Pub Date : 2024-07-25DOI: 10.1108/rpj-04-2024-0163
C. Jiang, Masrurotin Masrurotin, Maziar Ramezani, A. T. Wibisono, Ehsan Toyserkani, Wojciech Macek
Purpose Fused deposition modeling (FDM) nowadays offers promising future applications for fabricating not only thermoplastic-based polymers but also composite PLA/Metal alloy materials, this capability bridges the need for metallic components in complex manufacturing processes. The research is to explore the manufacturability of multi-metal parts by printing green bodies of PLA/multi-metal objects, carrying these objects to the debinding process and varying the sintering parameters. Design/methodology/approach Three different sample types of SS316L part, Inconel 718 part and bimetallic composite of SS316L/IN718 were effectively printed. After the debinding process, the printed parts (green bodies), were isothermally sintered in non-vacuum chamber to investigate the fusion behavior at four different temperatures in the range of 1270 °C−1530 °C for 12 h and slowly cooled in the furnace. All samples was assessed including geometrical assessment to measure the shrinkage, characterization (XRD) to identify the crystallinity of the compound and microstructural evolution (Optical microscopy and SEM) to explore the porosity and morphology on the surface. The hardness of each sample types was measured and compared. The sintering parameter was optimized according to the microstructural evaluation on the interface of SS316L/IN718 composite. Findings The investigation indicated that the de-binding of all the samples was effectively succeeded through less weight until 16% when the PLA of green bodies was successfully evaporated. The morphology result shows evidence of an effective sintering process to have the grain boundaries in all samples, while multi-metal parts clearly displayed the interface. Furthermore, the result of XRD shows the tendency of lower crystallinity in SS316L parts, whilst IN718 has a high crystallinity. The optimal sintering temperature for SS316L/IN718 parts is 1500 °C. The hardness test concludes that the higher sintering temperature gives a higher hardness result. Originality/value This study highlights the successful sintering of a bimetallic stainless steel 316 L/Inconel 718 composite, fabricated via dual-nozzle fused deposition modeling, in a non-vacuum environment at 1500 °C. The resulting material displayed maximum hardness values of 872 HV for SS316L and 755.5 HV for IN718, with both materials exhibiting excellent fusion without any cracks.
{"title":"Sintering parameter investigation for bimetallic stainless steel 316L/inconel 718 composite printed by dual-nozzle fused deposition modeling","authors":"C. Jiang, Masrurotin Masrurotin, Maziar Ramezani, A. T. Wibisono, Ehsan Toyserkani, Wojciech Macek","doi":"10.1108/rpj-04-2024-0163","DOIUrl":"https://doi.org/10.1108/rpj-04-2024-0163","url":null,"abstract":"Purpose\u0000Fused deposition modeling (FDM) nowadays offers promising future applications for fabricating not only thermoplastic-based polymers but also composite PLA/Metal alloy materials, this capability bridges the need for metallic components in complex manufacturing processes. The research is to explore the manufacturability of multi-metal parts by printing green bodies of PLA/multi-metal objects, carrying these objects to the debinding process and varying the sintering parameters.\u0000\u0000Design/methodology/approach\u0000Three different sample types of SS316L part, Inconel 718 part and bimetallic composite of SS316L/IN718 were effectively printed. After the debinding process, the printed parts (green bodies), were isothermally sintered in non-vacuum chamber to investigate the fusion behavior at four different temperatures in the range of 1270 °C−1530 °C for 12 h and slowly cooled in the furnace. All samples was assessed including geometrical assessment to measure the shrinkage, characterization (XRD) to identify the crystallinity of the compound and microstructural evolution (Optical microscopy and SEM) to explore the porosity and morphology on the surface. The hardness of each sample types was measured and compared. The sintering parameter was optimized according to the microstructural evaluation on the interface of SS316L/IN718 composite.\u0000\u0000Findings\u0000The investigation indicated that the de-binding of all the samples was effectively succeeded through less weight until 16% when the PLA of green bodies was successfully evaporated. The morphology result shows evidence of an effective sintering process to have the grain boundaries in all samples, while multi-metal parts clearly displayed the interface. Furthermore, the result of XRD shows the tendency of lower crystallinity in SS316L parts, whilst IN718 has a high crystallinity. The optimal sintering temperature for SS316L/IN718 parts is 1500 °C. The hardness test concludes that the higher sintering temperature gives a higher hardness result.\u0000\u0000Originality/value\u0000This study highlights the successful sintering of a bimetallic stainless steel 316 L/Inconel 718 composite, fabricated via dual-nozzle fused deposition modeling, in a non-vacuum environment at 1500 °C. The resulting material displayed maximum hardness values of 872 HV for SS316L and 755.5 HV for IN718, with both materials exhibiting excellent fusion without any cracks.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141802544","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-24DOI: 10.1108/rpj-08-2023-0277
U. M. Dilberoglu, U. Yaman, M. Dolen
Purpose This study aims to thoroughly examine the milling process applied to fused filament fabrication (FFF) parts. The primary objective is to identify the key variables in creating smooth surfaces on FFF specimens and establish trends about specific parameters. Design/methodology/approach In this study, PLA and ABS samples fabricated by FFF are subjected to side milling in several experiments. Achievable surface quality is studied in relation to material properties, milling parameters, tooling and macrostructure. The surface finish is quantified using profile measurements of the processed surfaces. The study classifies the created chips into categories that can be used as criteria for the anticipated quality. Spectral analysis is used to examine the various surface formation modes. Thermal monitoring is used to track chip formation and surface temperature changes during the milling process. Findings This study reveals that effective heat dissipation through proper chip formation is vital for maintaining high surface quality. Recommended methodology demands using a tool with a substantial flute volume, using high positive rake and clearance angles and optimizing the feed-per-tooth and cutting speed. Disregarding these guidelines may cause the surface temperature to surpass the material’s glass transition, resulting in inferior quality characterized by viscous folding. For FFF thermoplastics, optimal milling can bring the average surface roughness down to the micron level. Originality/value This research contributes to the field by providing valuable guidance for achieving superior results in milling FFF parts. This study includes a concise summary of the theoretically relevant insights, presents verification of the key factors by qualitative analysis and offers optimal milling parameters for 3D-printed thermoplastics based on systematic experiments.
