Pursa i3. However, the printing process of
using ABS material without external heat bed had failed where they peeled away from the printing
platform. Therefore, the result of the experiment is only presented with 3 type of printing; ABS with
heat bed, PLA without heat bed and PLA with heat bed.
5
1234567890
International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012062 doi:10.1088/1757-899X/210/1/012062
Figure 7a. Photograph of specimens (front
view) from left 30º, 45º and 60º
Figure 7b. Photograph of specimens (back
view) from top 30º, 45º, and 60º
Figure 7a and 7b is shows the photograph of printed specimen with angle 30º, 45º and 60º. As
shown in the photograph, the specimen with 30º of angle shows the fewest shape error especially in
the front view of the specimens.
3.1. Measurement results
Data of the measurement has been obtained from the process of laser scanning and metrology process.
It has shown that there is some geometry error based on shape.
Figure 8. Photograph of specimen with angle
45º printed using Polylactic Acid (PLA) material
Figure 9. 3D comparison between actual
drawing and scanned specimen that has been
analyzed using the metrology software with
minimum and maximum labeled for the
spectrum level
Figure 8 and 9 shows an example from one of the printed specimen that went through the 3D
comparison analysis between the actual drawing and the scanned printed specimen. The spectrum
colors shows the comparison of the geometry for each of the specimen. As in the figure, the maximum
and minimum of deformation spectrum are 0.5 mm and -0.5 mm corresponding to the tolerance of the
analysis. The red color shown the positive of deformation spectrum while blue color is the negative of
deformation spectrum and then green color is nearly to the dimension of theoretical. Based on the
analysis data, the maximum and average of the deformation are 0.4994 mm and 0.1388 mm. As in the
figure 9, the rectangular shaped at the center of specimen is shows few of red area while most of top
45°
30°
60°
45°
30°
60°
Min
Max
6
1234567890
International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012062 doi:10.1088/1757-899X/210/1/012062
surface shown blue color and green. Table 3, 4 and 5 shows the result of deformation error from
measurement of metrology process.
Table 3. Deformation error from measurement from specimens with 30º of angle
Specimens
Pincushion
Trapezoid
Curling
Blocked shrinkages
t
b
h
b
h₁
h₂
d
d₂
d₃
h
1
0.8168
0.2683
0.4080
0.5732
0.1497
0.0864
9.2111
21.3766
3.1463
0.0833
2
2.4176
1.7934
0.7086
1.2975
0.0179
0.0087
1.6314
17.2267
9.8791
0.0936
3
-
-
-
-
-
-
-
-
-
-
4
0.7832
0.2176
0.3149
0.0469
0.0376
0.1213
1.0110
20.0640
12.9380
0.0356
Table 4. Deformation error from measurement from specimens with 45º of angle
Specimens
Pincushion
Trapezoid
Curling
Blocked shrinkage
t
b₁
h₃
b₂
h₁
h₂
d₁
d₂
d₃
h₄
1
0.1721
0.1225
0.0076
0.1154
0.0459
0.0219
1.9968
21.8371
0.8987
0.0043
2
0.2115
0.1331
0.0883
0.3917
0.0682
0.0437
1.6837
11.6780
22.9900
0.1041
3
-
-
-
-
-
-
-
-
-
-
4
0.1699
0.5910
0.1518
0.0508
0.0604
0.1357
10.9160
17.8978
14.0234
0.0284
Table 5. Deformation error from measurement of specimens with 60º of angle
Specimens
Pincushion
Trapezoid
Curling
Blocked shrinkage
t
b₁
h₃
b₂
h₁
h₂
d₁
d₂
d₃
h₄
1
0.4654
0.3159
0.3007
0.5037
0.0564
0.0077
0.0199
20.5490
2.2459
0.0160
2
1.1335
1.2020
0.6418
0.2787
0.0464
0.0137
0.3373
14.7331
14.9542
0.0927
3
-
-
-
-
-
-
-
-
-
-
4
0.2526
0.4126
0.3976
0.8385
0.2993
0.1957
10.9160
19.8973
3.1310
0.0439
7
1234567890
International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012062 doi:10.1088/1757-899X/210/1/012062
3.2. Effect of angle
Figure 10. Total deformation of princushion, curling, trapezoid and blocked shrinkage effects.
