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1

The influence of polymer materials and internal density on the parameters of fused filament fabrication samples during tensile testing

Gontarz-Kulisiewicz Małgorzata, Budzik Grzegorz, Dziubek Tomasz, Sobolewski Bartłomiej, Przeszłowski Łukasz

Advances in Science and Technology. Research Journal

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2025

|

Vol. 19, no. 9

410--427

EN

This article presents a strength analysis of selected polymer materials (ABS (acrylonitrile butadiene styrene), PLA (polylactic acid), HABS (hard acrylonitrile butadiene styrene), HIPS (high-impact polystyrene), PC/ABS (acrylonitrile butadiene styrene with polycarbonate), and S&S (strong and soft)) used in the FFF method based on a static tensile test. Standardized type 1A specimens with varying filling densities of the internal grid structure were tested, specifically at densities of 13%, 15%, 20%, 65%, 80%, and fully filled. Additionally, the fractures of the samples following the strength tests were examined and described.

2

Analysis of fused filament fabrication / fused deposiotion modelling applications for production of casting patterns used in sand casting

Bernat Łukasz, Kroma Arkadiusz

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 7

427--439

EN

This paper presents an analysis of FFF/FDM (Fused Filament Fabrication / Fused Deposiotion Modeling) applications for production of casting patterns used in sand casting, with particular emphasis on short-run and prototype production. For this purpose, casting patterns of different shape and height of incremental layer (0.29 mm, 0.19 mm, 0.14 mm and 0.09 mm) were made of Z-ABS filament produced by Zortrax. Geometrical and dimensional analysis of the patterns was carried out, surface roughness parameters were measured, and a visual analysis of the surface was performed. In order to evaluate the conclusions observed based on the analysis of casting patterns, 130 x 102.5 x 37.5 mm sized shaped castings were designed and manufactured from aluminum and grey cast iron, which were also subjected to analysis. The last element of the research was a visual analysis of the reproduction of markings on the castings.

3

Environmental marine degradation of pla/wood composite as an alternative sustainable boat building material

Baris-Camli Selin, Neser Gokdeniz, Sozen Ayberk

Polish Maritime Research

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2024

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nr 1

127--134

EN

In this study, which can be considered a contribution to the global effort to produce sustainable materials and to search new manufacturing methods for the boat building industry, the performance of a 3D printable polylactic acid and recycled wood (PLAW) composite was investigated under the simulated operational conditions of a boat. The wood used in the composite was yellow pine (Pinus sylvestris), a local wood widely used in boat building and 8% by weight in the composite. For the study, tensile and compressive strength tests were performed in both atmospheric and post-aging conditions, using composite samples produced by the additive manufacturing method. The durations of the accelerated aging before the experiments were one, two and four weeks. During these aging periods, water spraying, a salty fog environment and a drying cycle were applied at elevated temperatures and at equal time intervals, daily. The effect of wood additive on the composite and the joining efficiency of the components were also examined with scanning and optical microscopes. The performance of the obtained composite and the effects of aging on performance were measured using two different thermal analyses: differential scanning calorimetry and thermogravimetric analysis. From the results obtained, it can be seen that PLAW composite can be used in the manufacture of structural elements subjected to relatively low loads in boats. It is an option that will provide integrity in the future interior design of wooden boats.

4

Optimizing Fused Deposition Modelling Process Parameters for Medical Grade Polymethylmethacrylate Flexural Strength

Obaeed Nareen Hafidh, Hamdan Wisam K.

