Fused Deposition Modeling Based 3D Printing (Materials Forming, Machining and Tribology)

Description

This book covers 3D printing activities by fused deposition modeling process. The two introductory chapters discuss the principle, types of machines and raw materials, process parameters, defects, design variations and simulation methods. Six chapters are devoted to experimental work related to process improvement, mechanical testing and characterization of the process, followed by three chapters on post-processing of 3D printed components and two chapters addressing sustainability concerns. Seven chapters discuss various applications including composites, external medical devices, drug delivery system, orthotic inserts, watertight components and 4D printing using FDM process. Finally, six chapters are dedicated to the study on modeling and optimization of FDM process using computational models, evolutionary algorithms, machine learning, metaheuristic approaches and optimization of layout and tool path. Preface Contents 1 Introduction to Fused Deposition Modeling Based 3D Printing Process Abstract 1 3D Printing 2 Material Extrusion 3 Introduction of Fused Deposition Modeling 4 FDM Process and Working Principle 5 FDM Printer Types 5.1 Printer Types as Per Configuration 5.1.1 Cartesian FDM Printers 5.1.2 Delta FDM Printers 5.1.3 Polar FDM Printers 5.1.4 Robotic Arm FDM Printers 5.2 Printer Types as Per Technology Source 6 Material Feedstock 7 Process Parameters 7.1 Extrusion Temperature 7.2 Nozzle Diameter 7.3 Build Orientation 7.4 Layer Thickness 7.5 Raster Width 7.6 Raster Angle 7.7 Shell and Associated Parameters 7.8 Infill Pattern 7.9 Infill Density 7.10 Air Gap 7.11 Print Speed 7.12 Build Volume Temperature 7.13 Build Platform Temperature 7.14 Skirt and Brim 7.15 Processing Parameter Correlations 8 Defects in FDM Printed Parts 9 Advantages and Limitations References 2 Fused Deposition Modeling Based 3D Printing: Design, Ideas, Simulations Abstract 1 Introduction 2 Design Variations 3 Latest Process Variation and Process Mechanisms 3.1 Polymer Printing 3.2 Food Printing 3.3 Live-Cell Printing 4 Printing Methods and Technologies 4.1 Single-Nozzle Multi-material Printers 4.2 Multi-nozzle Printers 4.3 Full-Color Printers 4.4 Parallel FDM Printing 5 Simulations 6 Energy Efficiency 7 Conclusion References 3 Calorimetry, Structure and Morphology of Printed Samples from Biodegradable Materials Using FDM 3D Printing Technology Abstract 1 Introduction 2 Materials and Methods 3 Results and Discussions 3.1 Calorimetric Analysis (DSC) for Printed Samples from Biodegradable Materials 3.2 Surface and Structure Analysis for Printed Samples from Biodegradable Materials 3.3 EDX Chemical Analysis for Printed Samples Made of Biodegradable Materials 3.4 XRD Analysis 4 Conclusions Acknowledgements References 4 Experimental Investigation on FDM Fabricated Tetra Chiral Auxetic Structures Under Uniaxial Compressive Loading Abstract 1 Introduction 2 Methodology 2.1 Design of Experiment 2.2 Modeling of Configurations of Structure 2.3 FDM Fabrication 2.4 Response Measurement 3 Results and Discussion 3.1 Effect of Geometric Parameters on Responses 3.1.1 Effect of Ligaments Thickness and Chiral Radius on Compressive Modulus and Strength 3.1.2 Effect of Ligaments Thickness and Chiral Radius on Plateau Stress 3.1.3 Effect of Ligaments Thickness and Chiral Radius on SEA 3.2 Predictive Models for Responses 3.2.1 Predictive Model of Compressive Modulus 3.2.2 Predictive Model for Compressive Strength 3.2.3 Predictive Model for Plateau Stress 3.2.4 Predictive Model for Energy Absorption Per Unit Volume 3.2.5 Predictive Model for Energy Absorption Per Unit Mass 3.3 Single-Objective Optimization 3.4 Multi-objective Optimization 4 Conclusion References 5 Experimental Study of Drilling 3D Printed Polylactic Acid (PLA) in FDM Process Abstract 1 Introduction 2 Methodology 3 Results and Discussion 4 Conclusion