Search

3D printing, specifically fused deposition modeling (FDM) of poly-ether-ether-ketone (PEEK), is one of the most powerful and efficient state-of-the-art manufacturing techniques. However, FDM of PEEK is challenging. Indeed, it is critical to consider specific 3D printing parameters and filament feedstock quality to achieve optimum mechanical properties in the 3D-printed PEEK parts. In this paper, we investigate the effect of specific 3D printing parameters such as nozzle and chamber temperature, print speed, and layer height on the mechanical properties of 3D-printed PEEK. Moreover, we explore the effect of filament quality on the structures' mechanical properties. In that regard, we developed PEEK filaments using a customized extruder setup in-house and used those laboratory-developed filaments (LD) to 3D print PEEK structures suitable for mechanical testing (tensile, compression, and flexural testing) and compared them to the mechanical properties of 3D-printed parts that were developed using commercially available (CA) filaments. Results indicate that an optimum combination of a nozzle and chamber temperature, print speed, and layer height is appropriate to achieve 3D-printed parts with optimum mechanical properties. Notably, results confirmed no significant differences between the specimen groups developed using LD and CA filaments, highlighting that the LD filaments were of comparable quality to the CA ones. The highest mean strengths recorded for the parts printed with the LD filaments were 106.45 MPa (compressive), 85.43 MPa (tensile), and 102.63 MPa (flexural). This paper confirms that high-quality PEEK-based filaments can be developed in-house to yield 3D-printed PEEK parts with optimum mechanical properties. [ABSTRACT FROM AUTHOR]

In recent years, 3D printing technology has played an essential role in fabricating customized products at a low cost and faster in numerous industrial sectors. Fused deposition modeling (FDM) is one of the most efficient and economical 3D printing techniques. Various materials have been developed and studied, and their properties, such as mechanical, thermal, and electrical, have been reported. Numerous attempts to improve FDM products' properties for applications in various sectors have also been reported. Still, their applications are limited due to the materials' availability and properties compared to traditional fabrication methods. In 3D printing, the process parameters are crucial factors for improving the product's properties and reducing the machining time and cost. Researchers have recently investigated many approaches for expanding the range of materials and optimizing the FDM process parameters to extend the FDM process's possibility into various industrial sectors. This paper reviews and explains various techniques used in 3D printing and the various polymers and polymer composites used in the FDM process. The list of mechanical investigations carried out for different materials, process parameters, properties, and the FDM process's potential application was discussed. This review is expected to indicate the materials and their optimized parameters to achieve enhanced properties and applications. Also, the article is highly anticipated to provide the research gaps to sustenance future research in the area of FDM technologies. [ABSTRACT FROM AUTHOR]

Additive manufacturing (AM) technology is capable of efficiently building complex shapes when compared with traditional manufacturing methods. Fused deposition modeling (FDM) is one of the AM processes, and it produces a great variety of polymeric parts. Therefore, it is essential to determine the relationship that exists among its process parameters, productivity and sustainability, quality of the final piece, and its structural performance. This paper presents an experimental study centered on optimizing five responses associated with FDM: energy consumption of the 3D printer, processing time, part's dimensional accuracy, the quantity of material used to print the pieces, and mechanical strength of the specimens. The model material employed was acrylonitrile styrene acrylate. The effects of five key process parameters on the responses were studied using the Taguchi methodology and analysis of variance (ANOVA). These parameters were layer thickness, filling pattern, orientation angle, printing plane, and position of the piece on the build platform. A desirability analysis was employed to determine the set of process parameters that provided the best trade-off among all the considered variables. The results showed that the approach presented in this work allowed for simultaneous optimization of all the observed variables for the 3D printing process. [ABSTRACT FROM AUTHOR]

Additive Manufacturing technology has a significant impact on the modern world because of its ability to fabricate highly complex computerized geometrics. Pure 3D-printed polymer parts have limited potential applications due to inherently inferior mechanical and anisotropic properties. For more utilization and versatility, the addition of fillers has enhanced their functionalities. 3D printing has innovative advantages including low cost, minimal wastage, customized geometry, and ease of material change. This review reveals the development of 3D printing techniques of matrix composite materials with improving properties and their applications in the fields of aerospace, automotive, biomedical, and electronics. A general introduction is given on AM techniques mainly fused deposition modeling (FDM), Powder-liquid 3D printing (PLP), selective laser sintering (SLS), stereolithography (SLA), digital light processing (DLP), and robocasting. Process methodologies and behavior of different filler additives, reinforcement fibers, nanoparticles, and ceramic polymer composites are discussed. Also, some major issues of difficulty including printing parameters, homogeneous desperation of fillers, nozzle clogging due to filler aggregation, void formation, augmented curing time, and anisotropic attributes are addressed. In the end, some capabilities and shortcomings are pointed out for further development of 3D-printing technology. [ABSTRACT FROM AUTHOR]

Fused deposition modelling is an additive manufacturing technology that is widely employed to produce good quality products with complex geometries at a low cost and with efficient manufacturing and delivery logistics. The mechanical properties can be enhanced by studying the numerous FDM parameters and by using new materials. In this work, was studied the mechanical properties tensile strength, flexural strength, and impact energy of 3D printed parts manufactured with FDM technology and PLA-graphene raw material by varying the infill and layer thickness parameters using a statistical technique CCD—central composite design. Due to the layered production process, 3D printed parts exhibit anisotropic behaviour. In the tests, the flat orientation and honeycomb infill pattern were maintained. The results showed that the mechanical properties improve as the linear layer thickness parameter increases. The behaviour was different in each test for the linear infill parameter. The mechanical properties, tensile strength and flexural strength, increased as the infill increased, while impact energy decreased as infill increased. The relationship between mechanical properties and printing time/weight was also evaluated. [ABSTRACT FROM AUTHOR]