A Review: Fused Deposition Modeling – A Rapid Prototyping ProcessIRJET Journal
This document provides an overview of fused deposition modeling (FDM), a rapid prototyping process. FDM involves layer-by-layer deposition of thermoplastic materials using an extrusion nozzle to build 3D parts from CAD data. Key aspects covered include:
- The FDM process involves heating and extruding plastic filaments through a nozzle to build parts layer-by-layer.
- Common thermoplastics used include ABS and PLA, and process parameters like orientation, layer thickness, and raster width impact part quality.
- FDM can produce functional prototypes and has applications in industries like aerospace, consumer goods, and automotive for prototyping, tooling, and low-volume production
Fused Deposition Modeling (FDM) is an additive manufacturing process developed by Stratasys where plastic or wax filament or pellets are heated and extruded through a nozzle to build 3D parts layer by layer, with each new layer bonding to the previous one. The material hardens immediately after extrusion from the nozzle. A variety of thermoplastics can be used with layer thicknesses ranging from 0.013 to 0.005 inches and X-Y plane resolution of 0.001 inches achievable.
- A 3-month-old baby named Kaiba was born with a deadly defect called tracheobronchomalacia where his pulmonary artery was intertwined over his bronchus, preventing air from reaching his left lung. He required a ventilator to survive.
- Doctors at Michigan hospital used a 3D printer to create an artificial windpipe made of a special thermoplastic called Polycaprolactone that was designed to exactly fit Kaiba's needs.
- The 3D printed windpipe was implanted and allowed Kaiba to live a normal life without needing intensive care. His case demonstrated how 3D printing can be used to create customized implants for conditions that were previously considered irreparable.
The document discusses additive manufacturing (AM) and rapid prototyping (RP) processes. It describes the historical development of AM and defines it as a process that builds up a 3D component in layers by depositing material based on a digital 3D design. Stereolithography (SLA) is discussed as one of the earliest AM techniques, using a laser to cure liquid resin into layers to build a part. The Solid Object Ultraviolet-Laser Printer (SOUP) system is also described, which uses a laser to scan and solidify resin according to cross-sectional data. Finally, the document outlines the eight generic steps in the AM process.
Rapid prototyping allows for quick production of physical prototypes directly from 3D CAD files. There are three main types of rapid prototyping processes: subtractive processes which remove material, additive processes which build parts up layer-by-layer such as fused deposition modeling and stereolithography, and virtual prototyping which uses simulation and visualization. Rapid prototyping reduces the time needed to produce prototypes from days to hours and allows for quick iteration in the design process. It can also be used to create tools for manufacturing operations.
The document discusses various metal additive manufacturing techniques including powder bed fusion, directed energy deposition, binder jetting, and sheet lamination. Powder bed fusion techniques like selective laser melting use a laser to selectively fuse metal powder layers. Directed energy deposition techniques like laser engineered net shaping use a laser and metal powder or wire feedstock to deposit material. Binder jetting uses inkjet printing of a binder to join metal powder particles. Sheet lamination techniques like ultrasonic additive manufacturing bond metal foils using ultrasonic vibration. The document explores the process parameters, microstructures, and applications of these various metal 3D printing methods.
IRJET- 3D-Printing in Additive ManufacturingIRJET Journal
This document summarizes research on 3D printing and additive manufacturing techniques for polymers. It discusses several common 3D printing methods like fused deposition modeling, stereolithography, digital light processing, selective laser sintering, three-dimensional printing, laminated object manufacturing, and PolyJet technology. It also reviews studies evaluating the mechanical properties of 3D printed parts under different loading conditions and the effects of fillers and post-processing on mechanical properties. The goal is to understand the strengths of 3D printed parts for practical applications and facilitate standardization of mechanical testing methods.
A Review: Fused Deposition Modeling – A Rapid Prototyping ProcessIRJET Journal
This document provides an overview of fused deposition modeling (FDM), a rapid prototyping process. FDM involves layer-by-layer deposition of thermoplastic materials using an extrusion nozzle to build 3D parts from CAD data. Key aspects covered include:
- The FDM process involves heating and extruding plastic filaments through a nozzle to build parts layer-by-layer.
- Common thermoplastics used include ABS and PLA, and process parameters like orientation, layer thickness, and raster width impact part quality.
- FDM can produce functional prototypes and has applications in industries like aerospace, consumer goods, and automotive for prototyping, tooling, and low-volume production
Fused Deposition Modeling (FDM) is an additive manufacturing process developed by Stratasys where plastic or wax filament or pellets are heated and extruded through a nozzle to build 3D parts layer by layer, with each new layer bonding to the previous one. The material hardens immediately after extrusion from the nozzle. A variety of thermoplastics can be used with layer thicknesses ranging from 0.013 to 0.005 inches and X-Y plane resolution of 0.001 inches achievable.
- A 3-month-old baby named Kaiba was born with a deadly defect called tracheobronchomalacia where his pulmonary artery was intertwined over his bronchus, preventing air from reaching his left lung. He required a ventilator to survive.
- Doctors at Michigan hospital used a 3D printer to create an artificial windpipe made of a special thermoplastic called Polycaprolactone that was designed to exactly fit Kaiba's needs.
- The 3D printed windpipe was implanted and allowed Kaiba to live a normal life without needing intensive care. His case demonstrated how 3D printing can be used to create customized implants for conditions that were previously considered irreparable.
The document discusses additive manufacturing (AM) and rapid prototyping (RP) processes. It describes the historical development of AM and defines it as a process that builds up a 3D component in layers by depositing material based on a digital 3D design. Stereolithography (SLA) is discussed as one of the earliest AM techniques, using a laser to cure liquid resin into layers to build a part. The Solid Object Ultraviolet-Laser Printer (SOUP) system is also described, which uses a laser to scan and solidify resin according to cross-sectional data. Finally, the document outlines the eight generic steps in the AM process.
Rapid prototyping allows for quick production of physical prototypes directly from 3D CAD files. There are three main types of rapid prototyping processes: subtractive processes which remove material, additive processes which build parts up layer-by-layer such as fused deposition modeling and stereolithography, and virtual prototyping which uses simulation and visualization. Rapid prototyping reduces the time needed to produce prototypes from days to hours and allows for quick iteration in the design process. It can also be used to create tools for manufacturing operations.
The document discusses various metal additive manufacturing techniques including powder bed fusion, directed energy deposition, binder jetting, and sheet lamination. Powder bed fusion techniques like selective laser melting use a laser to selectively fuse metal powder layers. Directed energy deposition techniques like laser engineered net shaping use a laser and metal powder or wire feedstock to deposit material. Binder jetting uses inkjet printing of a binder to join metal powder particles. Sheet lamination techniques like ultrasonic additive manufacturing bond metal foils using ultrasonic vibration. The document explores the process parameters, microstructures, and applications of these various metal 3D printing methods.
IRJET- 3D-Printing in Additive ManufacturingIRJET Journal
This document summarizes research on 3D printing and additive manufacturing techniques for polymers. It discusses several common 3D printing methods like fused deposition modeling, stereolithography, digital light processing, selective laser sintering, three-dimensional printing, laminated object manufacturing, and PolyJet technology. It also reviews studies evaluating the mechanical properties of 3D printed parts under different loading conditions and the effects of fillers and post-processing on mechanical properties. The goal is to understand the strengths of 3D printed parts for practical applications and facilitate standardization of mechanical testing methods.
The document discusses several common ink jet printing techniques for additive manufacturing, including the Sanders Model Maker, Multi-Jet Modelling, Z402 Ink Jet System, and Genisys Xs printer. It describes the key components and processes of these systems, such as using ink jets to deposit liquid materials layer by layer, and how they are used to quickly produce prototypes and models.
Lecture: An introduction to additive manufacturingKhuram Shahzad
1) Additive manufacturing (AM), also known as 3D printing, is a process of building 3D objects by depositing materials layer by layer based on a digital model.
2) AM has various applications across industries and the global AM industry is valued at $8 billion in 2018 and expected to reach $23 billion by 2026.
3) Common AM techniques include fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), and polyjet modeling; they differ in the materials and joining processes used to build layers.
