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Correlation between printing parameters and residual stress in additive manufacturing: a numerical simulation approach

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Alzyod H. , Ficzere P.

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tom Vol. 29, Iss. 3

279-287

EN

Fused Deposition Modeling (FDM) is a widely used 3D printing technology that can create a diverse range of objects. However, achieving the desired mechanical properties of printed parts can be challenging due to various printing parameters. Residual stress is a critical issue in FDM, which can significantly impact the performance of printed parts. In this study, we used Digimat-AM software to conduct numerical simulations and predict residual stress in Acrylonitrile Butadiene Styrene (ABS) material printed using FDM. We varied six printing parameters, including printing temperature, printing speed, and infill percentage, with four values for each parameter. Our results showed that residual stress was positively correlated with printing temperature, printing speed, and infill percentage, and negatively correlated with layer thickness. Bed temperature did not have a significant effect on residual stress. Finally, using a concentric infill pattern produced the lowest residual stress. The methodology used in this study involved conducting numerical simulations with Digimat-AM software, which allowed us to accurately predict residual stress in FDM-printed ABS parts. The simulations were conducted by systematically varying six printing parameters, with four values for each parameter. The resulting data allowed us to identify correlations between residual stress and printing parameters, and to determine the optimal printing conditions for minimizing residual stress. Our findings contribute to the existing literature by providing insight into the relationship between residual stress and printing parameters in FDM. This information is important for designers and manufacturers who wish to optimize their FDM printing processes for improved part performance. Overall, our study highlights the importance of considering residual stress in FDM printing, and provides valuable information for optimizing the printing process to reduce residual stress in ABS parts.

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Polyurethanes as a Potential Medical-Grade Filament for Use in Fused Deposition Modeling 3D Printers – a Brief Review

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Przybytek A. , Gubańska I. , Kucińska-Lipka J. , Janik H.

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tom Vol. 26, no. 6 (132)

120--125

EN

The possibility of using 3D printing technology (3DP) in medical field is a kind of revolution in health care. This has contributed to a rapid growth in demand for 3D printers, whose systems and materials are adapted to strict medical requirements. In this paper, we reporta brief review of polyurethanes as a potential medical-grade filament for use in Fused Deposition Modeling (FDM) 3D printer technology. The advantages of polyurethanes as medical materials and the basic operating principles of FDM printers are presented. The review ofpresent solutions in the market and literature data confirms the large interest in 3D printing technologies for the production of advanced medical devices. In addition, it is shown that thermoplastic-elastomer polyurethanes may be an effective widespread class of material inthe market as thermoplastic filament for FDM 3D printers.

PL

Możliwość stosowania technologii druku 3D (3DP) do zastosowań w medycynie stanowi swego rodzaju rewolucję w służbie zdrowia. Przyczyniło się to do znaczącego wzrostu zapotrzebowania na nowe drukarki oraz materiały, które są dostosowane do wymagań medycznych. W artykule przedstawiono zalety materiałów poliuretanowych, które mogą znaleźć zastosowanie jako filamenty klasy medycznej do druku 3D w technologii Fused Deposition Modeling (FDM). Opisano również podstawowe zasady działania drukarek FDM. Przegląd dostępnych rozwiązań przemysłowych oraz doniesień literaturowych potwierdził słuszność stosowania technologii druku 3D do produkcji spersonalizowanych wyrobów medycznych, wskazując jednocześnie na niewystarczającą liczbę dostępnych certyfikowanych biomedycznych materiałów dedykowanych tej technologii.

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Comparative study of experimental thermographic data and finite element analysis on temperature evolution of PET-G layer deposition during additive manufacturing process

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Kowalski Ł. , Bembenek M. , Uhryński A. , Bajda S.

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tom Vol. 72, nr 1

art. no. e147926

EN

Additive manufacturing (AM) technologies have been gaining popularity in recent years due to patent releases – and in effect – better accessibility of the technology. One of the most popular AM technologies is fused deposition modeling (FDM), which is used to manufacture products out of thermoplastic polymers in a layer-by-layer manner. Due to the specificity of the method, parts manufactured in this manner tend to have non-isotropic properties. One of the factors influencing the part’s mechanical behavior and quality is the thermoplastic material’s bonding mechanism correlated with the processing temperature, as well as thermal shrinkage during processing. In this research, the authors verified the suitability of finite element method (FEM) analysis for determining PET-G thermal evolution during the process, by creating a layer transient heat transfer model, and comparing the obtained modelling results with ones registered during a real-time process recorded with a FLIR T1020 thermal imaging camera. Our model is a valuable resource for providing thermal conditions in existing numerical models that connect heat transfer, mesostructure and AM product strength, especially when experimental data is lacking. The FE model presented reached a maximum sample-specific error of 11.3%, while the arithmetic mean percentage error for all samples and layer heights is equal to 4.3%, which the authors consider satisfactory. Model-to-experiment error is partially caused by glass transition of the material, which can be observed on the experimental cooling rate curve after processing the temperature signal.