Optimizing Fused Deposition Modeling (FDM) Performance: A Comprehensive Essay.

1 Continuing review of existing literature in the relevant area and draw relevance to the proposed research project.
2 Execute a prepared research plan using appropriate methodologies.
3 Analyse and evaluate research findings to achieve intended project outcomes.
4 Write technical documents on ideas, concepts, arguments and conclusions professionally.
5 Communicate research results at a professional level through an oral presentation.

Introduction to Fused Deposition Modeling (FDM) technology

To optimize the performance of the FDM by finding the best suited Bed temperature which gives higher shape accuracy.  To find the optimum bed temperatures among the selected five temperatures by both practically as well as analytically. For this purpose we use a solid works software for developing the 3-D model, ANSYS for the simulation works.

3-D printer which mean merging of materials and to obtain 3-D view with help of monitor. This printer are used for quick fabricate and additive manufacturing. The object should be in different shape or structure are developed by using digital modal or additive manufacturing file. Before 10year 3-D printer are achieving in different way and now it is good to making prototype for different metal and plastic materials. Thermo plastics are advanced technology in 3-D printer and used for develop plastics by injection mold process.

In 1996 3-D printer are used to manufacturing plastic resin and it is highly accuracy. The FDM printer are widely used in company to manufacture PLA and ABS resin parts. The main process of the printer is to combine the binding substance and material.  And to deposit into printer one by one layer and then by using CAD software 3-D printer models are developed. It is one of the innovative machinery and due to enormous potential in manufacturing process & inventive concept it is developed recently. It also create three dimensional objects due to presence of incomparable device. The object should be coated after the object is manufactured and then only complete object is formed. The coating is finely object should be horizontally shared to form final product and that is essential to make the printer.

It is work on condition of additive manufacturing. The material has to be placed down in layer and layer are combined to become the base layer. In market printing process can be done by using thermoplastic ink.  This polymer having flexible temperature range and it is very soft, after processing it can be re-solidify and permit to cool.

From the above diagram we clearly known about that object is printed in print bed portion and is fully enclosed with epoxy resin material. Temperature should managed manually, depend upon object.

The microcontroller is used to control the nozzle and it engaged by command in print file. Certain printer necessity the USB port to declaim the file. The amount of ink and nozzle direction X, Y, Z organizes these all arranging by microcontroller. 3-D deliver high accuracy but less waste material.

History of 3D Printing and Fused Deposition Modeling (FDM)

The nozzle direction and amount of ink this message received from print file and they having various format to use. In old fashioned CAD system is used to create file, but now new designer, new scanner are available. The file can be converted into established format and it take much more time for modify, dividing the data. The translation of file format only occur in software program like blender, 3-D creation suite.

In chuck hull’s printer used to create only stereo lithography format and it support single extruder of layering process. When new printer create then open source and branded is developed. In two thousand fifteen the main objective is regulate 3-D print file, so 3-D manufacturing format was declared and it support in 3-D manufacturing format consortium.

There are different technique available in printing in that fused deposition modelling is a rapid prototyping. Now days it very well improved all around the world and using every field for reducing the waste material. The model construction in modern method that engaged anyplace and is finish should be according to the selecting methods and difficulty of model. The nozzle usually undertakes the heat so the material is melt and it is move in flat and also vertically by numerical controller.

‘Ala’aldinAlafaghani’ (2017) who studied about the various process parameters involved in the FDM method, they decides the final output quality of the project. He does the eighteen number of experiments in FDM method by changing the process parameters. And further tests are carried out in this method.

‘B.D. Parmar’ (2015) who studied the performance characteristics of the component produced by the FDM process and the factors which affects the accuracy of the final component size. Based on his work he conclude that the final component size depends on the various factors like the nozzle tip radius, temperature, etc.

‘Florent Le Bourhis’ (2013) who studied about the environmental aspects of the FDM technique. His study deals with the parameters which affects the final output and the environment. Based on his study he conclude that there are three set of parameters which is responsible for the final results. And they are material used in the technique, liquid used, and electrical power consumed by the process.

‘Ing. Andreas Gebhardt’ (2016) who studied about the basic 3-D printing technology evaluations, and its importance in various field of engineering and medicine etc. From his work we can get a knowledge about the outline of 3-D printing methods.

Working Principle of Fused Deposition Modeling (FDM)

‘KUMAR SINGH’ (2016) who studied about the FDM technique and how to improve the performance of this method. And finally he concludes that the quality of output was enhanced by the metal processing.

‘Nyeonsik Choi’ (2018) who studied about the environmental factors involved in the FDM technique which is used to increase dimensional precision of the finished component. From his research he conclude that the bed temperature of the FDM impacts the dimensional precision of the finished output.

‘Sheetal Ajit Chavan’ (2017) who studied the relation between the various process factor and the final mechanical properties of the product created by the FDM method. Based on his work he concludes that the mechanical properties of the finished product depends on the various process factors temperature, nozzle radius, etc.

‘Syed Hasan Masood’ (2016) who studied about the key parameters that have an impact on the final output of 3-D printing technique. Based on his work he conclude that there are various parameters involved in the FDM process. He said that there are six parameters play the very crucial role in the FDM process. And they are Deposit thickness, Air holes, Raster position, Shape positioning, Path breadth, and No of silhouettes. Finally he do the ANOVA system for identifying the major factors among the six parameters before stated. In the above six only three parameters plays an important role. And the optimum value the deposit thickness identified from his work was 0.3302 mile meter (mm), Air hole size and the raster position was taken as a zero. This is the extract we got from his work.

‘V. K. Srivastava’ (2017) who studied about the various methods involved in the 3-D printing technique. From his work he would conclude that 3-D printers are play the vital role in the area of additive manufacturing and prototyping.