Additive manufacturing Processes PDF by (badebhau4@gmail.com)Er. Bade Bhausaheb
Additive manufacturing (AM) processes build three-dimensional objects by adding material layer by layer based on a digital model. The document discusses several AM processes including powder bed fusion which uses lasers or electron beams to fuse powder materials together layer by layer. Key powder bed fusion techniques are direct metal laser sintering
The document provides an overview of additive manufacturing (AM) or 3D printing. It discusses the different families of AM, including powder bed fusion, material extrusion, binder jetting, vat photopolymerization, material jetting, direct energy deposition, and sheet lamination. It compares the various AM methods based on factors like deposition rate, feature resolution, part size limitations, and build speed. The document also outlines considerations for selecting suitable parts for AM and choosing the appropriate AM process based on the application.
10-10-05_04 Dan Larochelle: Rapid prototypingDarrell Caron
Rapid prototyping allows students to apply STEM concepts through hands-on projects, helping them better retain knowledge. Prototypes are essential tools in design that allow students to physically express ideas and test how designs fit, look, and function. Rapid prototyping creates objects quickly through additive manufacturing techniques like 3D printing, where a part is built layer by layer from a 3D digital model. This contrasts with subtractive techniques that remove material. Rapid prototyping provides benefits like getting feedback earlier in the design process and reducing costs and time to market versus traditional design and manufacturing.
The document discusses various types of additive manufacturing (3D printing) technologies. It describes extrusion deposit techniques like fused deposition modeling (FDM), powder bed fusion methods including selective laser sintering (SLS), and vat photopolymerization techniques like stereolithography (SLA). It also covers areas like binder jetting, 3D model file formats, applications in advanced manufacturing and medicine, and challenges with additively manufacturing metal matrix composites.
The document discusses rapid prototyping (RP), which allows prototypes to be made from a CAD model in hours or days rather than weeks. It describes various RP technologies including stereolithography, solid ground curing, droplet deposition manufacturing, laminated object manufacturing, fused deposition modeling, and selective laser sintering. These technologies differ in their starting materials, which can be liquids, solids like sheets, or powders, and how layers are added to build the final part in a layer-by-layer process from the CAD model.
This document discusses rapid prototyping and provides details on various rapid prototyping techniques. It begins by defining what a prototype is and explaining the development of rapid prototyping from manual methods to soft and then rapid prototyping using additive manufacturing. Specific rapid prototyping techniques covered include stereolithography (SLA), selective laser sintering (SLS), laminated object manufacturing (LOM), and fused deposition modeling (FDM). Applications of rapid prototyping include design, engineering analysis, and tooling. Advantages are listed as fast, accurate production with minimal material waste, while limitations include staircase effects and cost.
The document contains questions about rapid prototyping technologies and processes. It asks about liquid-based and solid-based rapid prototyping systems like stereolithography (SLA), selective laser sintering (SLS), and fused deposition modeling (FDM). Questions also cover topics like the STL file format used for 3D printing/additive manufacturing, materials used in different processes, advantages of rapid prototyping over traditional methods, and issues with current additive manufacturing technologies.
This document discusses methods for reducing the stair step effect in additively manufactured surfaces. It begins with an introduction to rapid prototyping and additive manufacturing processes. It then discusses common form errors in additive manufacturing, including flatness/straightness errors, cylindricity errors, and stair step errors. The document focuses on stair step errors, explaining that they occur due to the layered manufacturing process approximating surfaces. It then discusses several methods for reducing stair step errors, including adaptive slicing to vary layer thicknesses based on geometry, and ball burnishing as a post-processing technique to smooth layer edges through plastic deformation. Finally, it discusses factors that influence the effectiveness of ball burnishing, such as ball diameter, rolling pressure, and
TYPES OF RAPID PROTOTYPING - ADDITIVE PROCESSNurhuda Hayati
This document discusses several types of rapid prototyping (RP) technologies. It describes the input, method, materials, and applications of RP. It provides details on liquid-based systems like stereolithography (SLA), solid-based systems like fused deposition modeling (FDM), and powder-based systems like selective laser sintering (SLS). For each approach, it outlines the basic process, common materials used, advantages, and limitations. The document serves as an overview of fundamental RP concepts and several important RP techniques.
The document discusses materials for 3D printing. It begins by outlining the demands materials must meet for 3D printing processes including forming a proper feedstock, being processable by the fabrication method, being post-processable if needed, and having acceptable service properties. It then categorizes the main 3D printing processes and lists over 3000 common material types including plastics, metals, and ceramics. Specific polymers like thermoplastics and thermosets are discussed. The document concludes by discussing challenges for materials in additive manufacturing like achieving quality, consistency, a wide diversity of compositions, superior structures and properties, and low costs.
Definition, need, raw materials, types of processes
Photo polymerization
Binder jetting, material extrusion
Powder bed fusion
Sheet lamination, direct energy deposition
Limitations, strengths
Programming methods.
This document discusses rapid prototyping techniques, including liquid-based, solid-based, and powder-based systems. It provides details on stereolithography (SL), describing the process of building models layer-by-layer by curing liquid resin with a laser beam. Fused deposition modeling (FDM) is also summarized, which uses extruded thermoplastic to build parts layer by layer. Finally, selective laser sintering (SLS) is covered, using a laser beam to fuse powdered materials like nylon or metal into solid objects one layer at a time.
3D PRINTING- POWDER BASED ADDITIVE MANUFACTURING S. Sathishkumar
The document discusses three powder-based additive manufacturing systems: selective laser sintering (SLS), three dimensional printing (3DP), and laser engineered net shaping (LENS). SLS uses a laser to sinter powdered materials like plastic and metal together layer by layer. 3DP uses inkjet printheads to apply a binder to layers of powder to build parts. LENS uses a laser to melt metal powder as it is deposited, building parts layer by layer. Each system uses a different technique but all use lasers or binders to fuse powdered materials together to build 3D parts additively.
Rapid prototyping is an additive manufacturing process that automatically constructs physical models from CAD data. There are several types of rapid prototyping technologies, including stereolithography (SL), selective laser sintering (SLS), fused deposition modeling (FDM), and laminated object manufacturing (LOM). The document discusses these technologies and proposes using additive manufacturing and rapid prototyping to produce camshafts.
Rapid prototyping is a process that builds 3D objects from a digital CAD file layer by layer. It allows designers to quickly test designs by creating physical prototypes. Various techniques were developed in the 1960s-1980s including selective laser sintering which uses a laser to fuse powdered material. Rapid prototyping is now commonly used to build prototypes from 3D CAD models in hours rather than weeks. It offers advantages over traditional modeling like faster production and ability to modify designs easily.
An Analysis of Surface Roughness Improvement of 3D Printed Materialijsrd.com
3D printing is a process of making three dimensional solid objects from a digital model. 3D printing is achieved using additive processes, where an object is created by laying down successive layers of material. This work investigates surface finish improvement techniques used with 3D printed metal parts during the infiltration treatment. The goal is to produce an acceptable surface quality without performing a secondary machining process. Such a surface would be categorized as a D-series surface under the surface finish standards the injection molding process.
Use of rapid prototyping method for manufacture and examination of gear wheel...Saras Chandra
The document discusses the use of rapid prototyping methods for manufacturing and examining gear wheels. It analyzes various rapid prototyping techniques like SLA, FDM, SLS in terms of their suitability for producing gear wheel prototypes. It also describes preparing geometric data for rapid prototyping and issues with file formats. The document then evaluates the geometric accuracy of rapid prototyping for gear wheels through measurements. Finally, it discusses using rapid prototyping for gear wheel testing applications like tooth contact analysis and fatigue testing of non-involute gears.
Heat setting is a heat treatment applied to thermoplastic fabrics like polyester and nylon to impart dimensional stability. It involves heating the fabric above the glass transition temperature to allow polymer chains to rearrange into a stress-free configuration, then cooling to fix this new shape. Uneven heating can cause unlevel dyeing. Proper heat setting improves crease resistance but can reduce dye uptake if not done uniformly before dyeing. Stenters are commonly used and temperature, moisture, and processing time must be carefully controlled to avoid issues like fabric yellowing or stiffness.
The presentation covers all the methods of Rapid protoyping and various aspects related to it.
The Topics covered in the presentation are
1) Droplet Deposition Manufacturing
2) Laminated Object Manufacturing
3) Fused Deposition Modeling
4) Selective Laser Manufacturing
5) Sterolithography
This presentation is useful; for understanding the processes of rapid prototyping and its application.
Also this presentation includes the STL file format and problems with STL files.
The document discusses several common ink jet printing techniques for additive manufacturing, including the Sanders Model Maker, Multi-Jet Modelling, Z402 Ink Jet System, and Genisys Xs printer. It describes the key components and processes of these systems, such as using ink jets to deposit liquid materials layer by layer, and how they are used to quickly produce prototypes and models.
