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Strengthening of 3D printed fused deposition manufactured parts using the fill compositing technique.

Belter JT, Dollar AM - PLoS ONE (2015)

Bottom Line: In this paper, we present a technique for increasing the strength of thermoplastic fused deposition manufactured printed parts while retaining the benefits of the process such as ease, speed of implementation, and complex part geometries.By carefully placing voids in the printed parts and filling them with high-strength resins, we can improve the overall part strength and stiffness by up to 45% and 25%, respectively.We then show three-point bend testing data comparing solid printed ABS samples with those strengthened through the fill compositing process, as well as examples of 3D printed parts used in real-world applications.

View Article: PubMed Central - PubMed

Affiliation: Department of Mechanical Engineering and Material Science, Yale University, New Haven, Connecticut, United States of America.

ABSTRACT
In this paper, we present a technique for increasing the strength of thermoplastic fused deposition manufactured printed parts while retaining the benefits of the process such as ease, speed of implementation, and complex part geometries. By carefully placing voids in the printed parts and filling them with high-strength resins, we can improve the overall part strength and stiffness by up to 45% and 25%, respectively. We discuss the process parameters necessary to use this strengthening technique and the theoretically possible strength improvements to bending beam members. We then show three-point bend testing data comparing solid printed ABS samples with those strengthened through the fill compositing process, as well as examples of 3D printed parts used in real-world applications.

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Related in: MedlinePlus

Fingers of the i-HY hand are made using fill compositing to add strength to the 3D printed components.The red (dark) portion illustrates the internal reinforcing structure of the 3D printed part.
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pone.0122915.g001: Fingers of the i-HY hand are made using fill compositing to add strength to the 3D printed components.The red (dark) portion illustrates the internal reinforcing structure of the 3D printed part.

Mentions: In this paper, we discuss one method for greatly improving the mechanical strength of 3D printed components, via compositing with higher-strength resins filled into voids printed within the structure. The approach retains 3D printing’s benefits of fast and easy construction and the ability to make complex geometries, while only requiring a few straight-forward and easy to implement post-processing steps. Using FDM as a platform, we examine a number of different options for printing parts that can be filled with resins after printing, including hollow parts, sparse-filled prints, and prints with hollow channels oriented to maximize strength-to-weight ratio, and experimentally evaluate the changes in strength and stiffness via an ASTM standard three-point bend test (ASTM-D790 [6]). We further demonstrate the concept to improve strength in three practical applications: a spoked wheel, robotic finger link, and standard open-end wrench. The general process is illustrated in Fig 1.


Strengthening of 3D printed fused deposition manufactured parts using the fill compositing technique.

Belter JT, Dollar AM - PLoS ONE (2015)

Fingers of the i-HY hand are made using fill compositing to add strength to the 3D printed components.The red (dark) portion illustrates the internal reinforcing structure of the 3D printed part.
© Copyright Policy
Related In: Results  -  Collection

License
Show All Figures
getmorefigures.php?uid=PMC4400136&req=5

pone.0122915.g001: Fingers of the i-HY hand are made using fill compositing to add strength to the 3D printed components.The red (dark) portion illustrates the internal reinforcing structure of the 3D printed part.
Mentions: In this paper, we discuss one method for greatly improving the mechanical strength of 3D printed components, via compositing with higher-strength resins filled into voids printed within the structure. The approach retains 3D printing’s benefits of fast and easy construction and the ability to make complex geometries, while only requiring a few straight-forward and easy to implement post-processing steps. Using FDM as a platform, we examine a number of different options for printing parts that can be filled with resins after printing, including hollow parts, sparse-filled prints, and prints with hollow channels oriented to maximize strength-to-weight ratio, and experimentally evaluate the changes in strength and stiffness via an ASTM standard three-point bend test (ASTM-D790 [6]). We further demonstrate the concept to improve strength in three practical applications: a spoked wheel, robotic finger link, and standard open-end wrench. The general process is illustrated in Fig 1.

Bottom Line: In this paper, we present a technique for increasing the strength of thermoplastic fused deposition manufactured printed parts while retaining the benefits of the process such as ease, speed of implementation, and complex part geometries.By carefully placing voids in the printed parts and filling them with high-strength resins, we can improve the overall part strength and stiffness by up to 45% and 25%, respectively.We then show three-point bend testing data comparing solid printed ABS samples with those strengthened through the fill compositing process, as well as examples of 3D printed parts used in real-world applications.

View Article: PubMed Central - PubMed

Affiliation: Department of Mechanical Engineering and Material Science, Yale University, New Haven, Connecticut, United States of America.

ABSTRACT
In this paper, we present a technique for increasing the strength of thermoplastic fused deposition manufactured printed parts while retaining the benefits of the process such as ease, speed of implementation, and complex part geometries. By carefully placing voids in the printed parts and filling them with high-strength resins, we can improve the overall part strength and stiffness by up to 45% and 25%, respectively. We discuss the process parameters necessary to use this strengthening technique and the theoretically possible strength improvements to bending beam members. We then show three-point bend testing data comparing solid printed ABS samples with those strengthened through the fill compositing process, as well as examples of 3D printed parts used in real-world applications.

Show MeSH
Related in: MedlinePlus