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Journal of Manufacturing Processes 21 (2016) 39–45

Contents lists available at ScienceDirect

Journal of Manufacturing Processes


journal homepage: www.elsevier.com/locate/manpro

Technical Paper

Mechanical behaviour of ABS: An experimental study using FDM and


injection moulding techniques
Michael Dawoud ∗ , Iman Taha, Samy J. Ebeid
Mechanical Design and Production Engineering Department, Ain Shams University, El-Sarayat St. 1, Cairo 11517, Egypt

a r t i c l e i n f o a b s t r a c t

Article history: Fused deposition modelling (FDM) in contrast to injection moulding was studied to investigate the effect
Received 2 December 2014 of processing technique on the mechanical behaviour of virgin ABS. FDM parameters were further altered
Received in revised form 23 August 2015 in terms of varying raster angle and gap to further explore the potential of this technique. Results show
Accepted 3 November 2015
that an adequate selection of FDM parameters is able to reach mechanical properties comparable to those
Available online 9 December 2015
of injection moulded parts in both static and dynamic loading modes. Here, a negative raster gap proved
to be most significant in enhancing mechanical behaviour. A raster angle layup of −45◦ /+45◦ proves to
Keywords:
offer maximum tensile and impact strength, whereas highest flexural strength was recorded for a 0/90◦
Fused deposition modelling
DIY 3D printers
scaffolding system. In contrast, a positive gap drastically reduces the performance. Dimensional analysis
Injection moulding further show no significant alterations of dimensions are to be expected with varying raster angle and
Acrylonitrile butadiene styrene gap.
© 2015 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.

1. Introduction In recent years, FDM technology has gained a public interest


for its ease of use as well as the simplicity of the machinery itself.
3D Printing (3DP) is a technology used to directly convert 3D Today, many FDM machines are designed and constructed by hob-
Computer-Aided Design (CAD) data into physical prototype. Most byists as a Do-It-Yourself (DIY) machine for personal use [5]. These
3D printing techniques are based on slicing a CAD model into a even assume that in the coming years, many of our daily-use plas-
number of 2D layers and building them layer by layer to form the tic products, especially spare parts that are produced by Injection
prototype. Moulding (IM) will be replaced by CAD models that would be home
One of many available 3DP techniques is Fused Deposition Mod- printed for cost reductions and personalization. A problem, how-
elling (FDM) [1,2]. In this process a filament of material is melted ever, remains the expected loss in mechanical properties in contrast
in a heated nozzle and deposited on a build platform. By using a to the monofilament or the injected material [2,6].
3-axis motion system, this nozzle is moved in the XY plane prin- Whereas layer thickness, part orientation and raster width were
ting a layer of the prototype. When this layer is finished, the build proven to have little influence on mechanical properties [2,7], other
platform is moved down one step (known as the slice thickness) in printing parameters such as raster angle and air gap between two
the Z direction and the cycle is repeated for the next layer until the successive rasters were observed to significantly affect the perfor-
complete model is built-up [3]. mance of 3DP parts [2,7–9]. Sood et al. [2] observed that tensile
FDM technology is primarily used for rapid prototyping poly- strength is enhanced by increasing the raster angle. In contrast,
mer parts [3,4]. The choice of material depends on the type Vega et al. [8] reported a maximum tensile strength at a raster ori-
of application and desired properties. Nowadays, commonly entation of 0◦ to the tensile load. This angle of zero additionally
applied materials include Polylactic Acid (PLA) as a stiff and proved to be most suited for maximum flexural strength [2,8]. Fur-
environmentally-friendly material, Nylon for soft applications (e.g. ther investigations conducted by Sood et al. [7] show failure of 3D
bracelets), high density polyethylene (HDPE) for the production of parts due to buckling or debonding of adjacent rasters upon the
food-compatible parts and Acrylonitrile Butadiene Styrene (ABS) as application of compressive loads.
a general solution for tough parts with acceptable strength. A positive air gap was proposed to allow material flow towards
adjacent layers thus contributing to the enhancement of mechani-
cal properties [2]. In contrast, Ahn et al. [9] describe that a negative
∗ Corresponding author. Tel.: +20 1221271808. air gap of 0.003 (0.08 mm) between rasters increases part density
E-mail address: michael.dawoud@eng.asu.edu.eg (M. Dawoud). thus enhancing tensile behaviour. A more negative air gap leading

http://dx.doi.org/10.1016/j.jmapro.2015.11.002
1526-6125/© 2015 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
40 M. Dawoud et al. / Journal of Manufacturing Processes 21 (2016) 39–45

Table 1
Overview of previous work in FDM technology.