Lecture: An introduction to additive manufacturingKhuram Shahzad
1) Additive manufacturing (AM), also known as 3D printing, is a process of building 3D objects by depositing materials layer by layer based on a digital model.
2) AM has various applications across industries and the global AM industry is valued at $8 billion in 2018 and expected to reach $23 billion by 2026.
3) Common AM techniques include fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), and polyjet modeling; they differ in the materials and joining processes used to build layers.
Additive manufacturing Processes PDF by (badebhau4@gmail.com)Er. Bade Bhausaheb
Additive manufacturing (AM) processes build three-dimensional objects by adding material layer by layer based on a digital model. The document discusses several AM processes including powder bed fusion which uses lasers or electron beams to fuse powder materials together layer by layer. Key powder bed fusion techniques are direct metal laser sintering
The document provides an overview of additive manufacturing (AM) or 3D printing. It discusses the different families of AM, including powder bed fusion, material extrusion, binder jetting, vat photopolymerization, material jetting, direct energy deposition, and sheet lamination. It compares the various AM methods based on factors like deposition rate, feature resolution, part size limitations, and build speed. The document also outlines considerations for selecting suitable parts for AM and choosing the appropriate AM process based on the application.
10-10-05_04 Dan Larochelle: Rapid prototypingDarrell Caron
Rapid prototyping allows students to apply STEM concepts through hands-on projects, helping them better retain knowledge. Prototypes are essential tools in design that allow students to physically express ideas and test how designs fit, look, and function. Rapid prototyping creates objects quickly through additive manufacturing techniques like 3D printing, where a part is built layer by layer from a 3D digital model. This contrasts with subtractive techniques that remove material. Rapid prototyping provides benefits like getting feedback earlier in the design process and reducing costs and time to market versus traditional design and manufacturing.
The document discusses various types of additive manufacturing (3D printing) technologies. It describes extrusion deposit techniques like fused deposition modeling (FDM), powder bed fusion methods including selective laser sintering (SLS), and vat photopolymerization techniques like stereolithography (SLA). It also covers areas like binder jetting, 3D model file formats, applications in advanced manufacturing and medicine, and challenges with additively manufacturing metal matrix composites.
The document discusses rapid prototyping (RP), which allows prototypes to be made from a CAD model in hours or days rather than weeks. It describes various RP technologies including stereolithography, solid ground curing, droplet deposition manufacturing, laminated object manufacturing, fused deposition modeling, and selective laser sintering. These technologies differ in their starting materials, which can be liquids, solids like sheets, or powders, and how layers are added to build the final part in a layer-by-layer process from the CAD model.
This document discusses rapid prototyping and provides details on various rapid prototyping techniques. It begins by defining what a prototype is and explaining the development of rapid prototyping from manual methods to soft and then rapid prototyping using additive manufacturing. Specific rapid prototyping techniques covered include stereolithography (SLA), selective laser sintering (SLS), laminated object manufacturing (LOM), and fused deposition modeling (FDM). Applications of rapid prototyping include design, engineering analysis, and tooling. Advantages are listed as fast, accurate production with minimal material waste, while limitations include staircase effects and cost.
The document contains questions about rapid prototyping technologies and processes. It asks about liquid-based and solid-based rapid prototyping systems like stereolithography (SLA), selective laser sintering (SLS), and fused deposition modeling (FDM). Questions also cover topics like the STL file format used for 3D printing/additive manufacturing, materials used in different processes, advantages of rapid prototyping over traditional methods, and issues with current additive manufacturing technologies.
This document discusses methods for reducing the stair step effect in additively manufactured surfaces. It begins with an introduction to rapid prototyping and additive manufacturing processes. It then discusses common form errors in additive manufacturing, including flatness/straightness errors, cylindricity errors, and stair step errors. The document focuses on stair step errors, explaining that they occur due to the layered manufacturing process approximating surfaces. It then discusses several methods for reducing stair step errors, including adaptive slicing to vary layer thicknesses based on geometry, and ball burnishing as a post-processing technique to smooth layer edges through plastic deformation. Finally, it discusses factors that influence the effectiveness of ball burnishing, such as ball diameter, rolling pressure, and
TYPES OF RAPID PROTOTYPING - ADDITIVE PROCESSNurhuda Hayati
This document discusses several types of rapid prototyping (RP) technologies. It describes the input, method, materials, and applications of RP. It provides details on liquid-based systems like stereolithography (SLA), solid-based systems like fused deposition modeling (FDM), and powder-based systems like selective laser sintering (SLS). For each approach, it outlines the basic process, common materials used, advantages, and limitations. The document serves as an overview of fundamental RP concepts and several important RP techniques.
The document discusses materials for 3D printing. It begins by outlining the demands materials must meet for 3D printing processes including forming a proper feedstock, being processable by the fabrication method, being post-processable if needed, and having acceptable service properties. It then categorizes the main 3D printing processes and lists over 3000 common material types including plastics, metals, and ceramics. Specific polymers like thermoplastics and thermosets are discussed. The document concludes by discussing challenges for materials in additive manufacturing like achieving quality, consistency, a wide diversity of compositions, superior structures and properties, and low costs.
Definition, need, raw materials, types of processes
Photo polymerization
Binder jetting, material extrusion
Powder bed fusion
Sheet lamination, direct energy deposition
Limitations, strengths
Programming methods.
This document discusses rapid prototyping techniques, including liquid-based, solid-based, and powder-based systems. It provides details on stereolithography (SL), describing the process of building models layer-by-layer by curing liquid resin with a laser beam. Fused deposition modeling (FDM) is also summarized, which uses extruded thermoplastic to build parts layer by layer. Finally, selective laser sintering (SLS) is covered, using a laser beam to fuse powdered materials like nylon or metal into solid objects one layer at a time.
3D PRINTING- POWDER BASED ADDITIVE MANUFACTURING S. Sathishkumar
The document discusses three powder-based additive manufacturing systems: selective laser sintering (SLS), three dimensional printing (3DP), and laser engineered net shaping (LENS). SLS uses a laser to sinter powdered materials like plastic and metal together layer by layer. 3DP uses inkjet printheads to apply a binder to layers of powder to build parts. LENS uses a laser to melt metal powder as it is deposited, building parts layer by layer. Each system uses a different technique but all use lasers or binders to fuse powdered materials together to build 3D parts additively.
Rapid prototyping is an additive manufacturing process that automatically constructs physical models from CAD data. There are several types of rapid prototyping technologies, including stereolithography (SL), selective laser sintering (SLS), fused deposition modeling (FDM), and laminated object manufacturing (LOM). The document discusses these technologies and proposes using additive manufacturing and rapid prototyping to produce camshafts.
Rapid prototyping is a process that builds 3D objects from a digital CAD file layer by layer. It allows designers to quickly test designs by creating physical prototypes. Various techniques were developed in the 1960s-1980s including selective laser sintering which uses a laser to fuse powdered material. Rapid prototyping is now commonly used to build prototypes from 3D CAD models in hours rather than weeks. It offers advantages over traditional modeling like faster production and ability to modify designs easily.
An Analysis of Surface Roughness Improvement of 3D Printed Materialijsrd.com
3D printing is a process of making three dimensional solid objects from a digital model. 3D printing is achieved using additive processes, where an object is created by laying down successive layers of material. This work investigates surface finish improvement techniques used with 3D printed metal parts during the infiltration treatment. The goal is to produce an acceptable surface quality without performing a secondary machining process. Such a surface would be categorized as a D-series surface under the surface finish standards the injection molding process.
Use of rapid prototyping method for manufacture and examination of gear wheel...Saras Chandra
The document discusses the use of rapid prototyping methods for manufacturing and examining gear wheels. It analyzes various rapid prototyping techniques like SLA, FDM, SLS in terms of their suitability for producing gear wheel prototypes. It also describes preparing geometric data for rapid prototyping and issues with file formats. The document then evaluates the geometric accuracy of rapid prototyping for gear wheels through measurements. Finally, it discusses using rapid prototyping for gear wheel testing applications like tooth contact analysis and fatigue testing of non-involute gears.
Heat setting is a heat treatment applied to thermoplastic fabrics like polyester and nylon to impart dimensional stability. It involves heating the fabric above the glass transition temperature to allow polymer chains to rearrange into a stress-free configuration, then cooling to fix this new shape. Uneven heating can cause unlevel dyeing. Proper heat setting improves crease resistance but can reduce dye uptake if not done uniformly before dyeing. Stenters are commonly used and temperature, moisture, and processing time must be carefully controlled to avoid issues like fabric yellowing or stiffness.
