Fused deposition modelling (FDM) is the most economical additive manufacturing technique. The purpose of this paper is to describe a detailed review of this technique. Total 211 research papers published during the past 26 years, that is, from the year 1994 to 2019 are critically reviewed. Based on the literature review, research gaps are identified and the scope for future work is discussed.,Literature review in the domain of FDM is categorized into five sections – (i) process parameter optimization, (ii) environmental factors affecting the quality of printed parts, (iii) post-production finishing techniques to improve quality of parts, (iv) numerical simulation of process and (iv) recent advances in FDM. Summary of major research work in FDM is presented in tabular form.,Based on literature review, research gaps are identified and scope of future work in FDM along with roadmap is discussed.,In the present paper, literature related to chemical, electric and magnetic properties of FDM parts made up of various filament feedstock materials is not reviewed.,This is a comprehensive literature review in the domain of FDM focused on identifying the direction for future work to enhance the acceptability of FDM printed parts in industries.

Fused deposition modelling: a review

Current status and future directions of fused filament fabrication

The application of material extrusion-based additive manufacturing methods has recently become increasingly popular in the medical sector. Thereby, thermoplastic materials are likely to be used. However, thermoplastics are highly dependent on the temperature and loading rate in comparison to other material classes. Therefore, it is crucial to characterise these influences on the mechanical properties. On this account, dynamic mechanical analyses to investigate the application temperature range, and tensile tests at different crosshead speeds (103, 101, 10-1 and 10-3 mms-1) were performed on various 3D-printable polymers, namely polyetheretherketone (PEEK), polylactide (PLA), poly(methyl methacrylate) (PMMA), glycol-modified poly(ethylene terephthalate) (PETG), poly(vinylidene fluoride) (PVDF) and polypropylene (PP). It was found that the mechanical properties of PEEK, PLA, PMMA and PETG hardly depend on temperature changes inside the human body. PVDF and PP show a significant decrease in stiffness with increasing body temperatures. Additionally, the dependency of the stiffness on the strain-rate is increasing between PLA, PP, PEEK, PETG, PMMA and PVDF. Besides the mechanical integrity of these materials (strength, stiffness and its strain-rate and temperature dependency inside the body), the materials were further ranked considering their filling density as a measure of their processability. Hence, useful information for the selection of possible medical applications for each material and the design process of 3D-printed implants are provided.

Mechanical properties of polymeric implant materials produced by extrusion-based additive manufacturing.

The purpose of this paper is to review research studies on process optimisation and machine development that lead to the enhancement of final products in various aspects of the fused deposition modelling (FDM) process,An overview of the literature, focussing on process parameters, machine developments and material characterisations This study investigates recent research studies that studied FDM capabilities in printing a vast range of materials from thermoplastics to metal alloys,FDM is one of the most common techniques in additive manufacturing (AM) processes Many parameters in this technology have effects on three-dimensional printed products Therefore, it is necessary to obtain the optimum elements, for example, build orientation, layer thickness, nozzle diameter, infill pattern and bed temperature By selecting a proper variable range of parameters, the layers adhere strongly and building end-use products of high quality are achievable A vast range of materials and their properties from polymers to composite-based polymers are presented Novel techniques to print metal alloys and composites are examined to increase the productivity of the FDM process Additionally, defects such as shrinkage and warpage are discussed to eliminate the system’s limitations and improve the quality of final products Multi-axis and mobile machines brought enhancements throughout the process to eliminate obstacles such as staircase defects in the conventional FDM process In brief, recent developments were identified and a summary of major improvements was discussed in this study for future research,This paper is an overview that provides information about research and developments in FDM This review focusses on process optimisation and obstacles in printing polymers, composites, geopolymers and novel materials Therefore, machine characteristics were examined to find out the accessibility of printing novel materials for different applications

An overview of fused deposition modelling (FDM): research, development and process optimisation

