Journal articles on the topic 'Filament manufacturing'
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1
Dey, Arup, Isnala Nanjin Roan Eagle, and Nita Yodo. "A Review on Filament Materials for Fused Filament Fabrication." Journal of Manufacturing and Materials Processing 5, no. 3 (June 29, 2021): 69. http://dx.doi.org/10.3390/jmmp5030069.
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Fused filament fabrication (FFF) is one of the most popular additive manufacturing (AM) processes that utilize thermoplastic polymers to produce three-dimensional (3D) geometry products. The FFF filament materials have a significant role in determining the properties of the final part produced, such as mechanical properties, thermal conductivity, and electrical conductivity. This article intensively reviews the state-of-the-art materials for FFF filaments. To date, there are many different types of FFF filament materials that have been developed. The filament materials range from pure thermoplastics to composites, bioplastics, and composites of bioplastics. Different types of reinforcements such as particles, fibers, and nanoparticles are incorporated into the composite filaments to improve the FFF build part properties. The performance, limitations, and opportunities of a specific type of FFF filament will be discussed. Additionally, the challenges and requirements for filament production from different materials will be evaluated. In addition, to provide a concise review of fundamental knowledge about the FFF filament, this article will also highlight potential research directions to stimulate future filament development. Finally, the importance and scopes of using bioplastics and their composites for developing eco-friendly filaments will be introduced.
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Sasse, Jana, Lukas Pelzer, Malte Schön, Tala Ghaddar, and Christian Hopmann. "Investigation of Recycled and Coextruded PLA Filament for Additive Manufacturing." Polymers 14, no. 12 (June 14, 2022): 2407. http://dx.doi.org/10.3390/polym14122407.
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Polylactide acid (PLA) is one of the most used plastics in extrusion-based additive manufacturing (AM). Although it is bio-based and in theory biodegradable, its recyclability for fused filament fabrication (FFF) is limited due to material degradation. To better understand the material’s recyclability, blends with different contents of recycled PLA (rPLA) are investigated alongside a coextruded filament comprised of a core layer with high rPLA content and a skin layer from virgin PLA. The goal was to determine whether this coextrusion approach is more efficient than blending rPLA with virgin PLA. Different filaments were extruded and subsequently used to manufacture samples using FFF. While the strength of the individual strands did not decrease significantly, layer adhesion decreased by up to 67%. The coextruded filament was found to be more brittle than its monoextruded counterparts. Additionally, no continuous weld line could be formed between the layers of coextruded material, leading to a decreased tensile strength. However, the coextruded filament proved to be able to save on master batch and colorants, as the outer layer of the filament has the most impact on the part’s coloring. Therefore, switching to a coextruded filament could provide economical savings on master batch material.
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Suharjanto, G., and J. P. Adi. "Design and manufacture of polylacticacid (PLA) filament storage for 3-dimensional printing with composite material." IOP Conference Series: Earth and Environmental Science 998, no. 1 (February 1, 2022): 012028. http://dx.doi.org/10.1088/1755-1315/998/1/012028.
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Abstract 3-dimensional printing is an additive manufacturing (AM) method using polylacticacid (PLA) filaments. However, PLA filaments still have limitations such as the hygroscopic properties of the material. This type of filament easily absorbs air from air humidity, so it will have an impact on the chemical damage of PLA. In this research, a composite file storage area will be designed. The method of making this file storage area will use a composite material Medium Density Board (MDF) with a simple manufacturing method. The filament storage area is expected to prevent and reduce air absorption and the lifespan of filaments in PLA filaments, thus helping users of 3-dimensional printing produce better results.
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Schneevogt, Helge, Kevin Stelzner, Buket Yilmaz, Bilen Emek Abali, André Klunker, and Christina Völlmecke. "Sustainability in additive manufacturing: Exploring the mechanical potential of recycled PET filaments." Composites and Advanced Materials 30 (January 1, 2021): 263498332110000. http://dx.doi.org/10.1177/26349833211000063.
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Herein, the effects of recycled polymers on the mechanical properties of additively manufactured specimens, specifically those derived by fused deposition modelling, are determined. The intention is to investigate how 3D-printing can be more sustainable and how recycled polymers compare against conventional ones. Initially, sustainability is discussed in general and more sustainable materials such as recycled filaments and biodegradable filaments are introduced. Subsequently, a comparison of the recycled filament recycled Polyethylene terephthalate (rePET) and a conventional Polyethylene terephthalate with glycol (PETG) filament is drawn upon their mechanical performance under tension, and the geometry and slicing strategy for the 3D-printed specimens is discussed. Finally, the outcomes from the experiments are compared against numerically determined results and conclusions are drawn.
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Gao, Yi Qiang. "Structure and Properties of Double-Filament Tri-Component Combined Yarn." Advanced Materials Research 1035 (October 2014): 101–5. http://dx.doi.org/10.4028/www.scientific.net/amr.1035.101.
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Manufacturing process of combined yarn with different filament size and cotton roving has been discussed. It shows that filament feeding point has some effect on combined yarn structure and yarn properties. If the filaments are fed from different sides of the cotton strand, they usually wrap the strand in parallel. If the filaments are fed from the same side of the strand, they wrap the strand crossed more often. Filament feeding point has an effect on yarn hairiness while it affects yarn breaking strength, yarn breaking elongation and abrasion resistance slightly. Yarn property weight is determined by subjective empowerment and Borda method is used to analyze yarn property. It has proved that if the filaments are fed from different sides of the cotton strand, the filament-roving space is set at 4mm respectively; the combined yarn shows the best.
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Santos, Cyril, Daniel Gatões, Fábio Cerejo, and Maria Teresa Vieira. "Influence of Metallic Powder Characteristics on Extruded Feedstock Performance for Indirect Additive Manufacturing." Materials 14, no. 23 (November 24, 2021): 7136. http://dx.doi.org/10.3390/ma14237136.
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Material extrusion (MEX) of metallic powder-based filaments has shown great potential as an additive manufacturing (AM) technology. MEX provides an easy solution as an alternative to direct additive manufacturing technologies (e.g., Selective Laser Melting, Electron Beam Melting, Direct Energy Deposition) for problematic metallic powders such as copper, essential due to its reflectivity and thermal conductivity. MEX, an indirect AM technology, consists of five steps—optimisation of mixing of metal powder, binder, and additives (feedstock); filament production; shaping from strands; debinding; sintering. The great challenge in MEX is, undoubtedly, filament manufacturing for optimal green density, and consequently the best sintered properties. The filament, to be extrudable, must accomplish at optimal powder volume concentration (CPVC) with good rheological performance, flexibility, and stiffness. In this study, a feedstock composition (similar binder, additives, and CPVC; 61 vol. %) of copper powder with three different particle powder characteristics was selected in order to highlight their role in the final product. The quality of the filaments, strands, and 3D objects was analysed by micro-CT, highlighting the influence of the different powder characteristics on the homogeneity and defects of the greens; sintered quality was also analysed regarding microstructure and hardness. The filament based on particles powder with D50 close to 11 µm, and straight distribution of particles size showed the best homogeneity and the lowest defects.
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Peterson, Gregory I., Mete Yurtoglu, Michael B. Larsen, Stephen L. Craig, Mark A. Ganter, Duane W. Storti, and Andrew J. Boydston. "Additive manufacturing of mechanochromic polycaprolactone on entry-level systems." Rapid Prototyping Journal 21, no. 5 (August 17, 2015): 520–27. http://dx.doi.org/10.1108/rpj-09-2014-0115.
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Purpose – This paper aims to explore and demonstrate the ability to integrate entry-level additive manufacturing (AM) techniques with responsive polymers capable of mechanical to chemical energy transduction. This integration signifies the merger of AM and smart materials. Design/methodology/approach – Custom filaments were synthesized comprising covalently incorporated spiropyran moieties. The mechanical activation and chemical response of the spiropyran-containing filaments were demonstrated in materials that were produced via fused filament fabrication techniques. Findings – Custom filaments were successfully produced and printed with complete preservation of the mechanochemical reactivity of the spiropyran units. These smart materials were demonstrated in two key constructs: a center-cracked test specimen and a mechanochromic force sensor. The mechanochromic nature of the filament enables (semi)quantitative assessment of peak loads based on color change, without requiring any external analytical techniques. Originality/value – This paper describes the first examples of three-dimensional-printed mechanophores, which may be of significant interest to the AM community. The ability to control the chemical response to external mechanical forces, in combination with AM to process the bulk materials, potentiates customizability at the molecular and macroscopic length scales.