The presentation covers all the methods of Rapid protoyping and various aspects related to it.
The Topics covered in the presentation are
1) Droplet Deposition Manufacturing
2) Laminated Object Manufacturing
3) Fused Deposition Modeling
4) Selective Laser Manufacturing
5) Sterolithography
This presentation is useful; for understanding the processes of rapid prototyping and its application.
Also this presentation includes the STL file format and problems with STL files.
Product Development for Future using Rapid Prototyping TechniquesIRJET Journal
This document discusses rapid prototyping techniques for product development. It begins by defining rapid prototyping as a process that helps improve product quality and reduce prototyping costs by quickly building models from 3D computer designs. The two main types of rapid prototyping are additive manufacturing, which adds material to build a geometry, and subtractive manufacturing, which removes material from a solid. The document then examines several specific rapid prototyping techniques like stereolithography, laminated object manufacturing, selective laser sintering, 3D inkjet printing, and fused deposition modeling. It concludes that future developments in rapid prototyping will include making larger parts, improving surface finish and accuracy, and using new materials to further enhance the product
The document discusses various rapid prototyping technologies. It provides an overview of the basic 5-step rapid prototyping process of creating a CAD model, converting it to STL format, slicing the STL file, layer-by-layer construction, and clean and finish. It then describes several specific rapid prototyping methods - selective laser sintering, stereolithography, laminated object manufacturing, and fused deposition modeling - and compares their applications, advantages, disadvantages and specifications.
MSE-4105-Chapter-2-Manufacturing of Composites.pdfShamahaKhondoker
This document discusses various processing techniques and manufacturing processes for fiber-reinforced polymer matrix composites. It describes structural, semi-structural, and non-structural processing techniques based on fiber alignment. Various manufacturing processes are then discussed, including hand lay-up, pultrusion, resin transfer molding, filament winding, compression molding, injection molding, blow molding, and infiltration. Key factors affecting the selection of manufacturing processes are identified as production rate, cost, part requirements, geometry, and material.
prototype , type of 3D printer and MFG.pptxahmedtito21
The document discusses various rapid prototyping technologies including stereolithography, fused deposition modeling, laminated object manufacturing, selective laser sintering, and three dimensional printing. It provides details on how each technology works and compares their advantages and limitations. The document also discusses applications of rapid prototyping technologies, factors for selecting appropriate technologies, and challenges that need to be addressed to improve the technologies.
Rapid prototyping is a technology that builds physical 3D models directly from CAD data. It allows for faster product development by enabling corrections in early stages. The process involves slicing a 3D CAD model into layers, then depositing or solidifying materials layer-by-layer to build the model from the bottom up with no tooling required. Common rapid prototyping methods include stereolithography, fused deposition modeling, selective laser sintering, and 3D printing.
Rapid prototyping (RP) uses additive manufacturing techniques to quickly produce physical prototypes directly from 3D CAD models. There are several RP technologies categorized by the form of the starting material - liquid, solid or powder. RP allows faster prototyping compared to traditional methods and is useful for design validation, engineering analysis, tooling applications and small batch manufacturing. However, RP parts can have reduced accuracy and mechanical properties compared to final production components.
Rapid prototyping uses 3D printing technologies to quickly produce physical models from 3D CAD files. It allows engineers to test designs before full production. The document discusses the rapid prototyping process which includes: 1) Creating a CAD model, 2) Converting it to STL format, 3) Slicing the STL file into layers, 4) Constructing the model layer-by-layer using different techniques like stereolithography, fused deposition modeling or selective laser sintering, and 5) Cleaning and finishing the prototype. Rapid prototyping reduces costs and development time by finding design flaws earlier compared to traditional prototyping methods.
This document discusses rapid prototyping techniques such as stereolithography, selective laser sintering, fused deposition modeling, laminated object manufacturing, and 3D printing. It provides details on the processes, companies that develop the technologies, and applications. Rapid prototyping allows for quick fabrication of geometric shapes to create prototypes for testing form, fit, and function without using the final production materials or processes. STL files are commonly used as the standard file format for rapid prototyping systems.
Rapid prototyping technologies allow engineers to create physical prototypes of designs prior to full production. The document discusses the rapid prototyping process which involves:
1. Creating a CAD model and converting it to STL format.
2. Slicing the STL file into thin layers and constructing the prototype layer-by-layer using different techniques like stereolithography, selective laser sintering, or fused deposition modeling.
3. Post-processing the prototype by removing supports, cleaning, and finishing the surface.
Specific rapid prototyping methods like stereolithography, selective laser sintering, and fused deposition modeling are described in detail. The document also discusses applications and limitations of rapid
Additive manufacturing (AM) operates by adding layers of material together to make an object, unlike conventional manufacturing which subtracts material. AM allows for combining manufacturing and assembly into a single process. The main AM techniques are vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, sheet lamination, and directed energy deposition. AM provides advantages like customization and reduced waste but also has limitations like roughness and cost. Current research focuses on areas like smart components and additive manufacturing of dissimilar materials.
This document discusses various rapid prototyping and manufacturing techniques categorized by the type of material used - liquid, powder, or solid/foil based. Liquid based techniques discussed include stereolithography, which uses a laser to cure liquid resin into layers, and jetting systems, which use print heads to deposit both model and support materials. Powder based techniques like selective laser sintering fuse powdered materials using a laser. Solid/foil techniques such as fused deposition modeling deposit melted materials. The document provides details on the processes and materials used for different rapid prototyping methods.
Study on the Fused Deposition Modelling In Additive ManufacturingIJERD Editor
Additive manufacturing process, also popularly known as 3-D printing, is a process where a product
is created in a succession of layers. It is based on a novel materials incremental manufacturing philosophy.
Unlike conventional manufacturing processes where material is removed from a given work price to derive the
final shape of a product, 3-D printing develops the product from scratch thus obviating the necessity to cut away
materials. This prevents wastage of raw materials. Commonly used raw materials for the process are ABS
plastic, PLA and nylon. Recently the use of gold, bronze and wood has also been implemented. The complexity
factor of this process is 0% as in any object of any shape and size can be manufactured.
This document discusses fused deposition modeling (FDM), a type of additive manufacturing. FDM uses thermoplastic filament fed through an extruder head to deposit material layer by layer. The heated extruder head melts the filament and deposits it in thin layers on a platform according to a 3D computer model. Each new layer bonds to the previous layer, allowing three-dimensional objects to be built up from successive layers of material. FDM is a low-cost type of 3D printing that works well for prototypes and some end-use parts using thermoplastics like ABS and PLA. The document provides details on the FDM printing process and compares it to other additive manufacturing techniques.
The document provides an overview of 3D printing including its history, working principles, types of printing processes, and conclusions about its use. It discusses how 3D printing has gained importance in manufacturing over the past decade as an additive process. The working principle involves forming a 3D model, printing the model layer-by-layer, and finishing the model. Different printing types are described like stereolithography, laminated object manufacturing, and fused deposition modeling. In conclusion, 3D printing is positioned to become more widely used for prototyping and production, though challenges around quality and intellectual property protection remain.
Rapid prototyping is an additive manufacturing process that builds 3D models layer by layer directly from CAD data. It allows for quick fabrication of parts and reduces development time and costly mistakes compared to conventional machining. The document discusses various rapid prototyping technologies such as stereolithography, selective laser sintering, and fused deposition modeling. It provides details on the working, advantages, applications, and history of these additive manufacturing methods.
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Build Orientation Analysis in fused deposition modeling
1. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 1
INTRODUCTION
In the recent times, many manufacturing organizations are widely using
digital prototyping in different areas for product development. After the Machine
Component is digitally prototyped, and tested for the actual application, under
virtual conditions; and then in the manufacturing of the real prototype or product,
lot of alternative solutions and approaches will be involved. In order to prototype,
3D Printing technique is being used in the present world. This method is also called
as Additive Manufacturing process or Rapid prototyping. In this process, addition
of material is used in order to build the machine component or the component,
which is under manufacturing. There is no metal cutting and associated chips
production in 3D Printing process. In this method, the required complex shaped
components are modeled using CAD software and stored in .stl file format, which
in turn is loaded into the 3D Printing machine. The required components are
fabricated automatically with materials like ABS plastics. [ 8 ]
In the process of adopting 3D Printing Technology, Fused Deposition Modeling
(FDM) is one of the important processes that are used at present by many Industries.
