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Mechanical properties of ABS samples manufactured under different process conditions

Czyżewski Piotr, Marciniak Dawid, Sykutera Dariusz

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2024

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Vol. 72, nr 1

art. no. e147065

EN

The purpose of this study is to determine the effect of manufacturing conditions on the mechanical properties and structure of ABS parts. Two sets of samples with the same geometric characteristics were produced by fused deposition modelling (FDM) and injection molding (IM). The molding pressure and cooling rate were found to have a significant effect on shaping the mechanical properties and structure of ABS products. The manufacturing method and adopted process parameters have a significant impact on the degree of packing of macromolecules in the volume of the product and thus determine its density. Selected mechanical properties were determined and compared with their specific gravity. The research was carried out using tools and machines, i.e. injection molds of unique design and standard measuring stations. Tensile and bending strengths and Young’s modulus were related to the density of products obtained under different process conditions and having gradient and solid structures. The results provide useful information for engineers designing products using FDM technology. Relating tensile and flexural strength and Young’s modulus to the specific gravity of the product. It was found that the value of product properties is closely related to various process conditions, which further provides a true description of the products.

2

The Influence of Printing Parameters on Leakage and Strength of Fused Deposition Modelling 3D Printed Parts

Szczęch Marcin, Sikora Wojciech

Advances in Science and Technology. Research Journal

|

2024

|

Vol. 18, no 1

195--201

EN

Fused Deposition Modelling (FDM) 3D printing technology has become popular for producing prototypes and final parts in various industries, including the automotive, aerospace, and medical sectors. The leakage of such components is often an important factor in determining their possible applications. This paper focuses on researching the influence of printing parameters on leakage and relating the results to the strength of parts produced using this technology. The printing parameters considered were temperature and layer height. PLA (polylactic acid) was chosen as the material due to its biodegradability and biocompatibility. Leakage measurements were carried out using an empty cylinder-shaped vessel filled with air under pressure. The leakage value was observed as a pressure drop over time. It was shown that 3D-printed FDM vessels are not perfectly leak-proof, but the value of observed leakage may be acceptable for selected applications (leakage below 2.5 Pa/s). The results showed a high correlation be-tween the height of the printed layer in both the leakage and strength of the tested samples, while reducing the height increased the tightness and strength of the 3D-printed parts. The effect of printing temperature was less significant.

3

A Review on Additive Manufacturing – Methods, Materials, and its Associated Failures

Gade Siddhant, Vagge Shashikant, Rathod Manoj

Advances in Science and Technology. Research Journal

|

2023

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Vol. 17, no 3

40--63

EN

Nowadays, additive manufacturing (AM) has surpassed traditional machining in the realm of emerging manufacturing. In the case of conventional machining, where the material is removed by different processes (subtractive manufacturing), there is a possibility of warping and internal stress development. Rapid prototyping is another option to avoid all the drawbacks of conventional machining in terms of manufacturing cost, time, accuracy, and quality. Rapid prototyping of a product by adding material (additive manufacturing) is gaining commercial traction. Additive manufacturing is frequently employed for the fabrication and bulk customization of all kinds of intricate geometrical designs those are absurd by traditional manufacturing techniques. Additive manufacturing techniques are broadly divided into four categories: (a) material extrusion, (b) chain polymerization, (c) laser or electron beam assisted sintering, and (d) direct writing-based processes. This article is a cutting-edge review that focuses on additive manufacturing processes and materials used in additive manufacturing. The process parameters for experimentation are chosen based on the application for which the part is designed. Some input process factors influence others for a specific response, and these critical process parameters are identified and optimized. This paper also gives a synopsis of failures associated with some additive manufacturing methods and their preventive actions.

4

Topology optimization of a 3D part virtually printed by FDM

Antar I., Othmani M., Zarbane K., El Oumami M., Beidouri Z.

