Fused deposition modeling process

N. Mostafa, H.M. Syed, S. Igor, and G. Andrew, A study of melt flow analysis of an ABS-iron composite in fused deposition modelling process, Tsinghua Science Technology, 14(Supplement l) 29-37, June 2009. 

Figure 6.52 Illustration of the fused deposition modeling process.

Fig. 7.1 Fused deposition modelling process (adapted from Gibson et al. 2010a)...

Beaman JJ, Barlow JW, Bourell DL, Crawford RH, Marcus HL, Mcalea KP (1997) Solid freeform fabrication—a new direction in manufacturing. Kluwer Academic, Boston Bellehumeur C, Li L, Sun Q, Gu P (2004) Modeling of bond formation between polymer filaments in the fused deposition modeling process. J Manuf Process 6(2) 170-178. doi 10.1016/S1526-6125(04)70071-7... 

Since the objects are sintered, they are porous. It may be necessary to infiltrate the part, especially metals, with another material to improve mechanical characteristics. The closest competitor to this process is probably fused deposition modeling. 

Fused deposition modeling (FDM) is a technique that builds plastic objects by extmsion of a polymer-wax filament through a nozzle (Fig. 6.52). A modification of the technique, referred to as fused deposition of ceramics (FDC), has been developed to create ceramic components from particle-filled polymer filaments (73). Ceramic-polymer mixtures used in FDC are similar to those described earlier for injection molding of ceramics. The mixture is first extmded to form filaments with a diameter of 2 mm, after which the spooled filaments are fed into a computer-controlled extrusion head. Extrusion of the plastic mixture through a nozzle is used to form the object layer by layer. Subsequent processing steps follow those described for injection molded bodies. 

Fused deposition modeling Simple process large variety of polymers high porosity, interconnectivity, and surface area Possible use of high temperature heterogeneous pore size require support for fabrication of complex geometries 29,108,118... 

Fused deposition modelling and fused filament fabrication, as outlined above, is a melt-based process which uses heat to transform the material in to a more pliable manner. Tri-dimensional constructs require both building and support materials generally made from acrylonitrile-butadiene-styrene (ABS), polycarbonate (PC), blends of PC/ABS or polyphenylenesulfone (PPSU) (Wendel et al. 2008). 

Fig. 7.7 Neck growth between adjacent filament at 200 °C (Reprinted frran Journal of Manufacturing Processes, Vol. 6, Celine Bellehumeur, Longmei Li, (Jian Sun, Peihua On, Modeling of Bond Formation Between Polymer Filaments in the Fused Deposition Modeling...

Ahn D, Kweon J-H, Kwon S, Song J, Lee S (2009a) Representation of surface roughness in fused deposition modeling. J Mater Process Technol 209(15-16) 5593-5600. doi 10.1016/j. Jmatprotec.2009.05.016... 

Anitha R, Arunachalam S, Radhakrishnan P (2001) Critical parameters influencing the quality of prototypes in fused deposition modelling. J Mater Process Technol 118(l-3) 385-388... 

FIGURE 4.137 Extrusion processes on the example of Fused Deposition Modeling (FDM) Advantages and Disadvantages... 

Fused deposition modeling (FDM) is an extrusion process developed by Stratasys. Parts are built up in layers from extruded plastic strands. In principle, the FDM process is suitable for all materials that can be melted and extruded. Plastics such as ABS, ABSi, PC-ABS, PC, PC-ISO, and PPSF are typical of the materials used. The material for extrusion must be in filament form, with a circular cross-section and a diameter between 1 and 2 mm. The initial data in 3D CAD form are generally converted to SLA format, and this data is used to create 2D cross-sections as slices through the part to be produced. Although the material solidifies very quickly, structures made of support material are needed for cantilever structures. These supporting structures are subsequently easy to remove. Filaments of different materials are needed for the part and the supporting structure. Drive rollers carry the two filaments to an electrically heated plastifier, where the filaments are heated to just below melting temperature (Fig. 7.3). 

Basic Principles, Advantages, and Disadvantages Commercial Extrusion-Based RP Processes Fused deposition modeling (Stratsys Inc.)... 

Materials Development for Extrusion-Based RP Processes Materials for fused deposition modeling Materials for 3D bioplotting ... 

Fused deposition modeling (FDM) is an additive solid-based process as shown in Figure 15.6. A solid thermoplastic polymer is heated to the melting temperature and deposited through a nozzle in narrow strips in the y-direction. The nozzle is moved in the x-direction as subsequent strips are laid down (or the platform can be moved in the -X direction). The thickness t of each layer can be as small as 0.(X)4 in. (0.10 mm) and the width as small as O.Olin. (0.25 mm). The jc, y motion of the process for each layer is similar to that of an inkjet printer and thus the extension of this to RP is also known as 3D printing. 

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