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Antoniac, Iulian, Diana Popescu, Aurelian Zapciu, Aurora Antoniac, Florin Miculescu, and Horatiu Moldovan. "Magnesium Filled Polylactic Acid (PLA) Material for Filament Based 3D Printing." Materials 12, no. 5 (March 1, 2019): 719. http://dx.doi.org/10.3390/ma12050719.
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The main objective of this research is to prove the viability of obtaining magnesium (Mg) filled polylactic acid (PLA) biocomposites as filament feedstock for material extrusion-based additive manufacturing (AM). These materials can be used for medical applications, thus benefiting of all the advantages offered by AM technology in terms of design freedom and product customization. Filaments were produced from two PLA + magnesium + vitamin E (α-tocopherol) compositions and then used for manufacturing test samples and ACL (anterior cruciate ligament) screws on a low-cost 3D printer. Filaments and implant screws were characterized using SEM (scanning electron microscopy), FTIR (fourier transform infrared spectrometry), and DSC (differential scanning calorimetry) analysis. Although the filament manufacturing process could not ensure a uniform distribution of Mg particles within the PLA matrix, a good integration was noticed, probably due to the use of vitamin E as a precursor. The results also show that the composite biomaterials can ensure and maintain implant screws structural integrity during the additive manufacturing process.
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Legett, Shelbie A., John R. Stockdale, Xavier Torres, Chris M. Yeager, Adam Pacheco, and Andrea Labouriau. "Functional Filaments: Creating and Degrading pH-Indicating PLA Filaments for 3D Printing." Polymers 15, no. 2 (January 13, 2023): 436. http://dx.doi.org/10.3390/polym15020436.
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With the rapid pace of advancements in additive manufacturing and techniques such as fused filament fabrication (FFF), the feedstocks used in these techniques should advance as well. While available filaments can be used to print highly customizable parts, the creation of the end part is often the only function of a given feedstock. In this study, novel FFF filaments with inherent environmental sensing functionalities were created by melt-blending poly(lactic acid) (PLA), poly(ethylene glycol) (PEG), and pH indicator powders (bromothymol blue, phenolphthalein, and thymol blue). The new PLA-PEG-indicator filaments were universally more crystalline than the PLA-only filaments (33–41% vs. 19% crystallinity), but changes in thermal stability and mechanical characteristics depended upon the indicator used; filaments containing bromothymol blue and thymol blue were more thermally stable, had higher tensile strength, and were less ductile than PLA-only filaments, while filaments containing phenolphthalein were less thermally stable, had lower tensile strength, and were more ductile. When the indicator-filled filaments were exposed to acidic, neutral, and basic solutions, all filaments functioned as effective pH sensors, though the bromothymol blue-containing filament was only successful as a base indicator. The biodegradability of the new filaments was evaluated by characterizing filament samples after aging in soil and soil slurry mixtures; the amount of physical deterioration and changes in filament crystallinity suggested that the bromothymol blue filament degraded faster than PLA-only filaments, while the phenolphthalein and thymol blue filaments saw decreases in degradation rates.
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Schreil, Daniela, Georgi Zhilev, Alexander Matschinski, and Klaus Drechsler. "Development of a Test Bench for the Investigation of Thermoplastic-Thermoset Material Combinations in Additive Manufacturing." Materials Science Forum 1067 (August 10, 2022): 107–12. http://dx.doi.org/10.4028/p-3nvb83.
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To enhance the mechanical properties of fused filament fabricated parts, the process integrates continuous fibers. Currently, fibers are impregnated either with thermoplastics or with thermoset material, which is completely cured before printing and later combined with thermoplastic filament during the coextrusion process. A major problem about using cured thermoset matrix for the fibers is an insufficient bond between the fiber matrix and the thermoplastic material. A new approach proposed by the authors combine uncured thermoset matrices with thermoplastic filaments to form a substance-to-substance bond. To investigate the material and bonding behavior, a test bench is constructed. Its main purpose is to replicate the coextrusion of thermoplastic filament and thermoset impregnated continuous fibers. Parameters, such as temperature, tension and extrusion speed can be adjusted within the setup to accurately simulate the additive manufacturing process. Aluminum blocks including heater cartridges and thermocouples act as hot ends and impregnation units. Heated blocks compact the fiber strands. We tested different heating blocks containing flat and curved geometries including actual additive manufacturing nozzles to evaluate the impregnation behavior of the dry carbon fiber filaments. Approaches with additive manufacturing nozzles show the most promising results regarding fiber impregnation with thermoplastic material.
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Breški, Tomislav, Lukas Hentschel, Damir Godec, and Ivica Đuretek. "Suitability of Recycled PLA Filament Application in Fused Filament Fabrication Process." Tehnički glasnik 15, no. 4 (November 1, 2021): 491–97. http://dx.doi.org/10.31803/tg-20210805120621.
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Fused filament fabrication (FFF) is currently one of the most popular additive manufacturing processes due to its simplicity and low running and material costs. Support structures, which are necessary for overhanging surfaces during production, in most cases need to be manually removed and as such, they become waste material. In this paper, experimental approach is utilised in order to assess suitability of recycling support structures into recycled filament for FFF process. Mechanical properties of standardized specimens made from recycled polylactic acid (PLA) filament as well as influence of layer height and infill density on those properties were investigated. Optimal printing parameters for recycled PLA filaments are determined with Design of Experiment methods (DOE).
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Ramadhan, Mochamad Edoward, Mahros Darsin, Sains Ilham Akbar, and Danang Yudistiro. "Akurasi dimensi produk filamen 3d printing berbahan polipropilen menggunakan mesin ekstrusi." Jurnal Teknosains 11, no. 2 (May 9, 2022): 162. http://dx.doi.org/10.22146/teknosains.63878.
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Additive manufacturing (AM) has been trending topic in industrial revolution 4.0. One technique and the most widely used AM is fused deposition modeling (FDM), which uses a melted filament and deposited it layer by layer. The common filaments used are made of PLA, PP, and ABS, which are available at the online market with variety of prices depend on the quality. It is an advantage if we can make these filaments. In filament manufacturing, the dimensional accuracy is one of the most important factors to comply with the existing 3D printers. The aim of this research is to fabricate a filament made of PP, then assessed the quality based on the accuaray of the targeted diameter of 1.75 mm. The manufacturing process used a self-made plastic extrusion machine. Variations were made on three variables with three levels each. There are (i) heater band temperature with a minimum and maximum range (150/170 oC, 155/175 oC and 160/180 oC), (ii) winding speed (13 mm/s, 16 mm/,s and 19 mm/s), and (iii) roll distance to the nozzle set point (200 mm, 500 mm and 700 mm). Taguchi L9 design was used to design the experiments and analysis.Minitab 19 was employed to find the S/N ratio and analysis the variance (ANOVA). The results of the analysis state that two parameters have a significant effect on the dimensions of the filament, i.e. temperature and roll distance to the nozzle, while, the winding speed has no dominat effect. The best accuracy of filaments diameter was achieved when applying a combination of temperature (160/180 ⁰C), the distance between the nozzle to the roll of 700 mm, and winding speed of 13 mm/s.
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Afzal, Ali, Jean-Yves Drean, Omar Harzallah, Nabyl Khenoussi, Sheraz Ahmad, and Niaz-Ahmad Akhtar. "Development of multifunctional different cross-sectional shaped coaxial composite filaments for SMART textile applications." Textile Research Journal 87, no. 16 (September 2, 2016): 1991–2004. http://dx.doi.org/10.1177/0040517516663144.
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The aim of this study is to design a spinneret that can be used efficiently for the manufacturing of coaxial composite filaments. Poly(ethylene terephthalate) was used as resin matrix with 99.9% pure copper filament as the core. The characterization of the polymer was done to determine polymer thermal and rheological properties. Multi-shaped coaxial composite filaments were obtained after successful laboratory-scale melt extrusion machine modification and spinneret development. The cross-sectional surface and shape were analyzed with a scanning electron microscope. Coaxial filaments having the cross-section including elliptical, triangular, rectangular and circular shapes were developed. The characterization of spinneret design and coaxial composite filaments were also reported. The effect of spinneret design parameters on the cross-sectional shape of the filament were analyzed.