‘Young-Hyu Choi’ (2016) who studied the optimization method of the FDM process output and dimensional precision. Based on his study identified that the bed temperature of the FDM process impacts the final shape precision of the output produced by the FDM process. During his work he test the dimensional properties of the output for various bed temperatures.

‘ZixiangWeng’ (2016) who carried out his work in analyzing of thermal properties of the ABS material used in FDM technique. From his work he concludes that the addition of OMMT with (Organo Montmorillonite) gives the higher accuracy outputs.

First 3-D printer was developed by the Charles Chuck during 19^th century. This work was the mile stone in the evaluation of this technology. That creates a revolution in the production activities. That reduces the complications in the process of making the prototype in a company. That makes the prototype making as a fastest process. In 3-D printing technology the polymer wire was heated very perfectly and send to the nozzle. Then it forms the high precision layer of the polymer material. It was patented on nineteen eighty nine.

Factors Affecting the Performance of Fused Deposition Modeling (FDM)

Bower found and implement the new strategy named Rep Rep, here any one can improve the design of 3-D printer based on his own interest. Strategically this move gives the higher returns for him. EPSRC founded this project. They created their first machine named as Darwin and they released it in the year of Mar-2007. Second version was called as mendel released on two thousand nine. After 2010 the 3-D printing technology start to growth tremendously because of the decision of open sourcing. During the 2010 it is surpassed by the Maker Bot Thing-O- Matic. Wooden parts and LASER cut with parts are 3-D printed parts, some electrical parts are combined to make the most versatile machine that having the capability of additive manufacturing. Here the FDM technique gives more flexibility in the manufacturing a prototype other than all other existing techniques. So it plays a very huge market value than other 3-D printing machine tools.

There are various 3-D printing technologies are available, selection is based on the purpose and method which is used for printing and cost of the printers. Here there are six common types of 3-D printers are available and its mechanisms of the printers and methods for the printing purposes used are clearly explained below,

• Powder bed
• Laminated
• Light polymerized
• Powder bed
• Extrusion
• Wire

In this process the object can be viewed as digital data with help of CAD. And the process start here to fill the powder bed with the help of starch and gypsum plaster, the plaster activated by the liquid “binder” mostly using the water. The binder needs dye and add some additives to modify viscosity, surface, tension, and boiling point to relate print head specifications. Finally plaster parts specifically lack “green strength” and need infiltration by melted wax, epoxy, cyanoacrylate glue, etc. before usual handling. Different other powder-binder collaboration may be used to form objects by mechanical means or chemical. And the final part may be subjected to variant post-processing regimes like infiltration or bakeout. At the end model is finished the non-useful powder can be taken out by machine or man, this remove process is known as de-powdering process. Here various technologies are used they are

• Selective laser sintering
• Direct metal laser sintering
• Selective laser melting
• Selective heat sintering
• Electron beam melting
• Powder bed and inkjet head 3-D printing

This one of the 3D printing technology and uses the powdered materials to create 3D prints, This system uses a high-powered CO2 laser to break small particles of atomic material to develop 3 dimensional parts. The laser take the atomic particles selectively by scaning X&Y cross-sections on the surface of a powder bed.

Latest Trends and Developments in Fused Deposition Modeling (FDM)

It uses complex geometries which is not possible with other metal manufacturing methods. This is one of the direct metal laser melting. And it parts are stronger and denser than other metal parts then they can help to market first with faster turnaround times. It may allow to design the metals like aluminum or titanium. It not uses filament to printing, the 3D printed parts are manufactured from very good, granular Aluminum or Titanium powder.

The selective laser melting is a tool less construction process for metallic Material and it may be generative or additive. In SLM the metal which is processed is applied in powder form in a small and very thin layer on a build plate. The melting can be done by using the high-energy fiber laser, and the fine metal is in the form of powder. All of the components is done by using layer by layer.    

It is a fast and cost effective way to 3D print, here sheets are weld together and cut in the right geometry according to 3D model. These method is continuous prototyping system and is introduced by helisys. In these method object can printed in modified drilling or machining at the end of work. Laminated 3D printings are mostly used for the purpose of prototyping, and not for the production purpose. The major principle behind the laminated printing is coating, melting, and glue. In other words the materials are coated in the adhesive layer then the feeding roller warm the adhesive to melt it. And the layer is joined using glues. A laser or blade can be used to draw object geometry and build the crosses on the rest of the surface to finalize the object.    In this technique small area can be traced by laser and material used in this method are paper, plastic film and metal foil. The technology used here is laminated object manufacture.

In the method laser beam is exposed when plastic liquid is fall in light, when expose liquid change into solid with help of light beam. Here photopolymer, metal alloy, powdered polymer are used. In this process six technology are used,

• Stereo lithography
• Digital light processing
• Continuous liquid interface production

This is also known as stereo lithography apparatus, photo-solidification or resin printing, optical fabrication. It is one of the 3D printing technology commonly used for creating models, patterns, prototypes and part production inside a layer by using layer fashion used by the photo polymerization, and it is a process by which light causes molecules chain as a link and form the polymer.

Optimizing the Performance of Fused Deposition Modeling (FDM)

This technology is based on the optical micro-electro-mechanical. It is a display device uses a digital micro mirror device. And it was found by Larrry Homebeck in 1987. The working principles of DLP is created by microscopically small mirrors used out in a form of matrix on a semiconductor chip. The pixel are displayed in the mirror and the view of image is on the display, then the assumption about the image can be produced.

CLIP is a method of 3D printing to create smooth-sided solid objects of shapes using resins. And the mechanism behind CLIP is photo polymerization. The process start at the stage of liquid pool photopolymer resin. Then the pool bottom is transparent to ultraviolet light. An UV beam shines through the window, of the object. An oxygen membrane lies below resin, which makes a zone that is called “dead zone” used to prevent the resin from attacks on the window.

