Journal articles on the topic 'Additive manufacturing (FDM)'
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1
Beniak, Juraj, Peter Krizan, and Milos Matus. "CONDUCTIVE MATERIAL PROPERTIES FOR FDM ADDITIVE MANUFACTURING." MM Science Journal 2020, no. 1 (March 4, 2020): 3846–51. http://dx.doi.org/10.17973/mmsj.2020_03_2019135.
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Di Angelo, L., P. Di Stefano, and A. Marzola. "Surface quality prediction in FDM additive manufacturing." International Journal of Advanced Manufacturing Technology 93, no. 9-12 (July 24, 2017): 3655–62. http://dx.doi.org/10.1007/s00170-017-0763-6.
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Ch, Manoj,. "A REVIEW ON ADDITIVE MANUFACTURING (AM) MATERIAL - STATISTICS AND COMPARISIONS." INTERANTIONAL JOURNAL OF SCIENTIFIC RESEARCH IN ENGINEERING AND MANAGEMENT 08, no. 05 (May 5, 2024): 1–5. http://dx.doi.org/10.55041/ijsrem32619.
Abstract:
Fused deposition modeling, also known as FDM, boasts a major edge in the manufacturing industry for its remarkable capacity to craft intricate components sans pricey tooling or manual labor. As is the case with any engineering process, selecting the right process parameters plays a critical role in determining the quality of FDM products. Hence, precise calibration of these parameters is essential to elevate the durability and functionality of printed parts. Our study seeks to explore the influence of five crucial FDM parameters, including layer height and shell thickness, on the tensile strength of build parts, with the ultimate goal of optimizing overall product performance. Keywords:Fusion Deposition Modeling (FDM), Shell thickness, precise calibration, durability, functionality of printed parts.
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Siraj, Imran, and Pushpendra S. Bharti. "Assessing quality in extrusion based additive manufacturing technologies." Journal of Information and Optimization Sciences 45, no. 1 (2024): 25–46. http://dx.doi.org/10.47974/jios-1137.
Abstract:
Quality is a magic word that has fascinated the people since the early days of civilization and today, quality is the only mantra to survive. Quality is the only relevant attribute associated with product and processes that makes any technology in-demand. The quality of the parts produced by Additive Manufacturing (AM) Technologies depends on many factors, like print speed, nozzle temperature etc. The aim of this work is the identification of influence factors that affect the performance measures of extrusion based Additive Manufacturing (AM) technologies, namely, Fused Deposition Modelling (FDM). These processes can be characterized by a set of influence factors, like print speed, infill density, temperature; layer thickness and build orientation are responsible for quality of the product. In this work, Grey relational Analysis (GRA) is employed. GRA is a method which enables determination of the relational degree of every factor in the system. The method can be used for systems that are not completely described and with relatively few available data. Reliable technique of optimization GRA is clubbed with another established technique; called Interrelation ship Diagram (ID), to identify and optimize the influence factors, that yields highest performance characteristics. Manufacturing Combinations are evaluated against performance measures. In the earlier research, the authors have applied same tool, GRA clubbed with 7QC tools, to evaluate extrinsic and intrinsic qualities of the parts produced by FDM, In this research, the entire focus is paid to the intrinsic properties of the parts produced by FDM. This research will have a greater impact on the quality of the parts produced by the FDM.
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Skawiński, Piotr, Przemysław Siemiński, and Piotr Błazucki. "Applications of additive manufacturing (FDM method) in the manufacturing of gear." Mechanik, no. 12 (December 2015): 976/173–976/179. http://dx.doi.org/10.17814/mechanik.2015.12.582.
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Boyard, Nicolas, Olivier Christmann, Mickaël Rivette, Olivier Kerbrat, and Simon Richir. "Support optimization for additive manufacturing: application to FDM." Rapid Prototyping Journal 24, no. 1 (January 2, 2018): 69–79. http://dx.doi.org/10.1108/rpj-04-2016-0055.
Abstract:
Purpose This paper aims to present a new methodology to optimize the support generation within the fused deposition modeling process. Design/methodology/approach Different methods of support generation exist, but they are limited with regards to complex parts. This paper proposes a method dedicated to support generation, integrated into CAD software. The objective is to minimize the volume of support and its impact on a part’s surface finish. Two case studies illustrate the methodology. The support generation is based on an octree’s discretization of the part. Findings The method represents a first solid step in the support optimization for a reasonable calculation time. It has the advantage of being virtually automatic. The only tasks to be performed by the designer are to place the part to be studied with respect to the CAD reference and to give the ratio between the desired support volume and the maximum volume of support. Research limitations/implications In the case studies, a low gain in manufacturing time was observed. This is explained by the honeycomb structure of the support generated by a common slicing software, whereas the proposed method uses a “full” structure. It would be interesting to study the feasibility of an optimized support, with a honeycomb structure but with a preservation of the surface which is in contact with the part. Originality/value This solution best fits the needs of the designer and manufacturer already taking advantage of existing solutions. It is adaptable to any part if the withdrawal of support is taken into account. It also allows the designer to validate the generation of support throughout the CAD without breaking the digital chain.
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Cuan-Urquizo, Enrique, Mario Martínez-Magallanes, Saúl E. Crespo-Sánchez, Alfonso Gómez-Espinosa, Oscar Olvera-Silva, and Armando Roman-Flores. "Additive manufacturing and mechanical properties of lattice-curved structures." Rapid Prototyping Journal 25, no. 5 (June 10, 2019): 895–903. http://dx.doi.org/10.1108/rpj-11-2018-0286.
Abstract:
Purpose The purpose of this paper is to study the feasibility of the fabrication of circle arc curved-layered structures via conventional fused deposition modeling (FDM) with three-axis machines and to identify the main structural parameters that have an influence on their mechanical properties. Design/methodology/approach Customized G-codes were generated via a script developed in MATLAB. The G-codes contain nozzle trajectories with displacements in the three axes simultaneously. Using these, the samples were fabricated with different porosities, and their influence on the mechanical responses evaluated via tensile testing. The load-displacement curves were analyzed to understand the structure-property relationship. Findings Circled arc curved-layered structures were successfully fabricated with conventional three-axis FDM machines. The response of these curved lattice structures under tensile loads was mapped to three main stages and deformation mechanisms, namely, straightening, stretching and fracture. The micro-structure formed by the transverse filaments affect the first stage significantly and the other two minimally. The main parameters that affect the structural response were found to be the transverse filaments, as these could behave as hinges, allowing the slide/rotation of adjacent layers and making the structure more shear sensitive. Research limitations/implications This paper was restricted to arc-curved samples fabricated with conventional three-axis FDM machines. Originality/value The FDM fabrication of curved-structures with controlled porosity and their relation to the resulting mechanical properties is presented here for the first time. The study of curved-lattice structures is of great relevance in various areas, such as biomedical, architecture and aerospace.
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Parandoush, Pedram, Palamandadige Fernando, Hao Zhang, Chang Ye, Junfeng Xiao, Meng Zhang, and Dong Lin. "A finishing process via ultrasonic drilling for additively manufactured carbon fiber composites." Rapid Prototyping Journal 27, no. 4 (May 5, 2021): 754–68. http://dx.doi.org/10.1108/rpj-10-2019-0260.
Abstract:
Purpose Additively manufactured objects have layered structures, which means post processing is often required to achieve a desired surface finish. Furthermore, the additive nature of the process makes it less accurate than subtractive processes. Hence, additive manufacturing techniques could tremendously benefit from finishing processes to improve their geometric tolerance and surface finish. Design/methodology/approach Rotary ultrasonic machining (RUM) was chosen as a finishing operation for drilling additively manufactured carbon fiber reinforced polymer (CFRP) composites. Two distinct additive manufacturing methods of fused deposition modeling (FDM) and laser-assisted laminated object manufacturing (LA-LOM) were used to fabricate CFRP plates with continuous carbon fiber reinforcement. The influence of the feedrate, tool rotation speed and ultrasonic power of the RUM process parameters on the aforementioned quality characteristics revealed the feasibility of RUM process as a finishing operation for additive manufactured CFRP. Findings The quality of drilled holes in the CFRP plates fabricated via LA-LOM was supremely superior to the FDM counterparts with less pullout delamination, smoother surface and less burr formation. The strong interfacial bonding in LA-LOM proven to be superior to FDM was able to endure higher cutting force of the RUM process. The cutting force and cutting temperature overwhelmed the FDM parts and induced higher surface damage. Originality/value Overall, the present study demonstrates the feasibility of a hybrid additive and subtractive manufacturing method that could potentially reduce cost and waste of the CFRP production for industrial applications.
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Chen, Jian-Ming, Demei Lee, Jheng-Wei Yang, Sheng-Han Lin, Yu-Ting Lin, and Shih-Jung Liu. "Solution Extrusion Additive Manufacturing of Biodegradable Polycaprolactone." Applied Sciences 10, no. 9 (May 3, 2020): 3189. http://dx.doi.org/10.3390/app10093189.