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Ponsar, Hanna, Raphael Wiedey, and Julian Quodbach. "Hot-Melt Extrusion Process Fluctuations and Their Impact on Critical Quality Attributes of Filaments and 3D-Printed Dosage Forms." Pharmaceutics 12, no. 6 (June 3, 2020): 511. http://dx.doi.org/10.3390/pharmaceutics12060511.
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Fused deposition modeling (FDMTM) is a 3D-printing technology of rising interest for the manufacturing of customizable solid dosage forms. The coupling of hot-melt extrusion with FDMTM is favored to allow the production of pharma-grade filaments for the printing of medicines. Filament diameter consistency is a quality of great importance to ensure printability and content uniformity of 3D-printed drug delivery systems. A systematical process analysis referring to filament diameter variations has not been described in the literature. The presented study aimed at a process setup optimization and rational process analysis for filament fabrication related to influencing parameters on diameter inhomogeneity. In addition, the impact of diameter variation on the critical quality attributes of filaments (mechanical properties) and uniformity of mass of printed drug-free dosage forms was investigated. Process optimization by implementing a winder with a special haul-off unit was necessary to obtain reliable filament diameters. Subsequently, the optimized setup was used for conduction of rational extrusion analysis. The results revealed that an increased screw speed led to diameter fluctuations with a decisive influence on the mechanical resilience of filaments and mass uniformity of printed dosage forms. The specific feed load was identified as a key parameter for filament diameter consistency.
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Uhlmann, Eckart, and Christian Sommerfeld. "Dynamic Analysis of Abrasive Filaments in Contact with Different Workpiece Geometries." International Journal of Automation Technology 12, no. 6 (November 5, 2018): 892–900. http://dx.doi.org/10.20965/ijat.2018.p0892.
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Abrasive brushes are often used for surface finishing and deburring and consist of a brush body with fixed, highly flexible abrasive filaments. During the brushing process the highly flexible abrasive filaments deform tangentially and axially and adapt to the shape of the workpiece. The contact behaviour of abrasive brushes in the machining process is very complex and has been insufficiently investigated so far. Abrasive brushes consist of a brush body with fixed, highly flexible abrasive filaments and are often used for surface finishing and deburring. During the brushing process, the highly flexible abrasive filaments deform tangential and axial and adapt to the shape of the workpiece. The mentioned contact behavior of the abrasive brush during the machining process is complex, and has not yet been sufficiently investigated. To better understand the contact behavior and, thus, the brushing process, a model of an abrasive filament is proposed in this study. The model describes the dynamic behavior of a single filament in contact with different workpiece geometries. The filament is discretized into a multi-body system of rigid links connected with rotational springs and rotational dampers, and the workpiece is approximated by using a polynomial. The contact of the multi-body system representing the filament with the surface of the workpiece is described by using Hertz’s theory of elastic contact and Coulomb’s law of friction. Based on this, a system of equations of motion for the multi-body system is obtained by using Lagrangian mechanics. A numerical solution of the equation of motion system was calculated by using experimentally determined material and contact properties of the filament as a composite of a plastic matrix and abrasive grains. A comparison of the calculated results with experimental data yielded satisfactory agreement for the contact between the filament and different workpiece geometries.
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Subramani, Raja, S. Kaliappan, S. Sekar, Pravin P. Patil, R. Usha, Narapareddi Manasa, and E. S. Esakkiraj. "Polymer Filament Process Parameter Optimization with Mechanical Test and Morphology Analysis." Advances in Materials Science and Engineering 2022 (August 3, 2022): 1–8. http://dx.doi.org/10.1155/2022/8259804.
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3D printing is one of the emerging technologies in the manufacturing sector, and polymer materials play a vital role in the raw material of the additive manufacturing sector. This research explores reducing the production time by testing and analyzing the microstructure of the different polylactic acid (PLA) filament polymer samples. For this purpose, 15 pieces of ASTM (American society for testing and materials) D638 tensile samples with polylactic acid (PLA) filaments have been used exclusively with five different sets of modified process parameters in slicing software of 3D printing technology. The results of this research reveal the best PLA filament FDM production method in terms of time, mechanical strength, and FESEM analysis comparing all the results.
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Fabrizio, Matteo, Matteo Strano, Daniele Farioli, and Hermes Giberti. "Extrusion Additive Manufacturing of PEI Pellets." Journal of Manufacturing and Materials Processing 6, no. 6 (December 8, 2022): 157. http://dx.doi.org/10.3390/jmmp6060157.
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The simplest, most cost-efficient, and most widespread Additive Manufacturing (AM) technology is Extrusion Additive Manufacturing (EAM). Usually, EAM is performed with filament feedstock, but using pellets instead of filaments yields many benefits, including significantly lower cost and a wider choice of materials. High-performance polymers offer high strength even when produced with AM technique, allowing to produce near-net-shape functional parts. The production of these materials in filament form is still limited and expensive; therefore, in this paper, the possibility of producing AM components with engineering polymers from pellets will be thoroughly investigated. In this work, the effectiveness of a specially designed AM machine for printing high-performance materials in pellet form was tested. The material chosen for the investigation is PEI 1000 which offers outstanding mechanical and thermal properties, giving the possibility to produce with EAM functional components. Sensitivity analyses have been carried out to define a process window in terms of thermal process parameters by observing different response variables. Using the process parameters in the specified range, the additive manufactured material has been mechanically tested, and its microstructure has been investigated, both in dried and undried conditions. Finally, a rapid tool for sheet metal forming has been produced.
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Fico, Daniela, Daniela Rizzo, Valentina De Carolis, Francesco Montagna, and Carola Esposito Corcione. "Sustainable Polymer Composites Manufacturing through 3D Printing Technologies by Using Recycled Polymer and Filler." Polymers 14, no. 18 (September 8, 2022): 3756. http://dx.doi.org/10.3390/polym14183756.
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In the last years, the excessive use of plastic and other synthetic materials, that are generally difficult to dispose of, has caused growing ecological worries. These are contributing to redirecting the world’s attention to sustainable materials and a circular economy (CE) approach using recycling routes. In this work, bio-filaments for the Fused Filament Fabrication (FFF) 3D printing technique were produced from recycled polylactic acid (PLA) and artisanal ceramic waste by an extrusion process and fully characterized from a physical, thermal, and mechanical point of view. The data showed different morphological, thermal, rheological, and mechanical properties of the two produced filaments. Furthermore, the 3D objects produced from the 100% recycled PLA filament showed lower mechanical performance. However, the results have demonstrated that all the produced filaments can be used in a low-cost FFF commercial printer that has been modified with simple hand-made operations in order to produce 3D-printed models. The main objective of this work is to propose an example of easy and low-cost application of 3D printing that involves operations such as the reprocessing and the recyclability of materials, that are also not perfectly mechanically performing but can still provide environmental and economic benefits.
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Zarybnicka, Lucie, and Eliska Stranska. "Preparation of cation exchange filament for 3D membrane print." Rapid Prototyping Journal 26, no. 8 (July 6, 2020): 1435–45. http://dx.doi.org/10.1108/rpj-03-2019-0082.
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Purpose This paper aims to focus on the preparation of a cation exchange filament for three-dimensional (3D) fused deposition modeling (FDM). The polymeric binder was mixed with the selected conventional cation exchange resin and a filament was prepared using a mini extruder. Filaments were tested by mechanical properties, chemical properties, quality and melt flow index. Samples were prepared from granulate using a press, which were tested for electrochemical properties, thermal properties. The best result of ion exchange capacity (IEC) up to 3.0 meq/g of the dry matter was achieved with filament fill 65%. Permselectivity results above 90% were determined for 55%–65% filling of the cation exchanger. The results obtained are a promising step for the preparation of 3D printed cation exchange membranes (CEMs) with a defined structure. Design/methodology/approach The prepared granulates and filaments were evaluated using mechanical, rheological and thermal properties. Findings The prepared cation exchange filament can be used for the 3D printing process. The best result of IEC up to 3.0 meq/g of the dry matter was achieved with filament fill 65%. Permselectivity results above 90% were determined for 55%–65% filling of the cation exchanger, and area resistances 3.0 Ocm2 and specific resistances around 57 Ocm for 65% filling of the cation exchanger. The results obtained are a promising step for the preparation of 3D printed CEMs with a defined structure. Originality/value The prepared cation exchange filament. Using new materials for 3D print of cation exchange membrane. Production without waste. The possibility of producing 3D membranes with a precisely defined structure. Processing prepared filaments using a cheap FDM 3D printing method. New direction of membrane formation.
