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Alzyod H, Ficzere P. Optimizing fused filament fabrication process parameters for quality enhancement of PA12 parts using numerical modeling and taguchi method. Heliyon 2023; 9:e14445. [PMID: 36942227 PMCID: PMC10023978 DOI: 10.1016/j.heliyon.2023.e14445] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/19/2022] [Revised: 02/27/2023] [Accepted: 03/07/2023] [Indexed: 03/12/2023] Open
Abstract
Fused Filament Fabrication (FFF) is an Additive Manufacturing (AM) technique implemented in widespread applications and several components. Despite its benefits, the physics behind the FFF process is quite complicated and requires fast heating and cooling rate of the extruded material. Consequently, the component experiences extremely non-uniform internal stresses that might lead to warpage deformation. It is necessary to optimize the printing parameters as they are associated with the warpage deformation of printed components. One method for achieving this target is conducting physical tests that offer precise findings, but it is an expensive strategy. Another approach is to simulate the printing parameters with special software. In this work, Digimat-AM was employed to develop a thermomechanical Finite Element Model of the FFF to simulate parts made of Polyamide12 (PA12). An L27 orthogonal array, a tool of the Taguchi orthogonal array, and an analysis of variance (ANOVA) were used to estimate the impact of five printing parameters and their ultimate levels to improve the dimension's quality by minimizing the warpage deformation. Results showed a significant impact of the bed temperature on the warpage deformation values. The infill density contributed 2.84% in reducing the warpage deformation, and the rest of the parameters' contribution was less than 1% for each.
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2
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Identification and Mapping of Manufacturability Constraints for Extrusion-Based Additive Manufacturing. JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING 2021. [DOI: 10.3390/jmmp5020033] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
Abstract
This article develops and demonstrates a set of design-focused manufacturability constraints for the fused deposition modeling/fused filament fabrication (FDM/FFF) process. These can be mapped from the basic behavior and process characteristics and formulated in terms of implicit or explicit design constraints. When the FDM/FFF process is explored and examined for its natural limitations and behavior, it can provide a set of manufacturing considerations (advantages, limitations, and best practices). These can be converted into manufacturing constraints, which are practical limits on the ability of the process. Finally, these can be formulated in terms of design–useful manufacturability constraints. Many of the constants and parameters must be determined experimentally for specific materials. The final list of 54 major manufacturability constraints presented in this work will better inform designers considering using FDM/FFF as a manufacturing process, and help guide design decisions. After derivation and presentation of the constraint set, extensive discussion about practical implementation is provided at the end of the paper, including advice about experimentally determining constants and appropriate printing parameters. Finally, three case studies are presented which implement the constraints for simple design problems.
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Pandit S, Singh P, Sinha M, Parthasarathi R. Integrated QSAR and Adverse Outcome Pathway Analysis of Chemicals Released on 3D Printing Using Acrylonitrile Butadiene Styrene. Chem Res Toxicol 2021; 34:355-364. [PMID: 33416328 DOI: 10.1021/acs.chemrestox.0c00274] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Abstract
Additive manufacturing commonly known as 3D printing has numerous applications in several domains including material and biomedical technologies and has emerged as a tool of capabilities by providing fast, highly customized, and cost-effective solutions. However, the impact of the printing materials and chemicals present in the printing fumes has raised concerns about their adverse potential affecting humans and the environment. Thus, it is necessary to understand the properties of the chemicals emitted during additive manufacturing for developing safe and biocompatible fibers having controlled emission of fumes including its sustainable usage. Therefore, in this study, we have developed a computational predictive risk-assessment framework on the comprehensive list of chemicals released during 3D printing using the acrylonitrile butadiene styrene (ABS) filament. Our results showed that the chemicals present in the fumes of the ABS-based fiber used in additive manufacturing have the potential to lead to various toxicity end points such as inhalation toxicity, oral toxicity, carcinogenicity, hepatotoxicity, and teratogenicity. Moreover, because of their absorption, distribution in the body, metabolism, and excretion properties, most of the chemicals exhibited a high absorption level in the intestine and the potential to cross the blood-brain barrier. Furthermore, pathway analysis revealed that signaling like alpha-adrenergic receptor signaling, heterotrimeric G-protein signaling, and Alzheimer's disease-amyloid secretase pathway are significantly overrepresented given the identified target proteins of these chemicals. These findings signify the adversities associated with 3D printing fumes and the necessity for the development of biodegradable and considerably safer fibers for 3D printing technology.