Reference Machine Raster angle Other printing parameters Mechanical properties Form accuracy

[2,7] Stratasys 0, 30, 45, 60 Raster gap, raster width, layer thickness, layer Tension, compression Dimensions
orientation bending, impact
[8] Stratasys 0, 45, 90, 45/−45, 45/0 Layer orientation Tension, bending, impact –
[9,15] Stratasys 0, 90, 0/−90, 45/−45 Raster gap, raster width, printing temperature Tension, compression –
[6,16] Stratasys 0, 90 Raster gap, raster width, printing temperature Tension, torsion –
[10] Stratasys – No. of contours, layer orientation Tension –
[17] Stratasys 0/-90, 30/-60, 45/-45 Bending –
[18] Stratasys – Raster width, no. of contours, envelope – Voids
temperature, printing temperature
[19] Stratasys – Raster width, layer thickness, deposition speed – Roughness
[20] Stratasys – Raster width, layer thickness – Dimensions,
roughness
[21,22] Stratasys 0, 30, 60, 90, 0/−90, – Tension –
15/−75, 30/−60, 45/−45
Study DIY 0/−90, 15/−75, 30/−60, Raster gap Tension, bending, impact –
45/−45

to raster overlap would, however, lead to dimensional inaccuracy. deposition modelling in order to highlight the difference in
Similarly, Croccolo et al. [10] suggest improved strength through mechanical properties encountered by the different processing
increased number of contours. techniques. Further, the effect of FDM printing parameters on the
Table 1 gives an overview of the parameters and mechanical performance of printed parts is investigated, targeting the selec-
properties of FDM products intensively investigated in literature. tion of appropriate parameters that enable the fabrication of parts
However, literature lacks an in-depth study of the criss-cross (+/−) of comparable behaviour to injection moulding.
meshing system, where the raster angle in each layer is orthogonal
to the preceding layer. This meshing system is the main system used 2. Experimental work
by open source slicing software used in DIY 3D printer projects.
Studies are based, however, on commercially available FDM equip- 2.1. Materials
ment, relying on a single raster angle that is constant for all the
layers as a meshing system. In this context, based on the use Virgin ABS pellets supplied by Grand Pacific Petrochemical Corp
of DIY machines the authors propose a comparison of mechani- (D-150) [14] were used to extrude ABS filament for subsequent
cal properties for the commonly applied Acrylonitrile Butadiene FDM and injection moulding processing. Pellets were first dried at
Styrene material processed by injection moulding and fused 80 ◦ C for 24 h prior to extrusion into 1.7 ± 0.05 mm filaments using

Table 2
Dimensions of tensile, flexural, and impact specimens.

Tensile specimens

Parameter Injected specimen 3D printed specimen

Gauge length L0 [mm] 50 ± 0.5 50 ± 0.5


Length of parallel section L1 [mm] 60 ± 0.5 60 ± 0.5
Distance between shoulders L2 [mm] 107.5 120
Total length L3 [mm] 195 220
Width of the parallel section B1 [mm] 10 ± 0.2 10 ± 0.2
Width at ends B2 [mm] 20 ± 0.2 20 ± 0.2
Thickness H1 [mm] 4 ± 0.2 4 ± 0.2
Fillet Radius R [mm] 40 125

Bending and impact specimens

Overall length L [mm] 80 mm ± 0.2 80 mm ± 0.2


Width B [mm] 10 mm ± 0.2 10 mm ± 0.2
Thickness H [mm] 4 mm ± 0.2 4 mm ± 0.2
M. Dawoud et al. / Journal of Manufacturing Processes 21 (2016) 39–45 41

Table 3 2.3. Testing methods


Injection moulding parameters.