In this process, one important consideration is to minimize the quantity of support
material of the product, which has a large influence on the product as far as many
considerations such as reduction of time in the design phase, reducing the cost of
manufacturing (post-processing), improvement in the accuracy and surface finish
with which the product is being fabricated.[8]
2. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 2
1. FUSED DEPOSITION MODELING
Figure 1 Fused deposition modeling [5]
It is one of the more popular methods for generative manufacturing. In this process,
three-dimensional object are produced by depositing a molten thermoplastic material
layer by layer. Stratasys Inc. is commercially manufacturing machines for FDM. A
solid filament of thermoplastic material with 1.25 mm diameter is fed into an x-y
controlled extrusion head. The material is melted by a resistance heater at a temperature
of 180°F (1°F above its melting temperature). As the head is moved along the required
trajectory using computer control, the thermoplastic material is deposited by extruding
it through a nozzle by a precision volumetric pump. As the extruded material, deposited
as a fine layer, comes out with a temperature just above the melting point, it resolidifies
within 0.1 second by natural cooling. To ensure proper adhesion of the deposited fused
material to the previously deposited layer, the object temperature is maintained just
below the solidification temperature. After one layer is deposited, the platform,
supporting the object, is lowered by one layer thickness.
To maintain stability in the process, the rate of flow of the extruded molten filament
is controlled to match,
3. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 3
( i ) the travelling speed of the depositing head (which can go upto 380 mm/sec),
(ii) the desired thickness of the layer (that varies from 0.025 mm to 1.25 mm), and
(iii) the width of the deposited line (which varies from 0.23 mm to 6.25 mm).
The repeatability and positional accuracy of this process are claimed to be
about+0.025 mm with an overall tolerance of 0.125 mm over a cube with 305 mm sides.
The FDM process is still not very suitable for parts with very small features. The
typically-used materials for the process include investment casting wax, wax filled
adhesive material, and tough nylon-like material. Polymer type thermoplastics can also
be used. [ 5 ]
Advantages:
1. Strength and temperature capability of build materials.
2. Safe laser free operation.
3. Easy Post Processing.
4. Quick and cheap generation of models.
5. Easy and convenient date building.
6. No worry of possible exposure to toxic chemicals, lasers, or liquid polymer bath.
7. No wastage of material during or after producing the model.
8. No requirement of clean-up.
9. Quick change of materials.
Disadvantages:
1. Process is slower than laser based systems.
2. Build Speed is low.
3. Thin vertical column prove difficult to build with FDM.
4. Physical contact with extrusion can sometimes topple or at least shift thin vertical
columns and walls.
5. Restricted accuracy due to the size of the material used: wire of 1.27 mm diameter.
4. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 4
Applications:
1. Investment Casting.
2. Medical Applications
3. Flexible Components.
4. Conceptual modeling.
5. Fit, form and functional applications and models for further manufacturing procedures.
6. Investment casting and injection molding.
2. LAMINATED OBJECT MANUFACTURING
Figure 2 : Laminated Object Manufacturing
(Source: https://www.azom.com/article.aspx?ArticleID=1650)
Lamination implies a laying down of layers that are bonded adhesively to one another.
Several variations of laminated-object manufacturing (LOM) are available. The
simplest and least expensive versions of LOM involve using control software and vinyl
cutters to produce the prototype. Vinyl cutters are simple CNC machines that cut shapes
from vinyl or paper sheets. Each sheet then has a number of layers and registration
holes, which allow proper alignment and placement onto a build fixture. Figure
illustrates the manufacture of a prototype by laminated-object manufacturing with
5. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 5
manual assembly. Such LOM systems are highly economical and are popular in schools
and universities because of the hands-on demonstration of additive manufacturing and
production of parts by layers.
LOM systems can be elaborate, the more advanced systems use layers of paper
or plastic with a heat activated glue on one side to produce parts. The desired shapes are
burned into the sheet with a laser, and the parts are built layer by layer (Fig. 2 ). On
some systems, the excess material must be removed manually once the part is
completed. Removal is simplified by programming the laser to burn perforations in
crisscrossed patterns. The resulting grid lines make the part appear as if it had been
constructed from gridded paper with squares printed on it, similar to graph paper.[ 5 ]
System Parameters:
There are various controlling parameters such as laser power, heater
speed, material advance margin, and support wall thickness and heater
compression.
1.Laser Power:
It is the percentage of total laser output wattage. For e.g. LOM 1015 is operated
at a laser power of about 9% of maximum 25W laser or approximately 2.25W. This
value will be different for various materials or machines but essentially it is set to cut
through only one sheet of build material.
2.Heater Speed:
It is the rate at which hot roller passes across the top of the part. The rate is
given in inches/second. It is usually 6”/sec for `initial pass and 3”/sec for returning pass
of heater. The heater speed effects the lamination of the sheet so it must be set low
enough to get a good bond between layers.
3.Material Advance Margin:
It is the distance the paper is advanced in addition to length of the part.
6. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 6
4.Support Wall Thickness:
It controls the outer support box walls throughout a part. The support
wall thickness is generally set 0.25” in the X and Y direction, although this
value can be changed by operator.
5.Compression:
It is used to set the pressure that the heater roller exerts on the layer. It is
measured in inches which are basically the distance the roller is lifted from its initial
track by the top surface of part. Values for compression will vary for different machines
and materials, but are typically 0.015”-0.025”.
3. STEREOLITHOGRAPHY
a b c
Figure 3 : Stereolthography [ 3 ]
A common rapid-prototyping process-one that actually was developed prior to fused-
deposition modeling is stereolithography (STL). This process is based on the principle
of curing (hardening) a liquid photopolymer into a specific shape. A vat, containing a
mechanism whereby a platform can be lowered and raised is filled with a photocurable
liquid-acrylate polymer. The liquid is a mixture of acrylic monomers, oligomers
(polymer intermediates), and a photo initiator (a compound that undergoes a reaction
upon absorbing light).
7. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 7
At its highest position of the platform (a in figure), a shallow layer of liquid
exists above the platform. A laser generating an ultraviolet (UV) beam is focused upon
a selected surface area of the photopolymer and then moved around in the x-y plane.
The beam cures that portion of the photopolymer (say, a ring- x ; shaped portion) and
thereby produces a solid body. V The platform is then lowered sufficiently to cover the
cured polymer with another layer of liquid polymer, and the sequence is repeated. The
process is repeated until level b in Fig.3 is reached. Thus far, we have generated a
cylindrical part with a constant wall thickness. Note that the platform is now lowered by
a vertical distance ab.
At level b, the x-y movements of the beam define a wider geometry, so we
now have a flange-shaped portion that is being produced over the previously formed
part. After the proper thickness of the liquid has been cured, the process is repeated,
producing another cylindrical section between levels b and c. Note that the surrounding
liquid polymer is still fluid (because it has not been exposed to the ultraviolet beam) and
that the part has been produced from the bottom up in individual “slices.” The unused
portion of the liquid polymer can be used again to make another part or another
prototype. Note also that, like FDM, stereolithography can utilize a weaker support
material. In stereolithography, this support takes the form of perforated structures. After
its completion, the part is removed from the platform, blotted, and cleaned
ultrasonically and with an alcohol bath. Then the support structure is removed, and the
part is subjected to a final curing cycle in an oven. The smallest tolerance that can be
achieved in stereolithography depends on the sharpness of the focus of the laser;
typically, it is around 0.0125 mm. Oblique surfaces also can be of very high quality.[ 3 ]
Advantages:
1) Parts have best surface quality
2) High Accuracy
3) High speed.
8. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 8
Disadvantages:
1) It requires Post Processing. i.e. Post Curing.
2) Careful handling of raw materials required.
3) High cost of Photo Curable Resin.
Applications:
1) Investment Casting.
2) Wind Tunnel Modeling.
3) Tooling.
4) Injection Mould Tools.
4. SELECTIVE LASER SINTERING
Figure 4 : Selective Laser Sintering
Selective laser sintering (SLS) is a process based on the sintering of nonmetallic or less
commonly, metallic powders selectively into an individual object. The basic elements in
9. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 9
this process are shown in Fig.4.The bottom of the processing chamber is equipped with
two cylinders:
I. A powder-feed cylinder, which is raised incrementally to supply powder to the
part-build cylinder through a roller mechanism.
2. A part-build cylinder, which is lowered incrementally as the part is being
formed.