Journal of Achievements in Materials and Manufacturing Engineering

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2022

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Vol. 112, nr 1

25--32

EN

Purpose: This research work aims to exhibit the possibility to topologically optimize a mesostructured part printed virtually by FDM taking into account the manufacturing parameters. Design/methodology/approach: The topology optimization of a 3D part printed by FDM was carried out using the software ABAQUS. On the other hand, a numerical approach using a script based on G-code file has been achieved to create a virtual model. Then, it was optimized according to the Solid Isotropic Material with Penalization (SIMP) method, which minimizing the strain energy was the objective function and the volume fraction of 30% was the constraint. Findings: The final topological optimization design of the virtual model is approximately similar to the homogeneous part. Furthermore, the strain energy of the virtual model is less than the homogeneous part. However, the virtually 3D optimized part volume is higher than the homogeneous one. Research limitations/implications: In this study, we have limited our study on one layer owing to reduce the simulation time. Moreover, the time required to optimize the virtual model is inordinate. The ensuing study, we will optimize a multiple layer of the mesostructure. Practical implications: Our study provides a powerful method to optimize with accurately a mesostructure taken into consideration the manufacturing setting. Originality/value: In this paper, we have studied through an original approach the potential of topology optimization of a 3D part virtually printed by FDM. By means of our approach, we were able to optimize topologically the 3D parts printed by FDM taking into account the manufacturing parameters.

5

Effect of infill and density pattern on the mechanical behaviour of ABS parts manufactured by FDM using Taguchi and ANOVA approach

Othmani M., Zarbane K., Chouaf A.

Archives of Materials Science and Engineering

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2021

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Vol. 111, nr 2

66--77

EN

Purpose: The present work aims to investigate the effect of many infill patterns (rectilinear, line, grid, triangles, cubic, concentric, honeycomb, 3D honeycomb) and the infill density on the mechanical tensile strength of an Acrylonitrile Butadiene Styrene (ABS) test specimen manufactured numerically by FDM. Design/methodology/approach: Computer-Aided Design (CAD) software has been used to model the geometry and the mesostructure of the test specimens in a fully automatic manner from a G-code file by using a script. Then, a Numerical Design of Experiments (NDoE) has been carried out by using Taguchi method and the Analysis of Variance (ANOVA). The tensile behaviour of these numerical test specimens has been studied by the Finite Element Analysis (FEA). Findings: The FEA results showed that a maximal Ultimate Tensile Strength (UTS) was reached by using the ‘concentric’ infill pattern combined with an infill density of 30%. The results also show that the infill pattern and the infill density are significant factors. Research limitations/implications: The low infill densities of 20% and 30% that have already been used in many previous studies, we have also applied it in order to reduce the time of the simulations. Indeed, with high infill density, the simulations take a very excessive time. In an ongoing study, we predicted higher percentages. Practical implications: This study provided an important modelling tool for the design and manufacture of functional parts and helps the FDM practitioners and engineers to manufacture strong and lightweight FDM parts by choosing the optimal process parameters. Originality/value: This study elucidated the effect of various infill patterns on the tensile properties of the test specimens and applied for the first time a NDoE using numerical test specimens created by the mesostructured approach, which considerably minimized the cost of the experiments while obtaining an error of 6.8% between the numerical and the experimental values of the UTS.

6

Rapid Manufacturing of Individualized Prosthetic Sockets

Górski Filip, Suszek Ewa, Wichniarek Radosław, Kuczko Wiesław, Żukowska Magdalena

Advances in Science and Technology. Research Journal

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2020

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Vol. 14, no 1

42--49

EN

The paper presents the experimental process of manufacturing individualized prosthetic sockets out of thermoplas‑ tic material, using an additive manufacturing technology of Fused Deposition Modelling. The patient was an adult male with an amputated forearm. His stump was 3D scanned using a low‑cost 3D scanner in a semi‑automated manner. Then, the anthropometric data was used for the creation of a model of a prosthetic socket, which was subsequently manufactured. Three different 3D printers were used, with three different materials (ABS, nylon and PC) and three different sets of process parameters. The paper contains the descriptions of the process, its results and opinions by the patient, leading to the selection of an optimal process course variant.

