Purpose – The purpose of this paper is to systematically and critically review the literature related to process design and modeling of fused deposition modeling (FDM) and similar extrusion-based additive manufacturing (AM) or rapid prototyping processes. Design/methodology/approach – A systematic review of the literature focusing on process design and mathematical process modeling was carried out. Findings – FDM and similar processes are among the most widely used rapid prototyping processes with growing application in finished part manufacturing. Key elements of the typical processes, including the material feed mechanism, liquefier and print nozzle; the build surface and environment; and approaches to part finishing are described. Approaches to estimating the motor torque and power required to achieve a desired filament feed rate are presented. Models of required heat flux, shear on the melt and pressure drop in the liquefier are reviewed. On leaving the print nozzle, die swelling and bead cooling are ...

https://forums.reprap.org/file.php?1,file=42240,filename=A_review_of_melt_extrusion_additive_manufacturing_processes_Process_design_and_modeling.pdf

A review of melt extrusion additive manufacturing processes: I. Process design and modeling

Purpose – The purpose of this paper is to investigate the mechanisms controlling the bond formation among extruded polymer filaments in the fused deposition modeling (FDM) process. The bonding phenomenon is thermally driven and ultimately determines the integrity and mechanical properties of the resultant prototypes.Design/methodology/approach – The bond quality was assessed through measuring and analyzing changes in the mesostructure and the degree of healing achieved at the interfaces between the adjoining polymer filaments. Experimental measurements of the temperature profiles were carried out for specimens produced under different processing conditions, and the effects on mesostructures and mechanical properties were observed. Parallel to the experimental work, predictions of the degree of bonding achieved during the filament deposition process were made based on the thermal analysis of extruded polymer filaments.Findings – Experimental results showed that the fabrication strategy, the envelope temper...

Effect of processing conditions on the bonding quality of FDM polymer filaments

https://hal.archives-ouvertes.fr/hal-02119698/document

Mechanical properties of components fabricated with open-source 3-D printers under realistic environmental conditions

A review on additive manufacturing of polymer-fiber composites

Purpose – The purpose of this paper is to critically review the literature related to dimensional accuracy and surface roughness for fused deposition modeling and similar extrusion-based additive manufacturing or rapid prototyping processes. Design/methodology/approach – A systematic review of the literature was carried out by focusing on the relationship between process and product design parameters and the dimensional and surface properties of finished parts. Methods for evaluating these performance parameters are also reviewed. Findings – Fused deposition modeling® and related processes are the most widely used polymer rapid prototyping processes. For many applications, resolution, dimensional accuracy and surface roughness are among the most important properties in final parts. The influence of feedstock properties and system design on dimensional accuracy and resolution is reviewed. Thermal warping and shrinkage are often major sources of dimensional error in finished parts. This phenomenon is explor...

A review of melt extrusion additive manufacturing processes: II. Materials, dimensional accuracy, and surface roughness

Modeling of Bond Formation Between Polymer Filaments in the Fused Deposition Modeling Process

Composite Modeling and Analysis for Fabrication of FDM Prototypes with Locally Controlled Properties

FDM process fabricates prototypes by extruding a semi-molten filament through a heated nozzle onto a platform. The semi-molten material solidifies with the neighboring material diffusely after deposition. The bonding quality among ABS filaments in FDM2000 process determines the integrity and mechanical property of resultant prototypes. This paper describes heat transfer analysis of the FDM process. Sintering experiments were carried out to evaluate qualitatively the dynamics of bond formation between polymer filaments. Quantitative predictions of the degree of bonding achieved during the filament deposition process were made, based on experimental data used in conjunction with heat transfer and sintering models.

Longmei Li

Papers

Modeling of Bond Formation Between Polymer Filaments in the Fused Deposition Modeling Process

Composite Modeling and Analysis for Fabrication of FDM Prototypes with Locally Controlled Properties

Investigation of Bond Formation in FDM Process