This technique used for 3-D object for a ceramics, glass but not famous for that. In the printer wire supply is connected with head and it can be able to adjust in various axis. By using high power radiation melt the necessary wire with help of laser beam projector. It similar to extrusion process but here nozzle supply is in different direction. The feed rate is used control the modal shape. Material used in this method is metal alloy here direct energy deposition techniques is used.

In this method the object can be develop cross sectional and this process is finished by warm and cold both condition. The materials used in this process are ceramic, metal, polymer, rubber. The necessary object is warmed and then it fit into the vessel in press. The fake vessel is placed ahead it. And material can by pressed by push, if want enhanced possessions by using a hotness treated. Technology used in this process are

• Fused filament manufacture
• Direct ink writing
• Composite filament construction

This is a 3D printing technology, and using the mechanism of continuous filament of a thermoplastic material. This process starts from fed a coil using a large coil via a moving, heated printer extruder head. And the head is moved under the control of a computer and we can design the shape using the computer.

The direct ink writing otherwise known as Robocasting is a method of extrusion manufacturing additive method, and highly used in meso and micro-scales. The small nozzles is in controlled flow rates and deposited along a well-defined paths to fabricate shapes. This technology was deployed in US in 1995 as a procedure to allow geometrically complex green bodies to be made by the add-on manufacturing. Here a 3D model is segmented into many layers and a fluid commonly known as ink is extruded via a small nozzle as the nozzle’s position os controlled, then draw the shape of every layers which is in the model of CAD. The ink enters into the nozzle in a liquid state but retains its shape suddenly, exploiting the rheological that is the property of shear thinning.

Conclusion

 Here the 3D printing process are divided into two categories that is Fused Deposition Modelling and Selective Laser Sintering. While printing process the functional parts using carbon fiber-reinforced materials as feedstock.

In this method by using of CAD to manufacture a near-net-shape. The machining instruction can be done by support processor to essential cutting instrument pathway for making a portion. In this method use very less amount of natural resource and to complete the machining by old-style work approaches. The material used in this process are iron compound. The technology used in this method is electron ray freeform construction.

Software’s are widely used in 3-D printers to instruct them. Basically the software they are used in 3-D printing technique was classified into 3 types based on its functions. And they are

• CAD software
• CAM Software
• Printer Control Software

CAD Software - They are used to make the initial computer design of the component to be produced.

CAM Software – They are used to make the control commands of the various moving parts in the printer.

Printer Control Software – They are used to control the printer’s components like feed rate of the material, temperature and some other parameters.

Example for the various soft wares

In the area of 3-D printing technology the first and foremost function was develop a 3-D model of the product to be produced. That process was done by the help of the software tools. They are known as 3-D modeling soft wares. They have an options to extrude and revolve the       2-D object. These are the basic ways to convert the 2-D design into 3-D design. That helps to visualize the final output without creating it. Here also we can render the object developed by the software. For this purpose there are many soft wares are available in the market here we would see about the mostly used software throughout the world.   

This one of the 3-D modeling software widely used for 3-D printing applications. This software gives higher precision work. In this software also we can able to make company logo design. That is available as a free software. But it also have its premium versions. On those versions we can access many tools. It has a simple and effective user interface. There are huge tutorials are also available on the internet. By using this software we can making the interior designs simply. This software also available in the VR devices. That is much easier for the presentation works.

References

It was online based 3-D modeling software. So we can use this software through online. By using those software we can able to create simple designs like basic shapes. It has a great tutorials, they made this software easy. The format changing also possible in this software. That has online library of tones of shapes, so user can simply able to use this template. It suits for beginning learners. Here the user can retrieve the shape from the online. Then the user can alternate this file based on his requirement.

It is also one of the free software widely used. Here user can able to create the design with variety of shape and size. There is no hidden charges are there in this software. This available as open source software. But we can’t use this software for professional purpose. It is only used for training purpose. It has all the basic features.

This is little bit higher version than above seen soft wares. Because it has a higher functional properties. In this software a higher performance tools are learned quickly. This software helps to design the complicated architectural designs. It has a free version as well as premium version.

This is the mostly used 3-D modeling software in the industry. This is a registered product of DSS. This software contains bunch of features like in built simulation and reverse engineering. We can buy solid works software in a customized product. Where we can adjust the features based on our requirements. By using this software we can produce a detailed curves in the design with the aid of “nurbs”. By using this software we can make a resizing operation simply.

That was a product of world’s best 3-D modeling software provider. They provide the large no variety of software versions. This also works by the “nurbs” system so we can create the higher detailed shapes in the diagram. By using this software we can make the complex shapes and structures. But this also has some difficulties. This one of the most functional software loaded with bunch of features. But the user interaction was not too good.

This software was developed by the Autodesk. That is mostly used in industries because of its loaded features. This allows a user to perform simulating operations. They respond the user feedback in a very good manner. This software loaded with the variety of tools. The most important feature was it allows to view the design developed by another software. Here conversion work not necessary. So unaccounted losses are rectified.

This mostly used for animating purpose by the animators. This software provides the higher capability during the surface modeling. Even though it was an animation software it is also capable of doing 3-D printing design. They are best suited for the artistic works like sculpting. That contains the finest rendering feature. But the cost of this software was too high.

This also mostly used for animating purpose. But it has the capability to use as the 3-D modeling software. Here we can able to perform the shading operation. But the limitation is we can’t use this software in Linux based OS or IOS. It only suited for windows based computers. Most of the game makers are use this software. 

This one of the well-known 3-D modeling software. Here we can simply perform the slicing operations for 3-D printers. It has the higher capability at the same time it is available as a free software.

This the latest software in its era. By using this software we can work from different places. Because it was cloud centered software. So the various teams can work on the similar project. We can also able to back up the design in the cloud disk. This software available in market for monthly rental method.