Abstract:
Polycaprolactone (PCL) is a resorbable semicrystalline polymer that degrades slowly via hydrolysis and has applications in medical implants and drug delivery. As a result of its low melting point, PCL can be processed easily by conventional polymer processing techniques. However, the additive manufacturing of PCL remains a challenge, mainly due to the fact that there are no commercially available filaments for traditional fused deposition modeling (FDM). Furthermore, when the materials are fabricated via FDM for drug delivery applications, the high temperature may deactivate the incorporated drugs/biomolecules. This study investigates the solution extrusion additive manufacturing of PCL using a lab-developed solution-type device. The device comprises a solution extrusion feeder, driving stepper motors, a power source, a syringe equipped with a dispensing tip, an accumulation platform, and a control interface. The influences of different manufacturing parameters on part quality were evaluated. The experimental results suggest that the tensile strength of the additively manufactured parts increases with fill density but decreases with the ratio of PCL to dichloromethane (DCM) and moving speed of the dispensing tip. Parts fabricated by 90° print orientation of infill exhibited the greatest mechanical strength. The fabricated parts tend to heal the gaps among strips after additive manufacturing, but tiny pores can still be seen on the surfaces.
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Hernandez-Contreras, Adriana, Leopoldo Ruiz-Huerta, Alberto Caballero-Ruiz, Verena Moock, and Hector R. Siller. "Extended CT Void Analysis in FDM Additive Manufacturing Components." Materials 13, no. 17 (August 30, 2020): 3831. http://dx.doi.org/10.3390/ma13173831.
Abstract:
Additive manufacturing (AM) is the term for a number of processes for joining materials to build physical components from a digital 3D model. AM has multiple advantages over other construction techniques, such as freeform, customization, and waste reduction. However, AM components have been evaluated by destructive and non-destructive testing and have shown mechanical issues, such as reduced resistance, anisotropy and voids. The build direction affects the mechanical properties of the built part, including voids of different characteristics. The aim of this work is an extended analysis of void shape by means of X-ray computed tomography (CT) applied to fused deposition modeling (FDM) samples. Furthermore, a relation between the tensile mechanical properties and digital void measurements is established. The results of this work demonstrate that void characteristics such as quantity, size, sphericity and compactness show no obvious variations between the samples. However, the angle between the main void axis and the mechanical load axis α shows a relation for FDM components: when its mean value μ(α) is around 80 (degrees) the yield strength and Young’s modulus are reduced. These results lead to the formulation of a novel criterion that predicts the mechanical behavior of AM components.
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Georgopoulou, Antonia, Lukas Egloff, Bram Vanderborght, and Frank Clemens. "A Sensorized Soft Pneumatic Actuator Fabricated with Extrusion-Based Additive Manufacturing." Actuators 10, no. 5 (May 10, 2021): 102. http://dx.doi.org/10.3390/act10050102.
Abstract:
Soft pneumatic actuators with a channel network (pneu-net) based on thermoplastic elastomers are compatible with fused deposition modeling (FDM). However, conventional filament-based fused deposition modeling (FDM) printers are not well suited for thermoplastic elastomers with a shore hardness (Sh < 70A). Therefore, in this study, a pellet-based FDM printer was used to print pneumatic actuators with a shore hardness of Sh18A. Additionally, the method allowed the in situ integration of soft piezoresistive sensing elements during the fabrication. The integrated piezoresistive elements were based on conductive composites made of three different styrene-ethylene-butylene-styrene (SEBS) thermoplastic elastomers, each with a carbon black (CB) filler with a ratio of 1:1. The best sensor behavior was achieved by the SEBS material with a shore hardness of Sh50A. The dynamic and quasi-static sensor behavior were investigated on SEBS strips with integrated piezoresistive sensor composite material, and the results were compared with TPU strips from a previous study. Finally, the piezoresistive composite was used for the FDM printing of soft pneumatic actuators with a shore hardness of 18 A. It is worth mentioning that 3 h were needed for the fabrication of the soft pneumatic actuator with an integrated strain sensing element. In comparison to classical mold casting method, this is faster, since curing post-processing is not required and will help the industrialization of pneumatic actuator-based soft robotics.
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Dama Y. B. "Application of Nonlinear Analysis in Evaluating Additive Manufacturing Process for Engineering Design Features: A Study and Recommendations." Communications on Applied Nonlinear Analysis 31, no. 1s (May 16, 2024): 94–105. http://dx.doi.org/10.52783/cana.v31.559.
Abstract:
In today’s world, Additive Manufacturing (AM) is quickly becoming the dominant manufacturing technology. Massive development has occurred in recent decades, and it is occurring at a much faster rate. It has also progressed from simple prototype to actual end-use items and manufacturing tools. Various manufacturing processes, such as SLS, LENS, FDM, PolyJet, SLA, LTP, DMLS FDM, and binder jet printing, are produced using additive manufacturing techniques. Layer by layer material deposition/addition is a critical component in all these operations, which is why this technology is known as additive manufacturing. Rapid prototyping, 3D printing, digital manufacturing, and other such names are used. Automotive, Aerospace components, medical equipment parts, consumer goods and gadgets, fashion sector, jewelry, and other industries employ additive manufacturing.Currently all designed parts can manufacture using either subtractive or additive manufacturing processes. However, distinct design elements established for production provide additional manufacturing obstacles in metal substation and metal addition manufacturing procedures. As the number of parts made directly utilizing additive manufacturing techniques grows, it is critical to compile a list of the best design for manufacturing principles applicable for various additive manufacturing procedures. This will assist the design community in ensuring that items are developed for additive manufacturing rather than generic strategy and produced.The primary goal of this effort is to evaluate and comprehend the various additive processes and choose the optimal design for manufacturing procedures to be used. As a result, one should be prepared to select a suitable additive manufacturing process for printing based on the design aspects of the component to be produced.
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Behseresht, Saeed, and Young Ho Park. "Additive Manufacturing of Composite Polymers: Thermomechanical FEA and Experimental Study." Materials 17, no. 8 (April 20, 2024): 1912. http://dx.doi.org/10.3390/ma17081912.
Abstract:
This study presents a comprehensive approach for simulating the additive manufacturing process of semi-crystalline composite polymers using Fused Deposition Modeling (FDM). By combining thermomechanical Finite Element Analysis (FEA) with experimental validation, our main objective is to comprehend and model the complex behaviors of 50 wt.% carbon fiber-reinforced Polyphenylene Sulfide (CF PPS) during FDM printing. The simulations of the FDM process encompass various theoretical aspects, including heat transfer, orthotropic thermal properties, thermal dissipation mechanisms, polymer crystallization, anisotropic viscoelasticity, and material shrinkage. We utilize Abaqus user subroutines such as UMATHT for thermal orthotropic constitutive behavior, UEPACTIVATIONVOL for progressive activation of elements, and ORIENT for material orientation. Mechanical behavior is characterized using a Maxwell model for viscoelastic materials, incorporating a dual non-isothermal crystallization kinetics model within the UMAT subroutine. Our approach is validated by comparing nodal temperature distributions obtained from both the Abaqus built-in AM Modeler and our user subroutines, showing close agreement and demonstrating the effectiveness of our simulation methods. Experimental verification further confirms the accuracy of our simulation techniques. The mechanical analysis investigates residual stresses and distortions, with particular emphasis on the critical transverse in-plane stress component. This study offers valuable insights into accurately simulating thermomechanical behaviors in additive manufacturing of composite polymers.
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Wang, Yanen, Ray Tahir Mushtaq, Ammar Ahmed, Ammar Ahmed, Mudassar Rehman, Mudassar Rehman, Aqib Mashood Khan, et al. "Additive manufacturing is sustainable technology: citespace based bibliometric investigations of fused deposition modeling approach." Rapid Prototyping Journal 28, no. 4 (October 25, 2021): 654–75. http://dx.doi.org/10.1108/rpj-05-2021-0112.