{"title":"A comprehensive guide to milling techniques for smoothing the surfaces of 3D-printed thermoplastic parts","authors":"U. M. Dilberoglu, U. Yaman, M. Dolen","doi":"10.1108/rpj-08-2023-0277","DOIUrl":"https://doi.org/10.1108/rpj-08-2023-0277","url":null,"abstract":"Purpose\u0000This study aims to thoroughly examine the milling process applied to fused filament fabrication (FFF) parts. The primary objective is to identify the key variables in creating smooth surfaces on FFF specimens and establish trends about specific parameters.\u0000\u0000Design/methodology/approach\u0000In this study, PLA and ABS samples fabricated by FFF are subjected to side milling in several experiments. Achievable surface quality is studied in relation to material properties, milling parameters, tooling and macrostructure. The surface finish is quantified using profile measurements of the processed surfaces. The study classifies the created chips into categories that can be used as criteria for the anticipated quality. Spectral analysis is used to examine the various surface formation modes. Thermal monitoring is used to track chip formation and surface temperature changes during the milling process.\u0000\u0000Findings\u0000This study reveals that effective heat dissipation through proper chip formation is vital for maintaining high surface quality. Recommended methodology demands using a tool with a substantial flute volume, using high positive rake and clearance angles and optimizing the feed-per-tooth and cutting speed. Disregarding these guidelines may cause the surface temperature to surpass the material’s glass transition, resulting in inferior quality characterized by viscous folding. For FFF thermoplastics, optimal milling can bring the average surface roughness down to the micron level.\u0000\u0000Originality/value\u0000This research contributes to the field by providing valuable guidance for achieving superior results in milling FFF parts. This study includes a concise summary of the theoretically relevant insights, presents verification of the key factors by qualitative analysis and offers optimal milling parameters for 3D-printed thermoplastics based on systematic experiments.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141808088","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-24DOI: 10.1108/rpj-11-2023-0413
Arthur de Carvalho Cruzeiro, Leonardo Santana, Danay Manzo Jaime, S. Ramôa, J. L. Alves, Guilherme Mariz de Oliveira Barra
Purpose This study aims to evaluate in situ oxidative polymerization of aniline (Ani) as a post-processing method to promote extrusion-based 3D printed parts, made from insulating polymers, to components with functional properties, including electrical conductivity and chemical sensitivity. Design/methodology/approach Extrusion-based 3D printed parts of polyethylene terephthalate modified with glycol (PETG) and polypropylene (PP) were coated in an aqueous acid solution via in situ oxidative polymerization of Ani. First, the feedstocks were characterized. Densely printed samples were then used to assess the adhesion of polyaniline (PAni) and electrical conductivity on printed parts. The best feedstock candidate for PAni coating was selected for further analysis. Last, a Taguchi methodology was used to evaluate the influence of printing parameters on the coating of porous samples. Analysis of variance and Tukey post hoc test were used to identify the best levels for each parameter. Findings Colorimetry measurements showed significant color shifts in PP samples and no shifts in PETG samples upon pullout testing. The incorporation of PAni content and electrical conductivity were, respectively, 41% and 571% higher for PETG in comparison to PP. Upon coating, the surface energy of both materials decreased. Additionally, the dynamic mechanical analysis test showed minimal influence of PAni over the dynamic mechanical properties of PETG. The parametric study indicated that only layer thickness and infill pattern had a significant influence on PAni incorporation and electrical conductivity of coated porous samples. Originality/value Current literature reports difficulties in incorporating PAni without affecting dimensional precision and feedstock stability. In situ, oxidative polymerization of Ani could overcome these limitations. However, its use as a functional post-processing of extrusion-based printed parts is a novelty.
