MANUFACTURING PROCESS-II

Lab Manual 02

Submitted to
Sir Farhan Raza

Submitted by
Abdul Rehman (2019-IM-37)
Experiment # 2 To demonstrate and familiarize the students with the proper
understanding of fused deposition modelling (FDM) RP system.

A. AIM
This empirical activity has been designed to introduce the in-depth understanding about
FDM present in RP lab of MTDC.

B. Methodology
The special need motivating the variety of rapid prototyping technologies arises because
product designers would like to have a physical model of a new part or product design
rather than a computer model or line drawing. The creation of a prototype is an integral
step in the design procedure. A virtual prototype, which is a computer model of the part
design on a CAD system, may not be adequate for the designer to visualize the part.
It certainly is not sufficient to conduct real physical tests on the part, although it is possible
to perform simulated tests by finite element analysis or other methods. Using one of the
available RP technologies, a solid physical part can be created in a relatively short time
(hours if the company possesses the RP equipment or days if the part fabrication must be
contracted to an outside firm specializing in RP). The designer can, therefore, visually
examine and physically feel the part and begin to perform tests and experiments to assess
its merits and shortcomings.

C. Description of procedure
Fused-deposition modelling (FDM) is an RP process in which a filament of wax or polymer
is extruded onto the existing part surface from a work head to complete each new layer.
The work head is controlled in the x-y plane during each layer and then moves up/down
by a distance equal to one layer in the z-direction. The starting material is a solid filament
with typical diameter 1.25 mm (0.050 in) fed from a spool into the work head that heats
the material to about 0.5 oC (1 oF) above its melting point before extruding it onto the part
surface. The extrudate is solidified and cold welded to the cooler part surface in about 0.1
second. The part is fabricated from
the base up, using a layer-by-layer procedure like other RP systems. An FDM system
with prototypes from it are shown in Figures 1 and 2 respectively.
FDM was developed by Stratasys Inc., which sold its first machine in 1990. The starting
data is a CAD geometric model that is processed by Stratasys’s software modules
QuickSlice; and SupportWorkTM. QuickSlice; is used to slice the model into layers, and
Support Work is used to generate any support structures that are required during the
build process. If supports are needed, a dual extrusion head and a different material
are used to create the supports. The second material is designed to readily be
separated from the primary modelling material. The slice (layer) thickness can be set
anywhere from 0.05 to 0.75mm (0.002 to 0.030 in). About 400mm of filament material
can be deposited per second by the extrusion work head in widths (called the road
width) that can be set between 0.25 and 2.5 mm (0.010 to
0.100 in). Starting materials are wax and several polymers, including ABS, polyamide,
polyethylene, polylactic acid (PLA) and polypropylene. These materials are ambienty
nontoxic, allowing the FDM machine to be set up in an office environment.

Fig. 1 FDM-HTS 300

 Fig. 2 Prototypes produced from HTS 300

Exercise Questions
1. What are the different issues faced during 4D printing?
2. Why do we use polymeric materials in the FDM RP system? Add the practical
engineering applications.
3. What are the medical applications of RP systems?
4. List the RP materials used in medical applications other than PLA.
5. What is the concept of support for part to be fabricated in FDM RP
technology?
LAB SESSION #2
1. What are the different issues faced during 4D Printing?
Following are some issues faced during 4D printing
• The high cost (because only a few companies are working on techniques that uses 4D
printing).
• It consumes a lot of energy (electricity).
• This printing is slow.
• There are only limited materials that can use in 4D printing. [1]
2. Why do we use polymeric materials in the FDM RP system? Add the practical
engineering applications.
The binding capacity and strength of polymers are high than the metals. They are utilized in many
ways from nylon stockings to commercial aircraft to artificial heart valves, the most useful and
important property of polymers is their molecular composition, molecules are in long chains and
within the processing, this is finished in producing the product.
Polymers are widely used in engineering field such as biotechnology, architecture, air and defence
industry, information and communication, transportation and environmental protection, etc. [2]
3. What are the medical applications of RP systems?
The most interesting and challenging applications of rapid prototyping technologies are in the field
of medicine. RP Medical Model has applied for complex surgery procedures, training, surgical
simulation, diagnosis, design, and construction of implants, as well as treatment plans for medical
devices.[3]
4. List the RP materials used in medical applications other than PLA.
• Polymethyl methacrylate
• Polyethylene
• Polypropylene
• Polycarbonate
• Polysulfone
• Polyvinyl chloride
• ABS
• Polyamide [4]
5. What is the concept of support for the part to be fabricated in FDM RP
technology?
Support structures are used to make any support that is required during the manufacturing
processes. A dual extrusion head and different materials are used to create support if they are
required. Distortion of the element, inflicting geometrical and dimensional errors can cause a lack
of guiding structures, for example, overhangs can affect surface flatness due to distortion. The
second material is designed to be readily separated from primary material modeling. Otherwise,
support systems are difficult to remove from internal cavities. Removal or braking strategies of
assisting systems may also cause damage to small functions of the element. [5]

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References

[1] [Online]. Available: https://www.machinedesign.com/3d-printing-cad/article/21831814/4d-

printing- on-the-rise. [Accessed 24 April 2021].

[2] J. Guo, "Why are there limited polymers for fused deposition modeling (FDM)?," 2014.

[3] M. T. Jelena Milovanović, "MEDICAL APPLICATIONS OF RAPID PROTOTYPING," vol. 5,

pp. 79-85, 2007.

[4] M. T. Jelena Milovanović, "MEDICAL APPLICATIONS OF RAPID PROTOTYPING," vol. 5,

pp. 79-85, 2007.

[5] X. X. d. J. S. Jingchao Jiang, "Support Structures for Additive Manufacturing: A Review," pp. 8-
11, 2018.