Parameter Value Density of specimens was measured using an Adam Equipment


Screw speed 180 rpm PW254 sensitive scale of 0.0001 g resolution and further equipped
Injection pressure 90 kg/cm2 with a density measuring kit.
Clamping pressure 105 kg/cm2 The effect of varying FDM parameters on dimensional accuracy
Holding time 35 s was investigated by measuring sample width and thickness using
a Mitutoyo Vernier Caliper at 0.01 mm accuracy. Average of 3 mea-
Table 4 surements was compared to the respective dimensions of the CAD
Sample designation and scaffolding setup. models to make statements about eventual dimensional variations.
Both injection moulded and FDM samples were tested for their
Designation Processing Raster angle Raster angle Gap (mm)
technique (even layers) (odd layers) mechanical behaviour. Tensile testing was conducted in compli-
ance to DIN EN ISO 527-2 using a Lloyd LRX Plus Universal Testing
I IM – – –
−P0 FDM 0 +90 −0.05 Machine equipped with a 5 kN load cell at a crosshead speed of
−P30 FDM +30 −60 −0.05 5 mm/min. 3-point bending was carried out according to the ASTM
−P45 FDM +45 −45 −0.05 standard 790-03 using the same Universal Testing Machine and test
−P75 FDM +75 −15 −0.05 speed.
+P0 FDM 0 +90 +0.05
Charpy impact strength was determined using un-notched sam-
+P30 FDM +30 −60 +0.05
+P45 FDM +45 −45 +0.05 ples in accordance to the ASTM standard 6110-04 applying a
+P75 FDM +75 −15 +0.05 BEIJING JINSHENGXIN digital impact testing machine, where a 2-
Joule hammer edgewise strikes the specimen.
SEM microscopy was performed using a CamScan Series 4
a Beier Machinery Co. Ltd. TSK 35 twin screw extrusion machine. scanning electron microscope using a 15 keV acceleration voltage.
Extruded filaments were partially pelletized into 3 mm pellets for Samples were gold sputtered prior to investigation.
injection moulding and the remainder wound on a drum for FDM.

2.2. Sample preparation 3. Results and discussion

Two sets of samples were prepared to perform a compari- 3.1. Density


son between injection moulded and filament deposition modelled
parts. Fig. 1 shows that injection moulded samples have the highest
Specimens for tensile, flexural and impact testing were prepared density of 1.054 g/cm3 , while the +P layups have the lowest den-
in compliance to DIN EN ISO 527-2, 178 and 179-1 standard, respec- sity of 0.943 g/cm3 . This result is conceivable in view of the fact that
tively having dimensions shown in Table 2. Injection moulding was injection moulding involves the application of high pressures that
performed using a Fu Chun Shin 60 ton, single screw hydraulic compact the material upon injection into the die cavity. Moreover,
injection moulding machine applying the injection parameters applied holding pressure during injection moulding additionally
listed in Table 3. compensates material shrinkage, resulting in more compact sam-
The effect of scaffolding angle, as well as air gap between rasters ples compared to FDM parts, where the individual rasters are
was studied by varying these parameters according to the experi- simply deposited next to each other.
mental setup summarized in Table 4. However, it can also be depicted from Fig. 1 that using negative
FDM samples were produced using a DIY FDM machine of air gaps between individual rasters is able to reach 98% of the max-
280 × 380 × 120 mm print volume, equipped with Marlin firmware imum IM density. In contrast, FDM parts produced at a positive air
that communicates with the user interface software Repitier-Host gap are much lower in density. This can be related to the fact that
version V1.0.4 obtained from [11]. STL files were generated using a positive air gap causes adjacent rasters to barely touch along a
Solid Works 2012 CAD software and further sliced for printing using
Slic3r program version 1.1.7 [13].
Similar specimens were prepared using the FDM technique. For
printed tensile samples, recommendations proposed by Croccolo
[10] were adopted, where the fillet radius was increased to 250 mm
to avoid stress concentrations. The CAD models for the various spec-
imens were sliced into layers of 0.5 mm thickness, resulting into 8
layers.
To prevent variation in FDM sample properties due to tempera-
ture differences on the build platform, each sample was printed
individually at the centre of the printing bed according to the
parameters given in Table 5.

Table 5
FDM parameters.

Parameter Value

Nozzle diameter 1 mm
Layer height 0.5 mm
No. of contours 1
Printing speed 30 mm/s
Nozzle temperature 250 ◦ C ± 5
Bed temperature 120 ◦ C
Fig. 1. Density of injection moulded and 3D printed parts.
42 M. Dawoud et al. / Journal of Manufacturing Processes 21 (2016) 39–45