Except the modeling software the slicing software also play the vital roles. Here the software slices the various layers in the developed 3-D modeling. This software converts the design created into multiple layers. These layers are then converted into G codes for the controlling the 3-D printers. It also provides the feature for enter the values for the working parameters like layer thickness, Nozzle temperature, speed of the work progress.

Net Fabb was the most powerful slicing software. The professional version of the software was available in the market with loaded features. That also analyze the STL files during the initial stage. Also the free trial version available on the market, that is useful for the learners.

This one of the slicing software used for 3-D printing operations. It was available as an open source format. It has the three slicing engines. And they are Skeinforge Repetier, Slic3r, and Cura Engine. It is capable of operating sixteen extruders with different operating conditions at the same time. The main advantage of this software was easy visualization of the final output printed by the 3-D printer. This gives an option to customize the software based on our needs. So the that is mostly used by the experts.

This the professional level software used for slicing operations. That has the auto correction option that is used to remove the flaws in the design and give the most suited solutions. That software increase the final quality of the print produced by the 3-D printers. In this software we can visualize the each and every stage of the work. But the initial cost must send by the person who need to use the 3-D printer. So this widely used in the advanced process like R&D operations and pattern making operations etc.

This the open source software which loaded with many features. This software allows the user to use incremental slice making on the real time, 3-D visualization. Most of the persons they use the software for 3-D printing operations. It has the fast processing engine. Higher precision results are obtained from the software.

This is the most widely used software by the beginners. But it also provides the advanced features. They are used whenever it necessary. It is available as an open source software.

This also a beginning level slicing software having the simple and functional user interface. It has the most efficient engine for converting the 3-D model into G Code.  It also contains the efficient visualizing feature.

This is the most basic slicing software. It only having the very basic user interface which is quite simple for the beginners.  Even though it can produce the high quality results. The basic version of this software only having the minimum features. Also premium versions also available. By using the basic software we can use only single head machines. For using the multi head machines we can need premium versions.

This also most widely used slicing software. It has the efficient engine to perform the slicing work. This is used on many 3-D printing machines.

This is the code conversion tool used for converting the STL file into G codes. It is outdated software because of the speed and features given by the other new soft wares.

3-D Printer OS was a cloud based slicing software. It used for all the process involved in the 3-D printing technology. Here user can able to rework on the design created. Also sharing the files features are loaded on this software.

In the 3-D printing technology that have a large variety of materials are available in the market. We have to select the best material which is fit for our use. Before selecting the material we have to learn about the materials used in this technology. In this technology polymers are widely used because it has the properties best suited for this technology. Here we would see about the various materials sued in this technology.

ABS was one kind of polymer most suited for Fused Deposition Modeling. The main application of this material was making for cellphone covers, house hold things, and automobile body parts. This material get soft while heating because of its thermoplastic behavior. It is capable of absorbing vibrations. It has higher flexibility nature. In fused deposition modeling process its temperature was exited to 230 °C - 260 °C.  It has higher toughness so it can be used below -15 °C and above 70 °C. It can be recyclable. In this material was permanent joints was made by the chemicals. This material was non-biodegradable. It start to shrink when it is exposed to the atmosphere. This is also available in molten form it is also used in some printing techniques. It available in the form of wire wounded on the reel. The use of this material was too easy. And consider this material in economic aspect it is fairly cheap material. It has a higher stiffness and tensile properties. That is in white color in when it was created in lab but it starts to become yellow due to oxidation process.

Merits of using Acrylonitrile Butadiene Styrene 

It has the tendency to form the shape easily when it heated to super heating temperature.

The shape produced by this material has higher accuracy in shape.

It has higher strength so widely used in automobile parts manufacturing.

This a decomposable plastic material. So it was ecofriendly material. It is made from the sources which are created from natural resources like maze. The process of working on this material was simple. It has tendency to contract, so we need to consider that while creating the CAD model. This material doesn’t require the heated plate (base plate for printing). The operating temperature of this material was lower than the operating temperature of ABS. and the value is 190.00 °C to 230.00 °C. It has higher solidification rate, so it requires fast operating. And also it start to lose its strength when exposed to atmosphere. It has a higher consistency. It is available in large no of colors, so we have an option to choose the color.

It is also called as ASA. Its mechanical properties are like ABS. But it has a tendency to with stand outer light conditions because of its higher Ultra Violate resistivity. It also requires the bed has a heat similar to Acrylonitrile Butadiene Styrene to avoid deforming. The printing strategy and methods are same as that Acrylonitrile Butadiene Styrene. During the molten state it emits the styrene, so the printing chamber must be enclosed with shield.

PET was a type of polymer widely used for making the use and throw cans. It is most suited material in the making of element related to food safety and conservations. It has higher degree of resistivity against the various chemicals. And it has the very lower operating temperature and the value is seventy five to ninety degree Celsius. It available in the form of wires wounded in the reel. It has a many other sub classifications within it. It is mostly recycled after every use because of its cent percent recycle nature. And it also doesn’t emit any smell during the process.

This is one of the material commonly used in engineering uses. Because it have more resistance to ductile and buckling process.  Its thermal resistivity was too good. But the problem with this material was it is capable of absorbing water vapor present in the atmosphere. So this material need some conservations like preserve it in closed containers. But it has some limitations while used as a filler material in printing like higher melting point.

These are the advanced synthetic materials used in printing process. By using this we can able to produce products which readily change its shape during the application of some external forces. So they are widely used by the stylists for making the synthetic mask used in movies.

This material which has a very high specific strength. So the product made by this material has very high strength products at lower weight. This are made by the very lean fiber of carbon added with some base material. Those base material may be the above stated polymers. This is called as the composite wire of carbon fiber and some other base materials. But the problem in this material was its clogging property, so it requires the special type of nozzle.

Hybrid materials are also composite materials which has the combination of both Polylactic acid with some other precipitates. Natural fiber also used in this material. The material has a high strength so it is widely used in the applications which requires high strength. They gives the different texture for the parts made by this material.

