基于正交实验的熔融沉积成型工艺参数的优化

采用商用聚乳酸（PLA）线材作为熔融沉积成型(FDM)打印材料,以拉伸强度和冲击强度为优化指标,设计正交试验,从分层厚度、打印速度、喷嘴温度、填充角度等元素探究成型工艺参数对FDM打印制件力学性能的影响。利用极差分析法,考察了各工艺参数对制件力学性能的影响情况,通过综合评分法和综合平衡法,获得了最优成型工艺参数组合并验证试验结果正确性。结果表明,分层厚度为0.3 mm,打印速度为90 mm/s,喷嘴温度为220 ℃,填充角度为45 °/45 °时,FDM制件的力学性能最优。     

3D打印参数对柔性聚乳酸服装面料力学性能的影响

针对熔融沉积成型(FDM)3D打印技术,以柔性聚乳酸(PLA)为打印材料,探讨了分层厚度、打印速度、打印温度、填充角度以及填充密度对3D打印服装面料力学性能的影响。打印模型的力学性能以拉伸强度和弹性模量为评价标准,采用单因素、正交试验分析法得到最优打印参数。结果表明:当填充密度为20%、分层厚度为0.3 mm、打印温度为210℃、填充角度为45°、打印速度为80 mm/s时,打印制品的力学性能最佳。     

FDM工艺参数对聚乳酸/石墨烯复合材料制件弯曲性能的影响

为了提高聚乳酸(PLA)复合材料3D打印制件的性能,采用三因素三水平正交试验设计,研究了用熔融沉积成型(FDM)工艺3D打印PLA/石墨烯复合材料制件过程中,打印层高、填充密度以及构建取向对制件弯曲性能的影响。结果表明,石墨烯对PLA/石墨烯复合材料制件有较好增强效果,各试验参数对3D打印PLA/石墨烯复合材料制件弯曲强度的影响大小顺序为：构建取向>填充密度>层高,且当构建取向为侧立方式,填充密度为80%,层高为0.2 mm时,制件具有最佳的弯曲强度;对复合材料制件弯曲弹性模量的影响大小依次为：填充密度>层高>构建取向,且当构建取向为侧立,填充密度为80%,层高为0.1 mm时,制件具有最佳的弯曲弹性模量。     

3D打印工艺参数对PLA试件拉伸强度的影响

为了提高熔融沉积成型工艺打印件的力学性能以及减少打印时间成本,利用3ds Max三维建模软件,设计出打印力学试件的三维模型,结合单因素和正交试验分析,研究了填充角度、打印速度、打印温度、填充密度以及分层厚度对聚乳酸(PLA)试件拉伸强度的影响,并对试件拉伸强度进行测试。结果表明,各参数对3D打印PLA试件的影响大小为:填充密度分层厚度填充角度打印温度打印速度,且当打印分层厚度为0.3 mm,打印速度为80 mm/s,打印温度为210℃,填充密度为40%,填充角度为45°,试件具有最优的拉伸强度。     

3D打印工艺对木粉/聚乳酸材料性能的影响

采用熔融沉积法(FDM)3D打印工艺制作木粉(WF)与聚乳酸(PLA)质量比为3：100的WF/PLA复合材料,研究了打印工艺参数对WF/PLA复合材料力学性能的影响,确定了最佳打印工艺条件,然后,在最佳条件下,打印WF与PLA质量比为11：100的WF/PLA复合材料,并且,将该材料的性能与FDM 3D打印PLA试样进行了对比。结果表明,当打印层厚度为0.1 mm、打印温度为220℃、打印速度为50 mm/s、填充密度为100%、沉积角度为0时,WF/PLA复合材料的力学性能最佳。在该工艺条件下,WF与PLA质量比为11：100的WF/PLA复合材料的拉伸强度、拉伸模量、弯曲强度、弯曲模量和冲击强度分别为纯PLA的89.61%、97.56%、82.86%、92.40%和95.04%,与纯PLA相比,复合材料的表面润湿性能较好,吸水率显著增大。     

尼龙线材FDM成型质量优化研究

为提高尼龙线材熔融沉积(FDM)成型精度和拉伸性能，基于试验法和灰色关联模型研究确定了尼龙线材的FDM成型精度和拉伸性能的影响因素并进行了优化分析。以打印速度、层厚、喷嘴温度、热床温度与填充密度为因素变量，以Z向成型精度、拉伸强度等成型质量为优化目标，进行了正交试验，并基于灰色关联分析和熵权法进行了成型质量与其因素变量间的灰色关联综合评价。结果表明，各影响因素对成型精度的灰色关联度大小依次为层厚>填充密度>喷嘴温度>热床温度>打印速度，对拉伸性能的灰色关联度大小依次为填充密度>喷嘴温度>热床温度>层厚>打印速度，各因素对成型质量综合影响程度大小依次为：层厚、填充密度、喷嘴温度、热床温度和打印速度，最优工艺参数组合为打印速度60 mm/s,层厚0.15 mm,喷嘴温度250℃,热床温度100℃,填充密度100%。研究结果为提高尼龙线材的FDM成型质量提供了数据支持。     