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Parnian, Pooyan, and Alberto D’Amore. "Fabrication of High-Performance CNT Reinforced Polymer Composite for Additive Manufacturing by Phase Inversion Technique." Polymers 13, no. 22 (November 19, 2021): 4007. http://dx.doi.org/10.3390/polym13224007.
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Additive Manufacturing (AM) of polymer composites has enabled the fabrication of highly customized parts with notably mechanical properties, thermal and electrical conductivity compared to un-reinforced polymers. Employing the reinforcements was a key factor in improving the properties of polymers after being 3D printed. However, almost all the existing 3D printing methods could make the most of disparate fiber reinforcement techniques, the fused filament fabrication (FFF) method is reviewed in this study to better understand its flexibility to employ for the proposed novel method. Carbon nanotubes (CNTs) as a desirable reinforcement have a great potential to improve the mechanical, thermal, and electrical properties of 3D printed polymers. Several functionalization approaches for the preparation of CNT reinforced composites are discussed in this study. However, due to the non-uniform distribution and direction of reinforcements, the properties of the resulted specimen do not change as theoretically expected. Based on the phase inversion method, this paper proposes a novel technique to produce CNT-reinforced filaments to simultaneously increase the mechanical, thermal, and electrical properties. A homogeneous CNT dispersion in a dilute polymer solution is first obtained by sonication techniques. Then, the CNT/polymer filaments with the desired CNT content can be obtained by extracting the polymer’s solvent. Furthermore, optimizing the filament draw ratio can result in a reasonable CNT orientation along the filament stretching direction.
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Vakharia, Ved S., Lily Kuentz, Anton Salem, Michael C. Halbig, Jonathan A. Salem, and Mrityunjay Singh. "Additive Manufacturing and Characterization of Metal Particulate Reinforced Polylactic Acid (PLA) Polymer Composites." Polymers 13, no. 20 (October 14, 2021): 3545. http://dx.doi.org/10.3390/polym13203545.
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Affordable commercial desktop 3-D printers and filaments have introduced additive manufacturing to all disciplines of science and engineering. With rapid innovations in 3-D printing technology and new filament materials, material vendors are offering specialty multifunctional metal-reinforced polymers with unique properties. Studies are necessary to understand the effects of filament composition, metal reinforcements, and print parameters on microstructure and mechanical behavior. In this study, densities, metal vol%, metal cross-sectional area %, and microstructure of various metal-reinforced Polylactic Acid (PLA) filaments were characterized by multiple methods. Comparisons are made between polymer microstructures before and after printing, and the effect of printing on the metal-polymer interface adhesion has been demonstrated. Tensile response and fracture toughness as a function of metal vol% and print height was determined. Tensile and fracture toughness tests show that PLA filaments containing approximately 36 vol% of bronze or copper particles significantly reduce mechanical properties. The mechanical response of PLA with 12 and 18 vol% of magnetic iron and stainless steel particles, respectively, is similar to that of pure PLA with a slight decrease in ultimate tensile strength and fracture toughness. These results show the potential for tailoring the concentration of metal reinforcements to provide multi-functionality without sacrificing mechanical properties.
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Dhopte, Prof V. D., Gaurav S. Parate, Madhur P. Narkhede, and Aarthav Bhongade. "Design and Fabrication of PET Filament Making Machine." International Journal for Research in Applied Science and Engineering Technology 10, no. 4 (April 30, 2022): 1529–31. http://dx.doi.org/10.22214/ijraset.2022.41568.
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Abstract: 3D printing is a form of additive manufacturing technology where a 3D object is created by laying down successive layers of material. It is mechanized method whereby 3D objects are quickly made on a reasonably sized machine connected to a computer containing blueprints for the object. As 3D printing is growing fast and giving a boost to product development, the factories doing 3D printing need to continuously meet the printing requirements and maintain an adequate amount of inventory of the filament. As the manufactures have to buy these filaments from various vendors, the cost of 3D printing increases. To overcome the problem faced by the manufacturers, small workshop owners, the need of 3D filament making machine arises. This project focuses on designing and fabricating a portable fused deposition 3D printer filament making machine with cheap and easily available components to draw 2 mm diameter ABS filament. Keywords: 3D printing, filament, recycling, PET bottles, machine
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Dhopte, Prof Vikrant, Pranay Khapre, Onkar Bhagat, and Himanshu Warhokar. "Design and Fabrication of PET Filament Making Machine." International Journal for Research in Applied Science and Engineering Technology 10, no. 4 (April 30, 2022): 1460–63. http://dx.doi.org/10.22214/ijraset.2022.41519.
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Abstract: 3D printing is a form of additive manufacturing technology where a 3D object is created by laying down successive layers of material. It is mechanized method whereby 3D objects are quickly made on a reasonably sized machine connected to a computer containing blueprints for the object. As 3D printing is growing fast and giving a boost to product development, the factories doing 3D printing need to continuously meet the printing requirements and maintain an adequate amount of inventory of the filament. As the manufactures have to buy these filaments from various vendors, the cost of 3D printing increases. To overcome the problem faced by the manufacturers, small workshop owners, the need of 3D filament making machine arises. This project focuses on designing and fabricating a portable fused deposition 3D printer filament making machine with cheap and easily available components to draw 2 mm diameter ABS filament. Keywords: 3D printing, filament, recycling, PET bottles, machine
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Xu, Kang, Dongya Li, Erwei Shang, and Yu Liu. "A Heating-Assisted Direct Ink Writing Method for Preparation of PDMS Cellular Structure with High Manufacturing Fidelity." Polymers 14, no. 7 (March 24, 2022): 1323. http://dx.doi.org/10.3390/polym14071323.
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In response to the fact that most of the current research on silicone 3D printing suffers from structure collapse and dimensional mismatch, this paper proposes a heating-assisted direct writing printing method for commercial silicone rubber materials for preparing silicone foam with enhanced fidelity. In the experimental processes, the effects of substrate temperature, printing pressure, and printing speed on the filament width were investigated using a controlled variable method. The results showed the following: (1) the diameter of silicone rubber filaments was positively correlated with the printing pressure and substrate temperature, but negatively correlated with the printing speed; (2) the filament collapse of the large filament spaced foams was significantly improved by the addition of the thermal field, which, in turn, improved the mechanical properties and manufacturing stability of the silicon foams. The heating-assisted direct writing process in this paper can facilitate the development of the field of microelectronics and the direct printing of biomaterials.
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Zárybnická, Lucie, Radek Ševčík, Jaroslav Pokorný, Dita Machová, Eliška Stránská, and Jiří Šál. "CaCO3 Polymorphs Used as Additives in Filament Production for 3D Printing." Polymers 14, no. 1 (January 4, 2022): 199. http://dx.doi.org/10.3390/polym14010199.
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Nowadays, additive manufacturing—also called 3D printing—represents a well-established technology in the field of the processing of various types of materials manufacturing products used in many industrial sectors. The most common type of 3D printing uses the fused filament fabrication (FFF) method, in which materials based on thermoplastics or elastomers are processed into filaments. Much effort was dedicated to improving the properties and processing of such printed filaments, and various types of inorganic and organic additives have been found to play a beneficial role. One of them, calcium carbonate (CaCO3), is standardly used as filler for the processing of polymeric materials. However, it is well-known from its different applications that CaCO3 crystals may represent particles of different morphologies and shapes that may have a crucial impact on the final properties of the resulting products. For this reason, three different synthetic polymorphs of CaCO3 (aragonite, calcite, and vaterite) and commercially available calcite powders were applied as fillers for the fabrication of polymeric filaments. Analysis of obtained data from different testing techniques has shown significant influence of filament properties depending on the type of applied CaCO3 polymorph. Aragonite particles showed a beneficial impact on the mechanical properties of produced filaments. The obtained results may help to fabricate products with enhanced properties using 3D printing FFF technology.