The name that explains the nature of the material. Yes it can dissolved when it requires. It is used for the applications like core making in mold, and pattern making for special purpose molding process.

This material which are fabricated from the powdered form of the polyamides. . It has the higher bio compatibility. So they are used to produce the products they need to interact the edibles.  But it is soluble in alcohol. So can’t use this for making the product that should be make a contact with alcohol.  For making the engineering products like gears high quality polyamides should be used.

They were produced by mixing the polyamides with the Al particles. It has a higher mechanical properties and thermal properties. They are preferred in the application that needs the same look like Al. but it has some limitations.

It is also a thermally expanding and contracting plastic. That is a most common material preferred to making the automobile parts, basic house hold products. It starts to expand when exposed to Ultra Violate rays.

As already said there are many method are available for the 3-D printing operation. So the choosing of the correct process for current requirement was very crucial process. and also it requires an expert to take the decisions. There are many selection strategy was followed by the industrial persons. Here we would see about the most common strategy, and that was selection based on the materials. Now we would see the selection of different process based on the different materials.

For this material mostly the FDM process was used. Sometimes the SLS technique also used. SLS gives the best quality in the end product. But the production cost of this method was relatively high. So we use this method wherever we need the highest quality output. Otherwise we simply use the FDM method. That is economically viable.

For this kind of material the best suited method was Material Jetting SLA/ DLP. These methods are mostly used wherever the highest aesthetic output are required.  The product produced by this method has higher stiffness. And good mechanical projects.

For metals the most suited method was Binder Jetting and DMLS/ SLM. Where the binder jetting was used wherever the cost would be considered. Because it has lower operating price when compared to the other methods. But DMLS/ SLM has the superior mechanical characteristics.

Using of 3D printing several benefits are °Ccur in businesses and also in individual way. Here 3D printer benefits are provides,

The injection mold and subtractive production are popular in developing field before 3D printer creation. After that it’s processing is fast than other system. For example compare the speed between the car and horse, their speed is dissimilar. The conservative developed process can combine in both technology, 3D printing finishing the designing work and test within days not several weeks.

The failure of design simply °Ccur in old fashioned methods and that become poor quality also. For example in manufacturing company to prepare a cake microvan with mixture of all ingredients. If did not mix well some problem °Ccur that is air fizz and that not satisfies the customer so it become failure. Similarly same problem °Ccur in injection mold so 3D printer is used. It allow procedure in step by step for the object manufacturing and it produce good quality product.

The costly molding tool is very difficult for verified by the designer in product manufacturing field. So this printing technology is very useful for designer to verifying the costly mold tool and also prototype of the product without any risky factor. These technology is actually fast then you imagine concept and product developed in cheaply.

The 3D printer proved as vigor efficient technology and it have competence of provided that good environment according to the process manufacturing. It produce only less amount of waste, so it become environmental friendly. It does not have any harmful to the environment pollution   

In modern technology the part and organ of the humanoid is manufactured this process is called as bioprinting. Until now it is experimental processing only, not have authority to implement. This technology is not only manufacturing organ and also elimination of organ which is made of only for unique character patients.

3-D printing technology has more advantages at the same time it also have some limitations in the process. We discus about the various limitations in the process.

• Physical Size
• Minimum wall thickness
• Water tightness
• Surface Curviness

Physical Size

Physical size of the product was the main parameter considered in the 3-D printing. Due to the limited size of the printing machine we can able to make some limitations in the physical size. If the required size was larger than the capacity of the printer we can make those parts into some small parts then we need to join as the single part.

Minimum Wall Thickness

For 3-D printing the component must have some minimum thickness of the wall. Without this thickness that is not possible to a product by this method. That minimum size varies with the various method of printing.

Surface Curviness

The curve shapes produced by this technology was not a true curve. We can able to create a hollow curvy surface using this technique. This is the limitation of this method.

In Industrial Prototyping 3-d Printer Is used for rapid manufacturing process and which is agree various product in iteration for quickly access the solution in optimum. It applicable for a saving money and time as planning of product development and create assurance gaining of tooling in production. The improvement and expansion of the process and material. With use of this printer it reduce the transportation cost also because of it widely spread around the world. The last operation take place comparable way in manufacturing, simple acceptance of the continued improvement process. In 3-D printing the production is take place in direct and fast manner which allows to complete the product easy and very fast. Application °Ccur various manner that explained below,

In this industry the purpose of 3-D printer is to associate the improvement of new product in dental and biomedical industry. It very useful in dental for fitting the cavity in dental top and its tool is produced with plastic being formed in vacuum purpose of made dental aligners. Use of this printer inserting the plate for handicapped persons in knees and hip for useful purpose. It reduces the waste during production so it widely populated. Helpful for the patient who are misery from several diseases like cancer, osteoporosis etc. now the recent development in 3-D printing is to enlargement of skin, seventeen bone and human organ 3-D printing.

Here it is used to print the replacement parts for airplane. Normally the aerospace organization are partnership with several research foundation and that regard with forwarding machinery to manufacturing submission. To create aircraft with new material and new method using of 3-D printer. The aircraft development companies are partnership with 3-D printing to improvement of material and development of application in aerospace industry. To view the aircraft in 3-D model it is useful for analyzing what condition is there these are identified.

A vehicle can be manufactured by 3-D printer in modern world. The urbee is first car produced by 3-D printer and created in year of two thousand ten over and done with U.S engineering student and stratasys 3-D printer manufacturing company. It has innovative look and it is mixture vehicle. The American manufacturing company create a vehicle completely with 3-D printer in year of two thousand fourteen. Later that introduced another car with eighty percentage completion of 3-D printer is named as LM3-D swim. Next year this company create automotive part with help of 3-D printer and also presented self-driving vehicle.  