References 6 Mechanical Properties of 3D-Printed Elastomers Produced by Fused Deposition Modeling Abstract 1 Introduction 2 Mechanical Behavior of Elastomers 3 FDM-Printed Elastomers and Testing 4 Effect of Process Parameters on the Mechanical Properties 4.1 Comparison with Injection Molding 4.2 Nozzle Temperature 4.3 Raster and Build Orientation 4.4 Layer Height 4.5 Infill Ratio/Cellular Structures 4.6 Composites and Polymer Blends 5 Conclusions and Future Research Directions References 7 Mechanical Characterization of Fused Deposition Modeling (FDM) 3D Printed Parts Abstract 1 Introduction 2 Filament Materials 3 Printing Parameters in FDM 3.1 Extruder Geometry 3.2 Processing Parameters 3.3 Structural Parameters 3.3.1 Orientation 3.3.2 Raster Angle 3.3.3 Layer Thickness 3.3.4 Infill Density, Infill Pattern and Air Gap 3.3.5 Printing Speed 4 Mechanical Properties 4.1 Nozzle Diameter and Layer Thickness 4.2 Orientation and Raster Angle 4.3 Infill Patterning and Density 4.4 Nozzle Temperature 5 Conclusion References 8 Mechanical and Tribological Characteristics of Polymer Composites Developed by Fused Filament Fabrication Abstract 1 Introduction 2 Synthesis of Polymer Composites in FFF 3 Tensile and Impact Strength of Parts Developed by FFF 4 Tribological Characteristics of FFF Parts 5 Scope of Filaments in Near Future 6 Conclusions References 9 The Surface Quality Improvement Methods for FDM Printed Parts: A Review Abstract 1 Introduction 2 FDM: The Most Widely Used AM Process 3 Surface Finish Improvement Techniques for the FDM Printed Parts 3.1 Pre-processing Techniques for Improving the Surface Quality of FDM Printed Parts 3.1.1 In-Process Techniques Build Orientation Layer Thickness Raster Width and Contour Width Air Gap Raster Angle Model Temperature 3.1.2 Adaptive Slicing Slicing of the Three-Dimensional-Computer-Aided Design (3D-CAD) Tessellated Model Direct Slicing Software 3.2 Post-processing Techniques for Improving the Surface Quality of FDM Printed Parts 3.2.1 Mechanical finishing Techniques Manual Sanding Abrasive Flow Machining (AFM) Abrasive Jet Deburring Sandblasting Vibratory Bowl finishing Barrel Tumbling Hot Cutter Machining Ball Burnishing Process Magnetic Abrasive Finishing (MAF) Friction Stir Processing (FSP) 3.2.2 Chemical Finishing Techniques Manual Painting Acetone Dipping Vapor Smoothing Electroplating 3.2.3 Thermal Finishing Techniques Laser-Based Surface Processing CNC Assisted Selective Melting (SM) Tool 3.2.4 Hybrid-Based Surface Finishing 4 Conclusions 5 Future Scope References 11 Post-processing of FDM 3D-Printed Polylactic Acid Parts by CNC Trimming Abstract 1 Introduction 2 Methodology 3 Results and Discussion 4 Conclusion References 12 Sustainable Product Development by Fused Deposition Modelling Process Abstract 1 Introduction 2 Materials and Methods Towards Sustainable Approach 3 Sustainability Concerns of Additive Manufacturing and Future Trends 4 Summary References 13 Sustainability Analysis of Fused Deposition Modelling Process Abstract 1 Introduction 1.1 Stereolithography 1.2 Laminated Object Manufacturing (LOM) 1.3 Selective Laser Sintering (SLS) 1.4 Fused Deposition Modelling (FDM) 1.5 Laser Engineered Net Shaping (LENS) 1.6 3D Printing (3DP) 2 Cost Analysis in Presence of Uncertainty 2.1 Build Time Estimation in FDM 2.2 Cost Calculation 2.3 Incorporation of Uncertainty in Cost Estimation 3 Impact on Environment 3.1 Energy Consumed During Melting of the Filament 3.2 Energy Consumed During Extrusion 3.3 Energy Consumed in Heating the Baseplate 3.4 Energy Consumed by the Movable Platform 3.5 Miscellaneous Energy Consumptions 4 Social Issues 4.1 Employment and Working Conditions 4.2 Health and Wellness 4.3 Education and Training 4.4 Authorization and Legal Issues 4.5 A Quantitative Method for Evaluating the Penalty Due to Reduction in Employment 5 Case Studies 5.1 Cost Estimation 5.2 Application of Fuzzy Arithmetic in Cost Estimation 