Additive manufacturing (AM) technology is capable of efficiently building complex shapes when compared with traditional manufacturing methods. Fused deposition modeling (FDM) is one of the AM processes, and it produces a great variety of polymeric parts. Therefore, it is essential to determine the relationship that exists among its process parameters, productivity and sustainability, quality of the final piece, and its structural performance. This paper presents an experimental study centered on optimizing five responses associated with FDM: energy consumption of the 3D printer, processing time, part's dimensional accuracy, the quantity of material used to print the pieces, and mechanical strength of the specimens. The model material employed was acrylonitrile styrene acrylate. The effects of five key process parameters on the responses were studied using the Taguchi methodology and analysis of variance (ANOVA). These parameters were layer thickness, filling pattern, orientation angle, printing plane, and position of the piece on the build platform. A desirability analysis was employed to determine the set of process parameters that provided the best trade-off among all the considered variables. The results showed that the approach presented in this work allowed for simultaneous optimization of all the observed variables for the 3D printing process.

Optimization of printing parameters in fused deposition modeling for improving part quality and process sustainability

In this paper, we investigated the process variable effects on the damage and deformational behavior of fused deposition modeling (FDM) three-dimensional (3D)-printed specimens by performing tensile tests and inverse identification analyses. A characterization of the effects of different parametric variations of 3D-printed specimens on fracture properties are a matter of considerable significance that are often overlooked. By combining the infill density and the layer thickness options that are available in the 3D printer machine, six groups with different structural configurations can be obtained. The data and images obtained from experiments are employed to investigate the failure mechanism of 3D-printed specimens and demonstrate the relationship that exists between structural variations and fracture mechanical properties. On the basis of experimental results, a Gurson-type porous plasticity model was used within a 3D continuum finite element model to characterize the process–damage parameter relationship through an inverse identification process.

Characterization of process–deformation/damage property relationship of fused deposition modeling (FDM) 3D-printed specimens

In this paper, we present a novel approach to enhance the mechanoluminescence (ML) sensitivity of composite made with epoxy resin and strontium aluminate co-doped with europium ions and dysprosium ...

Enhancement of mechanoluminescence sensitivity of SrAl2O4: Eu2+, Dy3+/Epoxy composites by ultrasonic curing treatment method

Multiscale damage plasticity modeling and inverse characterization for particulate composites

This paper proposes a stochastically coupled thermo-chemical and viscoelastic model and provides new insights from comparisons of the cure-induced residual stresses and distortions between various ...

Cure-induced residual stress buildup and distortions of CFRP laminates with stochastic thermo-chemical and viscoelastic models: Experimental verifications

Mechanoluminescence (ML), which emits light upon external mechanical stress, was applied to fibrous composites. Herein, ML particles were incorporated into poly(vinylidene fluoride) (PVDF) and polyacrylonitrile (PAN) electrospun webs to prepare ML/PVDF and ML/PAN composite fabrics. The produced fabrics were treated with O2 and C4F8 plasma to modify the wetting properties, then the effects of composite wettability on the light-emitting response in dry and wet conditions were investigated. The light intensity was greatly decreased when the composite fabrics absorbed water. When the composites were hydrophobized by the C4F8 plasma-enhanced chemical vapor deposition process, the original light intensity was protected in wet conditions, while maintaining the water vapor transmission rate. As the clothing material would be exposed to moisture in varied situations, the reduced ML sensitivity in wet conditions may limit the application of ML composite fabrics. The findings suggest a facile strategy to fabricate moisture-resistant, breathable mechanoluminescence composite fabrics.

https://www.mdpi.com/2073-4360/12/8/1720/pdf

Water-Resistant Mechanoluminescent Electrospun Fabrics with Protected Sensitivity in Wet Condition via Plasma-Enhanced Chemical Vapor Deposition Process.

Tomas Webbe Kerekes

Papers

Characterization of process–deformation/damage property relationship of fused deposition modeling (FDM) 3D-printed specimens

Enhancement of mechanoluminescence sensitivity of SrAl2O4: Eu2+, Dy3+/Epoxy composites by ultrasonic curing treatment method

Multiscale damage plasticity modeling and inverse characterization for particulate composites

Cure-induced residual stress buildup and distortions of CFRP laminates with stochastic thermo-chemical and viscoelastic models: Experimental verifications

Water-Resistant Mechanoluminescent Electrospun Fabrics with Protected Sensitivity in Wet Condition via Plasma-Enhanced Chemical Vapor Deposition Process.