The recent improvement in 3-D printer is very benefits for mechanical techniques and also develop any object in any metal. It is one of the most innovative in worldwide and to become very famous in year of two thousand seventeen. It reducing the cost and improving the productivity in industrialized and manufacturing. Now in field of healthcare and automation 3-D printer is necessary. Some development are given below,

• Printer with welding.
• Increasing speed of printer.
• Influential individual submissions.
• Printing in space.
• Low cost.
• Phone printer.

The size of the object should be based on size of the 3-D printer. Group of member from Dutch to manufacture a 3-D print furniture by using new method that is the print head is made in steel and it connected with robot arm. It operational with company of Autodesk and Henijman and they all discussed to print the bridge model. This is small stage of using 3-D printing in arena of building automation.

In around world 3-D printer become very famous but there is some disadvantage is °Ccur that is speed of printer is very slow. To rectify this draw back a new innovation °Ccur is to rise the speed of the printer. In many company the main compliant is not complete the job or work within a time. So it leads to main drawback of the 3-D printer.  

The 3-D printing technology is very useful in field of biomedicine also. It is highly potential to changing the people life better.  This printing is alter the individual people life cycle and using of this we can do paralyzed walk. Ekso Bionics is joined with Scott Summitt’s 3-D system to create a suit and it help for a spinal damage patient. Their all capacity to walk with help of the suit. The company gave the suit to Amanda boxtel after the analyzing of full body. At last Boxtel capable to walk again with help of Ekso Bionics suit. Now it manufacture for mechanical aids.

Elon musk and his assistances are testing and developing a 3-D printer SuperDraco missile engine. Before that Etsy said that is difficult to build a printer print in space. At last developing and testing of SuperDraco is successful. Finally the rocket with 3-D printer is delivered different changes in space transportable.

In 3-D printing give any kind of innovation toward injured, toward space and toward manufacturing in a domestic phrase said that to develop the tool in a plastic stuff. The maximum companies are take decision the product should be in everyman bazaar except XYZ Company. The chief executive officer, Simon shan said that 3-D printer send to all school in china and this plan execute by Chinese government.

Now recent trend is that printer should print with help of mobile light to polymerize fluid gum. It is developed by Jeng-Ywan he is lecturer of mechanical engineering and dean in National Taiwan University of Science and Technology. In these trend only small printer is used at end product. It is not available in market.

In this process thermoplastic solid are used for a nonstop filament and this method need huge coil through a stirring crown. By using head jet the melted materials supply to the rising work piece. The monitor is supervisory the motion of a head. This process also called as hard based AM machinery. It is wire technology and its head is organized by hotness extrude. The support structure is develop and built with help of water decipherable solid. First step is that insert the necessary shape of structure that you want and then fill molten material with help of necessary vessel. The molten metal inject into the growth of work piece and after some time removing the supporting structure. Finally the wanted material is obtained. These step are explained given below diagram,

In this method the using dual kind of material such as demonstrating material and secondary material. In famous industry FDM is used to raise the construction and developed process. There are three stages involve in FDM is

• Pre-processing
• Manufacture
• Post-processing

The process starts with project case should be import, selecting the option and develop the coating. In this process estimate coating into different layer and it’s ranging from 0.0050 inches to 0.0130 inches in altitude. Using this collection of records the tool pathway can be making by the software and it travel the extrude crown. These steps are done by catalyst EX with fully automated and transfer the object to printer. In preprocessing stage that contains three process. And they are

• Generating CAD
• Convert CAD file into STL
• Transfer to AM Machine & STL File Manipulation

In this stage you can make 3-D model using any one of the modeling software you have. This is used to visualize the final shape of the product. That gives the structural representation of the final product. For this purpose there are too many software are available in market. Here we use Solid work software as a modeling tool.

In this stage you need to transform the CAD file format into STL (Standard Tessellation Language). This format was created in the year of 1987.  The latest machines uses this format file with files like ZPR, ObjDF etc. 

In this stage you need to make a copy of the STL document to the printer’s control computer. This process was similar as the setup stage in a 2D printing properties. So user can able to give the properties of the print like position and orientation, etc.

The manufacturing process is started up with using “print” press switch. Dual material used for one make the part and another one is secondary purpose and to enter into the head. The plastics can be converted into ribbon, crudely size of human curls. By changing the position of part material and secondary material leads to credit the layer as 0.0050 inch. In this process there are two process are involved. And they are

• Initial setup
• Start the process

This step is based on what type of printer we have. In this stage we have to load the materials for the use. And all the physical arrangements required for the printer was done on this section. This step was very important in the whole process. In our requirement we need to load the ABS filament into the machine.

This process would be done by the machine itself. After starting the process we don’t need to do anything. Whole process consumes time based on its complexness. Some process takes nearly some hours to some days. Here the machine makes the shape given by layer by layer.  In FDM the nozzle ejects the material in the form of molten state.

When the work is complete cavity is removed and complete it by coating and strip off and secondary material is hold it in necessary place.  Various stages involved in this process was,

• Support Removal
• Sanding
• Cold Joining
• Gap Filling
• Polishing
• Priming and Painting
• Vapor Smoothing
• Metal Plating

During the production of parts by using the 3-D printing technology we can give the support for the hanging area of the component. There are two types of supports are available, and they are listed below,

• Standard
• Disolvable

This is the softening process. Here all the burs created during the removal of support was softened.

Cold Joining

During the production of large size components that not made by single pause. So we made the parts into some small pieces and then they are joined by the help of resins.

Gap Filling

This process was carried out for filling the gaps due to the layer by layer formation. This will be done by the filling the gaps by the filling materials like gums and resins.

Polishing

This was carried out for remove the coarse finish in the product. It gives the good aesthetics to the product. In some case the surface finishing was too important.

Priming and Painting

This is the process of making the layer over the product to give required color and protection purpose.

Vapor Smoothing

This process also carried out for the finishing purpose.