First, a thin layer of powder is deposited in the part-build cylinder. Then a
laser beam guided by a process-control computer using instructions generated by the
three-dimensional CAD program of the desired part is focused on that layer, tracing and
sintering a particular cross section into a solid mass. The powder in other area remains
loose, yet it supports the sintered portion. Another layer of powder is then deposited;
this cycle is repeated again and again until the entire three-dimensional part has been
produced. The loose particles are shaken off, and the part is recovered. The part does
not require further curing-unless it is a ceramic, which has to be fired to develop
strength.
A variety of materials can be used in this process, including polymers (such as
ABS, PVC, nylon, polyester, polystyrene, and epoxy), wax, metals, and ceramics with
appropriate binders. It is most common to use polymers because of the smaller, less
expensive, and less complicated lasers required for sintering. With ceramics and metals,
it is common to sinter only a polymer binder that has been blended with the ceramic or
metal powders. if desired, the part can be carefully sintered in a furnace and infiltrated
with another metal.[ 3 ]
Purpose of Selective Laser Sintering:
1. To provide a prototyping tool.
2. To decrease the time and cost of design to product cycle.
3. It can use wide variety of materials to accommodate multiple application throughout the
manufacturing process.
Advantages:
1. Wide range of build materials.
2. High throughput capabilities.
3. Self-supporting build envelop.
10. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 10
4. Parts are completed faster.
5. Damage is less.
6. Less wastage of material.
Disadvantages:
1. Initial cost of system is high.
2. High operational and maintenance cost.
3. Peripheral and facility requirement.
Applications:
1. As conceptual models.
2. Functional prototypes.
3. As Pattern masters.
5. THREE DIMENSIONAL PRINTING
Figure 5 : Three dimensional printing [ 3 ]
In the three dimensional printing (3DP) process, a print head deposits an inorganic
binder material onto a layer of polymer, ceramic, or metallic powder. A piston,
supporting the powder bed, is lowered incrementally, and with each step a layer a
deposited and then fused by the binder.
11. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 11
Multi jet modeling and poly Jet processes are sometimes referred to as three
dimensional printing technologies, because they operate similarly to inkjet printers, but
incorporate a third (thickness) direction. In fact, 3DP has been used interchangeably
with rapid prototyping or digital manufacturing to include all rapid prototyping
operations; however, 3DP is most commonly associated with printing a binder onto
powder. Three dimensional printing allows considerable flexibility in the materials and
binders used. Commonly used powder materials as blends of polymers and fibers,
foundry sand, and metals. The effect is a three dimensional analog to printing
photographs, using three ink colors (red, cyan, and blue) on an ink jet printer.
The parts produced through the 3DP process are somewhat porous, and thus
may lack strength. [ 3 ]
12. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 12
FUSED DEPOSITION MODELING
Figure 6: Fused Deposition modeling
In order to create a complex physical object from a digital set of instructions, many
mechanical systems must work together to get the job done correctly. In addition to
these mechanical systems, software used to control the nozzle temperature, motor
speeds & direction, and methods in which the printer lays out the material are equally
important to create a highly accurate model.
The nozzle in a 3D printer has one of the most important jobs of all the
mechanical systems. It is the last mechanical device that is used to build up a 3D object
and it’s design and functionality is extremely important when it comes to the accuracy
and build quality of the printer. The biggest contributor to the performance of the nozzle
is its orifice size. Typically, the nozzle size used on many 3D printers is 0.4mm. This
size is small enough to produce high quality parts while maintaining reasonable build
times. Printers such as the Makerbot Replicator use this size nozzle. Depending on the
over-all goal of the part being printed however, these nozzles can be changed to larger
diameters in order to increase the speed of the print job. While doing so will decrease
the horizontal accuracy, parts that will be used as rough drafts or that will be post
processed with fillers or paints will still perform as in-tended. It is important to never
set the layer height higher than the nozzle size. This will dramatically decrease the bond
13. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 13
strength between the layers and overall build quality. For example, if a 3D printer is
using a 0.6 mm nozzle, then the maximum layer height should not exceed 0.5 mm.
While the nozzle is used to direct molten plastics in a precise manner, it’s other
job is to convert the solid coil of plastic material into the molten state by utilizing a
heating element within the extruder assembly. This heating element can be a vitreous
enamel resistor, a nichrome wire, or a cartridge heater. In addition to the heating
element, there is usually a thermistor (temperature sensor) integrated into the extruder
assembly to control the required temperature for the specific material being used. For
example, one of the most common materials used in FDM is PLA (polylactic acid)
which has a melting temperature of around 160 degrees Celsius. In contrast, another
very popular material used is nylon. This material requires extrusion between 240 and
270 degrees Celsius. It is very important to use the correct extrusion temperature in
order to minimize the risk of the nozzle jamming and also maximize the bond between
bead layers. The design of the extruder is very important to not only the printing
accuracy, but also to the overall performance and maintenance of the printer. While the
bottom end of the extruder must be able to heat the material to a desired temperature
within a few degrees, the upper end must remain as cool as possible in order to avoid
jamming. This is due to the feed mechanism located above the extruder, which requires
the filament material to be in a completely solid state in order to function properly. One
way to decrease heat transfer from the heating element to the feed mechanism and in
turn decreasing the chance of jamming, is to use fans to cool the top end of the extruder.
Depending on the type of model being printed, and the type of material being used, a
heated bed may be important to maintain the structure’s shape while it cools. Since
plastics shrink as they cool, a quick temperature drop could cause the corners of a part
to curl up off of the printer bed. To minimize this risk, some printers incorporate an
electronically heated bed that keeps the temperature steady. This allows the model to
cool at a more even rate and improve its overall dimensional accuracy.
There are many factors that contribute to the build quality of a 3D printed part.
The extruder assembly which includes the extruder, heating element, & nozzle
contribute greatly to the overall build quality.[ 1 ]
14. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 14
VARIOUS PROCESS PARAMETERS OF FDM PROCESS
Figure 7 : Various Process Parameter of FDM Process
1:Layer thickness
Layer thickness refers to the distance traveled in the z-direction between successive layers, and
has a direct impact on the build time and the surface quality of sloped surfaces. Each of the
three different nozzle tip sizes on the FDM 2000 (T10, T12, and T16) has an associated range
of recommended layer thickness. The layers in an FDM model are determined by the extrusion-
die diameter, which typically ranges from 0.050 to 0.12 mm. This thickness represents the best
achievable in the vertical direction. In the x-y plane, dimensional accuracy can be as fine as
0.025 mm as long as a filament can be extruded into the feature. The thickness of the layer
increases, the roughness increases. Layer thickness is the thickness of layer deposited by nozzle
tip and the value of layer thickness depends on the material and tip size.
This is the vertical height change from one layer to the next. While a smaller layer
height yields a higher resolution part, the build time is much longer. On the other
hand, large layer heights take much less time to produce but also decrease the surface
15. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 15
quality. As mentioned before, the layer height must not exceed the nozzle diameter.
This will lead to little or no bond between the layers. [ 1 ]
Figure 8 : Effect of Layer Thickness on Surface Finish
2.Build Orientation:
Part-build orientation is the only variable examined which is defined within the CAD stage of
the FDM process. Build orientation is varied by rotating the .STL file with respect to the
machine coordinate system. The important aspects of the orientation include the z-height of the
part and the angle each part surface or facet creates with the x-y plane or machine table. The z-
height can vary between the limits of the minimum layer feasible (0.178mm) and the maximum
height of the FDM2000 work envelope (25.4cm). The experimentation focused on orientations
requiring minimal or no support material.[ 6 ]
Part build orientation or orientation refers to the inclination of the part in the build platform
with respect to X, Y, and Z axis, where X and Y-axis are considered parallel to build platform
and Z- axis is along the direction of part build.
Tangent
Vertical
Normalθ
θ=Build orientation
t=Slice thickness
Figure 9: Build orientation [ 4 , 7 ]
16. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 16
2. Build time
Build time is important as it directly affects the cost of the part and is dependent on the part
deposition orientation as the sum of areas of all slices is different in different orientations. The
accurate estimation of build time for FDM processed parts require slicing of the part,
calculation of the area of the slices, generation of roads for laying the extruded material from a
nozzle, acceleration and deceleration of the nozzle tip while laying the material, and other non-
productive times like lowering the platform after deposition of a layer. Therefore, accurate
estimation of build time is tedious and time consuming.
3.Raster Orientation
The direction of the beads of material (roads) relative to the loading of the part.Raster angle
refers to the angle of the raster pattern with respect to the X axis on the bottom part layer.