本研究旨在评估苯胺（Ani）的原位氧化聚合作为一种后处理方法，可将绝缘聚合物制成的挤压式 3D 打印部件提升为具有导电性和化学敏感性等功能特性的部件。首先，对原料进行了表征。然后使用密集印刷的样品来评估聚苯胺（PAni）的附着力和印刷部件的导电性。最后，选择了用于 PAni 涂层的最佳候选原料进行进一步分析。最后，采用田口方法评估印刷参数对多孔样品涂层的影响。结果色度测量显示，在拉出测试中，PP 样品的颜色发生了显著变化，而 PETG 样品的颜色没有发生变化。与聚丙烯相比，PETG 的 PAni 含量和导电率分别高出 41% 和 571%。涂覆后，两种材料的表面能都有所下降。此外，动态机械分析测试表明，PAni 对 PETG 动态机械性能的影响微乎其微。参数研究表明，只有层厚度和填充模式对 PAni 的掺入和涂层多孔样品的导电性有显著影响。Ani 的原位氧化聚合可以克服这些限制。然而，将其用作挤压印刷部件的功能性后处理工艺则是一项创新。
{"title":"Functional post-processing of extrusion-based 3D printed parts: polyaniline (PAni) as a coating for thermoplastics components","authors":"Arthur de Carvalho Cruzeiro, Leonardo Santana, Danay Manzo Jaime, S. Ramôa, J. L. Alves, Guilherme Mariz de Oliveira Barra","doi":"10.1108/rpj-11-2023-0413","DOIUrl":"https://doi.org/10.1108/rpj-11-2023-0413","url":null,"abstract":"\u0000Purpose\u0000This study aims to evaluate in situ oxidative polymerization of aniline (Ani) as a post-processing method to promote extrusion-based 3D printed parts, made from insulating polymers, to components with functional properties, including electrical conductivity and chemical sensitivity.\u0000\u0000\u0000Design/methodology/approach\u0000Extrusion-based 3D printed parts of polyethylene terephthalate modified with glycol (PETG) and polypropylene (PP) were coated in an aqueous acid solution via in situ oxidative polymerization of Ani. First, the feedstocks were characterized. Densely printed samples were then used to assess the adhesion of polyaniline (PAni) and electrical conductivity on printed parts. The best feedstock candidate for PAni coating was selected for further analysis. Last, a Taguchi methodology was used to evaluate the influence of printing parameters on the coating of porous samples. Analysis of variance and Tukey post hoc test were used to identify the best levels for each parameter.\u0000\u0000\u0000Findings\u0000Colorimetry measurements showed significant color shifts in PP samples and no shifts in PETG samples upon pullout testing. The incorporation of PAni content and electrical conductivity were, respectively, 41% and 571% higher for PETG in comparison to PP. Upon coating, the surface energy of both materials decreased. Additionally, the dynamic mechanical analysis test showed minimal influence of PAni over the dynamic mechanical properties of PETG. The parametric study indicated that only layer thickness and infill pattern had a significant influence on PAni incorporation and electrical conductivity of coated porous samples.\u0000\u0000\u0000Originality/value\u0000Current literature reports difficulties in incorporating PAni without affecting dimensional precision and feedstock stability. In situ, oxidative polymerization of Ani could overcome these limitations. However, its use as a functional post-processing of extrusion-based printed parts is a novelty.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141808855","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-22DOI: 10.1108/rpj-01-2024-0025
Alessandro Bove, Fulvio Lieske, F. Calignano, Luca Iuliano
Purpose Material extrusion (MEX) is one of the most known techniques in the additive manufacturing (AM) sector to produce components with a wide range of polymeric and composite materials. Moisture causes alterations in material properties and for filaments strongly hygroscopic like nylon-based composites this means greater ease of deterioration. Drying the filament to reduce the moisture content may not be sufficient if the humidity is not controlled during printing. The purpose of this study is to achieve the recovery of a commercial nylon-based composite filament by applying process optimization using an open source MEX machine. Design/methodology/approach A statistical approach based on Taguchi’s method allowed to achieve an ultimate tensile strength (UTS). A verification of the geometrical capabilities of the process has been performed according to the standard ISO/ASTM 52902-2019. Chemical tests were also carried out to test the resistance to corrosion in acid and basic solutions. Findings An UTS of 71.37 MPa was obtained, significantly higher than the value declared by the filament’s manufacturer (Stratasys Inc., USA). The best configuration of process parameters leads to good geometrical deviations for flat surfaces, in a range of 0.01 and 0.38 for flatness, while cylindrical faces showed more important deviations from the nominal values. The good applicability of the material in corrosive environments has been confirmed. Originality/value This study examined the performance restoration potential of a nylon composite filament that was significantly affected by storage conditions. For the filament manufacturer, if the material remains in ambient air for an hour or idle in the machine for more than 24 h, the material may no longer be suitable for printing. The study highlighted that the drying of the filament must not be temporary but constant to guarantee printability, and, by acting on the process parameters, it is possible to obtain better mechanical properties than declared by the manufacturer.