Metal Plating

This is the process of coat the metal layer on the surface of the produced plastic component. For this process electro plating method was used.

Removing the finished product from the printer

After completing the layer by layer printing, there is a need of removing the unwanted flux material from the printer. In this stage all the safety measures must be followed. Because we are handling the hazardous chemicals and higher amount of heat.

In this project consider a cuboid having 100 mm length, 50 mm width and 50 mm thickness. That was created by the solid works software. Solid work was a registered 3D modeling software of ‘DSS’. Now we see the stages involved in the design process.

The first step was opening the Solid works software. Then start a new design by clicking the “File – New – Part” the command. After that select the working plane. Then create the rectangle having the dimensions of breadth – 50 mm and thickness – 50 mm by using the below command “Sketch – Rectangle – Create”.  Then convert the created 2 D element as a 3 D element by using the below instructions “Features – Extrude” for the length of 100 mm. Then save this design. Now we created the cuboid by using the sloid works software. Then we may proceed the further analysis activities.

All the real problems faced by the industry was can’t able to try in real world. Because it would be highly hazardous or high costly material are consumed during the process. So we can’t do this. But we can’t directly produce before all the analysis are carried out. So we can simulate those problems with the help of computer (By solving the mathematical model of the problem). This process is called as the simulation part. Here we use ANSYS 19.0 Software to simulate our problem. Now we are going to see about the process involved in this simulation stage. In this simulation stage there are three stages are there. And they are

• Preprocessing
• Solution
• Postprocessor

Preprocessing

In this stage the basic material property declaration, element type declaration are takes place. The material element chosen for our project work was “SOLID 92”. And the bed of the printer having “CONTACT 172”. They are selected from the preprocessor section. After selected the material type we need to enter the properties of the ABS material. Here the following properties are entered.

Thermal conductivity – 0.2 W/m °C

Specific heat capacity- 1.47 KJ/kg °C

Density - 1005 kg/m³

Volume resistivity       - 3.5 x 10¹⁶ ? cm

After giving all the material properties we need to draw the element in the ANSYS software unless you can load the already developed 3 D model (Developed by other 3 D modeling software). After create or import the 3 D model we need to split the model into small blocks. This process was known as meshing. Here the mesh was created by the mesh tool.

This is the second process in the simulation phase.  Here we can add a thermal loads to the created model. In our problem the solid block has a uniform temperature of 230 °C. The bed temperatures are continuously varied. There are five value of bed temperatures are considered. Based on the five temperatures we need to select the best suited temperature value for our problem.

Selection of analysis type – In this step first we need to select the analysis type as “steady state thermal” by following the below steps. First need to select ‘solution’ tap, then click ‘analysis type’, then click ‘new analyses, the select the ‘steady state thermal’.

Define load – In this we are going to give all the thermal loads regarding to the requirements. This can be achieved by following procedures. Press the ‘solution tap’, then click ‘apply’ option, then click the thermal load, enter temperature values.

Solve – This step the mathematical model for the design was calculated using finite element algorithm. At first press the solve button, then simply press the current LS method. Then click OK button when it asks any question. After completing this process that shows solution was done.

This step allows a user to view the generated calculation results. Here user can able to generate various graphs for the problem solved by the user. Here we can generate the deformed shape for our problem. Deformed shape of the component was generated. User also can able animate this deformed shape.

Optimization

It is the process of finding suitable value for the specified domain. The value is either minimum or maximum which provide accurate regardless of the solution. In industry they are focused on ever-changing the traditional methods into rapid prototyping. Due to compatibility of the obtainable materials in rapid prototyping technique not achieve full application. To rectify this drawback develop an innovative material and it’s having larger features than conservative material. Another method is changing the process parameter during construction stage so it improve the properties. The dimension of all value should be measured in micrometer. The essential for functional parts is mechanical properties and also to learn several process parameter on mechanical properties. In this case we are going to see five process parameter,

• Layer thickness
• Orientation
• Raster angle
• Raster width
• Air gap
• Nozzle temperature
• Bed Temperature

The thickness of nozzle layer is one of the parameter in fused deposition modelling. To minimize the thickness of nozzle layer to get accurate quality model or object. The technical specification of layer thickness, the maximum perseverance of layer is 20μm. Here the printing speed should be limited as 30-300mm/s. the main factor of nozzle diameter is 0.4mm. The printer must handle that file is designed as model or object and then is converted into a necessary format and the separating model into thin coating is known as slicing. The travel speed of the printer is similar than that of printer speed is 30-350mm/s. In the software set the necessary setting for change the parameter is filament temperature and shell thickness.

The dimension for the frame in Z direction very high compared to other direction, is 38.8cm. In Y direction is having 34.2cm and in X has 35.7cm. In two thousand twelve it presented as fast and more accurate 3-D printer.

The height of dropped portion from the nozzle is known as layer thickness. The impact of the building layer is observe by parameter of layer thickness.

The model or object should be placed in the position is orientation. 

The inner part constructed with various angle with help of deposited beads. Positioning object is to get model very accurately and better quality. The build orientation refer to inclination of the part in build platform with respect to X, Y, Z axis.

It is angle which the way of raster with respect to loading way of stress. The glass transition temperature and shrinkage are very low in fabrication part due to extruded material is cool from transition temperature to chamber temperature that is resulting of higher stress developed inside that leads to cracking and failure of the model or object. The path of model dropped is relative to the loading part. The temperature view are at in bottom layer, the glass transition temperature increases and suddenly decreases in movement of extrusion head. The diffusion phenomenon is more in bottom layer as compare to upper layer.

It is rectangular in shape used to show the image in screen and the physical dimension of the screen is higher than the raster size. According to the resolution

The raster width is also known as road or path width. It is an installation path related to tip size. The main function of the raster width is to fill the inner region of part curve. Narrow and wide filling pattern or path is to be observed. The raster width is placed at axial direction is lengthier than that of sample printed and therefore less filament are used to fill the width.

