Investigation of mechanical and structural properties based on bond development under different printing conditions in fused deposition modelling

Abstract

Fused Deposition Modelling (FDM) 3D printing presents a compelling alternative to conventional manufacturing methods from a professional research perspective. Its unique attributes address key challenges inherent in traditional manufacturing paradigms. As such, FDM emerges as a catalyst for advancing manufacturing practices, offering researchers avenues for exploration in efficiency, sustainability, and design innovation. One of the main obstacles of FDM technologies is the poor mechanical properties of fabricated parts, resulting in the lack of functionality and its low production rate. The research centred on a systematic exploration of temperature-associated printing parameters within the domain of FDM. Temperature measurement techniques were employed to track temperature changes during printing and cyclic heating based on different printing parameters. Next, the physical dimensions of printed rasters was correlated with bonding mechanisms, and their effect on mechanical properties (e.g. tensile, flexural, impact strengths) was quantified. As an auxiliary study, the research was also supplemented with investigations on other printing parameters such as printing speed, layer height, deposition sequence and raster orientation which also affected the temperature development during the printing process. The research findings provided crucial insights into the ramifications of printing parameters that induced temperature changes. In the present work, the underlying mechanism of physical bonding between printed rasters were investigated and related to the mechanical properties of fabricated parts. Results showed that changes to printing temperature was most significant due to its reheating effect on previously deposited layers. This promotes the spreading of deposited rasters resulting in a reduction of size and percentage of voids was observed when cross section of the fabricated parts were examined. It was ascertained that the mechanical properties improved due to better developed physical bonds when printing temperature increases due to its reduced viscosity. By refining printing parameters in accordance with the findings, users can achieve superior mechanical performance. Thereby, they can enhance the applicability of FDM technology across various industries and driving advancements in additive manufacturing methodologies, fostering innovation and efficiency in production processes.