7

Prototyping of an Individualized Multi-Material Wrist Orthosis Using Fused Deposition Modelling

Górski Filip, Kuczko Wiesław, Weiss Weronika, Wichniarek Radosław, Żukowska Magdalena

Advances in Science and Technology. Research Journal

|

2019

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Vol. 13, no 4

39--47

EN

The paper presents the design and manufacturing process of an individualized wrist orthosis. The patient’s upper limb was 3D scanned and the orthosis was designed using a CAD system. Each part of the orthosis consists of two different materials that fulfill different functions. By using the double-head Fused Deposition Modelling machine it was possible to produce these parts in a single process without the need for additional assembly operations. The orthosis has been tested for mutual fit of parts, strength and comfort of use.

8

Effect of printing parameters on the mechanical properties of parts fabricated with open-source 3D printers in PLA by fused deposition modeling

Ouhsti M., El Haddadi B., Belhouideg S.

Mechanics and Mechanical Engineering

|

2018

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Vol. 22, nr 4

895--907

EN

3D polymer-based printers have become easily accessible to the public. Usually, the technology used by these 3D printers is Fused Deposition Modelling (FDM). The majority of these 3D printers mainly use acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) to fabricate 3D objects. In order for the printed parts to be useful for specific applications, the mechanical properties of the printed parts must be known. The aim of this study is to determine the tensile strength and elastic modulus of printed materials in polylactic acid (PLA) according to three important printing parameters such as deposition angle, extruder temperature and printing speed. The central composite design (CCD) was used to reduce the number of tensile test experiments. The obtained results show that the mechanical properties of printed parts depend on printing parameters. Empirical models relating response and process parameters are developed. The analysis of variance (ANOVA) was used to test the validity of models relating response and printing parameters. The optimal printing parameters are determined for the desired mechanical properties.

9

Structure Control in Fiber Reinforced Polymer Composites in Additive Manufacturing Technologies

Prusinowski A., Kaczyński R.

Machine Dynamics Research

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2018

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Vol. 42, No. 3

17--25

EN

The main reason for the authors to discuss the subject is the need to ﬁll the gaps in the knowledge regarding the abrasive wear of polymer composites with reinforcement in the form of short carbon ﬁbers that can be used in additive manufacturing technologies. The illustrated design of the extrusion head makes it possible to obtain a composite with a matrix in the form of a thermoplastic and reinforcement as carbon ﬁbers evenly spaced along the extrusion axis. The results of the simulation of heat propagation in the extrusion head and the ﬂow of the matrix material in the nozzle are shown. This paper presents the research on the mixing process of the matrix material in the designed system and describes further planned tests. The output materials were obtained at various amounts of the PLA matrix material fed in at both entrances to the extrusion head. Mixing of materials has been shown by obtaining different colors of the outgoing material using two different colors of one type of input material.

10

Influence of Printer Head Velocity on FDM Deposited Path Deformations

Wzorek A., Bajkowski J. M.

Machine Dynamics Research

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2018

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Vol. 42, No. 1

117--127

EN

Fused deposition modeling is a technology, which uses print head’s nozzle that is moved in three dimensions, during extraction of the filament material. The common issue is the fact, that the quality parameters of the deposited model are significantly influenced by the actual material’s flow rate. Although highest accuracy of the model should be obtained when the mass flow rate is directly proportional to an actual velocity of the printer’s head, the discrepancy between expected and real flow rate causes deformations and inaccuracies of the printed path. This phenomena is especially visible during acceleration and deceleration of the printhead. Development of commercially efficient measurement method may be used in software calibration of the material mass flow. In perspective, direct feedback control of material flow rate could increase correlation of quality and print time of deposited models that can lead to an FDM printing process enhancements and refinements in an efficient manner. The influence of the 3D printer’s head velocity on the width of the deposited path is studied using visual methods.