Specifying the raster angle is very important in parts that have small curves. The typical
allowed raster angles are from 0° to 90°. Raster width is the width of the material bead used
for raster. Larger value of raster width will build a part with a stronger interior. Smaller value
will require less production time and material. The value of raster width varies based on
nozzle tip size. Vertical to Z axis is Axial and Perpendicular to Z axis is Tranverse.
Figure10: Raster orientation [ 2 ]
4. Model Build Temperature:
The temperature of the heating element for the model material .This controls how molten the
material is as it is extruded from the nozzle. Model temperature is the liquefier chamber
temperature. This is the temperature at which the model material is melted. The variation in
model temperature would affect the fluidity of the material as it is being laid. This factor was
selected to see if it influences the surface roughness. The levels considered were 250
o
C,
270
o
C and 280
o
C. At higher temperatures it was expected that the material would be in a
17. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 17
more fluid state, thus it would lead to more bulging of the material as it is being laid down.
This would result in rounding off of the stair-steps thus leading to better surface finish.
5.The interior fill strategy
The general path plan used in filling the inner portion of each layer. The user is offered three
possible interior fill types, as represented in order of decreasing material usage:
solid;
part fast;
cross hatch. and
Low density
If prototype function does not require a densely solid object, the user may want to decrease the
amount of material used and the total build time by selecting part fast (medium material usage)
or cross hatch (minimum material usage). [ 6 ]
6.Structure of Support Material
It is common for more advanced software to allow the user to modify how the support material
is utilized. Usually, this task is handled by the software automatically. There are certain cases
where this may be beneficial. For example, if a user finds that a printed object is warped after it
is completed, then adding additional supports to the object during the print process can help
prevent this. Another example would mostly be used as a last resort. If the user finds that the
bed of the printer is not level, then the Raft option could be used. [ 1 ]
7.Speed :
The maximum speed of the machine is governed by the firm-ware installed on the motor
controllers. However, it can be beneficial to adjust the speed in order to decrease the build time
(fast), or increase the build quality (slow). The speed settings can be split in three categories;
the perimeter, infill, and travel speed. The perimeter speed is the speed at which the print head
moves while printing the perimeter of the model. The infill speed is the speed at which the print
head moves during the infill operation. And lastly, the travel speed is the speed at which the
print head moves from one location to another while not printing. For example, if there are
18. Build orientation analysis in FDM
Mechanical Engineering, Sipna COET, Amravati Page 18
multiple parts being printed at once, then the travel speed will be the speed of the print head
when it is traveling to the other part to be printed. Typical speeds for the perimeter and infill
are 50mm/sec and 70mm/sec, respectively. [ 1 ]
8.Perimeters :
This is the number of times the printer will draw the outer surface of a layer before proceeding
on to the infill. Usually, there are 2 layers printed before the infill is done. The user may select
to add more layers in order to increase the strength of the outer surface. This will however,
increase the build time. Perimeter to raster air gap refers to gap between the inner most contour
and the edge of the raster fill inside of the contour. [ 1 ]
9.Air Gap:
This is the space between the beads of FDM material. The default is zero, meaning that the
beads just touch. It can be modified to leave a positive gap, which means that the beads of
material do not touch. This results in a loosely packed structure that builds rapidly. It can also
be modified to leave a negative gap, meaning that two beads partially occupy the same space.
This results in a dense structure which requires a longer build time. Air gap refers to the gap
between adjacent raster tool paths on the same layer.
Air gap between roads
Z
Figure11: the air gap between roads [ 2 ]
19. Build orientation analysis in FDM
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DESIGN OF EXPERIMENT
1. Problem Statement:
To analyze the effect of layer thickness (L.T), Orientation about X axis (θx),
Orientation about Y axis (θy) on the change in volume of model material (M.M) and
support material (S.M) required for a selected interior fill pattern as well as to
investigate the effect of the afore said factors on the time required to build the model.
Silencer of a two wheeler is considered as a sample component to conduct the
experimentation.
A solid CAD model of silencer was modeled using CATIA V5. The stl file of the
above model was imported to CatalystEx 4.4 software for conducting simulation runs.
Observations about volume of model and support material required and time taken for
fabrication were recorded by simulating the fabrication of the sample model as per
different settings of independent parameters obtained from DOE.
Figure 12 : CAD model of Silencer
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The Silencer component is designed using CATIA V 5, as shown in Fig.12 . The
CAD model of the Silencer component is converted into .stl file format. It is loaded into
CatalystEx 4.4 software of printing (FDM) machine.
A sample position of the component at 90 degrees is shown in Fig. 13.
Figure 13: CAD model of the Silencer in 90°
2. Design Of Experiment:
As the Catalyst Ex 4.4 software provides control over limited process
parameters, following factors were selected as independent variables:
1. Orientation about X axis (θx)
2. Orientation about Y axis (θy)
3. Layer Thickness (LT)
Range of variables :
1. θx:- 0 to 180°
2. θ y:- 0 to 180°
3. L.T:- 0.007 to 0.01
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STATISTICAL ANALYSIS & MODELING
Regression analysis is a set of statistical processes for estimating the relationships
among variables. It includes many techniques for modeling and analyzing several variables,
when the focus is on the relationship between a dependent variable and one or
more independent variables. More specifically, regression analysis helps one understand how
the typical value of the dependent variable changes when any one of the independent variables
is varied, while the other independent variables are held fixed.
Most commonly, regression analysis estimates the conditional expectation of the
dependent variable given the independent variables – that is, the average value of the dependent
variable when the independent variables are fixed. Less commonly, the focus is on a quantile,
or other location parameter of the conditional distribution of the dependent variable given the
independent variables. In all cases, a function of the independent variables called the regression
function is to be estimated.
1. Hypothesis:
We start analyzing the data by considering that no relationship exist between the dependent and
independent variables i.e., we propose a Null Hypothesis at the initial stage. The regression
analysis along with ANNOVA is carried out to accept or reject the hypothesis.
2. Analyzing effect of θx on
Table 3 : Data set for analyzing the effect of θx
Independent Variables Dependent Variables
θx θy LT MM SM T
0 0 0.01 2.53 1.75 8.34
22.5 0 0.01 2.47 2.11 10
45 0 0.01 2.38 1.97 11.05
67.5 0 0.01 2.34 1.27 9.58
90 0 0.01 2.34 1.18 9.12
112.5 0 0.01 2.34 1.06 9.15
135 0 0.01 2.35 2.17 11.27
157.5 0 0.01 2.39 2.39 10.12
180 0 0.01 2.39 2.33 8.56
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i. Support Material ( S.M. )
Regression Analysis: θx Vs. SM
Regression Statistics
Multiple R 0.330915
R Square 0.109505
Adjusted R
Square
-0.03891
Standard Error 0.558676
Observations 8
ANOVA
Df SS MS F
Significance
F
Regression 1 0.230288 0.230288 0.737822 0.423343
Residual 6 1.872712 0.312119
Total 7 2.103
Coefficients
Standard
Error
t Stat P-value
Intercept 1.476786 0.435317 3.39244 0.014632 0.411604
θx 0.003291 0.003831 0.858966 0.423343 -0.00608
Residual Plots for SM:
Graph 1 : θx Vs. SM
(P≥0.05) Null hypothesis can’t be rejected.
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ii. Model Material ( M.M )
Regression Analysis: θx Vs. MM
Regression Statistics
Multiple R 0.592142
R Square 0.350632
Adjusted R
Square
0.257865
Standard Error 0.057108
Observations 9
ANOVA
Df SS MS F
Significance
F
Regression 1 0.012327 0.012327 3.779714 0.092965
Residual 7 0.022829 0.003261
Total 8 0.035156
Coefficients
Standard
Error
t Stat P-value
Intercept 2.449556 0.0351 69.78719 3.26E-11
θx -0.00064 0.000328 -1.94415 0.092965
Residual Plots for MM
Graph 2 : θx Vs.MM
(P≥0.05) Null hypothesis can not be rejected.
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iii. Time
Regression Analysis: θx Vs. T
Regression Statistics
Multiple R 0.295739
R Square 0.087462
Adjusted R
Square
-0.06463
Standard Error 0.979743
Observations 8
ANOVA
Df SS MS F
Significance
F
Regression 1 0.552005 0.552005 0.575067 0.476973
Residual 6 5.759382 0.959897
Total 7 6.311388
Coefficients
Standard
Error
t Stat P-value Lower 95%
Intercept 10.37214 0.76341 13.5866 9.87E-06 8.504146
0 -0.0051 0.006719 -0.75833 0.476973 -0.02154
Residual Plots for T:
Graph 3 : θx Vs. T
(P≥0.05) Null hypothesis can not be rejected.