Figure 10 indicate the results to the pincushion, curling, trapezoid and blocked shrinkage effects
that tabulated form the experiments. The graph was plot based on the total deformation for each
effects. By referring to the plotted graph, pincushion and trapezoid effects resulted from PLA with
heat bed type of specimen has the highest value of deformation especially for the specimens that was
built with 30º of angle. Moreover, based on the result for PLA without heat bed, most of graphs shows
has lower total deformation than other type of specimens. ABS material that has been printed using
heat bed shows that it has lower total deformation compared to PLA with heat bed.
For the curling effect, the result shows that the ABS material that printed using heat bed has high
deformation since it has been built with 45º and 60º of angle. This maybe because of the
environmental factors that has affecting result to the printing process where the solidification of the
material might be different from each other. The ABS material has known issue of solidification in 3D
printing.
The effect of the angle shows that the total deformation has lower value when it built with angled
45º. Therefore, it may conclude that best angle of printing with those material is by using 45º of angle
while the other angle is resulted has higher value of total deformation.
8
1234567890
International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012062 doi:10.1088/1757-899X/210/1/012062
3.3. Type of error
Figure 11. Total of warping deformation by type of error from specimens with 45º of angle
Based on the previous result, the experiment shows that the specimens with 45º of angle are the
best compared to the other angle. Thus, figure 11 generally shows the result of total error for the four
type of warping deformation. The pie chart shows the total warping deformation that separated by type
of material and method of printing. This chart shows that most of experiment has high blocked
shrinkages effects. ABS with heat bed shows 2%, 0%, 73% and 25% of pincushion, trapezoid, blocked
shrinkage and curling effects. Respectively. PLA material that printed without heat bed and with heat
bed shows higher blockade shrinkages where 90% and 93% respectively. Apart from that, the
pincushion and trapezoid effects has the lowest deformation among the specimens which is less than
2%. The curling effect shows that ABS material has 25% of deformation while PLA with and without
heat bed has 8% and 6% deformation.
3.4. Effect of material
Figure 12. Influence of
deformation based on total
deformation from material
ABS and PLA with heat
bed
The measured total deformation of the overall effects are shown through the bar chart as in figure
12. The bar chart has shown the pincushion and trapezoid effect has lower deformation than curling
and blocked shrinkage. This result came out similar for both of ABS and PLA material that been print
with heat bed. Moreover, the result shows the blocked shrinkage effect have the highest total
deformation for the both material. Moreover, the ABS material has less deformation compared to PLA
material for the blocked shrinkage effect. However, the ABS exhibit higher deformation for the
curling and pincushion effects compare to PLA material. Based on the chart and the observation, PLA
9
1234567890
International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012062 doi:10.1088/1757-899X/210/1/012062
material gives the best result where the surface finish and the warping deformation is better than ABS
material.
4. Conclusion
Based on the results, it shows that the highest value of deformation is, the lower quality of printing. In
the experiment of the geometry shape, the specimen built with 45º of angle that was been print using
PLA material without heat bed shows the lowest warping deformation. In addition, the results also
shows that blocked shrinkage effect has the highest value of deformation compare to curling,
pincushion and trapezoid. In addition, PLA material has the best material where it has low
deformation for the curling and pincushion effect compared to ABS material. PLA material printed
without heat bed have the lowest total deformation of pincushion, trapezoid and blocked shrinkage
effects with 0.2946mm, 0.1230mm and 22.7401mm respectively.
References
[1] Solidwild.wordpress.com, 2017, Additive Manufacturing | SolidWild. [online] Available at:
https://solidwild.wordpress.com/category/3d-printing-2/additive-manufacturing/ [Accessed 12
Mar. 2017]
[2] Yifan J, Yi W, Bing Z and Zhanqiang L 2017 Journal of Mechanical Processing Technology,
240 233-239
[3] M A Nazan, F R Ramli, M R Alkahari, M N Sudin and M A Abdullah 2016 Proc. of
Mechanical Engineering Research Day 2016 71-72
[4] Wohlers T, 2012. Wohlers Report 2012: Executive Summary.