11

Tribological properties of 3D printed components

Giemza B., Domański M., Deliś M., Kapica D.

Journal of KONBiN

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2018

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No. 48

447--463

EN

Additive manufacturing technology is developing in many industries, including aviation, automotive and others. 3D printing offers new possibilities in the field of designing and manufacturing of machines and devices’ components. The paper presents the results of tribological investigations of components produced in FDM printing technology. The authors presented the evaluation of sliding properties of the model friction couple – block on ring type – of available thermoplastic polymers and polymers’ composites under dry friction conditions. The authors assessed the influence of material type and printed structure on resistance to motion of prepared samples.

PL

Technologia wytwarzania przyrostowego jest rozwijana w wielu obszarach przemysłu, w tym w lotnictwie, motoryzacji i innych. Druk 3D oferuje nowe możliwości konstrukcyjne i wykonawcze urządzeń i elementów konstrukcyjnych. W artykule zaprezentowano wyniki badań właściwości tribologicznych elementów wytworzonych w technologii druku 3D FDM. Autorzy dokonali oceny właściwości ślizgowych modelowego węzła tarcia – typu rolka-klocek – dostępnych polimerów termoplastycznych oraz kompozytów polimerowych w warunkach tarcia suchego. Określono wpływ rodzaju materiału oraz struktury wydruku na opory ruchu wytworzonych próbek.

12

Easy and affordable method for rapid prototyping of tissue models in vitro using three-dimensional bioprinting

Bandyopadhyay A., Dewangan V. K., Vajanthri K. Y., Poddar S., Mahto S. K.

Biocybernetics and Biomedical Engineering

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2018

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Vol. 38, no. 1

158--169

EN

In vitro tissue model systems have attracted considerable attention in drug discovery owing to their ability to facilitate identification of promising compounds in the near-physiological environment during drug development. Additive manufacturing helps in mimicking com-plex geometries including the microarchitecture of the body tissues. Exploiting this emerg-ing technology, the present study demonstrates a simple and inexpensive approach for the fabrication of three-dimensional (3D) in vitro tissue models using a custom-designed automated bioprinting system. The bioink mixture comprised of a novel optimized compo-sition of widely known biomaterials including gelatin, alginate and hydrolyzed type-1 collagen to embed and print the C2C12 myoblast cells. The structural stability and integrity of the cells-laden constructs were found to be significantly consistent for more than 14 days in culture. Rheological and mechanical properties of the bioink blend were characterized to assess its efficacy for the fabrication of cells-laden tissue constructs. Scanning electron micrographs were acquired to analyze porosity of the scaffold for cellular growth and proliferation. The viability of cells embedded within the hydrogel was >80%, 3 h post-printing. We anticipate that the fabricated tissues will serve as an alternative model for in vitro toxicological and drug response studies.

13

Influence of sterilization of a product manufactured using fdm technology on its dimensional accuracy

Kuczko Wiesław, Wichniarek Radosław, Górski Filip, Banaszewski Jacek

Advances in Science and Technology. Research Journal

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2018

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Vol. 12, no 1

74--79

EN

Inter-operational surgery supplies manufactured additively using the FDM (Fused Deposition Modelling) technology are required to be sterilized before use. After manufacturing, the part should be sterilized using one of commonly used processes, without losing its dimensions and shape. The paper presents studies on manufacturing and sterilizing samples made out of ABS material and influence of the sterilization process on the dimensional accuracy of these samples.

14

Prototypowanie elektrycznej protezy dłoni z użyciem technik wytwarzania przyrostowego

Kowalczyk M.