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Affiliation(s)
- Shraddha Pandit
- Computational Toxicology Facility, CSIR-Indian Institute of Toxicology Research, Vishvigyan Bhawan, 31, Mahatma Gandhi Marg, Lucknow, Uttar Pradesh 226001, India.,Academy of Scientific and Innovative Research (AcSIR), Ghaziabad 201002, India
| | - Prakrity Singh
- Computational Toxicology Facility, CSIR-Indian Institute of Toxicology Research, Vishvigyan Bhawan, 31, Mahatma Gandhi Marg, Lucknow, Uttar Pradesh 226001, India.,Academy of Scientific and Innovative Research (AcSIR), Ghaziabad 201002, India
| | - Meetali Sinha
- Computational Toxicology Facility, CSIR-Indian Institute of Toxicology Research, Vishvigyan Bhawan, 31, Mahatma Gandhi Marg, Lucknow, Uttar Pradesh 226001, India.,Academy of Scientific and Innovative Research (AcSIR), Ghaziabad 201002, India
| | - Ramakrishnan Parthasarathi
- Computational Toxicology Facility, CSIR-Indian Institute of Toxicology Research, Vishvigyan Bhawan, 31, Mahatma Gandhi Marg, Lucknow, Uttar Pradesh 226001, India.,Academy of Scientific and Innovative Research (AcSIR), Ghaziabad 201002, India
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Polymer Selection for Hot-Melt Extrusion Coupled to Fused Deposition Modelling in Pharmaceutics. Pharmaceutics 2020; 12:pharmaceutics12090795. [PMID: 32842703 PMCID: PMC7558966 DOI: 10.3390/pharmaceutics12090795] [Citation(s) in RCA: 46] [Impact Index Per Article: 11.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/01/2020] [Revised: 08/16/2020] [Accepted: 08/18/2020] [Indexed: 12/31/2022] Open
Abstract
Three-dimensional (3D) printing offers the greatest potential to revolutionize the future of pharmaceutical manufacturing by overcoming challenges of conventional pharmaceutical operations and focusing design and production of dosage forms on the patient’s needs. Of the many technologies available, fusion deposition modelling (FDM) is considered of the lowest cost and higher reproducibility and accessibility, offering clear advantages in drug delivery. FDM requires in-house production of filaments of drug-containing thermoplastic polymers by hot-melt extrusion (HME), and the prospect of connecting the two technologies has been under investigation. The ability to integrate HME and FDM and predict and tailor the filaments’ properties will extend the range of printable polymers/formulations. Hence, this work revises the properties of the most common pharmaceutical-grade polymers used and their effect on extrudability, printability, and printing outcome, providing suitable processing windows for different raw materials. As a result, formulation selection will be more straightforward (considering the characteristics of drug and desired dosage form or release profile) and the processes setup will be more expedite (avoiding or mitigating typical processing issues), thus guaranteeing the success of both HME and FDM. Relevant techniques used to characterize filaments and 3D-printed dosage forms as an essential component for the evaluation of the quality output are also presented.
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Quality Performance Evaluation of Thin Walled PLA 3D Printed Parts Using the Taguchi Method and Grey Relational Analysis. JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING 2020. [DOI: 10.3390/jmmp4020047] [Citation(s) in RCA: 19] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/07/2023]
Abstract
This paper investigates the quality performance of FDM 3D printed models with thin walls. The design of experiments method (DOE) was used and nine models of the same size were fabricated in a low-cost 3D printer using polylactic acid (PLA) material. Two limited studied parameters were considered (extraction temperature and wall thickness), each one having three levels. External X and Y dimensions were measured using a micrometer, as well as four surface roughness parameters (Ra, Rz, Rt, Rsm) with a surface tester. Two optimization techniques (the Taguchi approach and Grey relational analysis) were utilized along with statistical analysis to examine how the temperature and wall thickness affect the dimensional accuracy and the surface quality of the parts. The results showed that high extraction temperature and median wall thickness values optimize both dimensional accuracy and surface roughness, while temperature is the most important factor.