5.3 Estimation of Energy Consumption 5.4 Application of Fuzzy Arithmetic in Energy Consumption 5.5 Overall Sustainability Analysis 6 Conclusion References 14 Fabrication of Composite Structures via 3D Printing Abstract 1 Introduction 2 AM Technologies for Fabrication of Structures 2.1 Material Extrusion Additive Manufacturing 2.2 Powder Bed Fusion Additive Manufacturing 2.3 Binder Jetting Additive Manufacturing 2.4 Material Jetting Additive Manufacturing 2.5 Vat Photopolymerization Additive Manufacturing 2.6 Directed Energy Deposition Additive Manufacturing 2.7 Sheet Lamination Additive Manufacturing 3 Conventional Manufacturing Techniques for Composite Structures 4 Material Extrusion AM for Fabrication of Composite Structures 5 Applications of 3D Printing Technologies 6 Conclusions and Future Perspectives References 15 Use of FDM Technology in Healthcare Applications: Recent Advances Abstract 1 Introduction 2 Technology Evolution: From Monomaterial to Multimaterial 2.1 Mosaic Colour or Non-mixed Colours 2.1.1 Independent Head Concept 2.1.2 Tool Changer Concept 2.2 Mixed Colours or Single Head Multicolour Management 2.2.1 Mix of Colours Based on the Sequential Passage of Filaments 2.2.2 Mix of Colours Based on Mixture-Based Nozzle Approach 3 Relationship Between FFF and Other AM Technologies 4 Training Models and Surgical Planning Prototypes 4.1 Oncology 4.2 Cardiology 4.3 Osteology 5 Surgical Guides 6 3D Bio-Printing 7 Medical Devices 8 FDM Against COVID-19 9 Conclusion Funding References 16 Fused Filament Fabrication for External Medical Devices Abstract 1 Introduction 2 Orthoses and Prostheses 3 Need for FFF Built O&P Devices 4 Stages in Manufacturing of O&P Devices 4.1 Anatomical Data Acquisition and Measurement 4.2 Data Transformation 4.3 Design and Customization 4.4 Biomechanical Simulation 4.5 Material Selection 4.6 Fabrication and Assembly 4.7 Post-processing and Sterilisation 5 Standards and Regulatory Approval 6 Challenges in FFF for Building External Medical Devices 7 Case Studies 7.1 Orthoses 7.1.1 Hybrid Model for the Customized Wrist Orthosis 7.1.2 FFF Built Ankle-Foot Orthosis 7.2 Prosthetics 7.2.1 Prosthetic Hand for Children 7.2.2 Prosthetic Glove for Hand Rehabilitation 8 Research Trends 8.1 Orthosis Using Smart Memory Alloys and FFF 8.2 Antibacterial Prostheses Using FFF 9 Conclusions Acknowledgements References 17 Potential Advanced Drug Delivery Systems Based on Hydrogels in 3D Printing Technology for Cancer Treatment Abstract 1 Introduction 2 Selected Cancers and Treatment Methods 2.1 Cancer in Statistics 2.2 Cancer Types 2.2.1 Carcinoma 2.2.2 Sarcoma 2.2.3 Leukemia 2.2.4 Lymphoma 2.2.5 Multiple Myeloma 2.2.6 Melanoma 2.2.7 Brain and Spinal Cord Tumors 2.2.8 Other Types of Tumors 2.3 Cancer Treatment Methods 2.3.1 Surgery 2.3.2 Chemotherapy 2.3.3 Radiation Therapy 2.3.4 Another Therapies 3 Drug Delivery Systems 3.1 Stimuli-Responsive Hydrogels 3.2 Route of Administration 3.2.1 Ocular 3.2.2 Oral 3.2.3 Vaginal and Rectal 3.2.4 Transdermal 3.2.5 Brain Treatment 4 Hydrogel-Based Inks for 3D Printing in Cancer Treatments 4.1 Materials and Forms of Applications in Cancer Treatment 4.1.1 Materials 4.1.2 Forms of Applications 4.2 3D Printed Structures as In Vitro Cancer Models 5 Future Outlook and Concluding Remarks Funding References 18 3D Printed Personalized Orthotic Inserts Using Photogrammetry and FDM Technology Abstract 1 Introduction 1.1 Subtractive Manufacturing Versus Additive Manufacturing 1.2 Trends in Additive Manufacturing 2 FDM Technology 2.1 Limitations of FDM Technology in 3D Printing 2.2 Quality Issues 2.3 FDM Process Parameters 3 Methodology 3.1 Photogrammetry Technology 3.2 Technique for 3D Reconstruction of Orthotic Inserts 4 Results and Discussions 5 Conclusion References 19 Manufacturing of Watertight Housing for Electronic Equipment by Fused Deposition Modeling Abstract 1 Introduction 2 Materials and Method 2.1 3D Modeling of the