Fused deposition modeling (FDM) is commonly used to print different products with highly complex features. Process parameters for FDM are divided into controllable or uncontrollable parameters. The most critical ones are built orientation, layer thickness, infill pattern, infill density, and nozzle diameter. This study investigates the effects of combined infill patterns in 3D printed products. Five patterns (solid, honeycomb, wiggle, grid, and rectilinear) were combined in samples to analyze their effects on mechanical properties for tensile strength analysis. Polylactic acid (PLA) samples were printed in different build orientations through two directions: flat and on-edge. The limitation was that the software and machine could not combine the infill patterns. Thus, the patterns were designed and assembled in computer aided design (CAD) software. Finite element analysis (FEA) was used to determine the patterns' features and results showed honeycomb and grid have the highest strength while their weights were lighter compared to solid. Moreover, 0° samples in both flat and on-edge direction had the strongest layer adhesion and the best quality. In contrast, perpendicular samples like 60° and 75° showed poor adhesion and were the weakest specimens in both flat and on-edge, respectively. In brief, by increasing the build orientation, the strength decreases in this study.
Fused deposition modelling (FDM) opens new ways across the industries and helps to produce complex products, yielding a prototype or finished product. However, it should be noted that the final products need high surface quality due to their better mechanical properties. The main purpose of this research was to determine the influence of computer numerical control (CNC) machining on the surface quality and identify the average surface roughness (Ra) and average peak to valley height (Rz) when the specimens were printed and machined in various build orientations. In this study, the study samples were printed and machined to investigate the effects of machining on FDM products and generate a surface comparison between the two processes. In particular, the block and complex specimens were printed in different build orientations, whereby other parameters were kept constant to understand the effects of orientation on surface smoothness. As a result, wide-ranging values of Ra and Rz were found in both processes for each profile due to their different features. The Ra values for the block samples, printed samples, and machined samples were 21, 91, and 52, respectively, whereas the Rz values were identical to Ra values in all samples. These results indicated that the horizontal surface roughness yielded the best quality compared to the perpendicular and vertical specimens. Moreover, machining was found to show a great influence on thermoplastics in which the surfaces became smooth in the machined samples. In brief, this research showed that build orientation had a great effect on the surface texture for both processes.
Recently, natural fiber-reinforced polymers (NFRPs) have become important materials in many engineering applications; thus, to employ these materials some final industrial processes are needed, such as cutting, trimming, and drilling. Because of the heterogeneous nature of NFRPs, which differs from homogeneous materials such as metals and polymers, several defects have emerged when processing the NFRPs through traditional cutting methods such as high surface roughness and material damage at cutting zone. In order to overcome these challenges, unconventional cutting methods were considered. Unconventional cutting methods did not take into account the effects of cutting forces, which are the main cause of cutting defects in traditional cutting processes. The most prominent unconventional cutting processes are abrasive waterjet (AWJM) and laser beam (LBM) cutting technologies, which are actually applied for cutting various NFRPs. In this study, previously significant studies on cutting NFRPs by AWJM and LBM are discussed. The surface roughness, kerf taper, and heat-affected zone (HAZ) represent the target output parameters that are influenced and controlled by the input parameters of each process. However, this topic requires further studies on widening the range of material thickness and input parameter values.
The bio-inspired structure (e.g., honeycomb) has been studied for its ability to absorb energy and its high strength. The cell size and wall thickness are the main elements that alter the structural ability to withstand load and pressure. Moreover, adding a secondary structure can increase the compressive strength and energy absorption (EA) capability. In this study, the bio-inspired structures are fabricated by fused deposition modelling (FDM) technology using polylactic acid (PLA) material. Samples are printed in the shape of a honeycomb structure, and a starfish shape is used as its reinforcement. Hence, this study focuses on the compression strength and EA of different cell sizes of 20 and 30 mm with different wall thicknesses ranging from 1.5 to 2.5 mm. Subsequently, the deformation and failure of the structures are determined under the compression loading. It is found that the smaller cell size with smaller wall thickness offered a crush efficiency of 69% as compared to their larger cell size with thicker wall thickness counterparts. It is observed that for a 20 mm cell size, the EA and maximum peak load increase, respectively, when the wall thickness increases. It can be concluded that the compression strength and EA capability increase gradually as the cell size and wall thickness increase.
Patients suffering bone fractures in different parts of the body require implants that will enable similar function to that of the natural bone that they are replacing. Joint diseases (rheumatoid arthritis and osteoarthritis) also require surgical intervention with implants such as hip and knee joint replacement. Biomaterial implants are utilized to fix fractures or replace parts of the body. For the majority of these implant cases, either metal or polymer biomaterials are chosen in order to have a similar functional capacity to the original bone material. The biomaterials that are employed most often for implants of bone fracture are metals such as stainless steel and titanium, and polymers such as polyethene and polyetheretherketone (PEEK). This review compared metallic and synthetic polymer implant biomaterials that can be employed to secure load-bearing bone fractures due to their ability to withstand the mechanical stresses and strains of the body, with a focus on their classification, properties, and application.
Fused deposition modeling (FDM) is currently used in several fields, such as architecture, manufacturing, and medical applications. FDM was initially developed to produce and create prototypes, but the expense appears excessive for producing final products. Nevertheless, in this day and age, engineers have developed a low-cost 3D printer. One of the major issues with low-cost 3D printers is the low dimensional accuracy and high tolerances of the printed products. Herein, different printing parameters, i.e., layer thickness, printing speed, and raster angle, need to be investigated to enhance the surface roughness of the parts produced using FDM. Thus, the present study focuses on investigating the performance of the surface finish produced by FDM by manipulating different parameters such as layer thickness, printing speed, and raster angle. Taguchi's method, based on the L9 array for experimental design, was employed to elucidate the response variables. The sample model was developed following ISO standards, utilizing polylactic acid (PLA)-aluminum as the filament material. The analysis of variance results indicated that the layer thickness and raster angle significantly affect the surface roughness of the printed parts, with statistical P-values of 0.016 and 0.039, respectively. This enables an easy selection of the optimal printing parameters to achieve the desired surface roughness. The dimensional accuracy of the fabricated part was also evaluated. Thirteen dimensions of the part features were analyzed, and the results showed that the FDM machine exhibited good accuracy for most of the shapes, with a deviation below 5%.