adjacent rasters [18]. In contrast, a positive air gap leads to the


formation of in-plane neighbouring cylindrical rasters that barely
touch, leading to week axial bonds. Thus, part integrity is primarily
achieved through bonding to subsequent layers and not within the
same layer. This concept is supported by SEM micrographic anal-
ysis, as illustrated in Fig. 3, where the fracture surfaces of tensile
samples of printed +P0, and −P0 are shown in contrast to injection
moulding.
Further, it can be depicted from Fig. 2 that varying raster angle
seems to have a more significant effect on tensile strength when
deposited with a positive gap, compared to raster angle variation
at a negative gap. These observations were additionally supported
by ANOVA [12] at a 95% confidence level and can be related to the
clear position of the individual rasters, which signify the effect of
the printing angle thus directly affecting its mechanical behaviour.
At this point it is worth mentioning, that behaviour observed in this
study come opposing to the observations reported by Sood et al. [2],
where a negative air gap was assumed to cause thermal stresses to
the material by reheating the adjacent layers, thus concluding that
Fig. 2. Tensile strength of injection moulded and 3D printed parts.
increased air gap favours increase in strength.
Ziemian et al. [21,22] report that the effect of raster angle is of
line (resulting from the cylindrical raster shape), whereas a neg- high influence on the tensile properties of FDM samples. A single
ative raster gap, designed for overlapping rasters causes adjacent 90◦ angle was reported to exhibit highest mechanical properties
filaments to partially squeeze and fill in the air gap in between. while a 0◦ raster orientation yields lowest mechanical properties.
This is due to the fact that at a raster angle ≤45◦ the sample strength
3.2. Tensile strength is mainly dependant on the inter-raster bonding. In the criss-cross
layup, however, sample strength is a result of the interaction of
Fig. 2 shows the effect of production technique and 3DP parame- two orientations, where only the layers >45◦ orientation positively
ters on tensile strength. It becomes evident that there is a difference contribute to the behaviour.
in tensile strength between injection moulded (37.7 MPa) and FD In this respect, it becomes apparent that with a positive air gap
modelled (34.3 MPa) specimens, the latter being the highest tensile a scaffolding angle of zero results in least tensile strength val-
strength for printed samples observed at −P45. This is expected ues of 28.1 MPa. At this angle the load is only partially carried
in view of the more compact injection moulded part, as proven by the individual rasters, where only rasters parallel to the load-
by density measurements. In addition, the nature of the injection ing direction positively contribute to load bearing, whereas layers
moulding process, in which molten material is introduced to a composed of transverse rasters have negligible effect. A further
chilled cavity, allows the formation of crystals, which in turn brings increase in raster angle up to 45◦ further increases tensile strength,
along increased mechanical properties. In contrast, in the FDM pro- where raster alignment results in a maximum resolved load bearing
cess, the molten filaments are deposited on a warm bed kept at area. At an angle of 75◦ the effectively load subjected area is again
120 ◦ C where it is then left to air cool — a condition which favours reduced, thus decreasing part tensile strength. In view of Fig. 3c,
an amorphous, and thus less strong polymer structure. The observa- this behaviour can be regarded in compliance to the behaviour of
tions made at this stage lie in complete agreement with the findings fibrous structures or composites.
reported by Ahn et al. [9].
Comparing tensile strength of FDM samples produced at pos- 3.3. Flexural strength
itive and negative air gaps, Fig. 2 shows that a negative air gap
results in higher tensile strength. Again, this can be attributed to Fig. 4 shows the flexural strength of bending samples produced
the increased density of these parts, where rasters are allowed to by injection moulding and FDM at different conditions. Following
slightly overlap resulting in stronger interfacial bonding between a similar trend to tensile behaviour, samples prepared by injection

Fig. 3. SEM of the fracture surface of tensile samples of (a) injection moulded, (b) −P0 and (c) +P0 samples.
M. Dawoud et al. / Journal of Manufacturing Processes 21 (2016) 39–45 43

Fig. 6. Impact strength of injection moulded and 3D printed parts.


Fig. 4. Flexural strength of injection moulded and 3D printed parts.