Medical Robotics Reports

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2017

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vol. 6

47--54

PL

Tematem prezentowanej pracy jest prototyp elektrycznej protezy dłoni z użyciem technik wytwarzania przyrostowego. Przedstawione wyniki są rezultatem pracy inżynierskiej [1] pt. Prototypowanie elektrycznej protezy dłoni z użyciem technik wytwarzania przyrostowego, która została zrealizowana na kierunku Inżynieria Biomedyczna na Politechnice Poznańskiej. Celem pracy było zaprojektowanie i wytworzenie elektrycznej protezy dłoni metodą osadzania topionego materiału. Zastosowane rozwiązanie umożliwiło wykonanie sztucznej kończyny z możliwością zginania palców, a także przeciwstawiania i odprowadzania kciuka. Jej sterowanie zrealizowano przez elektrody, które odbierały sygnały napięcia mięśniowego. Były one przekazywane do czujnika pomiaru aktywności mięśni EMG, który przesyłał je do Arduino Leonardo. Płytka z mikrokontrolerem sterowała serwonapędami, których obrót orczyków wprawiał w ruch poszczególne palce. Założeniem pracy było zaprojektowanie lekkiej, funkcjonalnej i tańszej od dostępnych na rynku rozwiązań protezy dłoni. Część teoretyczna pracy omawia protezy i ich podział, przyczyny protezowania i stopnie amputacji. Część praktyczna przedstawia proces projektowania wraz z doborem parametrów sztucznej kończyny oraz jej wytworzenie. W zakończeniu podsumowano właściwości protezy takie jak: funkcjonalność, masa, koszt oraz czas wytwarzania elektrycznej protezy dłoni.

EN

The subject of this work is the prototyping of an electrical hand prosthesis using additive manufacturing technologies. The results, which were presented at Poznan University of Technology, represent a part of an engineering thesis of Biomedical Engineering Prototyping of electrical hand prosthesis using additive manufacturing technologies. The aim of this work was to design and manufacture a hand prosthesis by fused deposition modelling. The applied solution allowed to manufacture an artificial limb with ability to flex the fingers and to aditionally make moves such as the opposition and reposition of the thumb. The control was regulated by biomedical electrodes, which received the muscle tone signals and send them to the EMG muscle activity sensor and further to the Arduino Leonardo. The board with a microcontroller controlled the work of servomechanisms in which the rotation of the horn caused the fingers' movement. The assumption of this work was to design more lightweight, functional and cheaper solutions compared to commercially available electrical hand prosthesis. The theoretical part of this work discusses prostheses and their types, causes of substitution of prosthesis and levels of amputation. The practical part of this paper presents the process of designing an artificial limb with choices of parameters and manufacturing of the prosthesis. The conclusion of this experiment gives evidence for the existence of features of the prosthesis such as: functionality, mass, cost and manufacturing time.

15

Wykorzystanie druku 3D w zastosowaniach automotive

Caban J., Szala M., Kęsik J., Czuba Ł.

Autobusy : technika, eksploatacja, systemy transportowe

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2017

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R. 18, nr 6

573--579, CD

PL

W artykule scharakteryzowano najczęściej stosowane technologie druku 3D: metoda FFF/FDM, metoda SLA, metoda SLS oraz metoda CJP. Przedstawiono możliwości zastosowania druku 3D w przemyśle motoryzacyjnym oraz projektowaniu nowych elementów i części pojazdów. W części badawczej pracy zaprezentowano wybrane próbki elementów wydrukowanych w technologii druku 3D metodą FDM/FFF przy różnych parametrach druku w zakresie uzyskanej powierzchni i geometrii.

EN

The article presents the most commonly used 3D printing technologies: FFF / FDM method, SLA method, SLS method and CJP method. It presents the possibilities of 3D printing in the automotive industry and the design of new vehicle components and parts. In the research part of the work were presented selected samples of elements printed in FDM / FFF 3D printing technology with different printing parameters in the area of obtained surface and geometry.

16

Simulation of processes occurring in the extrusion head used in additive manufacturing technology

Prusinowski A., Kaczyński R.