{"title":"Restoration of a wet corrosion-resistant composite filament for material extrusion process","authors":"Alessandro Bove, Fulvio Lieske, F. Calignano, Luca Iuliano","doi":"10.1108/rpj-01-2024-0025","DOIUrl":"https://doi.org/10.1108/rpj-01-2024-0025","url":null,"abstract":"Purpose\u0000Material extrusion (MEX) is one of the most known techniques in the additive manufacturing (AM) sector to produce components with a wide range of polymeric and composite materials. Moisture causes alterations in material properties and for filaments strongly hygroscopic like nylon-based composites this means greater ease of deterioration. Drying the filament to reduce the moisture content may not be sufficient if the humidity is not controlled during printing. The purpose of this study is to achieve the recovery of a commercial nylon-based composite filament by applying process optimization using an open source MEX machine.\u0000\u0000Design/methodology/approach\u0000A statistical approach based on Taguchi’s method allowed to achieve an ultimate tensile strength (UTS). A verification of the geometrical capabilities of the process has been performed according to the standard ISO/ASTM 52902-2019. Chemical tests were also carried out to test the resistance to corrosion in acid and basic solutions.\u0000\u0000Findings\u0000An UTS of 71.37 MPa was obtained, significantly higher than the value declared by the filament’s manufacturer (Stratasys Inc., USA). The best configuration of process parameters leads to good geometrical deviations for flat surfaces, in a range of 0.01 and 0.38 for flatness, while cylindrical faces showed more important deviations from the nominal values. The good applicability of the material in corrosive environments has been confirmed.\u0000\u0000Originality/value\u0000This study examined the performance restoration potential of a nylon composite filament that was significantly affected by storage conditions. For the filament manufacturer, if the material remains in ambient air for an hour or idle in the machine for more than 24 h, the material may no longer be suitable for printing. The study highlighted that the drying of the filament must not be temporary but constant to guarantee printability, and, by acting on the process parameters, it is possible to obtain better mechanical properties than declared by the manufacturer.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141815147","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-19DOI: 10.1108/rpj-02-2024-0090
Fatih Huzeyfe Öztürk
Purpose Adhesive bonding is critical to the effectiveness and structural integrity of 3D printed components. The purpose of this study is to investigate the effect of joint configuration on failure loads to improve the design and performance of single lap joints (SLJs) in 3D printed parts. Design/methodology/approach In this study, adherends were fabricated using material extrusion 3D printing technology with polyethylene terephthalate glycol (PETG). A toughened methacrylate adhesive was chosen to bond the SLJs after adherend printing. In this study, response surface methodology (RSM) was used to examine the effect of the independent variables of failure load, manufacturing time and mass on the dependent variable of joint configuration; adherend thickness (3.2, 4.0, 4.8, 5.6, 6.4, and 7.2 mm) and overlap lengths (12.7, 25.4, 38.1, and 50.8 mm) of 3D printed PETG SLJs. Findings The strength of the joints improved significantly with the increase in overlap length and adherend thickness, although the relationship was not linear. The maximum failure load occurred with a thickness of 7.2 mm and an overlap of 50.8 mm, whilst the minimum failure load was determined with a thickness of 3.2 mm and an overlap of 12.7 mm. The RSM findings show that the optimum failure load was achieved with an adherend thickness of 3.6 mm and an overlap length of 37.9 mm for SLJ. Originality/value This study provides insight into the optimum failure load for 3D printed SLJs, reducing SLJ production time and mass, producing lightweight structures due to the nature of 3D printing, and increasing the use of these parts in load-bearing applications.
