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From its beginnings, up to a few years ago, additive manufacturing technology was able to produce models or prototypes which have limited use, because of materials mechanical properties. With advancement and invention of new materials, this is changing. Now, it is possible to create 3D prints that can be used as final products or functional tools, using technology and materials with low environmental impact. The goal of this study was to examine opportunities for production of paper embossing tools by fused deposition modelling (FDM) 3D printing. This study emphasises the use of environmentally friendly poly-lactic acid (PLA) materials in FDM technology, contrary to the conventional method using metal alloys and acids. Embossing of line elements and letters using 3D printed embossing tools was done on six different types of paper. Embossing force was applied using SHIMADZU EZ-LX Compact Tabletop Testing Machine. Each type of paper was repeatedly embossed using different values of embossing force (in 250 N increments, starting at 1000 N) to determine the optimal embossing force for each specific paper type. When determined, the optimal embossing force was used on ten samples for each paper type. Results of embossing were analysed and evaluated. The analysis consisted of investigating the effects of the applied embossing force and characteristics such as paper basis weight, paper structure, surface characteristic and fibre direction of the paper. Results show that paper characteristics determine the embossing force required for achieving a good embossing result. This means that with the right amount of embossing force, letters and borderlines can be equally well formed by the embossing process regardless of paper weight, surface characteristics, etc. Embossing tools produced in this manner can be used in case of the embossing elements that are not complex. The reason for this is the limitation of FDM technology and lack of precision needed for fine details. However, if the form is simple enough, results of pleasing quality can easily be achieved. [ABSTRACT FROM AUTHOR]

Manufacturing of the embossing tools customary implies use of metals such as zinc, magnesium, copper, and brass. In the case of short run lengths, a conventional manufacturing process and the material itself represent a significant cost, not only in the terms of material costs and the need for using complex technological systems which are necessary for their production, but also in the terms of the production time. Alternatively, 3D printing can be used for manufacturing similar embossing tools with major savings in production time and costs. However, due to properties of materials used in the 3D printing technology, expected results of embossing by 3D printed tools cannot be identical to metal ones. This problem is emphasized in the case of long run lengths and high accuracy requirement for embossed elements. The objective of this paper is primarily focused on investigating the influence of the printing speed on reproduction quality of the embossing tools printed with FDM (Fused Deposition Modelling) technology. The obtained results confirmed that printing speed as a process parameter affects the reproduction quality of the embossing tools printed with FDM technology: in the case of deposition rate of 90 mm/s was noted the poorest dimensional accuracy in relation to the 3D model, which is more emphasised in case of circular and square elements. Elements printed with the highest printing speed have a greater dimensional accuracy, but with evident cracks on the surface. [ABSTRACT FROM AUTHOR]