Additive manufacturing of PLA structures using fused deposition modelling: Effect of process parameters on mechanical properties and their optimal selection

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

Fused filament fabrication (FFF) is a 3D printing technique which allows layer-by-layer build-up of a part by the deposition of thermoplastic material through a nozzle. The technique allows for complex shapes to be made with a degree of design freedom unachievable with traditional manufacturing methods. However, the mechanical properties of the thermoplastic materials used are low compared to common engineering materials. In this work, composite 3D printing feedstocks for FFF are investigated, wherein carbon fibres are embedded into a thermoplastic matrix to increase strength and stiffness. First, the key processing parameters for FFF are reviewed, showing how fibres alter the printing dynamics by changing the viscosity and the thermal profile of the printed material. The state-of-the-art in composite 3D printing is presented, showing a distinction between short fibre feedstocks versus continuous fibre feedstocks. An experimental study was performed to benchmark these two methods. It is found that printing of continuous carbon fibres using the MarkOne printer gives significant increases in performance over unreinforced thermoplastics, with mechanical properties in the same order of magnitude of typical unidirectional epoxy matrix composites. The method, however, is limited in design freedom as the brittle continuous carbon fibres cannot be deposited freely through small steering radii and sharp angles. Filaments with embedded short carbon microfibres (∼100 μm) show better print capabilities and are suitable for use with standard printing methods, but only offer a slight increase in mechanical properties over the pure thermoplastic properties. It is hypothesized that increasing the fibre length in short fibre filament is expected to lead to increased mechanical properties, potentially approaching those of continuous fibre composites, whilst keeping the high degree of design freedom of the FFF process.

https://research-information.bris.ac.uk/files/159707908/1_s2.0_S2214860417305687_main.pdf

An investigation into 3D printing of fibre reinforced thermoplastic composites

Three-dimensional (3D) printed scaffold and material selection for bone repair

Purpose – The mechanical properties and surface finish of functional parts are important consideration in rapid prototyping, and the selection of proper parameters is essential to improve manufacturing solutions. The purpose of this paper is to describe how parts manufactured by fused deposition modelling (FDM), with different part orientations and raster angles, were examined experimentally and evaluated to achieve the desired properties of the parts while shortening the manufacturing times due to maintenance costs. Design/methodology/approach – For this purpose, five different raster angles (0°, 30°, 45°, 60° and 90°) for three part orientations (horizontal, vertical and perpendicular) have been manufactured by the FDM method and tested for surface roughness, tensile strength and flexural strength. Also, behaviour of the mechanical properties was clarified with scanning electron microscopy images of fracture surfaces. Findings – The research results suggest that the orientation has a more significant in...

Experimental investigation of FDM process for improvement of mechanical properties and production cost

Fused deposition modeling (FDM) is a rapidly growing 3D printing technology. However, printing materials are restricted to acrylonitrile butadiene styrene (ABS) or poly (lactic acid) (PLA) in most Fused deposition modeling (FDM) equipment. Here, we report on a new high-performance printing material, polyether-ether-ketone (PEEK), which could surmount these shortcomings. This paper is devoted to studying the influence of layer thickness and raster angle on the mechanical properties of 3D-printed PEEK. Samples with three different layer thicknesses (200, 300 and 400 μm) and raster angles (0°, 30° and 45°) were built using a polyether-ether-ketone (PEEK) 3D printing system and their tensile, compressive and bending strengths were tested. The optimal mechanical properties of polyether-ether-ketone (PEEK) samples were found at a layer thickness of 300 μm and a raster angle of 0°. To evaluate the printing performance of polyether-ether-ketone (PEEK) samples, a comparison was made between the mechanical properties of 3D-printed polyether-ether-ketone (PEEK) and acrylonitrile butadiene styrene (ABS) parts. The results suggest that the average tensile strengths of polyether-ether-ketone (PEEK) parts were 108% higher than those for acrylonitrile butadiene styrene (ABS), and compressive strengths were 114% and bending strengths were 115%. However, the modulus of elasticity for both materials was similar. These results indicate that the mechanical properties of 3D-printed polyether-ether-ketone (PEEK) are superior to 3D-printed ABS.

https://www.mdpi.com/1996-1944/8/9/5271/pdf

Influence of Layer Thickness and Raster Angle on the Mechanical Properties of 3D-Printed PEEK and a Comparative Mechanical Study between PEEK and ABS

Geopolymer is a porous inorganic material with a three-dimensional mesh structure, good mechanical properties, a simple preparation process (no sintering) and a low economic cost, and it is environmentally friendly. Geopolymer concrete has been widely used in the construction field, and many other studies have revealed that geopolymer will become one of the most promising inorganic materials with unique structure and properties. This paper provides a review of the development and current status of geopolymers and briefly explains the effects of material proportioning, experimental factors and activators on geopolymer performance. Because of the advantages of high specific surface area and high porosity, geopolymers could be used as adsorbent materials. This paper summarizes the research progresses of the adsorption of metal cations, anions, dyes, and gases by geopolymers, which emphasizes the geopolymer membranes in adsorption, and discusses the challenges and opportunities for the development of more efficient, sustainable and practical adsorption protocols.

/pdf/research-and-application-progress-of-geopolymers-in-2elez46r.pdf

Research and Application Progress of Geopolymers in Adsorption: A Review

Review on electrochemical carbon dioxide capture and transformation with bipolar membranes

Bipolar membranes, a new type of composite ion exchange membrane, contain an anion exchange layer, a cation exchange layer and an interface layer. The interface layer or junction is the connection between the anion and cation exchange layers. Water is dissociated into protons and hydroxide ions at the junction, which provides solutions to many challenges in the chemical, environmental and energy fields. By combining bipolar membranes with electrodialysis technology, acids and bases could be produced with low cost and high efficiency. The interface layer or junction of bipolar membranes (BPMs) is the connection between the anion and cation exchange layers, which the membrane and interface layer modification are vital for improving the performance of BPMs. This paper reviews the effect of modification of a bipolar membrane interface layer on water dissociation efficiency and voltage across the membrane, which divides into three aspects: organic materials, inorganic materials and newly designed materials with multiple components. The structure of the interface layer is also introduced on the performance of bipolar membranes. In addition, the remainder of this review discusses the challenges and opportunities for the development of more efficient, sustainable and practical bipolar membranes.

/pdf/composition-and-structure-progress-of-the-catalytic-1i20fpms.pdf

Composition and Structure Progress of the Catalytic Interface Layer for Bipolar Membrane

Mandible defect and the lack of dentition may result in facial deformity and chewing organ defects. It happens after the surgery of oral and maxillofacial tumors. This study aims at this problem. In this study, Finite Element Analysis (FEA) was employed to reconstruct the implanted mandible for customized patient. The 3D FEA model has great importance for biomechanical analysis. Though the analysis of the biomechanical situation with different numbers of dental implants, we can optimize the location and quantity of the implants. In this way, we can improve the quality of the implants, reduce the pain of patients, reduce the operation cost and avoid secondary surgery.

Di Zhao

Papers

Influence of Layer Thickness and Raster Angle on the Mechanical Properties of 3D-Printed PEEK and a Comparative Mechanical Study between PEEK and ABS

Research and Application Progress of Geopolymers in Adsorption: A Review

Review on electrochemical carbon dioxide capture and transformation with bipolar membranes

Composition and Structure Progress of the Catalytic Interface Layer for Bipolar Membrane

The Optimization Design of Dental Implant after the Mandible Tumor Resection and Reconstruction