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Azad MA, Olawuni D, Kimbell G, Badruddoza AZM, Hossain MS, Sultana T. Polymers for Extrusion-Based 3D Printing of Pharmaceuticals: A Holistic Materials-Process Perspective. Pharmaceutics 2020; 12:E124. [PMID: 32028732 PMCID: PMC7076526 DOI: 10.3390/pharmaceutics12020124] [Citation(s) in RCA: 130] [Impact Index Per Article: 32.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/01/2020] [Revised: 01/27/2020] [Accepted: 01/30/2020] [Indexed: 11/16/2022] Open
Abstract
Three dimensional (3D) printing as an advanced manufacturing technology is progressing to be established in the pharmaceutical industry to overcome the traditional manufacturing regime of 'one size fits for all'. Using 3D printing, it is possible to design and develop complex dosage forms that can be suitable for tuning drug release. Polymers are the key materials that are necessary for 3D printing. Among all 3D printing processes, extrusion-based (both fused deposition modeling (FDM) and pressure-assisted microsyringe (PAM)) 3D printing is well researched for pharmaceutical manufacturing. It is important to understand which polymers are suitable for extrusion-based 3D printing of pharmaceuticals and how their properties, as well as the behavior of polymer-active pharmaceutical ingredient (API) combinations, impact the printing process. Especially, understanding the rheology of the polymer and API-polymer mixtures is necessary for successful 3D printing of dosage forms or printed structures. This review has summarized a holistic materials-process perspective for polymers on extrusion-based 3D printing. The main focus herein will be both FDM and PAM 3D printing processes. It elaborates the discussion on the comparison of 3D printing with the traditional direct compression process, the necessity of rheology, and the characterization techniques required for the printed structure, drug, and excipients. The current technological challenges, regulatory aspects, and the direction toward which the technology is moving, especially for personalized pharmaceuticals and multi-drug printing, are also briefly discussed.
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Affiliation(s)
- Mohammad A. Azad
- Department of Chemical, Biological and Bioengineering, North Carolina A&T State University, Greensboro, NC 27411, USA; (D.O.); (G.K.)
| | - Deborah Olawuni
- Department of Chemical, Biological and Bioengineering, North Carolina A&T State University, Greensboro, NC 27411, USA; (D.O.); (G.K.)
| | - Georgia Kimbell
- Department of Chemical, Biological and Bioengineering, North Carolina A&T State University, Greensboro, NC 27411, USA; (D.O.); (G.K.)
| | - Abu Zayed Md Badruddoza
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA;
| | - Md. Shahadat Hossain
- Department of Engineering Technology, Queensborough Community College, City University of New York (CUNY), Bayside, NY 11364, USA;
| | - Tasnim Sultana
- Department of Public Health, School of Arts and Sciences, Massachusetts College of Pharmacy and Health Sciences (MCPHS), Boston, MA 02115, USA;
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A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics. JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING 2019. [DOI: 10.3390/jmmp3030064] [Citation(s) in RCA: 69] [Impact Index Per Article: 13.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
Abstract
Fused deposition modeling (FDM) is an additive manufacturing (AM) process that is often used to fabricate geometrically complex shaped prototypes and parts. It is gaining popularity as it reduces cycle time for product development without the need for expensive tools. However, the commercialization of FDM technology in various industrial applications is currently limited due to several shortcomings, such as insufficient mechanical properties, poor surface quality, and low dimensional accuracy. The qualities of FDM-produced products are affected by various process parameters, for example, layer thickness, build orientation, raster width, or print speed. The setting of process parameters and their range depends on the section of FDM machines. Filament materials, nozzle dimensions, and the type of machine determine the range of various parameters. The optimum setting of parameters is deemed to improve the qualities of three-dimensional (3D) printed parts and may reduce post-production work. This paper intensively reviews state-of-the-art literature on the influence of parameters on part qualities and the existing work on process parameter optimization. Additionally, the shortcomings of existing works are identified, challenges and opportunities to work in this field are evaluated, and directions for future research in this field are suggested.