熔融沉积3D打印工艺参数对圆弧制件轮廓精度的影响

采用正交试验设计,进行了圆弧弦长、成型角度、打印层厚、填充密度及打印速比五个工艺参数对熔融沉积3D打印圆弧制件轮廓精度的测试和结果分析,确定了轮廓精度影响程度由强到弱依次为:打印层厚＞圆弧弦长＞打印速比＞成型角度＞填充密度,其中打印层厚影响水平显著.在试验范围内,圆弧弦长8 mm,成型角度60°,打印层厚0.1 mm,...     

打印铺层结构及工艺参数对FDM构件力学性能的影响

为了获得性能优异的熔融沉积成型(FDM)构件,应用单轴拉伸试验,基于控制变量法,探讨了打印层厚、打印速度、打印温度等工艺参数及铺层结构对聚乳酸(PLA)试样力学性能的影响。结果表明,FDM打印方式会形成明显的层间界面,当承载方向与堆叠方向一致时,结构的承载能力最差;当铺层为±45°时,试样的弹性模量及拉伸强度达到最大值。且当打印层厚为0.3 mm,打印速度为默认值的70%,打印温度为230℃,可以获得相对最优的力学性能。     

基于正交试验的PETG/ABS复合制件熔融沉积成型工艺参数的优化

为了缩短熔融沉积成型(FDM)工艺的成型时间并改善产品的力学性能,采用FDM工艺方法对聚对苯二甲酸乙二醇-1,4-环己二甲醇酯(PETG)和丙烯腈-丁二烯-苯乙烯(ABS)两种线材进行3D打印,以成型时间、拉伸强度和拉伸弹性模量为优化指标,设计了基于正交试验法的三因素(打印速度、分层厚度、填充率)四水平的工艺参数优化方案。结果表明:PETG/ABS复合制件最优力学性能的参数组合是A4B1C3,即打印速度为30 mm/s、分层厚度为0.1 mm、填充率为75%。验证试验表明,拉伸强度为44.73 MPa、弹性模量为758.12 MPa、成型时间为113 min,优化参数后明显改善了力学性能,对双材料打印制品的生产具有一定的指导意义。     

3D打印零件的尺寸精度及控制

在大型零件的成形过程中，零件底部翘曲变形导致精度丧失是熔融沉积增材制造技术的一个突出问题。以熔融沉积成型（FDM）3D打印制件的底部翘曲变形为研究对象，建立了一种FDM翘曲变形的数学模型，通过标准正交试验设计研究喷嘴温度、分层厚度、托板温度、填充密度和堆积层数及断面长度对FDM 3D打印翘曲变形的影响，应用极差分析和方差分析得到了最优的工艺参数组合。研究结果表明，分层高度为0.2 mm，喷嘴温度为210℃，托板温度为55℃，填充率为40%，底层堆积层数为25层，断面长度为20 mm，此时翘曲变形量最小，为0.402 mm。对翘曲变形影响程度主次顺序为：分层厚度>堆积层数>喷嘴温度>断面长度>填充密度>托板温度。随着堆积层数的增加和断面长度的减小，翘曲变形量呈减小趋势。     

连续玻璃纤维增强PLA复合材料3D打印技术研究

以聚乳酸(PLA)为基体,连续玻璃纤维为增强体,采用熔融浸渍工艺制备连续玻璃纤维预浸丝,将制得的预浸丝作为3D打印耗材用于熔融沉积(FDM)的3D技术来制备连续玻璃纤维增强PLA复合材料试样,并研究了打印温度、层厚和打印速度对复合材料力学性能的影响。结果表明,当打印层厚为0. 5 mm,打印温度为230℃,打印速度为2 mm/s时,连续玻璃纤维增强PLA复合材料的弯曲性能最佳,弯曲强度和弯曲模量分别为327. 84 MPa和20. 293 GPa。综合考虑复合材料的力学性能、表面质量和尺寸稳定性,连续玻璃纤维增强PLA复合材料的最佳打印层厚为0. 5 mm,适宜的打印温度范围为200~220℃,打印速度范围为2~4 mm/s。     