Abstract:
Purpose Additive manufacturing (AM) technology has a huge influence on the real world because of its ability to manufacture massively complicated geometrics. The purpose of this study is to use CiteSpace (CS) visual analysis to identify fused deposition modeling (FDM) research and development patterns to guide researchers to decide future research and provide a framework for corporations and organizations to prepare for the development in the rapid prototyping industry. Three-dimensional printing (3DP) is defined to budget minimize manufactured input and output for aviation and the medical product industrial sectors. 3DP has implemented its potential in the Coronavirus Disease of 2019 (COVID-19) reaction. Design/methodology/approach First, 396 original publications were extracted from the web of science (WOS) with the comprehensive list and did scientometrics analysis in CS software. The parameters are specified in CS including the span (from 2011 to 2019, one year slice for the co-authorship and the co-accordance analysis), visualization (show the merged networks), specific criteria for selection (top 20%), node form (author, organization, region, reference cited; cited author, journal and keywords) and pruning (pathfinder and slicing network). Finally, correlating data was studied and showed the results of the visualization study of FDM research were shown. Findings The framework of FDM information is beginning to take shape. About hot research topics, there are “Morphology,” “Tensile Property by making Blends,” “Use of Carbon nanotube in 3DP” and “Topology optimization.” Regarding the latest research frontiers of FDM printing, there are “Fused Filament Fabrication,” “AM,” in FDM printing. Where “Post-processing” and “environmental impact” are the research hotspots in FDM printing. These research results can provide insight into FDM printing and useful information to consider the existing studies and developments in FDM researchers’ analysis. Research limitations/implications Despite some important obtained results through FDM-related publications’ visualization, some deficiencies remain in this research. With >99% of articles written in English, the input data for CS was all downloaded from WOS databases, resulting in a language bias of papers in other languages and neglecting other data sources. Although, there are several challenges being faced by the FDM that limit its wide variety of applications. However, the significance of the current work concerning the technical and engineering prospects is discussed herein. Originality/value First, the novelty of this work lies in describing the FDM approach in a Scientometric way. In Scientometric investigation, leading writers, organizations, keywords, hot research and emerging knowledge points were explained. Second, this research has thoroughly and comprehensively examined the useful sustainability effects, i.e. economic sustainability, energy-based sustainability, environmental sustainability, of 3DP in industrial development in qualitative and quantitative aspects by 2025 from a global viewpoint. Third, this work also described the practical significance of FDM based on 3DP since COVID-19. 3DP has stepped up as a vital technology to support improved healthcare and other general response to emergency situations.
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Ben hadj Hassine, Salem, Sami Chatti, Borhen Louhichi, and Abdennour Seibi. "Experimental Study of the Tensile Behavior of Structures Obtained by FDM 3D Printing Process." Polymers 16, no. 11 (May 31, 2024): 1562. http://dx.doi.org/10.3390/polym16111562.
Abstract:
Fused Deposition Modelling (FDM) is one of the layer-based technologies that fall under the umbrella term “Additive Manufacturing”, where the desired part is created through the successive layer-by-layer addition process with high accuracy using computer-aided design data. Additive manufacturing technology, or as it is commonly known, 3D (three-dimensional) printing, is a rapidly growing sector of manufacturing that is incorporated in automotive, aerospace, biomedical, and many other fields. This work explores the impact of the Additive Manufacturing process on the mechanical proprieties of the fabricated part. To conduct this study, the 3D printed tensile specimens are designed according to the ASTM D638 standards and printed from a digital template file using the FDM 3D printer Raise3D N2. The material chosen for this 3D printing parameter optimization is Polylactic acid (PLA). The FDM process parameters that were studied in this work are the infill pattern, the infill density, and the infill cell orientation. These factors’ effects on the tensile behavior of printed parts were analyzed by the design of experiments method, using the statistical software MINITAB2020.
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Cicala, Gianluca, Alberta Latteri, Barbara Del Curto, Alessio Lo Russo, Giuseppe Recca, and Silvia Farè. "Engineering Thermoplastics for Additive Manufacturing: A Critical Perspective with Experimental Evidence to Support Functional Applications." Journal of Applied Biomaterials & Functional Materials 15, no. 1 (January 26, 2017): 10–18. http://dx.doi.org/10.5301/jabfm.5000343.
Abstract:
Background Among additive manufacturing techniques, the filament-based technique involves what is referred to as fused deposition modeling (FDM). FDM materials are currently limited to a selected number of polymers. The present study focused on investigating the potential of using high-end engineering polymers in FDM. In addition, a critical review of the materials available on the market compared with those studied here was completed. Methods Different engineering thermoplastics, ranging from industrial grade polycarbonates to novel polyetheretherketones (PEEKs), were processed by FDM. Prior to this, for innovative filaments based on PEEK, extrusion processing was carried out. Mechanical properties (i.e., tensile and flexural) were investigated for each extruded material. An industrial-type FDM machine (Stratasys Fortus® 400 mc) was used to fully characterize the effect of printing parameters on the mechanical properties of polycarbonate. The obtained properties were compared with samples obtained by injection molding. Finally, FDM samples made of PEEK were also characterized and compared with those obtained by injection molding. Results The effect of raster to raster air gap and raster angle on tensile and flexural properties of printed PC was evidenced; the potential of PEEK filaments, as novel FDM material, was highlighted in comparison to state of the art materials. Conclusions Comparison with injection molded parts allowed to better understand FDM potential for functional applications. The study discussed pros and cons of the different materials. Finally, the development of novel PEEK filaments achieved important results offering a novel solution to the market when high mechanical and thermal properties are required.
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Alzyod, Hussein, and Peter Ficzere. "Correlation Between Printing Parameters and Residual Stress in Additive Manufacturing: A Numerical Simulation Approach." Production Engineering Archives 29, no. 3 (August 28, 2023): 279–87. http://dx.doi.org/10.30657/pea.2023.29.32.
Abstract:
Abstract Fused Deposition Modeling (FDM) is a widely used 3D printing technology that can create a diverse range of objects. However, achieving the desired mechanical properties of printed parts can be challenging due to various printing parameters. Residual stress is a critical issue in FDM, which can significantly impact the performance of printed parts. In this study, we used Digimat-AM software to conduct numerical simulations and predict residual stress in Acrylonitrile Butadiene Styrene (ABS) material printed using FDM. We varied six printing parameters, including printing temperature, printing speed, and infill percentage, with four values for each parameter. Our results showed that residual stress was positively correlated with printing temperature, printing speed, and infill percentage, and negatively correlated with layer thickness. Bed temperature did not have a significant effect on residual stress. Finally, using a concentric infill pattern produced the lowest residual stress. The methodology used in this study involved conducting numerical simulations with Digimat-AM software, which allowed us to accurately predict residual stress in FDM-printed ABS parts. The simulations were conducted by systematically varying six printing parameters, with four values for each parameter. The resulting data allowed us to identify correlations between residual stress and printing parameters, and to determine the optimal printing conditions for minimizing residual stress. Our findings contribute to the existing literature by providing insight into the relationship between residual stress and printing parameters in FDM. This information is important for designers and manufacturers who wish to optimize their FDM printing processes for improved part performance. Overall, our study highlights the importance of considering residual stress in FDM printing, and provides valuable information for optimizing the printing process to reduce residual stress in ABS parts.
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Patterson, Albert E., Charul Chadha, and Iwona M. Jasiuk. "Identification and Mapping of Manufacturability Constraints for Extrusion-Based Additive Manufacturing." Journal of Manufacturing and Materials Processing 5, no. 2 (April 10, 2021): 33. http://dx.doi.org/10.3390/jmmp5020033.
Abstract:
This article develops and demonstrates a set of design-focused manufacturability constraints for the fused deposition modeling/fused filament fabrication (FDM/FFF) process. These can be mapped from the basic behavior and process characteristics and formulated in terms of implicit or explicit design constraints. When the FDM/FFF process is explored and examined for its natural limitations and behavior, it can provide a set of manufacturing considerations (advantages, limitations, and best practices). These can be converted into manufacturing constraints, which are practical limits on the ability of the process. Finally, these can be formulated in terms of design–useful manufacturability constraints. Many of the constants and parameters must be determined experimentally for specific materials. The final list of 54 major manufacturability constraints presented in this work will better inform designers considering using FDM/FFF as a manufacturing process, and help guide design decisions. After derivation and presentation of the constraint set, extensive discussion about practical implementation is provided at the end of the paper, including advice about experimentally determining constants and appropriate printing parameters. Finally, three case studies are presented which implement the constraints for simple design problems.
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Asadollahi-Yazdi, Elnaz, Julien Gardan, and Pascal Lafon. "Multi-objective optimization approach in design for additive manufacturing for fused deposition modeling." Rapid Prototyping Journal 25, no. 5 (June 10, 2019): 875–87. http://dx.doi.org/10.1108/rpj-07-2018-0186.
Abstract:
Purpose This paper aims to provide a multi-objective optimization problem in design for manufacturing (DFM) approach for fused deposition modeling (FDM). This method considers the manufacturing criteria and constraints during the design by selecting the best manufacturing parameters to guide the designer and manufacturer in fabrication with FDM. Design/methodology/approach Topological optimization and bi-objective optimization problems are suggested to complete the DFM approach for design for additive manufacturing (DFAM) to define a product. Topological optimization allows the shape improvement of the product through a material distribution for weight gain based on the desired mechanical behavior. The bi-objective optimization problem plays an important role to evaluate the manufacturability by quantification and optimization of the manufacturing criteria and constraint simultaneously. Actually, it optimizes the production time, required material regarding surface quality and mechanical properties of the product because of two significant parameters as layer thickness and part orientation. Findings A comprehensive analysis of the existing DFAM approaches illustrates that these approaches are not developed sufficiently in terms of manufacturability evaluation in quantification and optimization levels. There is no approach that investigates the AM criteria and constraints simultaneously. It is necessary to provide a decision-making tool for the designers and manufacturers to lead to better design and manufacturing regarding the different AM characteristics. Practical implications To assess the efficiency of this approach, a wheel spindle is considered as a case study which shows how this method is capable to find the best design and manufacturing solutions. Originality/value A multi-criteria decision-making approach as the main contribution is developed to analyze FDM technology and its attributes, criteria and drawbacks. It completes the DFAM approach for FDM through a bi-objective optimization problem which deals with finding the best manufacturing parameters by optimizing production time and material mass because of the product mechanical properties and surface roughness.