Vessel 2.2 Design of Experiment 2.3 Generation of G-Code Files 2.4 3D Printing of the Vessels 2.5 Evaluation of the Watertighness of the Vessels 2.6 Design, 3D Printing and Evaluation of Housing for Electronic Equipment 3 Results 3.1 Watertightness Tests on Vessels 3.2 Watertightness Tests in Housing for Electronic Equipment 4 Discussion 5 Conclusion References 20 4D Printing by Fused Deposition Modeling (FDM) Abstract 1 Introduction 2 Shape Memory Polymers 2.1 Mechanisms 2.2 Reversible SMPs (Two-Way SME) 2.3 Triple and Multi SME 2.4 Stimulation 2.4.1 Thermal Stimulation 2.4.2 Athermal Stimulation 3 4D Printing by FDM 3.1 Challenges of 4D Printing by FDM 4 Application 4.1 Self-folding 4.2 Functionally Graded 4D Printing 4.3 UV-Assisted FDM 4.4 Self-deployable 4.5 Textile Applications 4.6 Energy Absorber 5 Future Outlook 6 Conclusion References 21 Computational Models: 3D Printing, Materials and Structures Abstract 1 Introduction 2 Modeling of Material Extrusion Process 3 Modeling of Bond Formation 4 Material Modeling of 3D Printed Parts 5 Modeling of Mechanical Behavior of 3D Printed Structures 6 Conclusions References 22 Multi-Objective Optimization for FDM Process Parameters with Evolutionary Algorithms Abstract 1 Introduction 2 FDM Process Parameters 2.1 Layer Thickness 2.2 Build Orientation 2.3 Extrusion Temperature 2.4 Infill Density 2.5 Infill Pattern 2.6 Number of Shells 2.7 Raster Width 2.8 Air Gap 2.9 Print Speed 3 Process Parameters Influence on 3D Printed Parts 3.1 Dimensional Accuracy 3.2 Surface Topology 3.3 Mechanical Properties 3.4 Build Time 3.5 Optimal Process Parameters 4 Multi-Objective Optimization for FDM Processes 4.1 Evolutionary Algorithms 4.2 Biologically-Inspired Optimization 4.3 Hybrid Algorithms 5 Potential Future Research Direction and Conclusions 5.1 Potential Future Research Directions 5.2 Conclusions References 23 Application of Machine Learning in Fused Deposition Modeling: A Review Abstract 1 Introduction 2 Machine Learning and Their Models 2.1 Supervised Algorithm 2.2 Unsupervised Algorithm 2.3 Reinforcement Learning 3 Machine Learning in FDM Process 3.1 Surface Roughness Prediction 3.2 Quality Monitoring System 3.3 Mechanical Properties 3.4 Geometric Deviations 3.5 Mixed Studies 4 Discussions and Future Scope References 24 Tool-Path Optimization in Material Extrusion Additive Manufacturing Abstract 1 Introduction 2 Particularities of the Path Planning for MEAM 2.1 Contour and Continuous Raster Segments 2.2 Head Repositioning or Idle Movements 2.3 Part Deposition Sequence (Sequential and Intercalated) 3 Problem Definition 3.1 Precedence Constraints 3.2 Relevant Data and Data Size 3.3 Similarities and Dissimilarities with the Classic Optimization Problems 3.4 Problem Variation According to the Layers 4 A Proposed Framework to Deal with the Problem 4.1 Points Preprocessing (Step 1) 4.1.1 Islands Analysis 4.1.2 Pruning the Island Points 4.2 Preliminary Sequence of Islands (Step 2) 4.3 Feasible Contour Route (Step 3) 4.4 Continuous Raster Segments Route (Step 4) 5 The Optimization Framework with the Nearest Insertion and 2-OPT Heuristics 6 Conclusions References 25 Metaheuristic Approaches for Modeling and Optimization of FDM Process Abstract 1 Introduction 2 Design of Experiment (DOE) 2.1 Response Surface Methodology (RSM) 2.2 Taguchi Robust Design 3 Industrial Artificial Intelligence 3.1 Artificial Neural Network (ANN) 3.2 Genetic Algorithm (GA) 3.3 Hybrid Methods 3.3.1 GA-RSM 3.3.2 GA-ANN 3.3.3 GA-ANFIS 4 FDM Challenges 4.1 Surface Roughness 4.2 Mechanical Properties 4.3 Build Time and Volume of Material 5 Conclusion References 26 Layout Optimization for FDM Process by Multi-objective Optimization Using RSM and GRA Abstract 1 Introduction 2 Extrusion Based AM Processes 3 Fused Deposition Modelling (FDM) 4 Methodology 4.1 RSM Based Experimentation 4.2 Multi Response Optimization Using GRA 5 Results and Discussion 6 Conclusions References