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no. 1

349--359

EN

The production of functional parts, including those employed by the biomedical industry has been achieved a promising candidate in Fused Deposition Modelling (FDM). The essential properties of these biomedical parts which manufactured by additive manufacturing as compared to some other conventional manufacturing processes depend on structural and process parameters rather than material properties alone. Regarding to the evaluation the flexural strength of medical-grade, Polymethylmethacrylate PMMA has been received relatively very little investigation to date. PMMA is a biocompatible filament that be used in manufacturing of patient-specific implants such as dental prosthesis and orthopaedic implants. The proposed work explores the effect of three process parameters that vary with respect of three levels on the flexural strength. These levels can be specified by layer height (120, 200, 280 µm), infill density (40, 65, 90 %) and skewing angle (0º, 45º, 90º) on the flexural strength of medical-grade PMMA. Maximum and minimum flexural strength that be obtained in this work about (93 and 57 MPa) respectively. The analysis of variance (ANOVA) results shows that the most effective factor is the layer height followed by infill density. The flexural strength rises significantly with decreases layer height and the skewing angle is in zero direction. The process parameters have been optimized through utilizing of genetic algorithms. The optimal results that emerged based on genetic algorithm technique are approximately (276 μm) as layer height, (46 %) infill density and skewing angle (89 º) which maximize the flexural strength to (97 MPa) at crossover for ten generation.

5

Viscoelastic characterization of additively manufactured acrylonitrile butadiene styrene

Witek Szczepan

Computer Methods in Materials Science

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2023

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Vol. 23, No. 2

39--44

EN

The main objective of this work was to characterize the viscoelastic properties of additively manufactured Acrylonitrile Butadiene Styrene based on tensile stress relaxation tests. The stress relaxation measurements were conducted with a temperature range of 25–100°C. The two-layer viscoplastic constitutive model was adopted to describe the elastic and viscous behavior of the investigated material. The model parameters were calibrated using an inverse analysis and stress relaxation data. The model’s predictive capabilities were assessed by comparing the model predictions with experimental data not included in the calibration process.

6

Three-Point Bending Response of Nylon 12 Obtained by Fused Filament Fabrication (FFF) Versus Selective Laser Sintering (SLS)

Baba Marius Nicolae, Voinea Gheorghe-Daniel, Lucaci Maria-Elisabeta

Archives of Metallurgy and Materials

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2023

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Vol. 68, iss. 4

1439--1446

EN

This study analyses the three-point bending behavior of Nylon 12 (PA12) specimens produced using two additive manufacturing technologies (i.e., fused filament fabrication and selective laser sintering). A Nylon 12 commercially available filament (from Fiberlab S.A.) was selected to employ the fused filament fabrication method (FFF) with a Prusa 3D desktop printer, whereas Nylon 12 sintering powder (from Formlabs Inc.) was chosen for selective laser sintering (SLS) using a benchtop industrial SLS platform, Formlabs Fuse 1, with a powder refresh ratio of 30%. The bending strength and flexural elasticity moduli were determined by following ISO 178:2019 standard specifications to assess the effect of two different technologies on the mechanical behavior of three-point bending specimens produced in three distinct build orientations (i.e., 0°, 45°, and 90°) relative to the printing platform. One-way ANOVA analysis, Tukey’s HSD, and Games-Howell tests are considered to assess the statistical variability of experimental data and compare the mean values of bending strength and flexural moduli. The testing results for the three orientations under question show notable differences and interesting similarities either in terms of strength or elasticity response for a significance p-level of 0.05.

7

The influence of Material Extrusion process parameters on the porosity and mechanical properties of PLA products for medical applications

Rusińska Małgorzata, Gruber Piotr, Ziółkowski Grzegorz, Łabowska Magdalena, Wilińska Karolina, Szymczyk-Ziółkowska Patrycja

Acta of Bioengineering and Biomechanics

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2023

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Vol. 25, no. 3

25--41

EN

The study addresses the growing need for personalized medicine and cost-effective manufacturing by investigating additive manufacturing (AM). It employs the Design of Experiments (DOE) to explore how fused filament fabrication (FFF) parameters affect porosity and mechanical properties of medical-grade polylactide (PLA) samples.