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Rasselet, Damien, Anne-Sophie Caro-Bretelle, Aurélie Taguet, and José-Marie Lopez-Cuesta. "Reactive Compatibilization of PLA/PA11 Blends and Their Application in Additive Manufacturing." Materials 12, no. 3 (February 5, 2019): 485. http://dx.doi.org/10.3390/ma12030485.
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The aim of this work was to study the properties of polylatic acid/polyamide 11 (PLA/PA11) blends compatibilized with a multifunctionalized epoxide, Joncryl®, and to evaluate the performance of such blends processed by Fused Deposition Modeling (FDM) 3D printing, compared to those produced by injection molding method. Blends containing different Joncryl contents from 0.5 to 3 wt% were prepared by twin-screw extrusion. Evaluation of thermal, rheological and mechanical properties of such blends proved that Joncryl acted as a compatibilizer. Results showed that Joncryl effects on blends properties were improved with increasing its content. A significant reduction of PA11 dispersed phases diameter and an improvement of tensile properties with a ductile behavior were achieved for the highest Joncryl contents. A significant elongation of PA11 dispersed phases was observed into FDM filaments and dog bone shaped specimens produced thereafter. Despite this peculiar morphology, FDM printed samples exhibited only enhanced stiffness but poor reinforcement and elongation at break in comparison with injected ones.
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Ding, Huan, Congyuan Zeng, Jonathan Raush, Kasra Momeni, and Shengmin Guo. "Developing Fused Deposition Modeling Additive Manufacturing Processing Strategies for Aluminum Alloy 7075: Sample Preparation and Metallographic Characterization." Materials 15, no. 4 (February 11, 2022): 1340. http://dx.doi.org/10.3390/ma15041340.
Abstract:
Currently, no commercial aluminum 7000 series filaments are available for making aluminum parts using fused deposition modeling (FDM)-based additive manufacturing (AM). The key technical challenge associated with the FDM of aluminum alloy parts is consolidating the loosely packed alloy powders in the brown-body, separated by thin layers of surface oxides and polymer binders, into a dense structure. Classical pressing and sintering-based powder metallurgy (P/M) technologies are employed in this study to assist the development of FDM processing strategies for making strong Al7075 AM parts. Relevant FDM processing strategies, including green-body/brown-body formation and the sintering processes, are examined. The microstructures of the P/M-prepared, FDM-like Al7075 specimens are analyzed and compared with commercially available FDM 17-4 steel specimens. We explored the polymer removal and sintering strategies to minimize the pores of FDM-Al7075-sintered parts. Furthermore, the mechanisms that govern the sintering process are discussed.
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Kim, Eunseob, Yong-Jun Shin, and Sung-Hoon Ahn. "The effects of moisture and temperature on the mechanical properties of additive manufacturing components: fused deposition modeling." Rapid Prototyping Journal 22, no. 6 (October 17, 2016): 887–94. http://dx.doi.org/10.1108/rpj-08-2015-0095.
Abstract:
Purpose This paper aims to investigate the water absorption behaviors and mechanical properties, according to water absorption and temperature, of components fabricated by fused deposition modeling (FDM) and injection molding. The mechanical properties of FDM and injection molded parts were studied under several environmental conditions. Design/methodology/approach FDM components can be used as load-carrying elements under a range of moisture and temperature conditions. FDM parts show anisotropic mechanical properties according to build orientation. Components were fabricated from acrylonitrile-butadiene-styrene in three different orientations. The mechanical properties of parts fabricated by FDM were compared to injection molded components made from the same material. Water absorption tests were conducted in distilled water between 20 and 60°C to identify the maximum water absorption rate. Both moisture and temperature were considered as environmental variables in the tensile tests, which were conducted under various conditions to measure the effects on mechanical properties. Findings The water absorption behavior of FDM components obeyed Fickian diffusion theory, irrespective of the temperature. High temperatures accelerated the diffusion rate, although the maximum water absorption rate was not affected. The tensile strength of FDM parts under dry, room temperature conditions, was approximately 26-56 per cent that of injection molded parts, depending on build orientation. Increased temperature and water absorption had a more significant effect on FDM parts than injection molded components. The tensile strength was decreased by 67-71 per cent in hot, wet environments compared with dry, room temperature conditions. Originality/value The water absorption behavior of FDM components was investigated. The quantitative effects of temperature and moisture on tensile strength, modulus and strain were also measured. These results will contribute to the design of FDM parts for use under various environmental conditions.
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Abouzaid, Khaoula, Sofiane Guessasma, Sofiane Belhabib, David Bassir, and Abdelkrim Chouaf. "Thermal mechanical characterization of copolyester for additive manufacturing using FDM." International Journal for Simulation and Multidisciplinary Design Optimization 10 (2019): A9. http://dx.doi.org/10.1051/smdo/2019011.
Abstract:
The main purpose of this study is to highlight the thermal and mechanical characterization of printed copolyester-based polymer. The variety of benefits of this material, such as its food contact compliance and important mechanical properties, have proved to be effective in huge field of applications, including medical sector and packaging uses. However, it has not received much attention for 3D printing processes. As the printing temperature is a key parameter of fused deposition modeling (FDM) process, the present study is started by analyzing its effect on the mechanical properties of printed copolyester under tensile loading. Indeed, the determination of temperature optimal values to print this material with FDM process is done based on tensile properties, including tensile strength, Young's modulus, ultimate tensile and yield strength, ductility and fracture toughness. The fracture properties of printed copolyester are also discussed using “scanning electron microscopy” (SEM). The results indicate a strong effect of the extrusion temperature on tensile properties. In addition, the analysis of copolyester sample microstructure reveals several damage mechanisms within the printed parts that reflect different types of wires fracture form subjected to the same tensile loading.
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Chaudhari, Madhuri, Bhagwan F. Jogi, and R. S. Pawade. "Comparative Study of Part Characteristics Built Using Additive Manufacturing (FDM)." Procedia Manufacturing 20 (2018): 73–78. http://dx.doi.org/10.1016/j.promfg.2018.02.010.
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Koizumi, Satoru, Takehiro Kawamura, and Tatsuya Mochizuki. "Study on CAM Software for Additive Manufacturing with FDM Method." International Journal of Automation Technology 11, no. 5 (August 30, 2017): 835–43. http://dx.doi.org/10.20965/ijat.2017.p0835.
Abstract:
A prototype hybrid machine was manufactured by combining five-axis laminate-shaping and five-axis cutting, and a CAM was developed for additive manufacturing under simultaneous five-axis control. Using a CAD surface as a shape-model for the laminate-shaping, the reproducibility of a shape in laminate-shaping or cutting was successfully enhanced. Moreover, a combination process of laminate-shaping and cutting was successfully defined by decomposing a shape into multiple parts. The prototype machine and CAM developed were investigated in a case study, and their usability was confirmed.
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Rinaldi, Marianna, Tommaso Ghidini, Federico Cecchini, Ana Brandao, and Francesca Nanni. "Additive layer manufacturing of poly (ether ether ketone) via FDM." Composites Part B: Engineering 145 (July 2018): 162–72. http://dx.doi.org/10.1016/j.compositesb.2018.03.029.
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Paterson, Abby Megan, Richard Bibb, R. Ian Campbell, and Guy Bingham. "Comparing additive manufacturing technologies for customised wrist splints." Rapid Prototyping Journal 21, no. 3 (April 20, 2015): 230–43. http://dx.doi.org/10.1108/rpj-10-2013-0099.
Abstract:
Purpose – The purpose of this paper is to compare four different additive manufacturing (AM) processes to assess their suitability in the context of upper extremity splinting. Design/methodology/approach – This paper describes the design characteristics and subsequent fabrication of six different wrist splints using four different AM processes: laser sintering (LS), fused deposition modelling (FDM), stereolithography (SLA) and polyjet material jetting via Objet Connex. The suitability of each process was then compared against competing designs and processes from traditional splinting. The splints were created using a digital design workflow that combined recognised clinical best practice with design for AM principles. Findings – Research concluded that, based on currently available technology, FDM was considered the least suitable AM process for upper extremity splinting. LS, SLA and material jetting show promise for future applications, but further research and development into AM processes, materials and splint design optimisation is required if the full potential is to be realised. Originality/value – Unlike previous work that has applied AM processes to replicate traditional splint designs, the splints described are based on a digital design for AM workflow, incorporating novel features and physical properties not previously possible in clinical splinting. The benefits of AM for customised splint fabrication have been summarised. A range of AM processes have also been evaluated for splinting, exposing the limitations of existing technology, demonstrating novel and advantageous design features and opportunities for future research.