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Boparai, Kamaljit Singh, Rupinder Singh, and Harwinder Singh. "Process optimization of single screw extruder for development of Nylon 6-Al-Al2O3 alternative FDM filament." Rapid Prototyping Journal 22, no. 4 (June 20, 2016): 766–76. http://dx.doi.org/10.1108/rpj-09-2014-0119.
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Purpose The purpose of this study is to investigate the process parameters of a single-screw extruder for development of Nylon6-Al-Al2O3-based alternative fused deposition modeling process (FDM) feedstock filament (in lieu of commercial acrylonitrile butadiene styrene filament). The effect of major screw extruder parameters on the tensile strength of fabricated filaments has also been analyzed. Design/methodology/approach The Taguchi experimental log has been designed for investigating the significance of input parameters of screw extruders (such as mean barrel temperature, die temperature, screw speed, material composition and speed of take up unit) on the tensile strength of fabricated filaments. The suitability of alternative material as an FDM filament has been verified by rheological investigations. The tensile strength of an alternative feedstock filament has been investigated experimentally according to the ASTM-638 standard. The analysis was performed by the analysis of variance (ANOVA) method with the help of MINITAB 17 software. The stiffness of the FDM printed parts with nine different feedstock filaments (prepared by selecting nine different combinations of analytical parameters) was determined by dynamic mechanical analysis (DMA). Findings The tensile strength of the feedstock filament was significantly affected by the variation of major input parameters during the processing of alternative material on a single-screw extruder. The ANOVA shows that two process parameters (namely, material composition and die temperature) were significant at the 5 per cent level (“F” value 41 and 21.96, respectively) and remaining two (mean barrel temperature and screw speed) were insignificant at the 5 per cent level. Further, a linear regression model has been developed to predict the tensile strength of the alternative feedstock FDM filament. The results highlight that a deviation of <1 per cent was observed (in the tensile strength of nine sets of experimental runs) as compared to the predicted values of the regression model. In addition to above, the DMA result also indicates that the filament fabricated with optimum combination of parameters has highest stiffness and is more suitable for the FDM system. Research limitations/implications During the processing of alternative material in a single-screw extruder and FDM system, the increase of filler contents adversely affects the contact surfaces. Practical implications The FDM parts with customized properties (viz., thermal and tribological) can be fabricated with alternative feedstock filament material. Originality/value The potential to consider alternative filament material for FDM system includes rapid manufacturing of functional parts, tailor-made grinding tools for dentists and rapid tooling of metal matrix composites having complex geometry.
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Vidakis, Nectarios, Markos Petousis, Lazaros Tzounis, Athena Maniadi, Emmanouil Velidakis, Nikolaos Mountakis, and John D. Kechagias. "Sustainable Additive Manufacturing: Mechanical Response of Polyamide 12 over Multiple Recycling Processes." Materials 14, no. 2 (January 19, 2021): 466. http://dx.doi.org/10.3390/ma14020466.
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Plastic waste reduction and recycling through circular use has been critical nowadays, since there is an increasing demand for the production of plastic components based on different polymeric matrices in various applications. The most commonly used recycling procedure, especially for thermoplastic materials, is based on thermomechanical process protocols that could significantly alter the polymers’ macromolecular structure and physicochemical properties. The study at hand focuses on recycling of polyamide 12 (PA12) filament, through extrusion melting over multiple recycling courses, giving insight for its effect on the mechanical and thermal properties of Fused Filament Fabrication (FFF) manufactured specimens throughout the recycling courses. Three-dimensional (3D) FFF printed specimens were produced from virgin as well as recycled PA12 filament, while they have been experimentally tested further for their tensile, flexural, impact and micro-hardness mechanical properties. A thorough thermal and morphological analysis was also performed on all the 3D printed samples. The results of this study demonstrate that PA12 can be successfully recycled for a certain number of courses and could be utilized in 3D printing, while exhibiting improved mechanical properties when compared to virgin material for a certain number of recycling repetitions. From this work, it can be deduced that PA12 can be a viable option for circular use and 3D printing, offering an overall positive impact on recycling, while realizing 3D printed components using recycled filaments with enhanced mechanical and thermal stability.
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Kim, Jung Sub, Chang Su Lee, Sang Won Lee, Sung-Min Kim, Jae Hyuk Choi, Haseung Chung, and Pil-Ho Lee. "Fabrication and characterization of hollow glass beads-filled thermoplastic composite filament developed for material extrusion additive manufacturing." Journal of Composite Materials 54, no. 5 (July 23, 2019): 607–15. http://dx.doi.org/10.1177/0021998319863836.
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This paper explores the characteristics of a new lightweight thermoplastic composite filament filled with hollow glass beads developed for material extrusion additive manufacturing. Compounding experiments, which mix hollow glass beads with neat acrylonitrile butadiene styrene matrix, were conducted using a twin-screw extruder to prepare composite filaments. Two different types of hollow glass beads were selected as the fillers of composite filament due to their varying densities. In order to characterize the final components produced using composite filament, various specimens were fabricated by a material extrusion additive manufacturing process. In order to characterize the physical properties of the specimens, measurements of density and flexural testing were performed. To identify the thermomechanical effects of hollow glass beads on the neat acrylonitrile butadiene styrene matrix, thermal diffusivity and specific heat were obtained. Consequently, the thermal conductivity of the specimen was derived from its density, thermal diffusivity, and specific heat capacity. The microstructures of the fractured interfaces of the specimens were also observed by scanning electron microscopy. The experimental results revealed that most of the hollow glass beads survived, thus bringing about lighter weight (lower density) and thermal insulation (lower thermal conductivity), which can be useful for numerous potential applications.
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Skrzek, Kinga, and Mariusz Piotr Hetmanczyk. "FABRICATION CYCLES COMPARISON OF ASSEMBLIES AND MONOLITHIC PARTS MADE BY 3D PRINTING METHOD." International Journal of Modern Manufacturing Technologies 13, no. 3 (December 25, 2021): 158–63. http://dx.doi.org/10.54684/ijmmt.2021.13.3.158.
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The article presents an analysis of the time-consuming, energy-consuming, and cost-consuming nature of 3D printing a three-dimensional polymer components made in two separate approaches: assembly and monolith structure of various materials (automatic filament change required). The introduction includes the definition of 3D printing, its advantages and examples of practical applications, as well as the reason for undertaking the researches described in the article. The justification of the form of 3D sample models was discussed in detail, as well as the methodology adopted by the authors for comparing the print characteristics and the steps of the printing cycles (print preparation, the course of the printing process and post-processing). A comparison of the materials consumption in the phasess of manual and automatic filament change in the mixer were also described. The test printout was made on the Prusa i3 MK3S printer for filament deposition (FDM or FFF methods). For automatic filament mixing, the Palette 2 Pro device was used. The conclusions also include guidelines for the design and production of models made in one continuous printing cycle (using automatic filament feeding devices). Monolithic elements are less accurate, while elements with replaceable filaments are cheaper, less energy-consuming and the material consumption is lower.
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Wankhade, Mamta H., and Satish G. Bahaley. "Design and Development of Plastic Filament Extruder for 3D Printing." IRA-International Journal of Technology & Engineering (ISSN 2455-4480) 10, no. 3 (May 9, 2018): 23. http://dx.doi.org/10.21013/jte.v10.n3.p1.
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<p>3D printing is a form of additive manufacturing technology where a three dimensional object is created by laying down successive layers of material. It is mechanized method whereby 3D objects are quickly made on a reasonably sized machine connected to a computer containing blueprints for the object. As 3D printing is growing fast and giving a boost to product development, the factories doing 3D printing need to continuously meet the printing requirements and maintain an adequate amount of inventory of the filament. As the manufactures have to buy these filaments from various vendors, the cost of 3D printing increases. To overcome the problem faced by the manufacturers, small workshop owners, the need of 3D filament making machine arises. This project focuses on designing and fabricating a portable fused deposition 3D printer filament making machine with cheap and easily available components to draw 1.75 mm diameter ABS filament.</p>
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Haryńska, Agnieszka, Iga Gubanska, Justyna Kucinska-Lipka, and Helena Janik. "Fabrication and Characterization of Flexible Medical-Grade TPU Filament for Fused Deposition Modeling 3DP Technology." Polymers 10, no. 12 (November 25, 2018): 1304. http://dx.doi.org/10.3390/polym10121304.