Optimization of 3D printing parameters for high-performance biodegradable materials

Developing 3D printing high-performance biodegradable materials is important to protect the environment and deal with emergencies such as COVID-19. Fused deposition modeling (FDM), one of the 3D printing methods, has many advantages, such as low cost and wide range of materials. However, the weak interlayer adhesion is an important factor restricting the development of FDM. In addition to the influence of material properties, the optimization of 3D printing parameters is also an important means to give full play to the inherent properties of materials. The optimal 3D printing parameters are conducive to the diffusion and entanglement of molecular chains between adjacent layers. PLA/PBAT/PLA-g-GMA (70/30/10 wt%, PLA-g-GMA was a compatibilizer synthesized in our lab) was used as the research object. This work aims to analyze the mechanical properties response of biodegradable polymers products manufactured through FDM. Herein, the effect of 3D printing parameters including layer thickness, nozzle temperature, printing speed and platform temperature have been systematically investigated by orthogonal experimental design. The result showed that the excellent performance of 3D printing specimen was obtained when the layer thickness was 0.15 mm, the printing speed was 50 mm·s⁻¹, the nozzle temperature was 200°C and the platform temperature was 50°C. The SEM images showed that the optimal 3D printing products had the best interlayer adhesion and the lowest porosity. Undergoing optimization of 3D printing processing, the yield strength and elongation at break of specimen increased by 115% and 229%, respectively. In this paper, the interlayer adhesion and mechanical properties of 3D printing products can be significantly improved by simply optimizing the 3D printing parameters without complex material modification. This work provided a new method for improving the interlayer adhesion of FDM and the mechanical properties of FDM products.     

Study of processing parameters in fused deposition modeling based on mechanical properties of acrylonitrile‐butadiene‐styrene filament

Four processing parameters, layer thickness, printing speed, raster angle, and building orientation were investigated in terms of their effects on mechanical properties, surface quality, and microstructure of acrylonitrile‐butadiene‐styrene (ABS) samples in fused deposition modeling (FDM) by orthogonal experiments. The results show that both the building orientation and the printing layer thickness have a great influence on the mechanical properties of ABS specimens. When the layer thickness is 0.1 mm, samples printed in horizontal direction have the best mechanical performance. The vertical‐direction‐built parts generally have the worst tensile strength and impact resistance. Moreover, the layer surface quality of the products becomes worse with the increasing of layer thickness and printing speed. The influence of layer thickness on the roughness of FDM samples is still very significant. These researches are of great significance to explore the FDM molding mechanism and optimize processing parameters to meet the performance demands. POLYM. ENG. SCI., 59:120–128, 2019. © 2018 Society of Plastics Engineers     

Anisotropy of poly(lactic acid)/carbon fiber composites prepared by fused deposition modeling

It is well known that 3D printed parts prepared by fused deposition modeling (FDM) exhibit large anisotropy of mechanical properties. In this article, poly(lactic acid; PLA)/carbon fiber (CF) composites with different built orientations (X, Y, Z) were prepared by FDM. The effects of printing temperature, speed, orientations, and layer thickness on the mechanical properties of the composites were systematically investigated. The mechanical properties of PLA/CF composites show more significant anisotropy. The orientation of the fibers along the printing direction is displayed by scanning electron microscopy. Printing parameters bring almost no effect on mechanical properties of the X-construct oriented specimen, and bring obvious effect on those of the Y-construct oriented specimen and Z-construct oriented specimen. According to the analysis, carbon fiber can amplify this anisotropy from layer fashion, and the key factors from printing parameters are porosity and bond strength between fuses. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48786.     

FDM 3D打印塑件翘曲变形影响因素的研究

针对熔融沉积成型(FDM)工艺易产生翘曲变形的缺陷,建立翘曲变形数学模型,利用正交试验研究了分层厚度、打印温度、托板温度、产品壁厚4个因素对打印试样翘曲变形的影响程度与趋势。结果表明,实验结果与数学模型相印证,得出分层厚度对翘曲变形影响程度最大,打印温度次之,托板温度与产品壁厚影响较小。通过优化FDM成型工艺参数,使打印精度提高了44.4 %,提高效果显著。     

芳纶增强复合材料波纹夹层3D打印与力学性能研究

为解决波纹夹层结构传统制备方法存在的问题,采用熔融沉积(FDM)3D打印技术制备芳纶增强聚乳酸复合材料波纹夹层结构,并研究切片层高与打印温度对波纹夹层结构力学性能的影响。结果表明:当试样的切片层高为0.1 mm,打印温度为210℃时,复合材料波纹夹层结构的力学性能最好;试样的弯曲强度和冲击强度与切片层高呈负相关;随着打印温度的升高,试样的弯曲强度和冲击强度呈现先增大后减小的趋势。通过分析复合材料电镜图发现,切片层高的降低,有利于芳纶与聚乳酸基体的结合。     

