Additive Manufacturing

Additive manufacturing (AM) is also recognized as rapid prototyping and commonly knew as
3D Printing. Ian Gibson, David Rosen in 2013 stated that the process of AM is by adding
materials layer by layer to produce the product, the size of the cross-section for each layer
must thin that is derived from CAD data. Each layer must have consistent thickness to
produce a result that approximate to the original data as illustrated in Figure 1. As the layer is
getting thinner, the more accurate product to its original. Liu, Huang et al., in 2014 found that
technology of AM gives two advantages which are first, it can redesign product with lesser
components and second, production of product can be done near to the clients (Liu, Huang,
Mokasdar, Zhou, & Hou, 2014). And the market of AM is expected to hit $3.1 billion
internationally by 2016 and $5.2 billion by 2020 (Liu et al., 2014).

Figure 1 CAD image of a teacup with additional image showing the building effects with
vary layer thickness (Ian Gibson,David Rosen, 2013)
Selective Laser Sintering (SLS)

Schmid, Amado, & Wegener, in 2015 explored that selective Laser Sintering (SLS) use
powder bed fusion as the polymer during additive manufacturing process. SLS produces
plastic parts by adding material layers consecutively (Schmid, Amado, & Wegener, 2015).
The research done by S. Dadbakhsh et al. concentrated on the impact of shape and powder
size ability of SLS process and TPU elastomer mechanical properties. SLS is one of the main
polymers AM techniques, in which three-dimensional parts are constructed by fusing
polymer powders in layer-by- layer approach. Liu et all., stated in their research in 2014 SLS
provides the capability to create complex and organic geometries not possible through other
manufacturing techniques (Liu et al., 2014). Meanwhile, Kruth, Wang, Laoui, & Froyen said
in 2003, SLS may be used to process nearly any material as long as it is available in powder
form and when heat is applied, the powder form will continue to fuse or sinter (Kruth, Wang,
Laoui, & Froyen, 2003). Figure 2 shows the overview on how SLS process should be done.

Figure 2 Schematic overview of SLS process

Recycle Material

In 2019, Andrady and Neal found that polymers present unique physical, thermal and
electrical properties that make them suitable for many applications. These plastics materials
can be modelled into a variety of products for a wide range of applications due to the fact that
thermoplastic polymers are inexpensive, lightweight and durable (Andrady & Neal, 2009).
When material undergoes recycling process it starts losing some of properties in terms of
tensile strength, wear properties and dimensional accuracy by Singh et al., (2017).

Fatigue

Fatigue may occur when repeated cyclic loadings are subjected on a member. This has been
approved by JONES (2009) that phenomenon of fatigue shows in form of cracks that evolve
in the structure at specific locations (JONES, 2009). Fatigue life is divided to three stages that
is shown as in Figure 3. Crack initiation period is the required cycle to start the crack.
Basically, it is the result from dislocation pile ups and imperfections such as scratch on
surface, voids and the surface roughness itself. Thus, fatigue is a surface phenomenon on
materials. As for crack growth, Azeez (2013) stated that, the number of cycles needed to
develop the crack to a critical size in a stable manner, usually monitored by the level of stress
(Azeez, 2013)

Figure 3 Stages of fatigue life