[5] W Z Wu, P Geng, J Zhao, Y Zhang, D W Rosen and H B Zhang 2014 Materials Research
Innovations, 18 12-16
[6] F R Ramli, M I Jailani, H Unjar, M R Alkahari and M A Abdullah 2015 Proc. of Mechanical
Engineering Research Day 2015 77-78
[7] Christoph S, Alexander Z, Michael F Z 2016 48th CIRP Conference on Manufacturing Systems
2015 1017-1022,
[8] Jane L D 2010 The Yellowing of Epoxy Resin Adhesives: Report on Natural Dark Aging 29 63-
76
[9] Davison S, 2010, The problems of restoring glass vessels 3-8
[10] UHU Stic safety data sheet, 2015, 12
[11] M A Nazan, F R Ramli, M R Alkahari, M N Sudin and M A Abdullah 2017 Proc. of
Mechanical Engineering Research Day 2017 145-146.
... In-depth research studies can provide a more comprehensive understanding of how these materials affect adhesion and aid in selecting an appropriate option [17] [18]. Partial detachment of printed structures from the printbed due to uneven crystallization and resulting warping / Figure 2.c5/ is a common issue faced during 3D printing processes [16] [19]. This issue can be addressed by establishing printing conditions that allow for slow and uniform cooling of the material during printing. ...
Preprint
Full-text available
In contemporary production processes and customization, 3D printing has emerged as a prominent method for prototyping. It offers the flexibility to create objects of diverse shapes, structures, sizes, and materials. However, integrating this technology into the textile industry to achieve textile-like structures poses challenges. The FDM method is currently the closest approach to prototyping such structures due to its ability to extrude monofilaments resembling traditional threads. Regrettably, attempts to produce structures with properties akin to textiles, including flexibility, durability, breathability, lightness, and fineness have been unsuccessful due to various limitations inherent in the technical setups of 3D printers. This study analyzes the key features of FDM printing that determine the feasibility of achieving authentic textile-like printed structures while clarifying the underlying logic behind their future purpose. Our objective is to assist future researchers in achieving the production of thin 3D-printed fibers (up to 100μm) regardless of structure type.
... Bed adhesion failure is one of the most common problems during the 3D-printing process, where it results in warpage, such as pincushioning, trapezoidal shapes, curling, and blocked shrinkages, which can be challenging to rectify [17,18]. To address bed adhesion failure, the application of adhesive to the bed was proposed to prevent product detachment [17]. ...
Article
Full-text available
Extrusion-based polymer three-dimensional (3D) printing, specifically fused deposition modeling (FDM), has been garnering increasing interest from industry, as well as from the research and academic communities, due to its low cost, high speed, and process simplicity. However, bed adhesion failure remains an obstacle to diversifying the materials and expanding the industrial applications of the FDM 3D-printing process. Therefore, this study focused on an investigation of the surface treatment methods for aluminum (Al) foil and their applications to 3D printer beds to enhance the bed adhesion of a 3D-printed polymer filament. Two methods of etching with sodium hydroxide and anodization with phosphoric acid were individually used for the surface treatment of the Al foil beds and then compared with an untreated foil. The etching process removed the oxide layer from the Al foil and increased its surface roughness, while the anodizing process enhanced the amount of hydroxide functional groups and contributed to the formation of nano-holes. As a result, the surface-anodized aluminum foil exhibited a higher affinity and bonding strength with the 3D-printed polymers compared with the etched and pristine foils. Through the increase in the success rate in 3D printing with various polymers, it became evident that utilizing surface-treated Al foil as a 3D printer bed presents an economical solution to addressing bed adhesion failure.
... The study's contribution lies in identifying that the most suitable method for testing the adhesion of the initial model layer is the perpendicular tensile test, presenting a lower risk of tearing the textile substrate. Nazan et al. presented research on warping deformations of printed models using FFF technology [5]. Laser scanning was utilized for deformation measurements and comparison against the nominal model. ...
