Cargando…

Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing

Metal 3D-printed parts are critical in industries such as biomedical, surgery, and prosthetics to create tailored components for patients, but the costs associated with traditional metal additive manufacturing (AM) techniques are typically prohibitive. To overcome this disadvantage, more cost-effect...

Descripción completa

Detalles Bibliográficos
Autores principales: Tosto, Claudio, Tirillò, Jacopo, Sarasini, Fabrizio, Sergi, Claudia, Cicala, Gianluca
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9412894/
https://www.ncbi.nlm.nih.gov/pubmed/36015518
http://dx.doi.org/10.3390/polym14163264
_version_ 1784775604870053888
author Tosto, Claudio
Tirillò, Jacopo
Sarasini, Fabrizio
Sergi, Claudia
Cicala, Gianluca
author_facet Tosto, Claudio
Tirillò, Jacopo
Sarasini, Fabrizio
Sergi, Claudia
Cicala, Gianluca
author_sort Tosto, Claudio
collection PubMed
description Metal 3D-printed parts are critical in industries such as biomedical, surgery, and prosthetics to create tailored components for patients, but the costs associated with traditional metal additive manufacturing (AM) techniques are typically prohibitive. To overcome this disadvantage, more cost-effective manufacturing processes are needed, and a good approach is to combine fused deposition modeling (FDM) with debinding-sintering processes. Furthermore, optimizing the printing parameters is required to improve material density and mechanical performance. The design of experiment (DoE) technique was used to evaluate the impact of three printing factors, namely nozzle temperature, layer thickness, and flow rate, on the tensile and bending properties of sintered 316L stainless steel in this study. Green and sintered samples were morphologically and physically characterized after printing, and the optimal printing settings were determined by statistical analysis, which included the surface response technique. The mechanical properties of the specimens increased as the flow rate and layer thickness increased and the nozzle temperature decreased. The optimized printing parameters for the ranges used in this study include 110% flow rate, 140 μm layer thickness, and 240 °C nozzle temperature, which resulted in sintered parts with a tensile strength of 513 MPa and an elongation at break of about 60%.
format Online
Article
Text
id pubmed-9412894
institution National Center for Biotechnology Information
language English
publishDate 2022
publisher MDPI
record_format MEDLINE/PubMed
spelling pubmed-94128942022-08-27 Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing Tosto, Claudio Tirillò, Jacopo Sarasini, Fabrizio Sergi, Claudia Cicala, Gianluca Polymers (Basel) Article Metal 3D-printed parts are critical in industries such as biomedical, surgery, and prosthetics to create tailored components for patients, but the costs associated with traditional metal additive manufacturing (AM) techniques are typically prohibitive. To overcome this disadvantage, more cost-effective manufacturing processes are needed, and a good approach is to combine fused deposition modeling (FDM) with debinding-sintering processes. Furthermore, optimizing the printing parameters is required to improve material density and mechanical performance. The design of experiment (DoE) technique was used to evaluate the impact of three printing factors, namely nozzle temperature, layer thickness, and flow rate, on the tensile and bending properties of sintered 316L stainless steel in this study. Green and sintered samples were morphologically and physically characterized after printing, and the optimal printing settings were determined by statistical analysis, which included the surface response technique. The mechanical properties of the specimens increased as the flow rate and layer thickness increased and the nozzle temperature decreased. The optimized printing parameters for the ranges used in this study include 110% flow rate, 140 μm layer thickness, and 240 °C nozzle temperature, which resulted in sintered parts with a tensile strength of 513 MPa and an elongation at break of about 60%. MDPI 2022-08-10 /pmc/articles/PMC9412894/ /pubmed/36015518 http://dx.doi.org/10.3390/polym14163264 Text en © 2022 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Tosto, Claudio
Tirillò, Jacopo
Sarasini, Fabrizio
Sergi, Claudia
Cicala, Gianluca
Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing
title Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing
title_full Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing
title_fullStr Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing
title_full_unstemmed Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing
title_short Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing
title_sort fused deposition modeling parameter optimization for cost-effective metal part printing
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9412894/
https://www.ncbi.nlm.nih.gov/pubmed/36015518
http://dx.doi.org/10.3390/polym14163264
work_keys_str_mv AT tostoclaudio fuseddepositionmodelingparameteroptimizationforcosteffectivemetalpartprinting
AT tirillojacopo fuseddepositionmodelingparameteroptimizationforcosteffectivemetalpartprinting
AT sarasinifabrizio fuseddepositionmodelingparameteroptimizationforcosteffectivemetalpartprinting
AT sergiclaudia fuseddepositionmodelingparameteroptimizationforcosteffectivemetalpartprinting
AT cicalagianluca fuseddepositionmodelingparameteroptimizationforcosteffectivemetalpartprinting