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Wang, Shushu, Rakshith Badarinath, El-Amine Lehtihet, and Vittaldas Prabhu. "Evaluation of Additive Manufacturing Processes in Fabrication of Personalized Robot." International Journal of Automation Technology 11, no. 1 (January 5, 2017): 29–37. http://dx.doi.org/10.20965/ijat.2017.p0029.
Abstract:
Customer participation in the design stage of creating personalized products is increasing. Additive manufacturing (AM) has become a popular enabler of personalization. In this study, we evaluate the fabrication of an open-source robot arm in terms of cost, build time, dimensional and locational accuracy, end-effector accuracy, and mechanical properties. The mechanical components of the table-top robot were fabricated using two different AM processes of fused deposition modeling (FDM) and material jetting (polymer jetting or PolyJet). A reduction of infill density by 50% in the FDM process slightly decreased the building time, material cost, and tensile strength, but induced a 95% reduction in yield strength. A simulation of the mechanical assembly using the CAD models for the robot and the expected tolerances of the components estimated the end-effector positioning accuracy as 0.01–0.22 mm. The 3D printed robot arm was redesigned and fabricated using the best evaluated process in this study.
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FICĂ, Sorin Alexandru, Andrei DIMITRESCU, and Claudiu BABIȘ. "Additive Manufacturing Through 3D Printing FDM-Fused Deposit Modeling of Top Cover." Annals of “Dunarea de Jos” University of Galati. Fascicle IX, Metallurgy and Materials Science 46, no. 2 (June 15, 2023): 28–32. http://dx.doi.org/10.35219/mms.2023.2.05.
Abstract:
In this work, it is proposed to make by additive manufacturing through 3D printing with FDM technology FDM (Fused Deposition Modeling - Modeling by Depositing Fusible Filament) some landmarks of the washing head which is common to the light water well drilling rigs FA100, FA125, FH150 and FG40.
A washing head like the FA100 washing head, which has the casing and the drilling fluid supply fittings, 3D printed from PETG and ABS+ filament, has never been made in Romania.
The main advantages of using this manufacturing technology are that by purchasing such equipment, a large number of different landmarks can be made and the final price of the landmark.
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Tsao, Che-Chih, Ho-Hsin Chang, Meng-Hao Liu, Ho-Chia Chen, Yun-Tang Hsu, Pei-Ying Lin, Yih-Lin Chou, et al. "Freeform additive manufacturing by vari-directional vari-dimensional material deposition." Rapid Prototyping Journal 24, no. 2 (March 12, 2018): 379–94. http://dx.doi.org/10.1108/rpj-01-2017-0014.
Abstract:
Purpose The purpose of this paper is to propose and demonstrate a new additive manufacturing approach that breaks the layer-based point scanning limitations to increase fabrication speed, obtain better surface finish, achieve material flexibility and reduce equipment costs. Design/methodology/approach The freeform additive manufacturing approach conceptually views a 3D article as an assembly of freeform elements distributed spatially following a flexible 3D assembly structure, which conforms to the surface of the article and physically builds the article by sequentially forming the freeform elements by a vari-directional vari-dimensional capable material deposition mechanism. Vari-directional building along tangential directions of part surface gives surface smoothness. Vari-dimensional deposition maximizes material output to increase build rate wherever allowed and minimizes deposition sizes for resolution whenever needed. Findings Process steps based on geometric and data processing considerations were described. Dispensing and forming of basic vari-directional and vari-dimensional freeform elements and basic operations of joining them were developed using thermoplastics. Forming of 3D articles at build rates of 2-5 times the fused deposition modeling (FDM) rate was demonstrated and improvement over ten times was shown to be feasible. FDM compatible operations using 0.7 mm wire depositions from a variable exit-dispensing unit were demonstrated. Preliminary tests of a surface finishing process showed a result of 0.8-1.9 um Ra. Initial results of dispensing wax, tin alloy and steel were also shown. Originality/value This is the first time that both vari-directional and vari-dimensional material depositions are combined in a new freeform building method, which has potential impact on the FDM and other additive manufacturing methods.
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Martins, Rui F., Ricardo Branco, Filippo Berto, Nuno Soares, and Sebastião Bandeira. "Structural Integrity of Polymeric Components Produced by Additive Manufacturing (AM)—Polymer Applications." Polymers 13, no. 24 (December 16, 2021): 4420. http://dx.doi.org/10.3390/polym13244420.
Abstract:
In the work presented herein, the structural integrity of polymeric functional components made of Nylon-645 and Polylactic acid (PLA) produced by additive manufacturing (Fused Deposition Modelling, FDM) is studied. The PLA component under study was selected from the production line of a brewing company, and it was redesigned and analyzed using the Finite Element Method, 3D printed, and installed under real service. The results obtained indicated that, even though the durability of the 3D printed part was lower than the original, savings of about EUR 7000 a year could be achieved for the component studied. Moreover, it was shown that widespread use of AM with other specific PLA components could result in even more significant savings. Additionally, a metallic hanger (2700 kg/m3) from the cockpit of an airplane ATR 70 series 500 was successfully redesigned and additively manufactured in Nylon 645, resulting in a mass reduction of approximately 60% while maintaining its fit-for-purpose. Therefore, the components produced by FDM were used as fully functional components rather than prototype models, which is frequently stated as a major constraint of the FDM process.
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T., Sathies, Senthil P., and Anoop M.S. "A review on advancements in applications of fused deposition modelling process." Rapid Prototyping Journal 26, no. 4 (January 30, 2020): 669–87. http://dx.doi.org/10.1108/rpj-08-2018-0199.
Abstract:
Purpose Fabrication of customized products in low volume through conventional manufacturing incurs a high cost, longer processing time and huge material waste. Hence, the concept of additive manufacturing (AM) comes into existence and fused deposition modelling (FDM), is at the forefront of researches related to polymer-based additive manufacturing. The purpose of this paper is to summarize the research works carried on the applications of FDM. Design/methodology/approach In the present paper, an extensive review has been performed related to major application areas (such as a sensor, shielding, scaffolding, drug delivery devices, microfluidic devices, rapid tooling, four-dimensional printing, automotive and aerospace, prosthetics and orthosis, fashion and architecture) where FDM has been tested. Finally, a roadmap for future research work in the FDM application has been discussed. As an example for future research scope, a case study on the usage of FDM printed ABS-carbon black composite for solvent sensing is demonstrated. Findings The printability of composite filament through FDM enhanced its application range. Sensors developed using FDM incurs a low cost and produces a result comparable to those conventional techniques. EMI shielding manufactured by FDM is light and non-oxidative. Biodegradable and biocompatible scaffolds of complex shapes are possible to manufacture by FDM. Further, FDM enables the fabrication of on-demand and customized prosthetics and orthosis. Tooling time and cost involved in the manufacturing of low volume customized products are reduced by FDM based rapid tooling technique. Results of the solvent sensing case study indicate that three-dimensional printed conductive polymer composites can sense different solvents. The sensors with a lower thickness (0.6 mm) exhibit better sensitivity. Originality/value This paper outlines the capabilities of FDM and provides information to the user about the different applications possible with FDM.
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Ahmed, Bilal Anjum, Uzair Nadeem, Abbas Saeed Hakeem, Anwar Ul-Hamid, Mohd Yusuf Khan, Muhammad Younas, and Hasan Aftab Saeed. "Printing Parameter Optimization of Additive Manufactured PLA Using Taguchi Design of Experiment." Polymers 15, no. 22 (November 10, 2023): 4370. http://dx.doi.org/10.3390/polym15224370.
Abstract:
Three-dimensional printing (3DP), known as additive layer manufacturing (ALM), is a manufacturing process in which a three-dimensional structure is constructed by successive addition of deposited layers. Fused Deposition Modeling (FDM) has evolved as the most frequently utilized ALM process because of its cost-effectiveness and ease of operation. Nevertheless, layer adhesion, delamination, and quality of the finished product remain issues associated with the FDM process parameters. These issues need to be addressed in order to satisfy the requirements commonly imposed by the conventional manufacturing industry. This work is focused on the optimization of the FDM process and post-process parameters for Polylactic acid (PLA) samples in an effort to maximize their tensile strength. Infill density and pattern type, layer height, and print temperature are the process parameters, while annealing temperature is the post-process parameter considered for the investigation. Analysis based on the Taguchi L18 orthogonal array shows that the gyroid infill pattern and annealing cycle at 90 °C results in a maximum ultimate tensile strength (UTM) of 37.15 MPa. Furthermore, the regression model developed for the five variables under study was able to predict the UTS with an accuracy of more than 96%.