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Analyzing effect of θy on
Table 4 : Data set for analyzing the effect of θy.
Independent Variables Dependent Variables
θx θy LT MM SM T
0 22.5 0.01 2.55 1.78 8.29
0 45 0.01 2.53 1.99 8.38
0 67.5 0.01 2.46 1.83 7.48
0 90 0.01 2.39 1.95 6.57
0 112.5 0.01 2.44 2.65 8.21
0 135 0.01 2.55 2.91 9.25
0 157.5 0.01 2.55 2.55 9.11
0 180 0.01 2.54 2.34 9.02
0 0 0.01 2.53 1.75 8.34
iv. Support material ( S. M )
Regression Analysis : θy Vs.SM
Regression Statistics
Multiple R 0.780276
R Square 0.608831
Adjusted R Square 0.552949
Standard Error 0.286691
Observations 9
ANOVA
Df SS MS F
Significance
F
Regression 1 0.895482 0.895482 10.89506 0.013107
Residual 7 0.575341 0.082192
Total 8 1.470822
Coefficients
Standard
Error t Stat P-value
Intercept 1.705778 0.17621 9.680344 2.65E-05
θy 0.00543 0.001645 3.300767 0.013107
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Residual Plots for SM
Graph 4 : θy Vs.SM
Regression Equation
SM = 1.706 + 0.00543 θy
(P ≤0.05) Null hypothesis can be rejected.
v. Model Material (M.M)
Regression Analysis :θy Vs.MM
Regression Statistics
Multiple R 0.046273
R Square 0.002141
Adjusted R Square -0.14041
Standard Error 0.063203
Observations 9
ANOVA
Df SS MS F
Significance
F
Regression 1 6E-05 6E-05 0.01502 0.905902
Residual 7 0.027962 0.003995
Total 8 0.028022
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Coefficients
Standard
Error t Stat P-value
Intercept 2.500444 0.038847 64.36684 5.74E-11
θy 4.44E-05 0.000363 0.122557 0.905902
Residual Plots for MM
Graph 5 : θy Vs MM
(P ≥0.05) Null hypothesis can not be rejected.
vi. Time
Regression Analysis : θy Vs. T
Regression Statistics
Multiple R 0.411568
R Square 0.169388
Adjusted R Square 0.050729
Standard Error 0.826598
Observations 9
ANOVA
Df SS MS F
Significance
F
Regression 1 0.975375 0.975375 1.427523 0.271076
Residual 7 4.782847 0.683264
Total 8 5.758222
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Coefficients
Standard
Error t Stat P-value
Intercept 7.784444 0.508057 15.32199 1.22E-06
θy 0.005667 0.004743 1.19479 0.271076
Residual Plots for T
Graph 6 : θy Vs. T
(P≥0.05) Null hypothesis can not be rejected.
Analyzing effect of θx * θy on
Table 5 : Data set for analyzing the effect of interaction θx* θy.
Independent Variables
Dependent
Variables
Independent Variables
Dependent
Variables
θx θy LT MM SM T θx θy LT MM SM T
22.5 90 0.01 2.69 1.93 6.54 90 113 0.01 2.47 2.78 9.5
112.5 157.5 0.01 2.34 2.21 11.23 90 180 0.01 2.33 1.49 9.4
157.5 67.5 0.01 2.4 2.6 8.55 180 113 0.01 2.4 1.91 7.6
45 90 0.01 2.66 1.94 6.45 157.5 22.5 0.01 2.39 2.58 10
157.5 180 0.01 2.39 2.42 10.33 0 67.5 0.01 2.46 1.82 7.1
67.5 90 0.01 2.69 1.96 7 67.5 0 0.01 2.34 1.27 9.6
157.5 45 0.01 2.4 2.78 10.05 0 0 0.01 2.53 1.75 8.3
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vii. Support material (SM)
Regression Analysis: θx* θy Vs. S.M.
Regression Statistics
Multiple R 0.317839
R Square 0.1552
Adjusted R
Square 0.077971
Standard Error 0.434229
Observations 81
ANOVA
Df SS MS F
Significance
F
Regression 2 1.652712 0.826356 4.382573 0.015712
Residual 78 14.70729 0.188555
Total 80 16.36
Coefficients
Standard
Error t Stat P-value
Intercept 1.902198 0.116196 16.37062 5.97E-27
θx*θy -0.000031 0.000010 -3.22 0.002
Regression Equation
For LT :0.010
SM = 1.669 + 0.00388 θx + 0.00484 θy - 0.000031 θx*θy
For LT :0.007
SM = 1.596 + 0.00388 θx + 0.00484 θy - 0.000031 θx*θy
34. Build orientation analysis in FDM
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Residual Plots for SM
Graph 7 : θx* θy Vs. SM
(P ≤0.05) Null hypothesis can be Rejected .
viii. Model Material ( M.M )
Regression Analysis: θx* θy Vs. M.M
Regression Statistics
Multiple R 0.544899
R Square 0.296915
Adjusted R
Square 0.278887
Standard Error 0.071831
Observations 81
ANOVA
Df SS MS F
Significance
F
Regression 2 0.169957 0.084979 16.46982 1.08E-06
Residual 78 0.402453 0.00516
Total 80 0.57241
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Coefficients
Standard
Error t Stat P-value
Intercept 2.495383 0.019221 129.8241 6.72E-93
θx*θy -0.00000 0.000002 -0.16 0.871
Residual plot for MM
Graph 8 : θx* θy Vs. MM
(P ≥0.05) Null hypothesis can not be rejected.
ix. Time
Regression Analysis: θx* θy Vs. T
Regression Statistics
Multiple R 0.155434
R Square 0.02416
Adjusted R
Square -0.00086
Standard Error 1.569214
Observations 81
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ANOVA
Df SS MS F
Significance
F
Regression 2 4.755231 2.377616 0.965556 0.385275
Residual 78 192.0697 2.462431
Total 80 196.8249
Coefficients
Standard
Error t Stat P-value
Intercept 8.955062 0.419907 21.32628 2.78E-34
θx* θy -0.000021 0.000044 -0.47 0.638
Residual plot for T
Graph 9: Interaction θx* θy Vs. Time (T)
(P ≥0.05) Null hypothesis can not be rejected.
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RESULT & DISCUSSION
The CAD model of silencer was simulated in Catalyst software in different
orientations as obtained from DOE. The observations were recorded regarding the
volume of model and support material required and the machine time required for
fabrication process. Regression analysis was carried out on the recorded data to
analyze the effect of independent variables θx, θy, and LT on MM,SM, and T.
Initially, Null hypothesis was proposed and regression analysis was carried
out to accept or reject the hypothesis. A p-value helps to determine the significant
relationship between the variables. The p-value is a number between o to 1 and
interpreted in the following ways:
A small p-value (typically ≤ 0.05 ) indicates significant relation between the
dependent and independent variables and thus the null hypothesis can be rejected.
A large p-value (typically ≥ 0.05) indicates no significant relation between the
dependent and independent variables and thus the null hypothesis can not be
rejected.
P value for θy Vs. SM & the interaction θx* θy Vs. SM are found to be significant &
hence the null hypothesis can be rejected for these two cases.
The regression equations for the above cases are as mentioned below:
Regression Equation
SM = 1.706 + 0.00543 θy
Graph 10 : θy Vs. SM
200150100500
3.0
2.8
2.6
2.4
2.2
2.0
1.8
1.6
θy
SM
Plot of θy Vs SM
SM = 1.706 + 0.00543 θy
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Regression Equation
For LT :0.010
SM = 1.669 + 0.00388 θx + 0.00484 θy - 0.000031 θx*θy
For LT :0.007
SM = 1.596 + 0.00388 θx + 0.00484 θy - 0.000031 θx*θy
Graph 11 : : Interaction θx*θy Vs Support Material (SM)
For all other combination presented above, the P value is insignificant & hence the null
hypothesis can not be rejected.
Thus it can be concluded that the volume of support material required is highly
dependent of θy and the interaction θx* θy.
200150100500
3.0
2.5
2.0
1.5
1.0
θy
SM
Plot of θX*θy Vs SM
I
0
I
50
I
100
I
150
I
200
θx
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