Article
Full-text available
The persistent challenge of adhesion in Fused Filament Fabrication (FFF) technology is deeply rooted in the mechanical and chemical properties of utilized materials, necessitating the exploration of potential resolutions. This involves adjustments targeting the interplay of printing parameters, the mechanical fortification of print beds, and the integration of more adhesive materials, resonating across user levels, from enthusiasts to complex industrial configurations. An in-depth investigation is outlined in this paper, detailing the plan for a systematically designed device. Engineered for FFF device installation, the device facilitates the detachment of printed models, while precisely recording the detachment process, capturing the maximum force, and its progression over time. The primary objective is fabricating a comprehensive measurement apparatus, created for adhesion assessment. The device is adaptable across diverse FFF machines and print bed typologies, conforming to pre-defined conditions, with key features including compactness, facile manipulability, and capacity for recurrent measurements. This pursuit involves evaluating adhesion levels in prints made from diverse materials on varying print bed compositions, aiming to establish a comprehensive database. This repository facilitates judicious material and bed type selection, emphasizing maximal compatibility. Emphasis is placed on operating within a thermally stable context, a pivotal prerequisite for consistent and reproducible results.
... Besides, high printing temperature decreased the viscosity of composite which promoted warping problems during the 3D printing. Nazan et al. 16 stated that a higher bed temperature caused edge warping of the 3D printed part. In addition, Das and co-authors 17 claimed that the FFF process would change the crystallization kinetics of the polypropylene and leads to form internal stresses in the 3D printed part. ...
Article
Full-text available
This study focused on the development of three‐dimensional (3D) polymer composite filament made of disposable chopstick (DC) and post‐consumer polypropylene (PPP). The PPP/DC composite parts were printed via fused filament fabrication (FFF) process. The effect of the printing temperature and different DC fiber content on the properties of the 3D printed parts were investigated. The printing temperature of 200–220°C was suitable for these filaments because the printing temperature did not show any thermal degradation, as proven by thermogravimetric analysis. Furthermore, the thermal stability of the 3D filament increased with DC content. The chemical modification with sodium hydroxide (NaOH) was carried out on DC to remove the unwanted organic components by showing changes in peak intensity in the Fourier transform infrared analysis. Moreover, the melt flow index of the composite filaments decreased with increasing of the DC content and caused the composites' viscosity increased. The results show that the optimum printing temperature of 210°C would reduce the warping and gave better tensile properties to the 3D printed parts. Nevertheless, the tensile strength and elongation at break of the 3D printed PPP/DC parts reduced as the DC content increased because the presence of some air gap and fiber pull out on the fracture surface of 3D printed parts, which are in line with the results observed from scanning electron microscopy. However, the tensile strength and elongation at break percentage of all 3D printed PPP/DC composite parts were higher in comparison with the 3D parts printed by commercial wood plastic composite filament.
Thesis
Full-text available
The FLM-process is a cost-efficient and comparatively fast additive manufacturing process for processing thermoplastics. Particularly in the processing of semi-crystalline thermoplastics, process-related deficiencies occur, such as a defective layer-bond and high deviations in shape due to material shrinkage and warpage. In the presented work, this problem is analysed on the basis of the state of the art, goals and an approach for the solution are derived. The layer bonding as well as the material shrinkage depends on the temperature-driven welding and crystallisation processes of the material extrusion. Local laser preheating of the substrate is intended to promote the welding between the layers. At the same time, it is investigated whether the crystallisation process and the associated material shrinkage is influenced by the intensive localised cooling of the deposited melt. A rotary print head has been developed and fully functionally integrated into the 2,5- dimensional FLM-process. A laser module for preheating the substrate and a compressed air cooler for directional cooling of the melt are guided around the extrusion nozzle on two independently rotating axes. In order to characterise this modified FLM-process, the target parameters component distortion and layer-bonding are empirically investigated as a function of the influencing factors nozzle temperature, laser power, cooling air pressure and layer time for the semi-crystalline material polyamide 12 (PA12). The experimental procedure includes the design of experiments, the development of suitable investigation and testing methods, the sample production and post-processing as well as the component testing and statistical evaluation of the results. With the modified FLM-process, the processing of PA12 can be optimised. In particular, the layer bonding can be increased, the warpage can be reduced by up to 44% and the anisotropy can be decreased. Furthermore, the dependency on process parameters such as extrusion-, printbed- and chamber-temperature as well as the disturbing influence of the layer time is reduced. Thus, extrusion and print bed temperatures can be lowered without loss of strength. Laser preheating compensates for high layer times of large components and achieves a good layer-bonding. The results of this work show the feasibility and the enormous potential of the modified FLM-process and provide the basis for further research as well as for the technology transfer to an optimised industrial FLM-process for semi-crystalline thermoplastics.