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The possibility of using additive manufacturing (AM) in the medicine area has created new opportunities in health care. This has contributed to a sharp increase in demand for 3D printers, their systems and materials that are adapted to strict medical requirements. We described herein a medical-grade thermoplastic polyurethane (S-TPU) which was developed and then formed into a filament for Fused Deposition Modeling (FDM) 3D printers during a melt-extrusion process. S-TPU consisting of aliphatic hexamethylene 1,6-diisocyanate (HDI), amorphous α,ω-dihydroxy(ethylene-butylene adipate) (PEBA) and 1,4 butandiol (BDO) as a chain extender, was synthesized without the use of a catalyst. The filament (F-TPU) properties were characterized by rheological, mechanical, physico-chemical and in vitro biological properties. The tests showed biocompatibility of the obtained filament as well as revealed no significant effect of the filament formation process on its properties. This study may contribute to expanding the range of medical-grade flexible filaments for standard low-budget FDM printers.
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Blok, Lourens, Marco Longana, and Benjamin Woods. "Fabrication and Characterisation of Aligned Discontinuous Carbon Fibre Reinforced Thermoplastics as Feedstock Material for Fused Filament Fabrication." Materials 13, no. 20 (October 20, 2020): 4671. http://dx.doi.org/10.3390/ma13204671.
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In this work, aligned discontinuous fibre composite (ADFRC) tapes were developed and investigated as precursors for a novel 3D printing filament. ADFRCs have the potential to achieve mechanical performance comparable to continuous fibre reinforced composites, given sufficient fibre length and high level of alignment, and avoid many of the manufacturing difficulties associated with continuous fibres, e.g., wrinkling, bridging and corner radii constraints. Their potential use for fused filament fabrication (FFF) techniques was investigated here. An extensive down-selection process of thermoplastic matrices was performed, as matrix properties significantly impact both the processing and performance of the filament. This resulted in four candidate polymers (ABS, PLA, Nylon, PETG) which were used to manufacture ADFRC tapes with a Vf of 12.5% using the high performance discontinuous fibre (HiPerDiF) technology and an in-house developed continuous consolidation module. Tensile stiffness and strength up to 30 GPa and 400 MPa respectively were recorded, showing that a discontinuous fibre filament has the potential to compete with continuous fibre filaments.
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Lee, Ching Hao, Farah Nadia Binti Mohammad Padzil, Seng Hua Lee, Zuriyati Mohamed Asa’ari Ainun, and Luqman Chuah Abdullah. "Potential for Natural Fiber Reinforcement in PLA Polymer Filaments for Fused Deposition Modeling (FDM) Additive Manufacturing: A Review." Polymers 13, no. 9 (April 27, 2021): 1407. http://dx.doi.org/10.3390/polym13091407.
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In this review, the potential of natural fiber and kenaf fiber (KF) reinforced PLA composite filament for fused deposition modeling (FDM) 3D-printing technology is highlighted. Additive manufacturing is a material-processing method in which the addition of materials layer by layer creates a three-dimensional object. Unfortunately, it still cannot compete with conventional manufacturing processes, and instead serves as an economically effective tool for small-batch or high-variety product production. Being preformed of composite filaments makes it easiest to print using an FDM 3D printer without or with minimum alteration to the hardware parts. On the other hand, natural fiber-reinforced polymer composite filaments have gained great attention in the market. However, uneven printing, clogging, and the inhomogeneous distribution of the fiber-matrix remain the main challenges. At the same time, kenaf fibers are one of the most popular reinforcements in polymer composites. Although they have a good record on strength reinforcement, with low cost and light weight, kenaf fiber reinforcement PLA filament is still seldom seen in previous studies. Therefore, this review serves to promote kenaf fiber in PLA composite filaments for FDM 3D printing. To promote the use of natural fiber-reinforced polymer composite in AM, eight challenges must be solved and carried out. Moreover, some concerns arise to achieve long-term sustainability and market acceptability of KF/PLA composite filaments.
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Borg, Gabriel, Szabolcs Kiss, and Arif Rochman. "Filament Development for Laser Assisted FFF 3D Printing." Journal of Manufacturing and Materials Processing 5, no. 4 (October 29, 2021): 115. http://dx.doi.org/10.3390/jmmp5040115.
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The aim of this paper was to develop filaments which can be used for laser assisted fused filament fabrication (FFF) 3D printing in order to increase the inter-layer bonding strength of the printed part. The filaments were developed from the most commonly used filament materials, acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) with the addition of different polymer additives. After performing near infrared (NIR) absorption tests, graphite was selected for further development as it possesses excellent NIR absorption capabilities whilst resulting in consistent filaments’ diameter and being economically viable. A conventional FFF 3D printer was initially used to test the printability of the developed filaments. Afterwards, a fiber couple laser diode was integrated within the printing head to heat up the previously extruded layer. The produced filaments were used to 3D print specimens for shear and tensile testing. With the laser heating, an increase of 14.5% in the elastic modulus and an increase of 27.8% in the tensile strength of the printed parts were noticed. This showed that adding additives into filament materials for localized laser heating is an effective method of increasing the inter-layer bonding, and therefore, the overall strength and durability of FFF 3D printed parts.
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Surisaeng, Jiratchaya, Warrayut Kanabenja, Nichaphat Passornraprasit, Chuanchom Aumnate, and Pranut Potiyaraj’. "Polyhydroxybutyrate/polylactic acid blends: An alternative feedstock for 3D printed bone scaffold model." Journal of Physics: Conference Series 2175, no. 1 (January 1, 2022): 012021. http://dx.doi.org/10.1088/1742-6596/2175/1/012021.
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Abstract In this research, we developed 3D printing filaments from polyhydroxybutyrate (PHB)/poly(lactic acid) (PLA) blends to further its use in a fused filament fabrication (FFF) 3D printing technique as an alternative feedstock for manufacturing bone scaffold model. The filaments were fabricated with blending ratios of PHB/PLA at 100/0, 90/10, 70/30, 50/50, 30/70, 10/90, and 0/100 %wt. using an extrusion process. Furthermore, 10 phr of polypropylene glycol (PPG) was added as a processing aid to enhance the processability. The results of MFR showed that the suitable temperature for 3D printing of all blended filaments is 190 °C. The changes in thermal properties indicate the partial compatibility between PHB and PLA in the blends. PLA plays a vital role in improving the mechanical properties of PHB. 3D printing filament from PHB/PLA blends has been successfully developed.
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Park, Soyeon, and Kun (Kelvin) Fu. "Polymer-based filament feedstock for additive manufacturing." Composites Science and Technology 213 (September 2021): 108876. http://dx.doi.org/10.1016/j.compscitech.2021.108876.
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Roulon, Stéphane, Ian Soulairol, Valérie Lavastre, Nicolas Payre, Maxime Cazes, Laurent Delbreilh, and Jean Alié. "Production of Reproducible Filament Batches for the Fabrication of 3D Printed Oral Forms." Pharmaceutics 13, no. 4 (March 31, 2021): 472. http://dx.doi.org/10.3390/pharmaceutics13040472.
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Patients need medications at a dosage suited to their physiological characteristics. Three-dimensional printing (3DP) technology by fused-filament fabrication (FFF) is a solution for manufacturing medication on demand. The aim of this work was to identify important parameters for the production of reproducible filament batches used by 3DP for oral formulations. Amiodarone hydrochloride, an antiarrhythmic and insoluble drug, was chosen as a model drug because of dosage adaptation need in children. Polyethylene oxide (PEO) filaments containing amiodarone hydrochloride were produced by hot-melt extrusion (HME). Different formulation storage conditions were investigated. For all formulations, the physical form of the drug following HME and fused-deposition modeling (FDM) 3D-printing processes were assessed using thermal analysis and X-ray powder diffraction (XRPD). Filament mechanical properties, linear mass density and surface roughness, were investigated by, respectively, 3-point bending, weighing, and scanning electron microscopy (SEM). Analysis results showed that the formulation storage condition before HME-modified filament linear mass density and, therefore, the oral forms masses from a batch to another. To obtain constant filament apparent density, it has been shown that a constant and reproducible drying condition is required to produce oral forms with constant mass.