{"title":"Optimization of adherend thickness and overlap length on failure load of bonded 3D printed PETG parts using response surface method","authors":"Fatih Huzeyfe Öztürk","doi":"10.1108/rpj-02-2024-0090","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0090","url":null,"abstract":"\u0000Purpose\u0000Adhesive bonding is critical to the effectiveness and structural integrity of 3D printed components. The purpose of this study is to investigate the effect of joint configuration on failure loads to improve the design and performance of single lap joints (SLJs) in 3D printed parts.\u0000\u0000\u0000Design/methodology/approach\u0000In this study, adherends were fabricated using material extrusion 3D printing technology with polyethylene terephthalate glycol (PETG). A toughened methacrylate adhesive was chosen to bond the SLJs after adherend printing. In this study, response surface methodology (RSM) was used to examine the effect of the independent variables of failure load, manufacturing time and mass on the dependent variable of joint configuration; adherend thickness (3.2, 4.0, 4.8, 5.6, 6.4, and 7.2 mm) and overlap lengths (12.7, 25.4, 38.1, and 50.8 mm) of 3D printed PETG SLJs.\u0000\u0000\u0000Findings\u0000The strength of the joints improved significantly with the increase in overlap length and adherend thickness, although the relationship was not linear. The maximum failure load occurred with a thickness of 7.2 mm and an overlap of 50.8 mm, whilst the minimum failure load was determined with a thickness of 3.2 mm and an overlap of 12.7 mm. The RSM findings show that the optimum failure load was achieved with an adherend thickness of 3.6 mm and an overlap length of 37.9 mm for SLJ.\u0000\u0000\u0000Originality/value\u0000This study provides insight into the optimum failure load for 3D printed SLJs, reducing SLJ production time and mass, producing lightweight structures due to the nature of 3D printing, and increasing the use of these parts in load-bearing applications.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141821421","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-19DOI: 10.1108/rpj-01-2024-0038
Alejandro Garcia Rodriguez, Marco Antonio Velasco Peña, Carlos A. Narváez-Tovar, Edgar Espejo Mora
Purpose This paper aims to investigate and explain the dual fracture behaviour of PA12 specimens sintered by selective laser sintering (SLS) as a function of wall thickness and build direction with a powder mixture 30:70. To achieve this objective, research related to chemical, thermal and structural behaviours as a function of the input variables was carried out to describe and explain why ductile-fragile behaviour occurs during fractures under uniaxial tension manufactured via a methodology of material analysis and manufacturing processes. Design/methodology/approach The factorial design 32 relates the fracture of PA12 tensile specimens to the horizontal, transverse and vertical build directions at 2.0, 2.5 and 3.0 mm thicknesses, respectively. Fractographic images revealed the fracture surfaces and their dual ductile-fragile behaviour related to the specimens’ measured crystalline, thermal, surface and chemical properties. Findings The study showed that thermal property variables differ depending on the input variables. The wall thickness variable affected this morphology the most, showing the highest percentage of the ductile area, followed by the transverse and vertical directions. It was determined that the failure in the vertical direction is due to crystalline gradients associated with the layer-by-layer construction process. The pore density may be closely related to generating ductile and brittle areas. Originality/value In this paper, fracture characterisation is performed based on the mechanical, chemical, structural, thermal and morphological properties of PA12 manufactured by SLS. In addition, a heatmap of porosities in cross-sections is constructed using a machine learning model (k-means) related to dual fracture behaviour. This research revealed significant differences in the fracture type according to the build direction. In addition, thin-section fractography provides a more detailed explanation of the fragile behaviour of the vertical direction associated with crystalline changes due to the direction of the sintering layers.
{"title":"Experimental analysis of failure behaviour of PA12 specimens manufactured by SLS as a function of wall thickness and build direction","authors":"Alejandro Garcia Rodriguez, Marco Antonio Velasco Peña, Carlos A. Narváez-Tovar, Edgar Espejo Mora","doi":"10.1108/rpj-01-2024-0038","DOIUrl":"https://doi.org/10.1108/rpj-01-2024-0038","url":null,"abstract":"Purpose\u0000This paper aims to investigate and explain the dual fracture behaviour of PA12 specimens sintered by selective laser sintering (SLS) as a function of wall thickness and build direction with a powder mixture 30:70. To achieve this objective, research related to chemical, thermal and structural behaviours as a function of the input variables was carried out to describe and explain why ductile-fragile behaviour occurs during fractures under uniaxial tension manufactured via a methodology of material analysis and manufacturing processes.\u0000\u0000Design/methodology/approach\u0000The factorial design 32 relates the fracture of PA12 tensile specimens to the horizontal, transverse and vertical build directions at 2.0, 2.5 and 3.0 mm thicknesses, respectively. Fractographic images revealed the fracture surfaces and their dual ductile-fragile behaviour related to the specimens’ measured crystalline, thermal, surface and chemical properties.\u0000\u0000Findings\u0000The study showed that thermal property variables differ depending on the input variables. The wall thickness variable affected this morphology the most, showing the highest percentage of the ductile area, followed by the transverse and vertical directions. It was determined that the failure in the vertical direction is due to crystalline gradients associated with the layer-by-layer construction process. The pore density may be closely related to generating ductile and brittle areas.\u0000\u0000Originality/value\u0000In this paper, fracture characterisation is performed based on the mechanical, chemical, structural, thermal and morphological properties of PA12 manufactured by SLS. In addition, a heatmap of porosities in cross-sections is constructed using a machine learning model (k-means) related to dual fracture behaviour. This research revealed significant differences in the fracture type according to the build direction. In addition, thin-section fractography provides a more detailed explanation of the fragile behaviour of the vertical direction associated with crystalline changes due to the direction of the sintering layers.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141823810","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-18DOI: 10.1108/rpj-02-2024-0087
Vishal Mishra, Jitendra Kumar, S. Negi, Simanchal Kar
Purpose The current study aims to develop a 3D-printed continuous metal fiber-reinforced recycled thermoplastic composite using an in-nozzle impregnation technique. Design/methodology/approach Recycled acrylonitrile butadiene styrene (RABS) plastic was blended with virgin ABS (VABS) plastic in a ratio of 60:40 weight proportion to develop a 3D printing filament that was used as a matrix material, while post-used continuous brass wire (CBW) was used as a reinforcement. 3D printing was done by using a self-customized print head to fabricate the flexural, compression and interlaminar shear stress (ILSS) test samples to evaluate the bending, compressive and ILSS properties of the build samples and compared with VABS and RABS-B samples. Moreover, the physical properties of the samples were also analyzed. Findings Upon three-point bend, compression and ILSS testing, it was found that RABS-B/CBW composite 3D printed with 0.7 mm layer width exhibited a notable improvement in maximum flexural load (Lmax), flexural stress at maximum load (sfmax), flex modulus (Ef) and work of fracture (WOF), compression modulus (Ec) and ILSS properties by 30.5%, 49.6%, 88.4% 13.8, 21.6% and 30.3% respectively. Originality/value Limited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.