Article
This research aims to perform a Systematic Review (RS) through the PRISMA 2020 Protocol, which presents to the reader the main problems and solutions of 3D printing processes, more specifically the Fusion Modeling and Deposition (FDM). The methodology adopted was a RS through the PRISMA 2020 Protocol, using as a research source the following databases: SciELO Brazil, Oasisbr, Google Scholar, Scopus and Web of Sciente. It was adopted as keywords: 3D printing; FDM; 3D printing parameters; printing problems and problems (and their respective English versions). As a result, we found 44 studies that met the inclusion criteria, developed mainly in China and Brazil. The problems found were categorized into 11 classes defined a posteriori: Adhesion of the first layer to the printing table; Effects of temperature on the printing result; Mechanical properties achieved in the printing process; Adhesion between layers; 3D printing software; Stringing; Geometric variations; Moisture in the filament; Surface finishing; Need for support structures in printing and multi-material printing. We highlight the importance of the contributions found in this RS for the optimization of the process of using 3D printers in educational environments, enabling teachers to develop printed objects with higher quality and without the need for unnecessary tests, thus reducing the loss of material and working time, facilitating their access and use of this technology.
Article
The additive machines, which use a range of laser-based or advanced printing techniques to build up models layer by layer offers several advantages. The technology offers freedom to the designers that enable the production of lightweight optimized components that are impossible to make with traditional techniques. The EADS team has already succeeded in growing aligned nanotubes within additive-layer manufacturing (ALM) structures. EADS used computerized stress analysis and topology optimization to reveal the location of the loads and stresses in the component and used that data to design a component that consists only of the sections that carry the load. Hague's team is working to reduce waste, weight and emissions during both the production of a component and its use with the use of additive techniques. Airbus is trailing components including control surfaces, cooling systems and the reduced-weight landing gear and bracket components.
Article
Shewhart type fuzzy charts have been immensely proposed to deal with several practical problems of fuzzy data in monitoring and examining manufacturing processes. In mediating the shortcomings of indistinguishable classification conditions of a recently proposed fuzzy (x) over bar and s charts,this paper aims at developing a quantitative approach based on the index of optimism for fuzzy judgement of online manufacturing processes. By quantifying the linguistic notion `rather' that is usually mentioned as a qualitative term in previous researches, we make it numerically measured in this study; as such, our thorough evaluation conditions of a manufacturing process, including in control, rather in-control, rather out of control and out of control, are more sufficient and justified. In addition, our proposed approach with the multi-intermittent states certainly overcome the constraints of binary classifications of traditional Shewhart type control charts when fuzzy data inevitably appear in practical manufacturing processes; hence, it fulfils the current literature of control charts.
Article
The properties derived from materials to be used in the repair and restoration of glass are given together with a list of materials in use. Methods for preparing glass for joining and formaking joins are outlined. Methods for making molds using dental wax, silicone rubber, clay and plaster of paris are described in detail together with the use of these moulds to prepare cast resin pieces to replace missing fragments of glass vessels.
Additive Manufacturing | SolidWild. [online] Available at: https://solidwild.wordpress.com/category/3d-printing-2/additive-manufacturing
  • Solidwild
  • Wordpress
  • J Yifan
  • W Yi
  • Bing Z Zhanqiang
Yifan J, Yi W, Bing Z and Zhanqiang L 2017 Journal of Mechanical Processing Technology, 240 233-239
  • F M A Nazan
  • M R Ramli
  • M R Alkahari
  • M A Sudin
  • Abdullah
M A Nazan, F R Ramli, M R Alkahari, M N Sudin and M A Abdullah 2016 Proc. of Mechanical Engineering Research Day 2016 71-72
  • P W Z Wu
  • Geng
  • Y Zhao
  • D Zhang
  • H B W Rosen
  • Zhang
W Z Wu, P Geng, J Zhao, Y Zhang, D W Rosen and H B Zhang 2014 Materials Research Innovations, 18 12-16
  • F Ramli
  • M Jailani
  • M Unjar
  • M A Alkahari
  • Abdullah
F R Ramli, M I Jailani, H Unjar, M R Alkahari and M A Abdullah 2015 Proc. of Mechanical Engineering Research Day 2015 77-78
  • L Jane
Jane L D 2010 The Yellowing of Epoxy Resin Adhesives: Report on Natural Dark Aging 29 63-76