Research on the Influence of Processing Parameters on the Specific Tensile Strength of FDM Additive Manufactured PET-G and PLA Materials

Optimizing tensile strength and energy consumption for FDM through Mixed-Integer Nonlinear Multi-objective optimization and design of experiments

This study presents a methodology for optimizing key parameters of a fused deposition modeling (FDM) printer to minimize energy consumption (EC) while exceeding a specified tensile strength (TS) threshold. Employing Design of Experiments (DoE) with Taguchi and Response Surface analysis, we identify influential parameters affecting TS and EC. A Mixed-Integer Nonlinear Multi-Objective Optimization model is then utilized to balance TS and EC, resulting in optimal parameter values. Validation using fabricated specimens demonstrates less than 5 % error in Tensile Strength and less than 2 % error in Energy Consumption, confirming the efficacy of the proposed methodology.

Impact of Rheology-Based Optimum Parameters on Enhancing the Mechanical Properties and Fatigue of Additively Manufactured Acrylonitrile-Butadiene-Styrene/Graphene Nanoplatelet Composites

This study investigates the interaction between static and fatigue strength and the rheological properties of acrylonitrile-butadiene-styrene (ABS) polymer reinforced with graphene nanoplatelets (GNPs) in both filament and 3D-printed forms. Specifically focusing on the effects of 1.0 wt.% GNPs, the study examines their influence on static/fatigue responses. The rheological behaviour of pure ABS polymer and ABS/GNPs nanocomposite samples, fabricated through material extrusion, is evaluated. The results indicated that the addition of 1.0 wt.% GNPs to the ABS matrix improved the elastic modulus of the nanocomposite filaments by up to about 34%, while reducing their ductility by approximately 60%. Observations revealed that the static and fatigue responses of the composite filament materials and 3D-printed parts were not solely attributed to differences in mechanical properties, but were also influenced by extrusion-related process parameters. The shark-skin effect, directly related to the material's rheological properties, had a major impact on static strength and fatigue life. The proposed method involved adjusting the temperature of the heating zones of the extruder during filament production to enhance the static response of the filament and using a higher nozzle temperature (270 °C) to improve the fatigue life of the 3D-printed samples. The findings reveal that the proposed parameter optimisation led to filaments with minimised shark-skin effects, resulting in an improvement in ultimate tensile strength compared to pure ABS. Moreover, the 3D-printed samples produced with a higher nozzle temperature exhibited increased fatigue lives compared to those manufactured under identical conditions as pure ABS.

Experimental investigation on fatigue life and tensile strength of carbon fiber-reinforced PLA composites based on fused deposition modeling

Fused deposition modeling (FDM) is a widely used additive manufacturing (AM) method that offers great flexibility in fabricating complex geometries without requiring expensive equipment. However, compared to other manufacturing methods, FDM-produced parts generally exhibit lower strength and fatigue life. To overcome this limitation, researchers have explored the use of fibers and reinforcements to enhance the mechanical properties of FDM parts. Nevertheless, the performance of FDM-produced parts can be significantly affected by various manufacturing parameters, including infill density, which is a key factor in balancing time and cost. In this study, the tensile strength and fatigue life of carbon fiber-reinforced polylactic acid (PLA) composites produced by FDM were investigated by varying the infill density (50 and 75%) and raster angle (0°, 45°, and 90°). The effects of 100% filling density, raster width, and nozzle diameter on mechanical properties were also examined. The experimental results demonstrated that increasing the infill density and decreasing the raster angle can enhance the tensile strength, although the fatigue behavior was found to be more complex and dependent on the infill density. The optimal parameters for producing FDM parts with improved mechanical properties were identified based on the analysis of the tensile strength and fatigue life data. This research has yielded significant findings concerning the diverse fatigue behavior associated with the raster angle at different infill densities. Specifically, noteworthy observations reveal that a raster angle of 45 degrees at 50% infill density, and a raster angle of 0 degrees at 75% infill density, exhibited the most prolonged fatigue life. This outcome can be ascribed to the specific loading conditions and the inherent strength of the sediment layer at the critical point of stress concentration.

Trimming flow, plasticity, and mechanical properties by cubic silsesquioxane chemistry

In this work, the possibility of managing the rheological and mechanical parameters of composites based on PLA with the use of cubic structures of organofunctional spherosilicates was verified. To accurately observe the effect of various organosilicon modifier substitutions on changes in composites' properties, we synthesized and used monofunctional octasubstituted derivatives as reference systems. The OSS/PLA systems were tested with concentrations of 0.1-2.5% (w/w) using extrusion to obtain a filament with a diameter of 1.75 mm. The printed samples underwent comprehensive tests including microscopic (SEM-EDS, optical microscope), rheological, thermal (TG, DSC, HDT), mechanical (impact and strength) as well as water contact angle tests. The work is interdisciplinary in nature and combines elements of organosilicon synthesis, materials engineering, and materials processing and characterization technology.