设计/方法/途径将回收的丙烯腈-丁二烯-苯乙烯（RABS）塑料与原生 ABS（VABS）塑料按 60:40 的重量比例混合，开发出一种 3D 打印长丝，用作基体材料，而使用后的连续黄铜丝（CBW）则用作增强材料。使用自定制的打印头进行三维打印，制造出弯曲、压缩和层间剪切应力（ILSS）测试样品，以评估构建样品的弯曲、压缩和 ILSS 性能，并与 VABS 和 RABS-B 样品进行比较。结果在三点弯曲、压缩和 ILSS 测试中发现，层宽为 0.7 mm 的 RABS-B/CBW 复合材料 3D 打印件在最大弯曲载荷 (Lmax)、最大载荷下的弯曲应力 (sfmax)、弯曲模量 (Ef) 和断裂功 (WOF)、压缩模量 (Ec) 和 ILSS 性能方面都有明显改善，分别提高了 30.5% 、49.6%、88.6%。原创性/价值关于喷嘴内浸渍技术用于 3D 打印金属纤维增强再生热塑性复合材料的研究还很有限。采用这种方法有可能制造出适用于工程应用的耐用高强度可持续复合材料，从而减少对原始材料的依赖。
{"title":"3D printing of continuous metal fiber-reinforced recycled ABS with varying fiber loading","authors":"Vishal Mishra, Jitendra Kumar, S. Negi, Simanchal Kar","doi":"10.1108/rpj-02-2024-0087","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0087","url":null,"abstract":"\u0000Purpose\u0000The current study aims to develop a 3D-printed continuous metal fiber-reinforced recycled thermoplastic composite using an in-nozzle impregnation technique.\u0000\u0000\u0000Design/methodology/approach\u0000Recycled acrylonitrile butadiene styrene (RABS) plastic was blended with virgin ABS (VABS) plastic in a ratio of 60:40 weight proportion to develop a 3D printing filament that was used as a matrix material, while post-used continuous brass wire (CBW) was used as a reinforcement. 3D printing was done by using a self-customized print head to fabricate the flexural, compression and interlaminar shear stress (ILSS) test samples to evaluate the bending, compressive and ILSS properties of the build samples and compared with VABS and RABS-B samples. Moreover, the physical properties of the samples were also analyzed.\u0000\u0000\u0000Findings\u0000Upon three-point bend, compression and ILSS testing, it was found that RABS-B/CBW composite 3D printed with 0.7 mm layer width exhibited a notable improvement in maximum flexural load (Lmax), flexural stress at maximum load (sfmax), flex modulus (Ef) and work of fracture (WOF), compression modulus (Ec) and ILSS properties by 30.5%, 49.6%, 88.4% 13.8, 21.6% and 30.3% respectively.\u0000\u0000\u0000Originality/value\u0000Limited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141827449","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-12DOI: 10.1108/rpj-10-2023-0378
Osama Habbal, Ahmad Farhat, Reem Khalil, Christopher Pannier
Purpose The purpose of this study is to assess a novel method for creating tangible three-dimensional (3D) morphologies (scaled models) of neuronal reconstructions and to evaluate its cost-effectiveness, accessibility and applicability through a classroom survey. The study addresses the challenge of accurately representing intricate and diverse dendritic structures of neurons in scaled models for educational purposes. Design/methodology/approach The method involves converting neuronal reconstructions from the NeuromorphoVis repository into 3D-printable mold files. An operator prints these molds using a consumer-grade desktop 3D printer with water-soluble polyvinyl alcohol filament. The molds are then filled with casting materials like polyurethane or silicone rubber, before the mold is dissolved. We tested our method on various neuron morphologies, assessing the method’s effectiveness, labor, processing times and costs. Additionally, university biology students compared our 3D-printed neuron models with commercially produced counterparts through a survey, evaluating them based on their direct experience with both models. Findings An operator can produce a neuron morphology’s initial 3D replica in about an hour of labor, excluding a one- to three-day curing period, while subsequent copies require around 30 min each. Our method provides an affordable approach to crafting tangible 3D neuron representations, presenting a viable alternative to direct 3D printing with varied material options ensuring both flexibility and durability. The created models accurately replicate the fidelity and intricacy of original computer aided design (CAD) files, making them ideal for tactile use in neuroscience education. Originality/value The development of data processing and cost-effective casting method for this application is novel. Compared to a previous study, this method leverages lower-cost fused filament fabrication 3D printing to create accurate physical 3D representations of neurons. By using readily available materials and a consumer-grade 3D printer, the research addresses the high cost associated with alternative direct 3D printing techniques to produce such intricate and robust models. Furthermore, the paper demonstrates the practicality of these 3D neuron models for educational purposes, making a valuable contribution to the field of neuroscience education.