3D打印成型工艺及其应用研究

从增材制造的实现原理出发,分析了当前几种主流三维（3D）成型工艺的技术特点、设备原理及实现流程。以工业级3D打印机为研究平台,将熔融沉积成型（FDM）工艺应用于复杂型腔结构和传动组件结构的快速成型,通过3D建模、数据转化、切片处理、工艺参数选择、模型包计算及工艺后处理等一系列环节的实践探索,明确了FDM成型工艺的技术原理与应用流程,并成功制作了丙烯腈丁二烯苯乙烯共聚物（ABS）材质的3D打印模型。结果表明,复杂型腔零件切片厚度为0.254 mm、传动组件切片厚度为0.178 mm时,3D成型件具有理想的工艺精度和打印效率。     

Fused Deposition Modeling of Polyolefins: Challenges and Opportunities

Polyolefins are the largest class of commercially available synthetic polymers that are extensively used in a variety of applications from commodities to engineering owing to their low cost of production, good physico-mechanical properties, light weight, good processability, and recyclability. Compared to conventional molding techniques, fused deposition modeling (FDM)-based 3D printing is a smart manufacturing technology for thermoplastics due to its low cost, ease of production of complex geometrical parts, rapid prototyping, and scalable customization. FDM 3D printing can be an ideal manufacturing technology for polyolefins to manufacture various complex parts. However, FDM 3D-printing of polyolefins is challenged bycritical printing problems like high warpage, dimensional inaccuracies, poor bed adhesion, and poor layer-to-layer adhesion. In this review, a fundamental understanding of polyolefins and their FDM 3D-printing process is established, and the recent progress of FDM 3D printing of polyolefins is summarized. Furthermore, strategies to overcome warpage and to improve mechanical strength of the 3D-printed polyolefins are provided. Finally, future prospectives of FDM 3D-printing of polyolefins are critically discussed to inspire prospective research in this field. It is believed that this review article can be tremendously useful for research work related to FDM of polyolefin-based materials.     

3D-printed polymer packing structures: Uniformity of morphology and mechanical properties via microprocessing conditions

Three-dimensional (3D) printing is an attractive approach to fabricate highly porous extremely lightweight structures for architecture antivibrational packaging. We report 3D printing processing of model packaging structures using biodegradable poly(lactic acid) (PLA) as a source material, with acrylonitrile butadiene styrene (ABS) utilized as a common 3D printing source material as a traditional benchmarked material. The effects of printing temperature, speed, and layer morphology on the layer-by-layer 3D-printed structures and their mechanical properties were considered. Three different characteristic morphologies were identified based on printing temperature; the microscopic surface roughness was dependent on the printing speed and layer height. We demonstrate that the mechanical performances and surface properties of 3D-printed PLA structures could be improved by optimization of printing conditions. Specifically, we evaluate that these PLA-based 3D structures printed exhibited better surface qualities and enhanced mechanical performance than traditional ABS-based structures. Results showed that the PLA-based 3D structures possessed the favorable mechanical performance with 34% higher Young's modulus and 23% higher tensile strength in comparison to the ABS-based 3D structures. This study provides guidelines for achieving high-quality 3D-printed lightweight structures, including smooth surfaces and durable mechanical properties, and serves as a framework to create biodegradable 3D-printed parts for human use.     

Adhesive bonding of 3D-printed ABS parts and wood

Additive manufacturing, also known as 3D printing technology, has experienced massive growth in the last decade. Instead of printing the entire product, 3D printing can be used to produce only the most complex parts, which are then combined with simple, non-printed parts from other materials to make the final product. In addition to mechanical connections, adhesive bonding is most commonly used to combine printed parts with other elements. In this study, the influence of 3D-printing parameters on the bond shear strength of 3D-printed Acrylonitrile-butadiene-styrene copolymer parts bonded to beech wood was investigated. Three printing settings with different layer thicknesses (0.39, 0.19, 0.09 mm) and a posttreatment method that utilized acetone vapour were used. The three different adhesives applied were commercial one-component polyurethane adhesive, hot melt adhesive for edge bonding, and a two-component polyurethane adhesive. The results show that the type of adhesive had the biggest influence on the strength of the bond. The highest bond strength was achieved using a two-component polyurethane adhesive. The type of failure (failure in wood, plastic, adhesive, or cohesive failure) depended greatly on the type of adhesive and thickness of the printed layer.