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Borille, Anderson Vicente, Jefferson de Oliveira Gomes, and Daniel Lopes. "Geometrical analysis and tensile behaviour of parts manufactured with flame retardant polymers by additive manufacturing." Rapid Prototyping Journal 23, no. 1 (January 16, 2017): 169–80. http://dx.doi.org/10.1108/rpj-09-2015-0130.
Abstract:
Purpose Flame-retardant plastics are used in critical applications, such as aircraft interior parts, when the occurrence of fire can lead to serious injury to people. However, there is a lack of related publications. The purpose of this study is to present experimental data regarding geometrical analysis, such as dimensional accuracy and surface roughness, tensile strength and elongation of parts manufactured with flame-retardant materials by additive manufacturing. Design/methodology/approach Two additive manufacturing processes, selective laser sintering (SLS) and fused deposition modeling (FDM), were selected to manufacture the parts to be evaluated. Each process used its respective polymer, that is polyamide with flame-retardant additive (PA) for SLS and polyphenylsulfone (PPSF) for FDM. The samples consist of tensile specimens and representative parts of different products. Tensile tests were performed using standard tensile test machines, and geometrical analyses were performed using coordinate measuring machine as well as surface roughness tester. Findings As each material can be, in commercial machines, produced by only one process, the material selection for final products has to consider the manufacturing process as well. In general, although the FDM/PPSF process provided specimens with the highest ultimate strength, because of its strong influence by the building direction, FDM/PPSF also provided the lowest strength. SLS/PA was able to provide average strength with less dependency on the build-up direction. The geometrical analysis showed that SLS/PA presents a much smoother surface, but FDM/PPSF presented slightly better dimensional accuracy. Originality/value There is still lack of publications on polymers with flame resistance or flame-retardant polymers. Thus, this paper brings new technical information about processing such materials.
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Faizaan, Mirza, Satish Shenoy, and Chandrakant R. Kini. "Tensile and Flexural Performance of Hybrid FDM and Compression Moulded PLA/Basalt Biocomposite." Materials Science Forum 1120 (April 18, 2024): 77–84. http://dx.doi.org/10.4028/p-duyo7m.
Abstract:
Emerging trends in extrusion-based additive manufacturing (AM) focus on improving the mechanical performance of pristine polymers with high strength reinforcing materials. Prominent reviews have indicated a heavy dependence on PLA polymer for fused deposition Modeling (FDM) based studies. To promote biodegradability, the effect of natural fibres as reinforcement has been widely researched in the literature. However, it is noted that discontinuous natural fibre reinforcement yields negative or negligible improvement in the strength and modulus of FDM-based biocomposites. Hence, an attempt to hybridise FDM with a conventional composite manufacturing method was made in this study by cladding natural fibre reinforcement over FDM-based polymer. Tensile and flexural test coupons were additively manufactured by FDM and reinforced with a skin of bi-directional woven basalt fibre through compression moulding. A 90% improvement in tensile strength and a similar significant increase in flexural strength was observed. Further, an average increment of 46.38% and 237.24% in tensile and flexural modulus, respectively, was achieved through this manufacturing technique. In conclusion, a drastic improvement in mechanical performance can be obtained through the hybridisation of manufacturing methods and needs further investigation towards the compatibility of adhesive materials with FDM polymers.
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Schmitt, Matt, Raj Mattias Mehta, and Il Yong Kim. "Additive manufacturing infill optimization for automotive 3D-printed ABS components." Rapid Prototyping Journal 26, no. 1 (January 6, 2020): 89–99. http://dx.doi.org/10.1108/rpj-01-2019-0007.
Abstract:
Purpose Lightweighting of components in the automotive industry is a prevailing trend influenced by both consumer demand and government regulations. As the viability of additively manufactured designs continues to increase, traditionally manufactured components are continually being replaced with 3D-printed parts. The purpose of this paper is to present experimental results and design considerations for 3D-printed acrylonitrile butadiene styrene (ABS) components with non-solid infill sections, addressing a large gap in the literature. Information published in this paper will guide engineers when designing fused deposition modeling (FDM) ABS parts with infill regions. Design/methodology/approach Uniaxial tensile tests and three-point bend tests were performed on 12 different build configurations of 20 samples. FDM with ABS was used as the manufacturing method for the samples. Failure strength and elastic modulus were normalized on print time and specimen mass to quantify variance between configurations. Optimal infill configurations were selected and used in two automotive case study examples. Findings Results obtained from the uniaxial tensile tests and three-point bend tests distinctly showed that component strength is highly influenced by the infill choice selected. Normalized results indicate that solid, double dense and triangular infill, all with eight contour layers, are optimal configurations for component regions experiencing high stress, moderate stress and low stress, respectively. Implementation of the optimal infill configurations in automotive examples yielded equivalent failure strength without normalization and significantly improved failure strength on a print time and mass normalized index. Originality/value To the best of the authors’ knowledge, this is the first paper to experimentally determine and quantify optimal infill configurations for FDM ABS printed parts. Published data in this paper are also of value to engineers requiring quantitative material properties for common infill configurations.
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Faludi, Jeremy, Cindy Bayley, Suraj Bhogal, and Myles Iribarne. "Comparing environmental impacts of additive manufacturing vs traditional machining via life-cycle assessment." Rapid Prototyping Journal 21, no. 1 (January 19, 2015): 14–33. http://dx.doi.org/10.1108/rpj-07-2013-0067.
Abstract:
Purpose – The purpose of this study is to compare the environmental impacts of two additive manufacturing machines to a traditional computer numerical control (CNC) milling machine to determine which method is the most sustainable. Design/methodology/approach – A life-cycle assessment (LCA) was performed, comparing a Haas VF0 CNC mill to two methods of additive manufacturing: a Dimension 1200BST FDM and an Objet Connex 350 “inkjet”/“polyjet”. The LCA’s functional unit was the manufacturing of two specific parts in acrylonitrile butadiene styrene (ABS) plastic or similar polymer, as required by the machines. The scope was cradle to grave, including embodied impacts, transportation, energy used during manufacturing, energy used while idling and in standby, material used in final parts, waste material generated, cutting fluid for CNC, and disposal. Several scenarios were considered, all scored using the ReCiPe Endpoint H and IMPACT 2002+ methodologies. Findings – Results showed that the sustainability of additive manufacturing vs CNC machining depends primarily on the per cent utilization of each machine. Higher utilization both reduces idling energy use and amortizes the embodied impacts of each machine. For both three-dimensional (3D) printers, electricity use is always the dominant impact, but for CNC at maximum utilization, material waste became dominant, and cutting fluid was roughly on par with electricity use. At both high and low utilization, the fused deposition modeling (FDM) machine had the lowest ecological impacts per part. The inkjet machine sometimes performed better and sometimes worse than CNC, depending on idle time/energy and on process parameters. Research limitations/implications – The study only compared additive manufacturing in plastic, and did not include other additive manufacturing technologies, such as selective laser sintering or stereolithography. It also does not include post-processing that might bring the surface finish of FDM parts up to the quality of inkjet or CNC parts. Practical implications – Designers and engineers seeking to minimize the environmental impacts of their prototypes should share high-utilization machines, and are advised to use FDM machines over CNC mills or polyjet machines if they provide sufficient quality of surface finish. Originality/value – This is the first paper quantitatively comparing the environmental impacts of additive manufacturing with traditional machining. It also provides a more comprehensive measurement of environmental impacts than most studies of either milling or additive manufacturing alone – it includes not merely CO2 emissions or waste but also acidification, eutrophication, human toxicity, ecotoxicity and other impact categories. Designers, engineers and job shop managers may use the results to guide sourcing or purchasing decisions related to rapid prototyping.
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Gotkhindikar, Nitin, Parshwa Mehta, Shrutika Londhe, Anushka Kulkarni, and Maithili Rekhe. "A Novel FDM Based Additive Manufacturing of PLA Components Using Optimized Deep Learning Strategy." International Journal for Research in Applied Science and Engineering Technology 10, no. 4 (April 30, 2022): 1042–49. http://dx.doi.org/10.22214/ijraset.2022.41436.
Abstract:
Abstract: Fused Deposit modeling (FDM) is an additive manufacturing (AM) process that's frequently used to fabricate geometrically complex shaped prototypes and complex parts. It's gaining market as it reduces cycle time for product development without the need for high priced tools. Still, the commercialization of FDM technology in other artificial operations is presently limited due to several failings, alike as inadequate mechanical properties, poor surface quality, and low dimensional accuracy. The rates of FDM- produced products are affected by other process parameters, for illustration, layer thickness, build angle, raster width, or print speed. The process parameters and their range depends on the section of FDM machines. Filament materials, nozzle dimensions, and the type of machine determine the range of other parameters. The optimum setting of parameters is supposed to ameliorate the rates of three-dimensional (3D) printed specimens and may reducepost-production work. This paper intensely reviews state-of-the- art literature on the influence of parameters on part qualities and the being work on process parameter optimization. Also, the failings of being workshop are linked, challenges and openings to work in this field are estimated, and directions for future research and development in this field are suggested Keywords: Fused deposition modelling; process parameters; part characteristics; optimization
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Chang, Gaoyuan, Xiaoxun Zhang, Fang Ma, Cheng Zhang, and Luyang Xu. "Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing." Materials 16, no. 19 (September 23, 2023): 6372. http://dx.doi.org/10.3390/ma16196372.