In FDM process the material was molted by heating the wire filament at the nozzle. We can vary the nozzle temperature according to the material which use for the purpose. For the material selected for the project was ABS. For this material the available operating temperature was (210 °C to 240 °C).

In FDM process the main parameter was Bed temperature, because that impacts on the final shape of the product developed by the FDM process. In FDM process the molten material was feed by the nozzle through the controlled path. So the molten material allowed to cool. During the cooling process solidification of the material was takes place. We know that the material that lost its shape during the cooling process because of shrinking. It leads to unwanted shape errors in the final outcome. So we need to compensate this shrinkage during the design stage itself. Instead of this complicated process we simply modify the cooling rate of the product printed by the FDM. For adjusting the cooling rate we simply reduce the temperature difference between the hot body and cold body. So here we would consider the five temperature values (40, 50, 70, and 90, 110). Analysis was carried out for those temperature by both manually and simulation method.

When the recovering of the printed material am amount of heat is applied on the product printed by the FDM printer. During this process the actual profile of the product was recovered. This profile restoring process rate depends on the properties of the material. By varying the temperature we can simply adjust the final shape of the product.

All the above described parameters are varied to optimize the FDM process. Among the all above showed parameters we take the temperature of the bed it plays the very crucial role in the dimensional accuracy of the project. So here we would see about the importance of the temperature of the bed in FDM and how it impacts on the final products quality.

Here we take five temperature values for the investigation. And the values are 40 °C, 50 °C, 70 °C, 90 °C, and 110 °C. They are the temperature values of bed. And the temperature of the nozzle was maintained at 220 °C. By conducting the experiment with these temperature values by practically and also analytically. We got the below showed results. And then by using the below formulae we found the percentage of errors in the final shape.

Analysis 1: Condition one was taken to analyze (T_B = 40 °C, T_N = 220 °C)

Here we can able to see the error in the shape visually. Deflection with original design was too high in the product produced by this temperature condition. So this not a good temperature setup for the FDM process. Because no one can accept this much of error in the shape. Various chamber temperature was obtained for this temperature setup was 32.50 °C in the top section of the chamber, 31.30 °C in the middle section of the chamber, and 28.70 °C in bottom section of the chamber.

Analysis 2: Condition two was taken to analyze (T_B = 50 °C, T_N = 220 °C)

Now take the bed temperature value as T_B = 50 °C and the nozzle temperature values as T_N = 220 °C.  The material was taken to the study was ABS polymer.

This also not a good temperature setup for the FDM process. Because here also we can able to see the deflection in the shape visually. This much of error was not accepted by the industries. Various chamber temperature observed for this process are 33.20 °C at its top portion, 30.90 °C at its middle portion, 29.30 °C at its bottom portion. The percentage of error in the shape was calculated by the formulae and its values are 93.70 % in its X axis, 94.20 % in its Y axis, and 14.00 % in its Z axis. This was happen because the shrinkage of the material when it allowed to solidify. So this error was called as shrinkage errors. They are must avoided for higher performances.

Analysis 3: Condition three was taken to analyze (T_B = 70 °C, T_N = 220 °C)

From analysis three we got the results, from this results that is clear that also have some shape errors but this time the error value get decreased over the existing analysis. But it also not in acceptable range. The various temperatures of the chamber are, 37.20 °C at its top portion, 32.50 °C at its center portion, and 30.60 °C at its bottom portion. The various shape errors calculated by the formula and the values are 80.90% in X direction, 84.60 % in Y direction and 7.90 % in its Z direction. This is lower than the previously calculated values. But we have reduce this as much as possible.

Analysis 4: Condition three was taken to analyze (T_B = 90 °C, T_N = 220 °C)

From the above showed figure that is clear the shape errors are reduced in this temperature setup. Even though it have some errors due to shrinking during the solidification.  The various chamber temperatures are 38 °C at its top section, 33.60 °C at its middle section, and 31.60 °C at its bottom section. And the calculated values of percentage of error are 74.10 % in X direction, 72.10 % in Y direction, and 6 % in its Z direction.

 Analysis 5: Condition three was taken to analyze (T_B = 110 °C, T_N = 220 °C)

From the above figure that was clear the perfect shape was get by set the bed temperature as T_B = 110 °C, and nozzle temperature as T_N = 220 °C. Even some errors are there but we simply neglect those errors. The various temperature was observed in the chamber, and they are 45.80 °C at its top portion, 34.10 °C at its middle portion and 31.20 °C at its bottom portion. And the percentage of errors are calculated as 3.44 % in X direction, 4 % in Y direction, and 0.239 % in Z direction.

From the above showed results that is clear if the bed temperature was increased the % of error get reduced. So the optimum bed temperature was found by the analysis was 110 °C. On this temperature the % error was too minimum, in all direction the percentage of error values not higher than 5 %.

Conclusion

As per the work carried on this project that is concluded that the optimum bed temperature for FDM process was identified as 110 °C. At this temperature the shape errors caused by shrinkage of the material when it allowed to solidify. Also the % of error was reduced below 5%. The maximum % of error 4%. It was identified in Y axis of the object. Minimum % error was identified as 0.239, and it was there in Z axis of the finished object. In X axis the percentage of error was 3.44 %.  And the other results for various bed temperature are calculated. For 50 °C temperature the shape error in X axis was 93.70 % as a medium error value, in Y axis 94.20 % as a maximum error value, and in Z axis that was 14 % as a minimum value for this temperature. For 70 °C the maximum value error was observed as 84.60 % in Y axis, minimum value of error was 7.90 % in Z axis, and 80.90 % in X axis. For the 90 °C temperature value the maximum shape error value was observed in X axis and the value was 74.10 % & minimum value of shape error was observed in Z direction and its value was 6 %. For this temperature the shape error value in Y axis was also observed as 72.10 %.

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