On the Thermomechanical Behavior of 3D-Printed Specimens of Shape Memory R-PETG

From commercial pellets of recycled polyethylene terephthalate glycol (R-PETG), 1.75 mm diameter filaments for 3D printing were produced. By varying the filament's deposition direction between 10° and 40° to the transversal axis, parallelepiped specimens were fabricated by additive manufacturing. When bent at room temperature (RT), both the filaments and the 3D-printed specimens recovered their shape during heating, either without any constraint or while lifting a load over a certain distance. In this way, free-recovery and work-generating shape memory effects (SMEs) were developed. The former could be repeated without any visible fatigue marks for as much as 20 heating (to 90 °C)-RT cooling-bending cycles, while the latter enabled the lifting of loads over 50 times heavier than the active specimens. Tensile static failure tests revealed the superiority of the specimens printed at larger angles over those printed at 10°, since the specimens printed at 40° had tensile failure stresses and strains over 35 MPa and 8.5%, respectively. Scanning electron microscopy (SEM) fractographs displayed the structure of the successively deposited layers and a shredding tendency enhanced by the increase in the deposition angle. Differential scanning calorimetry (DSC) analysis enabled the identification of the glass transition between 67.5 and 77.3 °C, which might explain the occurrence of SMEs in both the filament and 3D-printed specimens. Dynamic mechanical analysis (DMA) emphasized a local increase in storage modulus of 0.87-1.66 GPa that occurred during heating, which might explain the development of work-generating SME in both filament and 3D-printed specimens. These properties recommend 3D-printed parts made of R-PETG as active elements in low-price lightweight actuators operating between RT and 63 °C.

Optical and Mechanical Properties of Layered Infrared Interference Filters

The design and manufacturing technology of interference-absorbing short-wave filters based on a layered composition of Si-SiO on a sapphire substrate of various shapes was developed. A transition layer of SiO was applied to the surface of the substrate, alternating with layers of Si-SiO with an odd number of quarter-wave layers of materials with high (Si) and low refractive indices (SiO), and the application of an outer layer of SiO as an appropriate control of the materials' thickness. The optical properties of the infrared light filter were studied. It was established that the created design of the light filter provides the minimum light transmission in the visible region of the spectrum from 0.38 to 0.78 µm and the maximum in the near infrared region from 1.25 to 5 µm and has stable optical indicators. A method for studying the stress-strain state and strength of a multilayer coating of a light filter under the action of a local arbitrarily oriented load was developed. For simplicity in the analysis and for obtaining results in the analytical form, the one-dimensional model of the configuration "multilayer covering-firm substrate" constructed earlier by authors was used. From a mechanical point of view, the upper protective layer of the multilayer coating was modeled by a flexible plate, and the inner operational composite N-layer was subjected to Winkler's hypothesis about the proportionality of stresses and elastic displacements.

Performance Evaluation of CNT Reinforcement on Electroless Plating on Solid Free-Form-Fabricated PETG Specimens for Prosthetic Limb Application

The utility of polymers in the present decade is consistently increasing, giving scope to many applications from automobiles to prosthetics. Polymers used for solid free-form fabrication (SFFF), also known as 3D printing, comprise a quick fabrication process adopted by many industries to increase productivity and decrease the run time to cope with the market demands. In this research work, pure polyethylene terephthalate glycol (PETG) and multi-walled carbon nanotube (MWCNT)-PETG with an electroless metal layer coating and without a coating are discussed. The effect of the electroless metal layer coating on the reinforced PETG-MWCNT results in improved mechanical, tribological, and other surface properties. Pure PETG was incorporated with MWCNT nanofillers at 0.3 wt.% and extruded as a filament through a twin screw extruder with a 1.75 mm diameter and printed on ASTM standards. Tensile testing was performed on all four types of un-coated pure PETG, PETG-MWCNT, and metal-layer-coated PETG and PETG-MWCNT with a coating thickness of 26, 32, 54, and 88 μm. Dynamic mechanical analysis (DMA) showed that the coated PETG-MWCNT had the highest storage and loss modulus. The heat deflection temperature was improved to 88 °C for the coated PETG-MWCNT. The wear volume against the sliding distance at a load of 40, 50, and 60 N showed that the coefficient of friction decreased with an increase in the load. The scratch test results revealed the lowest penetration depth and lowest friction coefficient for the coated PETG-MWCNT sample. The water contact angle test showed that a greater coating thickness makes the sample surface more hydrophobic, and the microhardness test indicated that the indentation hardness value for the PETG-MWCNT was 92 HV. The study revealed that the metal-layer-coated PETG-MWCNT had better performance compared to the other specimens due to a good metal layer bonding on the PETG substrate. It was concluded that adding MWCNTs to a metal layer electroless coating improved the surface and mechanical properties of the PETG, and this may be suitable for many applications.