8

Surface Roughness Reduction in A Fused Filament Fabrication (FFF) Process using Central Composite Design Method

Kandananond Karin

Production Engineering Archives

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2022

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Vol. 28, Iss. 2

157--163

EN

The objective of this study is to optimize the fabrication factors of a consumer-grade fused filament fabrication (FFF) system. The input factors were nozzle temperature, bed temperature, printing speed, and layer thickness. The optimization aims to minimize average surface roughness (Ra) indicating the surface quality of benchmarks. In this study, Ra was measured at two positions, the bottom and top surface of benchmarks. For the fabrication, the material used was the Polylactic acid (PLA) filament. A response surface method (RSM), central composite design (CCD), was utilized to carry out the optimization. The analysis of variance (ANOVA) was calculated to explore the significant factors, interactions, quadratic effect, and lack of fit, while the regression analysis was performed to determine the prediction equation of Ra. The model adequacy checking was conducted to check whether the residual assumption still held. The total number of thirty benchmarks was fabricated and measured using a surface roughness tester. For the bottom surface, the analysis results indicated that there was the main effect from only one factor, printing speed. However, for the top surface, the ANOVA signified an interaction between the printing speed and layer thickness. The optimal setting of these factors was also recommended, while the empirical models of Ra at both surface positions were also presented. Finally, an extra benchmark was fabricated to validate the empirical model.

9

The FDM technique in processes of prototyping spare parts for servicing and repairing agricultural machines: a general outline

Łukaszewski Krzysztof, Buchwald Tatiana, Wichniarek Radosław

International Journal of Applied Mechanics and Engineering

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2021

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Vol. 26, no. 4

145--155

EN

The aim of this research was to determine the possibility of applying alternative techniques for the production of prototypes for spare parts in agriculture and to determine the possible directions of development of their applications in the engineering industry. Then, to determine which spare parts could be produced using the FDM technique, comparisons of the most important parameters of spare parts produced independently (using the FDM technique) and obtained from producers (produced using traditional methods in professional factories) were made. A number of factors were analysed, from technical parameters such as machine type, processed material and its consumption including required as support structures, to economic issues such as manufacturing or purchase delivery total time and cost. The FDM technique has proven itself in many ways in the production of spare parts for agricultural machinery.

10

Surface treatment of incrementally produced components in FFF (Fused Filament Fabrication) technology

Mrówka Maciej, Machoczek Tomasz, Szymiczek Małgorzata, Gągol Przemysław, Duda Sławomir, Marcoll Łukasz

Polimery

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2020

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T. 65, nr 1

51--59

EN

The aim of the conducted research was to examine the possibility of using chemical and physical methods of surface treatment of elements printed on a 3D printer. Elements were printed from polylactide (PLA) and acrylonitrile-butadiene-styrene (ABS) – materials most commonly used in fused filament fabrication (FFF) technology. Roughness measurements were made to assess the quality of individual methods. The best surface smoothness results were obtained during abrasive paper processing and after applying epoxy resin. The intended effect was also obtained after processing samples from PLA in chloroform fumes, and ABS samples in acetone vapors.

PL

Zbadano możliwości wykorzystania chemicznych i fizycznych metod obróbki powierzchniowej elementów wydrukowanych za pomocą drukarki 3D. Elementy wytworzono z polilaktydu (PLA) i kopolimeru akrylonitrylo-butadieno-styrenowego (ABS) – materiałów najpowszechniej stosowanych w technologii Fused Filament Fabrication (FFF). Jakość wykonania przy użyciu poszczególnych metod oceniano na podstawie chropowatości powierzchni wytworzonych elementów. Najlepszą gładkość powierzchni uzyskano w wyniku obróbki wydrukowanych elementów papierami ściernymi i nałożeniu żywicy epoksydowej. Zamierzony efekt uzyskano też w wyniku obróbki próbek z PLA w oparach chloroformu, a próbek z ABS w oparach acetonu.