moulding proved to have highest flexural strength of 72.5 MPa. In


apart. This explains the poor flexural behaviour compared to the
contrast, printed samples witness a flexural strength reduction of
P0 layout.
at least 12% (−P0), depending on scaffolding angle and raster gap.
Next to this drop in flexural strength, Fig. 4 also shows that
filament deposition at a positive gap further drastically reduces 3.4. Impact strength
flexural strength. Considering the effect of air gap, a raster angle of
zero shows a significant reduction from 63.8 to 41.8 MPa. Similar to Results of the impact testing, as presented in Fig. 5b, are shown
tensile strength findings varying raster angle has insignificant effect in Fig. 6 for both injection moulded and FDM samples at the
on flexural behaviour when a negative gap is applied. In contrast, various conditions under consideration. It can be noted that injec-
additionally supported by ANOVA at a 95% confidence level, a pos- tion moulded samples have highest impact strength of 79.7 kJ/m2 .
itive gap proves to bring along a significant effect of raster angle on Printed samples reach a maximum of 41.8 kJ/m2 at a raster gap
flexural strength. Again following tensile strength trend, increased of −0.05 mm and a scaffolding angle of 45◦ while a minimum of
scaffolding angle up to 45◦ readily increases flexural strength. At 18.3 kJ/m2 is recorded at +P75. This comes in contrast to Es-Said
this angle all printed layers contribute to load bearing. A minimum et al. [8], who reported that the 0◦ orientation has the highest tough-
of 32.1 MPa is however recorded at an angle of +P75◦ , where both ness over his sample composition. However, this can be related to
even and odd layers are unable to carry the full bending load. the fact that only a single scaffolding orientation per sample was
Unlike tensile strength, the maximum flexural strength is used, i.e. no alteration between even and odd layers.
recorded at −P0 configuration, an observation which complies with Unlike tensile and flexural strength analysis, ANOVA testing
the findings reported by Sood et al. [2]. Fig. 5a shows a schematic proves a significant effect of scaffolding angle on impact strength
representation of the P0 scaffolding layup subjected to bending for both positive and negative raster gaps.
load. The bottom layer, representing the odd layers within the sam- According to Sood et al. [2], the FDM technology causes ther-
ple, comprises filaments in a sample axis direction, which are able mal stresses between the rasters due to the deposition of a newly
to carry induced tensile stresses. In contrast, the top (even) lay- molten raster next to a partially solidified raster. These internal
ers are deposited at 90◦ to the axis of the sample thus carry minor stresses cause the crack to easily propagate between the deposited
loads in the case of a −P scaffolding. A positive air gap carries lower filaments. By altering the raster angle, the direction of induced
loads since the bonding between adjacent filaments in the even residual stresses is altered, consequently significantly affecting
layers are weaker than in the above case. At an angle of 45 a max- sample toughness.
imum resolved shear stress is observed causing filaments to slip
3.5. Dimensional accuracy

Fig. 7 shows exemplary photographs of bending specimens and


their fracture surface after testing. The images confirm the state-
ments made through density measurements. It can be observed
that the use of a negative gap results in denser material, where
the individual filaments are squeezed together resulting in a struc-
ture similar to that of injection moulded parts. In contrast, positive
raster gap results into obvious voids between the individual rasters,
leading to reduced density and reduced flexural properties. It is
further to be noted that the cross section of the rasters, which
is only recognizable in layups of positive gap, remains insignifi-
cantly changed with the alteration of the various angular layups.
The apparent oval cross section of the filaments in the layups +P30,
+P45 and +P75 is based on the angular view of the sample cross sec-
Fig. 5. Schematic representation of a P0 scaffolding subjected to (a) flexural load tion in addition to the partial flattening of semi-solid filaments on
and (b) impact load. a flat bed. However, it is notable that contour rasters still appear in
44 M. Dawoud et al. / Journal of Manufacturing Processes 21 (2016) 39–45

Fig. 7. Photographs of bending specimens and their cross section for the various layups under investigation.

a circular shape. This is because the contour layer is first deposited varying raster gap or angle on sample dimensions. These findings
forming the borders, after which the filling rasters are deposited are in agreement with observations stated by Sood et al. [23]. This
according to the predefined angles. can be understood in view of the printing mechanism, where gap
Fig. 8 further shows the average dimensions measured for the width is realised by controlling the amount of material extruded
various layups of tensile, flexural and impact specimens in contrast per raster while the extruding nozzle unaffectedly continues its
to the nominal sample size given by the applied standards. It can motion according to the foreseen G-code generated for the part.
be generally noted that the dimensional variations all lie within the Based on this, similar observations were made for thickness vari-
standards’ acceptable range of ±0.2 mm. Analysis of results using ation, where no significant difference amongst the various layups
ANOVA techniques revealed that there is no significant effect of has been detected.

Fig. 8. Average dimensions of tensile and flexural/impact specimens in (a) width and (b) thickness.
M. Dawoud et al. / Journal of Manufacturing Processes 21 (2016) 39–45 45

Fig. 9. Summary of −P results in contrast to injection moulding.

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