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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

The calculated maximum bending moment for the various fill-composite cross-sections shows the ability to increase the capable bending load by 25% or reduce the mass of the beam by 33% using fill compositing with Epoxy resin.
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pone.0122915.g004: The calculated maximum bending moment for the various fill-composite cross-sections shows the ability to increase the capable bending load by 25% or reduce the mass of the beam by 33% using fill compositing with Epoxy resin.

Mentions: The proposed technique creates a composite component that can leverage the added strength of the injected resin. The cross-section of the constructed samples can be analyzed to determine the effect of the added resin on the overall bending strength. Using the flexure strength properties of ABS (53.0 MPa) and Epoxy Resin (97.2 MPa) shown in Table 1, we can calculate the bending moment at failure using standard beam bending equations for each of the types of fill compositing described in the previous section. Fig 4 shows the cross-sections and associated beam stress profile for hollow filled samples and resin filled channels as compared to a standard solid printed ABS beam when subjected to three-point bending. The geometry is identical to the tested samples described in the following section. The results indicate that, for this geometry, we can expect a 25% improvement in capable bending loads through using the complete hollow filled with epoxy resin and a 5% improvement in strength with the epoxy filled resin channel geometry. However, the channel geometry shows that the bending strength can be maintained while reducing the overall beam mass by 33%. Here, Mmax is the maximum bending moment before failure.


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

Belter JT, Dollar AM - PLoS ONE (2015)

The calculated maximum bending moment for the various fill-composite cross-sections shows the ability to increase the capable bending load by 25% or reduce the mass of the beam by 33% using fill compositing with Epoxy resin.
© Copyright Policy
Related In: Results  -  Collection

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

pone.0122915.g004: The calculated maximum bending moment for the various fill-composite cross-sections shows the ability to increase the capable bending load by 25% or reduce the mass of the beam by 33% using fill compositing with Epoxy resin.
Mentions: The proposed technique creates a composite component that can leverage the added strength of the injected resin. The cross-section of the constructed samples can be analyzed to determine the effect of the added resin on the overall bending strength. Using the flexure strength properties of ABS (53.0 MPa) and Epoxy Resin (97.2 MPa) shown in Table 1, we can calculate the bending moment at failure using standard beam bending equations for each of the types of fill compositing described in the previous section. Fig 4 shows the cross-sections and associated beam stress profile for hollow filled samples and resin filled channels as compared to a standard solid printed ABS beam when subjected to three-point bending. The geometry is identical to the tested samples described in the following section. The results indicate that, for this geometry, we can expect a 25% improvement in capable bending loads through using the complete hollow filled with epoxy resin and a 5% improvement in strength with the epoxy filled resin channel geometry. However, the channel geometry shows that the bending strength can be maintained while reducing the overall beam mass by 33%. Here, Mmax is the maximum bending moment before failure.

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