11

A generic method to realize long fibers filled and large polymer parts in additive manufacturing

Hascoët Jean-Yves, Authelin Olivier, Rauch Matthieu

Journal of Machine Engineering

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2020

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Vol. 20, No. 1

107--116

EN

A general manufacturing methodology for long fibers filled and large polymer (LFFLP) parts will be proposed, which constitutes the major scientific contribution of the document. The input, output, control and analysis data at each step of the methodology will be specified. Experiments realized in the laboratory of Ecole Centrale de Nantes will demonstrate the relevance and effectiveness of this method applied to a 6-axis robot and the FFF process by showcasing two light and resistant lattice structures. The latter also highlight the capacity of 6-axis robots for orienting the deposition head in order to generate complex trajectories. Finally, perspectives and future research about this subject will be discussed such as the need to develop in-depth analyses of the manufacturing methodology. The possibility of using continuous fibres composites as material feedstock for robotized large dimensions FFF will also be covered.

12

Virtual additive manufacturing based on semicrystalline polymer polyetheretherketone (PEEK)

Bajerski Paweł, Pęcherski Ryszard B., Chudy Damian

Engineering Transactions

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2019

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Vol. 67, iss. 2

157--165

EN

Virtual additive manufacturing (AM) is one of the new directions of research that is necessary to improve AM technology. Abaqus/SIMULIA software allows to simulate the whole process using user subroutines to expand solver capabilities. Two of the most important subroutines are UepActivationVol and UMATHT. The UepActivationVol is related to an activation of elements in accordance with the defined path of the process. The second one the UMATHT is used to implement and combine thermal and crystallization process [2]. The presented investigations describe the dual crystallization kinetics model for considered high temperature thermoplastic material Polyetheretherketone (PEEK). Furthermore, it is shown how to analyse the overall process with use of Abaqus/SIMULIA software. The innovation of the presented approach lies in the proper interpreting of the G-Code from Computeraided manufacturing software (CAM), which is an input for the real machines dedicated to AM. The path (coordinates of discrete points) and time of particular steps of the manufacturing process are extracted from the G-Code and are included as input parameters in the simulation code. The discretized part is simplification of the Computer-aided design (CAD) geometry. The final results show the effect implemented in user subroutines. Additionally, Differential Scanning Calorimetry (DSC) test results are presented in order to calculate crystallization and melting parameters. The presented work is the basis of the following investigations covering prediction of residual stresses, volumetric shrinkage and deformations.

13

Zastosowanie metod szybkiego prototypowania w projektowaniu elementów wykonawczych bolidu klasy Formuła Student

Budzik G., Przeszłowski Ł., Kamiński F., Zborowski D., Krysa M.

Przegląd Mechaniczny

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2018

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nr 7-8

26--30

PL

Wytwarzanie elementów maszyn w metodach przyrostowych pozwala na pominięcie niektórych etapów podczas procesu technologicznego, a co za tym idzie skrócenie czasu wytworzenia prototypu. Metody przyrostowe dają możliwość wytwarzania w pełni użytkowych prototypowych części maszyn. W artykule przedstawiono przykład takiego rozwiązania bazującego na układzie dolotowym bolidu klasy Formuła Student. Jest to układ przeznaczony bezpośrednio do silnika Triumph Street Triple uwzględniający wszelkie wymogi związane z regulaminem konkursu Formuła Student. Przedstawiony dolot został w pełni wykonany w metodzie przyrostowej FFF (Fused Filament Fabrication) z termoplastycznego polimeru, jakim jest ABS.

EN

The production of prototype machine parts in incremental methods allows us to omit some of the stages during the technological process, and hence shorten the prototype’s production time. Incremental methods give the possibility of producing fully usable prototype parts of machines. The article presents an example of such a solution based on the formula of a Formula Student car based on the intake system. It is a system dedicated directly to the Triumph Street Triple engine taking into account all the requirements related to the Formula Student competition regulations. Presented engine intake has been fully made in incremental FFF (Fused Filament Fabrication) method from a thermoplastic polymer such as ABS.