Acta Mechanica et Automatica

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2017

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Vol. 11, no. 4

317--321

EN

The purpose of this research is unsatisfactory state of knowledge of the abrasive wear of composites with thermoplastic polymer as matrix material and reinforcing material in the form of short and focused carbon fibers that can be used in additive manufacturing technologies. The paper presents a conceptual design of an extrusion head used in Fused Deposition Technology, which allows for the implementation of appropriately stacked fibers at the level of detail production. Finite element simulation was performed to simulate the thermal effect of the system to demonstrate the effect of head cooling on the system. The assumed extrusion temperature of the material was obtained at a uniform nozzle temperature and stable temperature of the entire system. Flow simulation of thermoplastic polymer was carried out in the designed extrusion nozzle. By supplying 0.5 mm wire of 1.75 mm diameter thermoplastic material to the nozzle, the extrusion rate was 0.192 m/s. The proper design of the extrusion head for the intended applications has been demonstrated and the purpose of further research in this field has been confirmed.

17

3D printing technology as a tool in fabrication of elements for wheel model

Leśniewicz P.

Acta Innovations

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2017

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no. 23

5--16

EN

This paper illustrates an experience related to the use of 3D printing technology during the fabrication of elements for a supporting arm. The arm was a part of a test stand designed for an investigation of rotating wheels in contact with the ground. One of the crucial elements of a supporting arm is the hub, which was originally made from aluminium, however it was decided to replace it by the one made from ABS using 3D printing technology. The author decided to describe difficulties encountered during fabrication of the hub, together with a set of recommendations for future use of 3D printers.

18

Analiza wybranych problemów druku 3D metodą FFF

Furyk-Grabowska K., Wyszyński D.

Stal, Metale & Nowe Technologie

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2016

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nr 9-10

128--131

PL

W artykule opisano metodę druku 3D FFF (Fused Filament Fabrication) oraz przeprowadzono analizę wyników badań doświadczalnych, na podstawie których określono dokładność wymiarowo-kształtową otworów wykonanych metodą FFF.

EN

The paper presents the description of 3D printing using FFF (Fused Filament Fabrication) and some experimental studies aiming at the shape and size accuracy optimization and determination of the process limits.

19

Experimental Determination of Critical Orientation of ABS Parts Manufactured Using Fused Deposition Modelling Technology

Górski F., Wichniarek R., Kuczko W., Andrzejewski J.

Journal of Machine Engineering

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2015

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Vol. 15, No. 4

121--132

EN

The paper presents results of experiments aimed at determination of range of critical orientation for parts manufactured additively using the Fused Deposition Modelling method, out of ABS material. Numerous previous observations of plastic parts manufactured additively using the FDM process allowed concluding, that change of values of the manufacturing orientation (i.e. direction of layer slicing plane) has large influence on the macrostructure of obtained parts, thus affecting their strength and behaviour under load – the material behaves either as a thermoplastic with a yield point or as a brittle material with no yield point. The paper presents methodology and results of experiments aimed at determination of a certain value or value range, at which transition between the two behaviours occurs. The experiments consisted of tensile tests performed on samples manufactured additively in a pre-selected range of orientations. The obtained results – a value range valid for the selected type of load and sample shape – will be useful in future to help select an optimal orientation of part for a defined task.

20

Influence of filling type on strength of parts manufactured by Fused Deposition Modelling

Górski F., Wichniarek R., Kuczko W.

Journal of Machine Engineering

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2014

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Vol. 14, No. 3

113--125

EN

Fused Deposition Modelling technology allows to produce elements of very complex shapes without any additional tooling, which is why it has a broad range of industrial applications. Possibility of manufacturing parts with controlled degree of internal filling allows to shorten the manufacturing time and reduce volume of used material. The paper presents influence of layer filling type on part capability of carrying loads and economical coefficients of the manufacturing process. A problem of mechanical properties is important especially in case of elements used as functional prototypes. The paper presents methodology and results of experimental strength tests of samples with various types of internal filling. As a build material for test samples, ABS material was used. Composite samples were also used the ABS matrix produced by Fused Deposition Modelling was filled with chemically hardening polyurethane resin in a process developed by authors. The samples were subjected to destructive testing and their strength properties were compared.