{"title":"Application of fused filament fabrication 3D printing and molding to produce flexible, scaled neuron morphology models","authors":"Osama Habbal, Ahmad Farhat, Reem Khalil, Christopher Pannier","doi":"10.1108/rpj-10-2023-0378","DOIUrl":"https://doi.org/10.1108/rpj-10-2023-0378","url":null,"abstract":"\u0000Purpose\u0000The purpose of this study is to assess a novel method for creating tangible three-dimensional (3D) morphologies (scaled models) of neuronal reconstructions and to evaluate its cost-effectiveness, accessibility and applicability through a classroom survey. The study addresses the challenge of accurately representing intricate and diverse dendritic structures of neurons in scaled models for educational purposes.\u0000\u0000\u0000Design/methodology/approach\u0000The method involves converting neuronal reconstructions from the NeuromorphoVis repository into 3D-printable mold files. An operator prints these molds using a consumer-grade desktop 3D printer with water-soluble polyvinyl alcohol filament. The molds are then filled with casting materials like polyurethane or silicone rubber, before the mold is dissolved. We tested our method on various neuron morphologies, assessing the method’s effectiveness, labor, processing times and costs. Additionally, university biology students compared our 3D-printed neuron models with commercially produced counterparts through a survey, evaluating them based on their direct experience with both models.\u0000\u0000\u0000Findings\u0000An operator can produce a neuron morphology’s initial 3D replica in about an hour of labor, excluding a one- to three-day curing period, while subsequent copies require around 30 min each. Our method provides an affordable approach to crafting tangible 3D neuron representations, presenting a viable alternative to direct 3D printing with varied material options ensuring both flexibility and durability. The created models accurately replicate the fidelity and intricacy of original computer aided design (CAD) files, making them ideal for tactile use in neuroscience education.\u0000\u0000\u0000Originality/value\u0000The development of data processing and cost-effective casting method for this application is novel. Compared to a previous study, this method leverages lower-cost fused filament fabrication 3D printing to create accurate physical 3D representations of neurons. By using readily available materials and a consumer-grade 3D printer, the research addresses the high cost associated with alternative direct 3D printing techniques to produce such intricate and robust models. Furthermore, the paper demonstrates the practicality of these 3D neuron models for educational purposes, making a valuable contribution to the field of neuroscience education.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141834271","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-07-10DOI: 10.1108/rpj-02-2024-0073
F. Endress, Julius Tiesler, Markus Zimmermann
Purpose Metal laser-powder-bed-fusion using laser-beam parts are particularly susceptible to contamination due to particles attached to the surface. This may compromise so-called technical cleanliness (e.g. in NASA RPTSTD-8070, ASTM G93, ISO 14952 or ISO 16232), which is important for many 3D-printed components, such as implants or liquid rocket engines. The purpose of the presented comparative study is to show how cleanliness is improved by design and different surface treatment methods. Design/methodology/approach Convex and concave test parts were designed, built and surface-treated by combinations of media blasting, electroless nickel plating and electrochemical polishing. After cleaning and analysing the technical cleanliness according to ASTM and ISO standards, effects on particle contamination, appearance, mass and dimensional accuracy are presented. Findings Contamination reduction factors are introduced for different particle sizes and surface treatment methods. Surface treatments were more effective for concave design features, however, the initial and resulting absolute particle contamination was higher. Results further indicate that there are trade-offs between cleanliness and other objectives in design. Design guidelines are introduced to solve conflicts in design when requirements for cleanliness exist. Originality/value This paper recommends designing parts and corresponding process chains for manufacturing simultaneously. Incorporating post-processing characteristics into the design phase is both feasible and essential. In the experimental study, electroless nickel plating in combination with prior glass bead blasting resulted in the lowest total remaining particle contamination. This process applied for cleanliness is a novelty, as well as a comparison between the different surface treatment methods.
