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1 s2.0 S1526612515001395 Main
1 s2.0 S1526612515001395 Main
Technical Paper
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.
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
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
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. 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
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moulding process which results in higher material compaction in [7] Sood AK, Ohdar RK, Mahapatra SS. Experimental investigation and empirical
addition to the enhancement of crystalline structure, thus enhanc- modelling of FDM process for compressive strength improvement. J Adv Res
2012;3:81–90, http://dx.doi.org/10.1016/j.jare.2011.05.001.
ing mechanical strength.
[8] Vega V, Clements J, Lam T, Abad A, Fritz B, Ula N, et al. The effect of
However, this study shows that the adequate selection of FDM layer orientation on the mechanical properties and microstructure of a
parameters can yield parts of acceptable properties. Here, primar- polymer. J Mater Eng Perform 2011;20:978–88, http://dx.doi.org/10.1007/
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In contrast, however, dynamic behaviour is significantly affected [13] Slic3r http://slic3r.org/ (accessed February 1, 2014).
[14] Grand Pacific Petrochemical Corporation http://www.gppc.com.tw (accessed
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behaviour was related to internal stresses caused by thermal gra- [15] Montero M, Roundy S, Odell D. Material characterization of fused deposition
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As depicted in Fig. 9, parts fabricated according to the −P45 prin- [16] Rodrıı́guez JF, Thomas JP, Renaud JE. Design of fused-deposition ABS compo-
ting conditions are able to reach 91% of the tensile strength and nents for stiffness and strength. J Mech Des 2003;125:545, http://dx.doi.org/
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Next to mechanical performance, the FDM technique applied in
[19] Anitha R, Arunachalam S, Radhakrishnan P. Critical parameters influencing the
this study proved acceptable dimensional accuracy, lying within quality of prototypes in fused deposition modelling. J Mater Process Technol
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[21] Ziemian C, Sharma M. Anisotropic mechanical properties of ABS
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