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Full-Density Fused Deposition Modeling Dimensional Error as a Function of Raster Angle and Build Orientation: Large Dataset for Eleven Materials. JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING 2019. [DOI: 10.3390/jmmp3010006] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
Abstract
This paper describes the collection of a large dataset (6930 measurements) on dimensional error in the fused deposition modeling (FDM) additive manufacturing process for full-density parts. Three different print orientations were studied, as well as seven raster angles ( 0 ∘ , 15 ∘ , 30 ∘ , 45 ∘ , 60 ∘ , 75 ∘ , and 90 ∘ ) for the rectilinear infill pattern. All measurements were replicated ten times on ten different samples to ensure a comprehensive dataset. Eleven polymer materials were considered: acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), high-temperature PLA, wood-composite PLA, carbon-fiber-composite PLA, copper-composite PLA, aluminum-composite PLA, high-impact polystyrene (HIPS), polyethylene terephthalate glycol-enhanced (PETG), polycarbonate, and synthetic polyamide (nylon). The samples were ASTM-standard impact-testing samples, since this geometry allows the measurement of error on three different scales; the nominal dimensions were 3 . 25 mm thick, 63 . 5 mm long, and 12 . 7 mm wide. This dataset is intended to give engineers and product designers a basis for judging the accuracy and repeatability of the FDM process for use in manufacturing of end-user products.
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Valerga AP, Batista M, Salguero J, Girot F. Influence of PLA Filament Conditions on Characteristics of FDM Parts. MATERIALS 2018; 11:ma11081322. [PMID: 30065153 PMCID: PMC6117906 DOI: 10.3390/ma11081322] [Citation(s) in RCA: 40] [Impact Index Per Article: 6.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/30/2018] [Revised: 07/27/2018] [Accepted: 07/28/2018] [Indexed: 11/27/2022]
Abstract
Additive manufacturing technologies play an important role in Industry 4.0. One of the most prevalent processes is fused deposition modelling (FDM) due to its versatility and low cost. However, there is still a lack of standardization of materials and procedures within this technology. This work aims to study the relationship of certain operating parameters and the conditions of poly(lactic acid) (PLA) polymer with the results of the manufactured parts in dimensional terms, surface quality, and mechanical strength. In this way, the impact of some material characteristics is analyzed, such as the pigmentation of the material and the environmental humidity where it has been stored. The manufacturing parameter that relates to these properties has been the extrusion temperature since it is the most influential in this technology. The results are quite affected especially by humidity, being a parameter little studied in the literature.
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Affiliation(s)
- Ana Pilar Valerga
- Department of Mechanical Engineering and Industrial Design, Faculty of Engineering, University of Cadiz, Avenida de la Universidad de Cadiz, 10, Puerto Real, E-11519 Cadiz, Spain.
| | - Moisés Batista
- Department of Mechanical Engineering and Industrial Design, Faculty of Engineering, University of Cadiz, Avenida de la Universidad de Cadiz, 10, Puerto Real, E-11519 Cadiz, Spain.
| | - Jorge Salguero
- Department of Mechanical Engineering and Industrial Design, Faculty of Engineering, University of Cadiz, Avenida de la Universidad de Cadiz, 10, Puerto Real, E-11519 Cadiz, Spain.
| | - Frank Girot
- IKERBASQUE, Basque Foundation for Science, 48013 Bilbao, Spain.
- Faculty of Engineering, University of the Basque Country, Alameda de Urquijo s/n, 48013 Bilbao, Spain.
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