目的 使用激光束的金属激光粉末床熔融部件特别容易受到表面附着颗粒的污染。这可能会影响所谓的技术洁净度（例如 NASA RPTSTD-8070、ASTM G93、ISO 14952 或 ISO 16232 中的技术洁净度），而技术洁净度对于许多 3D 打印部件（例如植入物或液体火箭发动机）非常重要。本比较研究的目的是展示如何通过设计和不同的表面处理方法来提高清洁度。设计/方法/途径设计、制造凸面和凹面测试零件，并通过介质喷射、无电解镀镍和电化学抛光组合进行表面处理。根据 ASTM 和 ISO 标准对技术清洁度进行清洁和分析后，介绍了对颗粒污染、外观、质量和尺寸精度的影响。表面处理对凹形设计特征更有效，但初始和由此产生的绝对颗粒污染更高。结果进一步表明，清洁度与设计中的其他目标之间存在权衡。本文建议同时设计零件和相应的制造工艺链。将后处理特性纳入设计阶段既可行又必要。在实验研究中，无电解镍电镀与玻璃珠喷砂相结合，可使剩余颗粒污染总量降至最低。这种应用于清洁度的工艺是一种创新，也是对不同表面处理方法的一种比较。
{"title":"Technical cleanliness of additively manufactured Inconel 718: a comparative study of surface treatment methods","authors":"F. Endress, Julius Tiesler, Markus Zimmermann","doi":"10.1108/rpj-02-2024-0073","DOIUrl":"https://doi.org/10.1108/rpj-02-2024-0073","url":null,"abstract":"\u0000Purpose\u0000Metal laser-powder-bed-fusion using laser-beam parts are particularly susceptible to contamination due to particles attached to the surface. This may compromise so-called technical cleanliness (e.g. in NASA RPTSTD-8070, ASTM G93, ISO 14952 or ISO 16232), which is important for many 3D-printed components, such as implants or liquid rocket engines. The purpose of the presented comparative study is to show how cleanliness is improved by design and different surface treatment methods.\u0000\u0000\u0000Design/methodology/approach\u0000Convex and concave test parts were designed, built and surface-treated by combinations of media blasting, electroless nickel plating and electrochemical polishing. After cleaning and analysing the technical cleanliness according to ASTM and ISO standards, effects on particle contamination, appearance, mass and dimensional accuracy are presented.\u0000\u0000\u0000Findings\u0000Contamination reduction factors are introduced for different particle sizes and surface treatment methods. Surface treatments were more effective for concave design features, however, the initial and resulting absolute particle contamination was higher. Results further indicate that there are trade-offs between cleanliness and other objectives in design. Design guidelines are introduced to solve conflicts in design when requirements for cleanliness exist.\u0000\u0000\u0000Originality/value\u0000This paper recommends designing parts and corresponding process chains for manufacturing simultaneously. Incorporating post-processing characteristics into the design phase is both feasible and essential. In the experimental study, electroless nickel plating in combination with prior glass bead blasting resulted in the lowest total remaining particle contamination. This process applied for cleanliness is a novelty, as well as a comparison between the different surface treatment methods.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.4,"publicationDate":"2024-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141835322","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-06-13DOI: 10.1108/rpj-12-2023-0427
Chen Yu, Wei Tian
Purpose This paper aims to investigate the application of 3D printing technology, particularly using sand-type materials, in the creation of artificial rock models for rock mechanics experimentation. Design/methodology/approach Using a comprehensive analysis, this research explores the utilization of 3D printing technology in rock mechanics. Sand-type materials are specifically investigated for their ability to replicate natural rock characteristics. The methodology involves a review of recent achievements and experimentation in this field. Findings The study reveals that sand-type 3D printing materials demonstrate comparable properties to natural rocks, including brittle characteristics, surface roughness, microstructural features and crack propagation patterns. Research limitations/implications While the research establishes the viability of sand-type 3D printing materials, it acknowledges limitations such as the need for further exploration and validation. Generalizability may be constrained, warranting additional research to address these limitations. Originality/value This research contributes insights into the potential application of sand-type 3D printing materials in indoor rock physics experiments. The findings may guide future endeavors in fabricating rock specimens with consistent structures for practical rock mechanics applications.
{"title":"Application and prospective of sand-type 3D printing material in rock mechanics: a review","authors":"Chen Yu, Wei Tian","doi":"10.1108/rpj-12-2023-0427","DOIUrl":"https://doi.org/10.1108/rpj-12-2023-0427","url":null,"abstract":"\u0000Purpose\u0000This paper aims to investigate the application of 3D printing technology, particularly using sand-type materials, in the creation of artificial rock models for rock mechanics experimentation.\u0000\u0000\u0000Design/methodology/approach\u0000Using a comprehensive analysis, this research explores the utilization of 3D printing technology in rock mechanics. Sand-type materials are specifically investigated for their ability to replicate natural rock characteristics. The methodology involves a review of recent achievements and experimentation in this field.\u0000\u0000\u0000Findings\u0000The study reveals that sand-type 3D printing materials demonstrate comparable properties to natural rocks, including brittle characteristics, surface roughness, microstructural features and crack propagation patterns.\u0000\u0000\u0000Research limitations/implications\u0000While the research establishes the viability of sand-type 3D printing materials, it acknowledges limitations such as the need for further exploration and validation. Generalizability may be constrained, warranting additional research to address these limitations.\u0000\u0000\u0000Originality/value\u0000This research contributes insights into the potential application of sand-type 3D printing materials in indoor rock physics experiments. The findings may guide future endeavors in fabricating rock specimens with consistent structures for practical rock mechanics applications.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":null,"pages":null},"PeriodicalIF":3.9,"publicationDate":"2024-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141345534","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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