Abstract:
Metal FDM technology overcomes the problems of high cost, high energy consumption and high material requirements of traditional metal additive manufacturing by combining FDM and powder metallurgy and realizes the low-cost manufacturing of complex metal parts. In this work, 15-5PH stainless steel granules with a powder content of 90% and suitable for metal FDM were developed. The flowability and formability of the feedstock were investigated and the parts were printed. A two-step (solvent and thermal) debinding process is used to remove the binder from the green part. After being kept at 75 °C in cyclohexane for 24 h, the solvent debinding rate reached 98.7%. Following thermal debinding, the material’s weight decreased by slightly more than 10%. Sintering was conducted at 1300 °C, 1375 °C and 1390 °C in a hydrogen atmosphere. The results show that the shrinkage of the sintered components in the X-Y-Z direction remains quite consistent, with values ranging from 13.26% to 19.58% between 1300 °C and 1390 °C. After sintering at 1390 °C, the material exhibited a relative density of 95.83%, a hardness of 101.63 HRBW and a remarkable tensile strength of 770 MPa. This work realizes the production of metal parts using 15-5PH granules’ extrusion additive manufacturing, providing a method for the low-cost preparation of metal parts. And it provides a useful reference for the debinding and sintering process settings of metal FDM. In addition, it also enriches the selection range of materials for metal FDM.
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Qin, Qin, Jigang Huang, and Jin Yao. "A real-time adaptive look-ahead speed control algorithm for FDM-based additive manufacturing technology with Hbot kinematic system." Rapid Prototyping Journal 25, no. 6 (July 8, 2019): 1095–107. http://dx.doi.org/10.1108/rpj-11-2018-0291.
Abstract:
Purpose The purpose of this paper is to enhance the accuracy as well as efficiency of high-speed machining, avoid the speed fluctuation caused by acceleration/deceleration (ACC/DEC) and increase the smoothness of feedrate in continuous corners or curves machining. The Hbot kinematic system was analyzed and combined with fused deposition modeling-based (FDM) additive manufacturing (AM) technology. Then a real-time adaptive look-ahead speed control algorithm was proposed. Design/methodology/approach To validate the performance of Hbot kinematic system and the proposed speed control algorithm, the positioning accuracy of Hbot and cross structure was compared. Also, the experimental verification was conducted among FDM based 3-D printer with cross structure as well as open source speed control algorithm (FDM with cross-OS), cross structure and the proposed speed control algorithm (FDM with cross-PS) and Hbot structure, as well as the proposed speed control algorithm (FDM with Hbot-PS), respectively. Findings The results indicate that the Hbot kinematic system leads to the high stability of positioning accuracy due to the small motion inertia. Furthermore, the experimental verification shows that the efficiency, printing precision and surface finish of models for FDM with Hbot-PS are obviously higher than that for FDM with cross-PS as well as FDM with cross-OS, while FDM with cross-OS shows the worst performance. The contribution of Hbot kinematic system and the proposed speed control algorithm to FDM based AM technology was validated by this work. Practical implications The Hbot kinematic system and proposed speed control algorithm have the important implication of improving the accuracy of FDM machines, especially in the low-price range segment. Also, this work can help future system developers show a possible way of tackling the motion inertia problem. Originality/value The study of Hbot kinematic system and proposed algorithm are expected to advise the current research for improving the accuracy as well as the efficiency of FDM-based AM technology.
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Stöckli, Fritz, Fabio Modica, and Kristina Shea. "Designing passive dynamic walking robots for additive manufacture." Rapid Prototyping Journal 22, no. 5 (August 15, 2016): 842–47. http://dx.doi.org/10.1108/rpj-11-2015-0170.
Abstract:
Purpose Ongoing research in computational design synthesis of passive dynamic systems aims to automatically generate robotic configurations based on a given task. However, an automated design-to-fabrication process also requires a flexible fabrication method. This paper aims to explore designing and fabricating passive dynamic walking robots and all necessary components using single-material fused deposition modeling (FDM). Being able to fabricate all components of a robot using FDM is a step toward the goal of automated design and fabrication of passive dynamic robots. Design/methodology/approach Two different configurations of passive dynamic walking robots are re-designed to be fabricated using FDM. Different robotic joint assemblies are designed and tested. To arrive at feasible solutions, a modular design approach is chosen and adjustability of components after printing is integrated in the design. Findings The suitability of FDM for printing passive dynamic robots is shown to depend heavily on the sensitivity of the configuration. For one robot configuration, all components are printed in one job and only little assembly is needed after printing. For the second robot configuration, which has a more sensitive gait, a metal bearing is found to increase the performance substantially. Originality/value Printable, monolithic mechatronic systems require multi-material printing, including electronics. In contrast, passive dynamic systems not only have the potential to save energy and component cost compared to actuated systems but can also be fabricated using single-material FDM as demonstrated in this paper.
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Behseresht, Saeed, Allen Love, Omar Alejandro Valdez Pastrana, and Young Ho Park. "Enhancing Fused Deposition Modeling Precision with Serial Communication-Driven Closed-Loop Control and Image Analysis for Fault Diagnosis-Correction." Materials 17, no. 7 (March 22, 2024): 1459. http://dx.doi.org/10.3390/ma17071459.
Abstract:
Additive manufacturing (AM) also commonly known as 3D printing is an advanced technique for manufacturing complex three-dimensional (3D) parts by depositing raw material layer by layer. Various sub-categories of additive manufacturing exist including directed energy deposition (DED), powder bed fusion (PBF), and fused deposition modeling (FDM). FDM has gained widespread adoption as a popular method for manufacturing 3D parts, even for heavy-duty industrial applications. However, challenges remain, particularly regarding part quality. Print parameters such as print speed, nozzle temperature, and flow rate can significantly impact the final product’s quality. To address this, implementing a closed-loop quality control system is essential. This system consistently monitors part surface quality during printing and adjusts print parameters upon defect detection. In this study, we propose a simple yet effective image analysis-based closed-loop control system, utilizing serial communication and Python v3.12, a widely accessible software platform. The system’s accuracy and robustness are evaluated, demonstrating its effectiveness in ensuring FDM-printed part quality. Notably, this control system offers superior speed in restoring part quality to normal upon defect detection and is easily implementable on commercially available FDM 3D printers, fostering decentralized quality manufacturing.
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Wan, Qia, Youjian Xu, and Can Lu. "A fundamental study of parameter adjustable additive manufacturing process based on FDM process." MATEC Web of Conferences 189 (2018): 05001. http://dx.doi.org/10.1051/matecconf/201818905001.
Abstract:
In Fused deposition modeling (FDM) process, there has been a confliction between high productivity and high quality of products. The product resolution is proportional to the flow rate of heated material extrusion, which directly affects the build time. To reduce the build time with acceptable resolution, the idea of parameter adjustable printing process has been introduced. The controllable extruder was modified and two types of diameter changeable nozzle have been designed. This work realizes different resolution building based on the part geometry during FDM process, which can efficiently assure the quality of products and improve the productivity at the same time.
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Khan, Shaheryar Atta, Bilal Ahmed Siddiqui, Muhammad Fahad, and Maqsood Ahmed Khan. "Evaluation of the Effect of Infill Pattern on Mechanical Stregnth of Additively Manufactured Specimen." Materials Science Forum 887 (March 2017): 128–32. http://dx.doi.org/10.4028/www.scientific.net/msf.887.128.
Abstract:
Additive manufacturing has stepped down from the world of Sci-Fi into reality. Since its conception in the 1980s the technology has come a long way. May variants of the technology are now available to the consumer. With the advent of custom built (open source) Fused Deposition Modeling based printing technology Fused Filament Fabrication (FFF), FDM/FFF has become the most used Additive Manufacturing technology. The effects of the different infill patterns of FDM/FFF on the mechanical properties of a specimen made from ABS are studied in this paper. It is shown that due to changes in internal structures, the tensile strength of the specimen changes. The study also investigate the effect of infill pattern on the build time of the specimen. Extensive testing yielded the optimal infill pattern for FDM/FFF. An open source Arduino based RepRap printer was used for the preparation of specimen and showed promising results for rapid prototyping of custom built parts to bear high loads. The study can help with the increase in the use of additive manufacturing for the manufacturing of mechanically functioning parts such as prosthetics
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Liu, Jikai, Jingjing Yan, and Huangchao Yu. "Stress-constrained topology optimization for material extrusion polymer additive manufacturing." Journal of Computational Design and Engineering 8, no. 3 (May 29, 2021): 979–93. http://dx.doi.org/10.1093/jcde/qwab028.
