FDM process parameters influence over the mechanical properties of polymer specimens: A review

Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments.

Fused Deposition Modeling (FDM) is a widely used additive manufacturing technology for fabrication of complex geometric parts using thermoplastic polymers. The quality issues and inferior properties of fabricated parts limited this process to manufacture parts for industrial level applications. Reinforcing the polymer with nanoparticles, short fibers or continuous fibers improve mechanical, thermal and electrical properties compared to the neat polymer. Several works have been carried out since last two decades to print quality products through FDM by using composite materials. The success of expanding this technique to industrial applications depends on the preparation of printable composite feedstock filament and printing without defects. This article reviews the challenges involved in the preparation of composite feedstock filaments and printing issues during the printing of nano composites, short and continuous fiber composites. The printing process of various thermoplastic composites ranging from amorphous to crystalline polymers is discussed. Also, detailed explanation is given about the analytical and numerical models used for simulating the FDM printing process and for estimating the mechanical properties of the printed parts. This critical review mainly helps the young researchers working in the area of processing of composite materials via 3D printing.

A critical review on the fused deposition modeling of thermoplastic polymer composites

Fused deposition modeling (FDM) is an additive manufacturing (AM) process that is often used to fabricate geometrically complex shaped prototypes and parts. It is gaining popularity as it reduces cycle time for product development without the need for expensive tools. However, the commercialization of FDM technology in various industrial applications is currently limited due to several shortcomings, such as insufficient mechanical properties, poor surface quality, and low dimensional accuracy. The qualities of FDM-produced products are affected by various process parameters, for example, layer thickness, build orientation, raster width, or print speed. The setting of 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 various parameters. The optimum setting of parameters is deemed to improve the qualities of three-dimensional (3D) printed parts and may reduce post-production work. This paper intensively reviews state-of-the-art literature on the influence of parameters on part qualities and the existing work on process parameter optimization. Additionally, the shortcomings of existing works are identified, challenges and opportunities to work in this field are evaluated, and directions for future research in this field are suggested.

A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics

Fused deposition modeling (FDM) is one of the most widely used 3D printing techniques that utilizes polymers to create models, prototypes or even end products. Since 2009, the demand for FD...

Recent Developments in Fused Deposition Modeling-Based 3D Printing of Polymers and Their Composites

Compared to the common selective laser sintering (SLS) manufacturing method, fused deposition modeling (FDM) seems to be an economical and efficient three-dimensional (3D) printing method for high temperature polymer materials in medical applications. In this work, a customized FDM system was developed for polyether-ether-ketone (PEEK) materials printing. The effects of printing speed, layer thickness, printing temperature and filling ratio on tensile properties were analyzed by the orthogonal test of four factors and three levels. Optimal tensile properties of the PEEK specimens were observed at a printing speed of 60 mm/s, layer thickness of 0.2 mm, temperature of 370 °C and filling ratio of 40%. Furthermore, the impact and bending tests were conducted under optimized conditions and the results demonstrated that the printed PEEK specimens have appropriate mechanical properties.

https://www.mdpi.com/1996-1944/11/2/216/pdf

Mechanical Properties Optimization of Poly-Ether-Ether-Ketone via Fused Deposition Modeling

Amorphous polymers are heavily utilized materials in selective laser sintering (SLS) due to their good dimensional accuracy. However, sintered parts of amorphous polymers cannot be used as functional parts owing to their poor forming performance, including their low relative densities and tensile strength. Therefore, post-processing methods are employed to enhance the mechanical properties of amorphous polymers SLS parts without damaging their relatively high dimensional accuracy. In this study, the forming process of selective laser sintering (SLS) and post-processing on polystyrene (PS) was investigated. The orthogonal experiment was designed to obtain the optimal combination of process parameters. The effect of a single process parameter and the laser volumetric energy density (LVED) on dimension accuracy and warpage of the sintered parts were also discussed. In addition, a three-dimensional (3D) thermal model was developed to analyze the temperature fields of single-layer SLS parts and PS powder sintering mechanism. Then, infiltrating with epoxy resin was employed to enhance the mechanical properties of the PS parts. Good resin-infiltrated formulation was obtained based on the mechanical property tests and fractured surface analysis. This research provides guidance for SLS process and post-processing technology in polymers.

https://www.mdpi.com/2073-4360/11/6/956/pdf

Improvement on Selective Laser Sintering and Post-Processing of Polystyrene

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Mechanical Properties Optimization of Poly-Ether-Ether-Ketone via Fused Deposition Modeling

Improvement on Selective Laser Sintering and Post-Processing of Polystyrene