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Chen, Jingdong, and Douglas E. Smith. "Filament rheological characterization for fused filament fabrication additive manufacturing: A low-cost approach." Additive Manufacturing 47 (November 2021): 102208. http://dx.doi.org/10.1016/j.addma.2021.102208.
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Spoerk, Martin, Florian Arbeiter, Ivan Raguž, Clemens Holzer, and Joamin Gonzalez-Gutierrez. "Mechanical Recyclability of Polypropylene Composites Produced by Material Extrusion-Based Additive Manufacturing." Polymers 11, no. 8 (August 7, 2019): 1318. http://dx.doi.org/10.3390/polym11081318.
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Due to a lack of long-term experience with burgeoning material extrusion-based additive manufacturing technology, also known as fused filament fabrication (FFF), considerable amounts of expensive material will continue to be wasted until a defect-free 3D-printed component can be finalized. In order to lead this advanced manufacturing technique toward cleaner production and to save costs, this study addresses the ability to remanufacture a wide range of commercially available filaments. Most of them either tend to degrade by chain scission or crosslinking. Only polypropylene (PP)-based filaments appear to be particularly thermally stable and therefore suitable for multiple remanufacturing sequences. As the extrusion step exerts the largest influence on the material in terms of temperature and shear load, this study focused on the morphological, rheological, thermal, processing, tensile, and impact properties of a promising PP composite in the course of multiple consecutive extrusions as well as the impact of additional heat stabilizers. Even after 15 consecutive filament extrusions, the stabilized additively manufactured PP composite revealed an unaltered morphology and therefore the same tensile and impact strength as the initial material. As the viscosity of the material of the 15th extrusion was nearly identical to that of the 1st extrusion sequence, the processability both in terms of extrusion and FFF was outstanding, despite the tremendous amount of shear and thermal stress that was undergone. The present work provides key insights into one possible step toward more sustainable production through FFF.
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Kiran Karthik, Maridinapalli Sai, Havish Karanam Ramendra Karanam, and S. Senthur Prabu. "Experimental and Thermal Analysis of Desktop FDM 3D Printers "Ender 3" and "CR-10S Pro" Hot Ends." ECS Transactions 107, no. 1 (April 24, 2022): 12851–62. http://dx.doi.org/10.1149/10701.12851ecst.
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Nowadays, the desktop 3D printers are common in computer aided manufacturing and widely used in multiple applications across homes, offices, and in several business sectors, etc. A wide variety of filaments like PLA, ABS, PETG, TPU, etc. are now being used in Fused Deposition Modeling (FDM). These filaments require different temperatures to print. FDM is a process in which a material in its filament form is melted and deposited layer by layer to form the required object. The hot end of a printer plays a crucial role in the melting of these filaments for printing. It is a major component of a 3D printer, where the filament is brought to a semi-solid state, to extrude and deposit the filament in layers. In this research study, the hot end of "Ender 3" and "CR-10S Pro" are modeled using Computer Aided Designing software, and thermal analysis using Finite Element Analysis, is carried out by applying the maximum printing temperature of PLA for the two printer hot ends. To optimize the problem of wide temperature gradient which often results in clogs and jams across the hot end, the design of heat sink is modified to maximize heat dissipation. Alongside, the simulation result is also compared with manual experimental readings.
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Monnet, Wrya, Joseph Ray Carroll, and Paul Dirk Embery. "Using Solar Thermal Collectors for Plastic Recycling in Additive Manufacturing." UKH Journal of Science and Engineering 2, no. 1 (June 30, 2018): 43–47. http://dx.doi.org/10.25079/ukhjse.v2n1y2018.pp43-47.
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Solar thermal applications vary widely across many different fields. This research aims to introduce the concept of using solar thermal energy in a new application for recycling waste plastic for use in 3D printing. In some countries or regions, waste plastic is not collected for recycling and thrown into landfills. This leads to serious local and global environmental pollution. In additive manufacturing, plastic is one of the main materials used to build 3D models. In this work we suggest a novel way to produce extruded filament for 3D printing from waste plastic using solar energy. The concept relies on using a Scheffler fixed focus solar collector to heat the barrel of a filament extruder rather than using electrical heaters. The barrel of the filament extruder is heated by a receiver in the focal point of the solar collector. The molten plastic is then extruded through a nozzle to produce filament. This concept of using solar power for extruding 3D printing filament is an environmentally friendly way to turn waste plastic into useful 3D printing material especially in areas where recycling of plastics does not exist and electrical power is limited.
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Calignano, Flaviana, Massimo Lorusso, Ignanio Roppolo, and Paolo Minetola. "Investigation of the Mechanical Properties of a Carbon Fibre-Reinforced Nylon Filament for 3D Printing." Machines 8, no. 3 (September 4, 2020): 52. http://dx.doi.org/10.3390/machines8030052.
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Additive manufacturing (i.e., 3D printing) has rapidly developed in recent years. In the recent past, many researchers have highlighted the development of in-house filaments for fused filament fabrication (FFF), which can extend the corresponding field of application. Due to the limited mechanical properties and deficient functionality of printed polymer parts, there is a need to develop printable polymer composites that exhibit high performance. This study analyses the actual mechanical characteristics of parts fabricated with a low-cost printer from a carbon fibre-reinforced nylon filament. The results show that the obtained values differ considerably from the values presented in the datasheets of various filament suppliers. Moreover, the hardness and tensile strength are influenced by the building direction, the infill percentage, and the thermal stresses, whereas the resilience is affected only by the building direction. Furthermore, the relationship between the mechanical properties and the filling factor is not linear.
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Tosto, Claudio, Jacopo Tirillò, Fabrizio Sarasini, and Gianluca Cicala. "Hybrid Metal/Polymer Filaments for Fused Filament Fabrication (FFF) to Print Metal Parts." Applied Sciences 11, no. 4 (February 5, 2021): 1444. http://dx.doi.org/10.3390/app11041444.
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The exploitation of mechanical properties and customization possibilities of 3D printed metal parts usually come at the cost of complex and expensive equipment. To address this issue, hybrid metal/polymer composite filaments have been studied allowing the printing of metal parts by using the standard Fused Filament Fabrication (FFF) approach. The resulting hybrid metal/polymer part, the so called “green”, can then be transformed into a dense metal part using debinding and sintering cycles. In this work, we investigated the manufacturing and characterization of green and sintered parts obtained by FFF of two commercial hybrid metal/polymer filaments, i.e., the Ultrafuse 316L by BASF and the 17-4 PH by Markforged. The Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectrometry (EDS) analyses of the mesostructure highlighted incomplete raster bonding and voids like those observed in conventional FFF-printed polymeric structures despite the sintering cycle. A significant role in the tensile properties was played by the building orientation, with samples printed flatwise featuring the highest mechanical properties, though lower than those achievable with standard metal additive manufacturing techniques.
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Vakharia, Ved S., Hunter Leonard, Mrityunjay Singh, and Michael C. Halbig. "Multi-Material Additive Manufacturing of High Temperature Polyetherimide (PEI)–Based Polymer Systems for Lightweight Aerospace Applications." Polymers 15, no. 3 (January 21, 2023): 561. http://dx.doi.org/10.3390/polym15030561.
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Rapid innovations in 3-D printing technology have created a demand for multifunctional composites. Advanced polymers like amorphous thermoplastic polyetherimide (PEI) can create robust, lightweight, and efficient structures while providing high-temperature stability. This work manufactured ULTEM, a PEI-based polymer, and carbon-fiber-infused ULTEM multi-material composites with varying layering patterns (e.g., AAABBB vs. ABABAB) using fused filament fabrication (FFF). The microstructure of fractured surfaces and polished cross-sections determined that the print quality of layers printed closer to the heated bed was higher than layers closer to the top surface, primarily due to the thermal insulating properties of the material itself. Mechanical properties of the multi-material parts were between those of the single-material parts: an ultimate tensile strength and elastic modulus of 59 MPa and 3.005 GPa, respectively. Multi-material parts from the same filaments but with different layering patterns showed different mechanical responses. Prints were of higher quality and demonstrated a higher elastic modulus (3.080 GPa) when consecutive layers were printed from the same filament (AAABBB) versus parts with printed layers of alternating filaments (ABABAB), which showed a higher ultimate strength (62.04 MPa). These results demonstrate the potential for creatively designing multi-material printed parts that may enhance mechanical properties.
