The Influence of the Layer Height and the Filament Color on the Dimensional Accuracy and the Tensile Strength of FDM-Printed PLA Specimens

Among the FDM process variables, one of the less addressed in previous research is the filament color. Moreover, if not explicitly targeted, the filament color is usually not even mentioned. Aiming to point out if, and to what extent, the color of the PLA filaments influences the dimensional precision and the mechanical strength of FDM prints, the authors of the present research carried out experiments on tensile specimens. The variable parameters were the layer height (0.05 mm, 0.10 mm, 0.15 mm, 0.20 mm) and the material color (natural, black, red, grey). The experimental results clearly showed that the filament color is an influential factor for the dimensional accuracy as well as for the tensile strength of the FDM printed PLA parts. Moreover, the two way ANOVA test performed revealed that the strongest effect on the tensile strength was exerted by the PLA color (η² = 97.3%), followed by the layer height (η² = 85.5%) and the interaction between the PLA color and the layer height (η² = 80.0%). Under the same printing conditions, the best dimensional accuracy was ensured by the black PLA (0.17% width deviations, respectively 5.48% height deviations), whilst the grey PLA showed the highest ultimate tensile strength values (between 57.10 MPa and 59.82 MPa).

The Analysis of Mechanical Properties and Geometric Accuracy in Specimens Printed in Material Jetting Technology

The purpose of this research was to analyze polymer materials based on mechanical properties and geometrical parameters, such as the smallest material deviations and the best printing texture after three-dimensional (3D) printing in two methods of Material Jetting technology: PolyJet and MultiJet. This study covers checks for Vero Plus, Rigur, Durus, ABS, and VisiJet M2R-WT materials. Thirty flat specimens were printed both for 0 and 90 raster orientations. Specimen scans were superimposed on the 3D model from CAD software. Each of them was tested, paying attention to the accuracy and the layer thickness effect of printed components. Then, all specimens were subjected to tensile tests. The obtained data-Young's modulus and Poisson's ratio-were compared using statistical methods, focusing on the two most important parameters: the isotropy of the printed material in two directions and the characteristics close to linear. It was found that unitary surface deviation with general dimensional accuracy equal to ±0.1 mm was the common feature of printed models. Some small areas had lower accuracy depending on the material and printer device. Rigur material obtained the highest mechanical properties. Dimensional accuracy in Material Jetting technology as a function of layer parameters such as layer thickness and raster orientation was checked. The materials were checked in terms of relative isotropy and linearity. Additionally, similarities and differences between PolyJet and MultiJet methods were covered.

Effect of Printing Parameters on Dimensional Error, Surface Roughness and Porosity of FFF Printed Parts with Grid Structure

Extrusion printing processes allow for manufacturing complex shapes in a relatively cheap way with low-cost machines. The present study analyzes the effect of printing parameters on dimensional error, roughness, and porosity of printed PLA parts obtained with grid structure. Parts are obtained by means of the fused filament fabrication (FFF) process. Four variables are chosen: Layer height, temperature, speed, and flow rate. A two-level full factorial design with a central point is used to define the experimental tests. Dimensional error and porosity are measured with a profile projector, while roughness is measured with a contact roughness meter. Mathematical regression models are found for each response, and multi-objective optimization is carried out by means of the desirability function. Dimensional error and roughness depend mainly on layer height and flow rate, while porosity depends on layer height and printing speed. Multi-objective optimization shows that recommended values for the variables are layer height 0.05 mm, temperature 195 ºC, speed 50 mm/min, and flow rate 0.93, when dimensional error and roughness are to be minimized, and porosity requires a target value of 60%. The present study will help to select appropriate printing parameters for printing porous structures such as those found in prostheses, by means of extrusion processes.

Effect of Printing Parameters on Dimensional Error and Surface Roughness Obtained in Direct Ink Writing (DIW) Processes

Prostheses made from ceramic materials have the advantages of producing little debris and having good durability, compared with those made from metal and plastic. For example, hip prostheses require a porous external area that allows their fixation by means of osseointegration and a solid internal area that will be in contact with the femoral head. The manufacturing of complex ceramic shapes, by means of machining processes, for example, is complicated and can lead to breakage of the parts because of their fragility. The direct ink writing (DIW) process allows the printing of ceramic pastes into complex shapes that achieve their final strength after a heat treatment operation. This paper studies both the dimensional error and surface finish of porous zirconia prismatic parts prior to sintering. The variables considered are infill, layer height, printing speed, extrusion multiplier and bed temperature. The responses are the dimensional error of the lateral walls of the samples and an areal roughness parameter, the arithmetical mean height, Sa. Mathematical models are found for each response, and multiobjective optimization is carried out by means of the desirability function. The dimensional error depends mainly on the interaction between layer height and infill, while the roughness on the interaction between infill and printing speed. Thus, infill is an important factor for both responses. In the future, the behavior of compact printed parts will be addressed.

Surface Quality of 3D-Printed Models as a Function of Various Printing Parameters

Although 3D-printing is common in dentistry, the technique does not produce the required quality for all target applications. Resin type, printing resolution, positioning, alignment, target structure, and the type and number of support structures may influence the surface roughness of printed objects, and this study investigates the effects of these variables. A stereolithographic data record was generated from a master model. Twelve printing processes were executed with a stereolithography Desktop 3D Printer, including models aligned across and parallel to the printer front as well as solid and hollow models. Three layer thicknesses were used, and in half of all processes, the models were inclined at 15°. For comparison, eight gypsum models and milled polyurethane models were manufactured. The mean roughness index of each model was determined with a perthometer. Surface roughness values were approximately 0.65 µm (master), 0.87–4.44 µm (printed), 2.32–2.57 µm (milled), 1.72–1.86 µm (cast plaster/alginate casting), and 0.98–1.03 µm (cast plaster/polyether casting). The layer height and type and number of support structures influenced the surface roughness of printed models (p ≤ 0.05), but positioning, structure, and alignment did not.

The Influence of Manufacturing Parameters on the Mechanical Behaviour of PLA and ABS Pieces Manufactured by FDM: A Comparative Analysis

This paper presents a comparative study of the tensile mechanical behaviour of pieces produced using the Fused Deposition Modelling (FDM) additive manufacturing technique with respect to the two types of thermoplastic material most widely used in this technique: polylactide (PLA) and acrylonitrile butadiene styrene (ABS). The aim of this study is to compare the effect of layer height, infill density, and layer orientation on the mechanical performance of PLA and ABS test specimens. The variables under study here are tensile yield stress, tensile strength, nominal strain at break, and modulus of elasticity. The results obtained with ABS show a lower variability than those obtained with PLA. In general, the infill percentage is the manufacturing parameter of greatest influence on the results, although the effect is more noticeable in PLA than in ABS. The test specimens manufactured using PLA perform more rigidly and they are found to have greater tensile strength than ABS. The bond between layers in PLA turns out to be extremely strong and is, therefore, highly suitable for use in additive technologies. The methodology proposed is a reference of interest in studies involving the determination of mechanical properties of polymer materials manufactured using these technologies.