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Abstract This paper presents a comprehensive numerical and experimental study on stress-constrained topology optimization for Fused Deposition Modeling (FDM) additive manufacturing. The qp method is employed to avoid the singularity issue of stress-constrained problems. The P-norm function with stability transformation is adopted to build the global stress constraint with iterative corrections to eliminate the gap between the maximum local stress and the P-norm stress. The Heaviside projection is employed to generate clear-cut 0–1 designs. Two benchmark examples have been studied with the numerical algorithm. Experiments are performed on the topologically optimized MBB beam to investigate the impact of the FDM process parameters, including deposition path direction, building direction, and slicing layer height, on the resulted structural strength. The stress-constrained designs without and with Heaviside projection are comparatively tested with experiments. The stress-minimization designs subject to different P-norm parameters are compared both numerically and experimentally. Experiments show that the deposition path direction and the building direction evidently affect the derived structural strength. Moreover, overthin structural members may severely degrade the structural strength due to manufacturing and loading uncertainties.
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Beniak, Juraj, Ľubomír Šooš, Peter Križan, Miloš Matúš, and Vít Ruprich. "Resistance and Strength of Conductive PLA Processed by FDM Additive Manufacturing." Polymers 14, no. 4 (February 10, 2022): 678. http://dx.doi.org/10.3390/polym14040678.
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There is a large number of materials that can be used for FDM additive manufacturing technology. These materials have different strength properties, they are designed for different purposes. They can be highly strong or flexible, abrasion-resistant, or designed for example for environments with higher thermal loads. However recently new innovative and progressive materials have come to the practice, which include nano-composite particles, bringing new added value. One such material is the Conductive PLA material, which is capable of conducting electric current. The aim of this article is to present the material properties of this material. The article describes the design of the experiment, the process of measuring the resistance of samples printed by FDM device, measuring the maximum tensile strength of samples. The article includes a statistical evaluation of the measured data, with the determination of the significance of individual factors of the experiment as well as the evaluation of the overall result of the experiments.
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Cunico, Marlon Wesley Machado, Miriam Machado Cunico, Patrick Medeiros Cavalheiro, and Jonas de Carvalho. "Investigation of additive manufacturing surface smoothing process." Rapid Prototyping Journal 23, no. 1 (January 16, 2017): 201–8. http://dx.doi.org/10.1108/rpj-11-2015-0176.
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Purpose The additive manufacturing technologies have been facing an extraordinary growth along the past years. This phenomenon might be correlated with rise of low-cost FDM technologies into the non-professional market segment. In contrast with that, among the main disadvantages found in this sort of equipment are the final object finishing and low mechanical strength. For that reason, the purpose of this paper is to present and characterise a surface treatment which is based on solvent vapour attack and that is also known as smoothing process. In addition, a concise overview about the theory beneath this process is presented besides an experimental study that evaluates the main effects on the mechanical properties of object. Design/methodology/approach To analyse the benefits of this process, the authors preliminarily investigated the working mechanism that supports such surface treatment. It allowed them to identify and select a proper solvent for each material. The authors have also established that the exposure time repetition numbers (passes) were the main variables, whereas temperature, solvent type, drying time, object direction and object shape were constants. The main object dimensions, surface roughness, absorbed solvent mass and mechanical strength were the main study responses. Findings As a result of this work, the peak-peak roughness was reduced in 71 per cent, indicating the potential benefit of this process. On the other hand, excessive solvent exposure implied on relevant dimensional distortions and internal disruptures. It was also possible to see that the vapourised solvent penetrate into the object surface and fused layers and filaments. As consequence, the mechanical strength was also improved. Originality/value Despite the growth that additive manufacturing market segment has seen along the past years, the finishing and mechanical strength of low-cost equipment still lack for improvements. For that reason, applications like solvent vapour attack or smoothing process new perspectives for this non-professional segment, whereas roughness and mechanical strength are improved after its treatment. As a consequence, it is possible to consider a final object to be obtained directly from low-cost FDM in combination with smoothing process.
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Farina, Ilenia, Narinder Singh, Francesco Colangelo, Raimondo Luciano, Giulio Bonazzi, and Fernando Fraternali. "High-Performance Nylon-6 Sustainable Filaments for Additive Manufacturing." Materials 12, no. 23 (November 28, 2019): 3955. http://dx.doi.org/10.3390/ma12233955.
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This study deals with the development of Nylon-6 fused deposition modeling (FDM) filaments for additive manufacturing, which couples high mechanical performances with eco-sustainability. These filaments were extruded from recycled Nylon-6 granulates through a dedicated twin-screw extrusion line, which processes either pure Nylon-6 grains, or mixtures of such a material with minor fractions of acrylonitrile butadiene styrene (ABS) and titanium dioxide (TiO2). The rheological and thermal properties of the investigated filaments are analyzed, including melt flow index, melting temperature, and decomposition temperature, which are of the utmost importance when avoiding the overheating and decomposition of the material. Such a study is conducted in both pre-extrusion and post-extrusion conditions. The tensile strength, the wear resistance, and the printability of the examined recycled Nylon-6 filaments are also studied by comparing the properties of such filaments with those exhibited by different nylon-based filaments for FDM that are available in the market. The given results show that the recycling of Nylon-6 through the “caprolactam” regeneration route enables the newly formed material to retain high physical and mechanical properties, such as tensile strength at yield in the interval 55.79–86.91 MPa. Referring to the basic composition of the filaments examined in the present study, this remarkably high-yield strength is accompanied by a Young modulus of 1.64 GPa, and wear resistance of 92 µm, under a 15 min/1 kg load pin-on-disk test carried at the sliding speed of 250 rpm.
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Çevik, Ümit, and Menderes Kam. "A Review Study on Mechanical Properties of Obtained Products by FDM Method and Metal/Polymer Composite Filament Production." Journal of Nanomaterials 2020 (November 20, 2020): 1–9. http://dx.doi.org/10.1155/2020/6187149.
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In addition to traditional manufacturing methods, Additive Manufacturing (AM) has become a widespread production technique used in the industry. The Fused Deposition Modeling (FDM) method is one of the most known and widely used additive manufacturing techniques. Due to the fact that polymer-based materials used as depositing materials by the FDM method in printing of parts have insufficient mechanical properties, the technique generally has limited application areas such as model making and prototyping. With the development of polymer-based materials with improved mechanical properties, this technique can be preferred in wider application areas. In this context, analysis of the mechanical properties of the products has an important role in the production method with FDM. This study investigated the mechanical properties of the products obtained by metal/polymer composite filament production and FDM method in detail. It was reviewed current literature on the production of metal/polymer composite filaments with better mechanical properties than filaments compatible with three-dimensional (3D) printers. As a result, it was found that by adding reinforcements of composites in various proportions, products with high mechanical properties can be obtained. Thus, it was predicted that the composite products obtained in this way can be used in wider application areas.
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Ulkir, Osman, Mehmet Said Bayraklılar, and Melih Kuncan. "Raster Angle Prediction of Additive Manufacturing Process Using Machine Learning Algorithm." Applied Sciences 14, no. 5 (February 29, 2024): 2046. http://dx.doi.org/10.3390/app14052046.
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As additive manufacturing (AM) processes become integrated with artificial intelligence systems, the time and cost of the fabrication process decrease. In this study, the raster angle, an important parameter in the manufacturing process, was examined using fused deposition modeling (FDM), an AM method. The optimal value of this parameter varies depending on the designed product geometry. By changing the raster angle, the distribution of stresses and strains within the printed object can be modified, potentially influencing the mechanical behavior of the object. Thus, the correct estimation of the raster angle is essential for obtaining parts with high mechanical properties. The focus of this study is to reduce the fabrication time and cost of products by intertwining machine learning (ML) systems with mechanical systems. Its novelty is that ML has never been applied for FDM raster angle estimation. The estimation and modeling of the raster angle were performed using five different ML algorithms. These algorithms include a support vector machine (SVM), Gaussian process regression (GPR), an artificial neural network (ANN), decision tree regression (DTR), and random forest regression (RFR). Data for training were generated using various shapes and geometries, then trained in the MATLAB software, and a prediction model between the input parameters and the raster angle was created. The predicted model was evaluated using five performance criteria. The RFR model predicts the raster angle in the FDM test data with R-squared (R2) = 0.92, an explained variance score (EVS) = 0.92, a mean absolute error (MAE) = 0.012, a root mean square error (RMSE) = 0.056, and a mean squared error (MSE) = 0.0032. These values are R2 = 0.93, EVS = 0.93, MAE = 0.010, RMSE = 0.051, and MSE0.0025 for the training data. RFR is significantly superior to the other prediction algorithms. The proposed model predicts the optimum raster angle for any geometry.