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Arrigo, Rossella, Daniele Battegazzore, Giulia Bernagozzi, Fulvia Cravero, David Norberto Ribero Pedraza, and Alberto Frache. "Recycled PP for 3D Printing: Material and Processing Optimization through Design of Experiment." Applied Sciences 12, no. 21 (October 26, 2022): 10840. http://dx.doi.org/10.3390/app122110840.
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In this work, blends that were based on first use PP added with talc (PPt) and recycled polypropylene (r-PP) were designed and formulated, aiming at producing filaments that are suitable for 3D printing fused filament fabrication (FFF) processes. A preliminary characterization of PPt/r-PP blends at different weight ratios allowed selecting two systems showing adequate rheological behavior for FFF. The selected blends were melt compounded in a twin-screw extruder, optimizing the processing conditions through a design of experiments approach, involving the use of Taguchi’s method. The materials that were prepared with the optimized processing conditions, hence showing the best performance in terms of rheological behavior and thermal characteristics, were then selected for the production of the filament and for the subsequent FFF processing. Finally, the morphology of the filament and the mechanical properties of 3D-printed samples were assessed, demonstrating the achievement of satisfactory results in terms of performances. In general, the obtained results clearly demonstrated that a proper optimization of both material and processing conditions offers the possibility of using recycled PP-based formulations for additive manufacturing processes, hence allowing a remarkable valorization of a low added-value material through its utilization for an innovative and sustainable manufacturing approach.
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Aumnate, C., A. Pongwisuthiruchte, P. Pattananuwat, and P. Potiyaraj. "Fabrication of ABS/Graphene Oxide Composite Filament for Fused Filament Fabrication (FFF) 3D Printing." Advances in Materials Science and Engineering 2018 (November 6, 2018): 1–9. http://dx.doi.org/10.1155/2018/2830437.
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Additive manufacturing, the so-called three-dimensional (3D) printing, is a revolutionary emerging technology. Fused filament fabrication (FFF) is the most used 3D printing technology in which the melted filament is extruded through the nozzle and builds up layer by layer onto the build platform. The layers are then fused together and solidified into final parts. Graphene-based materials have been positively incorporated into polymers for innovative applications, such as for the mechanical, thermal, and electrical enhancement. However, to reach optimum properties, the graphene fillers are necessary to be well dispersed in polymers matrix. This study aims to emphasise the interest of producing ABS/graphene oxide (GO) composites for 3D printing application. The ABS/GO composite filaments were produced using dry mixing and solvent mixing methods before further melt extruded to investigate the proper way to disperse GO into ABS matrix. The ABS/GO composite filament with 2 wt.% of GO, prepared from the solvent mixing method, was successfully printed into a 3D model. By adding GO, the tensile strength and Young’s modulus of ABS can be enhanced. However, the ABS/GO composite filament that was prepared via the dry mixing method failed to print. This could be attributed to the aggregation of GO, leading to the die clogging and failure of the printing process.
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Heuer, Anselm, Pascal Pinter, and Kay André Weidenmann. "Analysis of the Effects of Raster Orientation in Components Consisting of Short Glass Fibre Reinforced ABS of Different Fibre Volume Fraction Produced by Additive Manufacturing." Key Engineering Materials 742 (July 2017): 482–89. http://dx.doi.org/10.4028/www.scientific.net/kem.742.482.
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Additive manufacturing provides the ability to produce structural components featuring complex shapes in one step, compared to traditional methods of production. Therefore, additive manufacturing has recently gained attention for the direct production of parts. Using fibre reinforced filaments offers the opportunity to improve the mechanical properties of FFF printed components. In order to dimension them correctly, the mechanical properties of additive manufactured samples based on glass fibre reinforced filaments were determined. Additionally, the influence of extrusion paths resulting in a distinct fibre orientation were taken into account. Samples were produces by FFF-method (Fused Filament Fabrication) from three materials: Bulk ABS and short glass fibre reinforced ABS featuring 5 wt% and 10 wt% fibre content. Additionally, samples were printed in two different raster orientations of 0° and 90°. Three different sample types were manufactured in order to perform tension, flexural and impact tests. Prior to printing the samples, the slicer parameters were optimized for usage with the fibre reinforced filament. To determine the FOD (Fibre Orientation Distribution) and FLD (Fibre Length Distribution), the samples were scanned using a CT. Results show that fibre reinforced filaments used in this contribution can increase stiffness to 150 % of the bulk material in printing direction with a fibre weight content of 10 %. CT investigations have shown that the orientation of fibres is primary aligned to the printing path.
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Pyteraf, Jolanta, Witold Jamróz, Mateusz Kurek, Joanna Szafraniec-Szczęsny, Daniel Kramarczyk, Karolina Jurkiewicz, Justyna Knapik-Kowalczuk, et al. "How to Obtain the Maximum Properties Flexibility of 3D Printed Ketoprofen Tablets Using Only One Drug-Loaded Filament?" Molecules 26, no. 11 (May 22, 2021): 3106. http://dx.doi.org/10.3390/molecules26113106.
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The flexibility of dose and dosage forms makes 3D printing a very interesting tool for personalized medicine, with fused deposition modeling being the most promising and intensively developed method. In our research, we analyzed how various types of disintegrants and drug loading in poly(vinyl alcohol)-based filaments affect their mechanical properties and printability. We also assessed the effect of drug dosage and tablet spatial structure on the dissolution profiles. Given that the development of a method that allows the production of dosage forms with different properties from a single drug-loaded filament is desirable, we developed a method of printing ketoprofen tablets with different dose and dissolution profiles from a single feedstock filament. We optimized the filament preparation by hot-melt extrusion and characterized them. Then, we printed single, bi-, and tri-layer tablets varying with dose, infill density, internal structure, and composition. We analyzed the reproducibility of a spatial structure, phase, and degree of molecular order of ketoprofen in the tablets, and the dissolution profiles. We have printed tablets with immediate- and sustained-release characteristics using one drug-loaded filament, which demonstrates that a single filament can serve as a versatile source for the manufacturing of tablets exhibiting various release characteristics.
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Das, Subrata. "Mechanical failure of mulberry and tasar silk." Tekstilna industrija 69, no. 2 (2021): 16–20. http://dx.doi.org/10.5937/tekstind2102016d.
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This article investigates the tensile and twist failure of mulberry and tasar silk filaments. The mulberry and tasar filaments were subjected to uniaxial loading on Instron tensile tester at different rate of extensions and gauge lengths. Furthermore, the number of turns to rupture the silk filaments was tested using a twist tester. The results showed that the mulberry filament has higher tensile and twist strength than that of tasar filament. The SEM photomicrographs of the region of fracture divulged that the tensile and twist failure of mulberry and tasar filaments take place in catastrophic and non-catastrophic modes, respectively.
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Vanaei, Hamid Reza, Mohammadali Shirinbayan, Michael Deligant, Sofiane Khelladi, and Abbas Tcharkhtchi. "In-Process Monitoring of Temperature Evolution during Fused Filament Fabrication: A Journey from Numerical to Experimental Approaches." Thermo 1, no. 3 (October 27, 2021): 332–60. http://dx.doi.org/10.3390/thermo1030021.
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Fused filament fabrication (FFF), an additive manufacturing technique, unlocks alternative possibilities for the production of complex geometries. In this process, the layer-by-layer deposition mechanism and several heat sources make it a thermally driven process. As heat transfer plays a particular role and determines the temperature history of the merging filaments, the in-process monitoring of the temperature profile guarantees the optimization purposes and thus the improvement of interlayer adhesion. In this review, we document the role of heat transfer in bond formation. In addition, efforts have been carried out to evaluate the correlation of FFF parameters and heat transfer and their effect on part quality. The main objective of this review paper is to provide a comprehensive study on the in-process monitoring of the filament’s temperature profile by presenting and contributing a comparison through the literature.