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Fused Deposition Modeling (FDM) is a widely used 3D printing technology that can create a diverse range of objects. However, achieving the desired mechanical properties of printed parts can be challenging due to various printing parameters. Residual stress is a critical issue in FDM, which can significantly impact the performance of printed parts. In this study, we used Digimat-AM software to conduct numerical simulations and predict residual stress in Acrylonitrile Butadiene Styrene (ABS) material printed using FDM. We varied six printing parameters, including printing temperature, printing speed, and infill percentage, with four values for each parameter. Our results showed that residual stress was positively correlated with printing temperature, printing speed, and infill percentage, and negatively correlated with layer thickness. Bed temperature did not have a significant effect on residual stress. Finally, using a concentric infill pattern produced the lowest residual stress. The methodology used in this study involved conducting numerical simulations with Digimat-AM software, which allowed us to accurately predict residual stress in FDM-printed ABS parts. The simulations were conducted by systematically varying six printing parameters, with four values for each parameter. The resulting data allowed us to identify correlations between residual stress and printing parameters, and to determine the optimal printing conditions for minimizing residual stress. Our findings contribute to the existing literature by providing insight into the relationship between residual stress and printing parameters in FDM. This information is important for designers and manufacturers who wish to optimize their FDM printing processes for improved part performance. Overall, our study highlights the importance of considering residual stress in FDM printing, and provides valuable information for optimizing the printing process to reduce residual stress in ABS parts.

Additive manufacturing using fused deposition modelling (FDM) is an affordable and efficient way to produce functional parts and prototypes. However, the FDM-manufactured parts, particularly those made of polylactic acid (PLA), has some drawbacks regarding accuracy and surface finish. To address this, post-processing techniques such as ironing can be applied. However, little is known about the effect of ironing process parameters on surface roughness, and there is a lack of comparative studies on contact and non-contact measurement methods. This study aims to address these gaps by investigating the impact of path speed, ironing spacing, and flow rate on the surface roughness of FDM-produced PLA samples using both contact and non-contact measurement methods. The results show that the ironing process can lead to a significant reduction in surface roughness values, and careful optimization of process parameters can further minimize roughness. The study highlights the advantages and limitations of contact and non-contact methods for surface roughness analysis and provides guidance on selecting the appropriate method for a given application and material. [ABSTRACT FROM AUTHOR]

Warping deformation poses a significant challenge in the material extrusion process of ABS additive manufacturing, impacting dimensional accuracy and part quality. In this study, we aimed to optimize the printing factors to minimize warping deformation and enhance the overall performance of ABS-printed parts. The studied parameters included bed temperature, printing speed, chamber temperature, and printing temperature. To overcome the limitations of time-consuming and costly laboratory experiments, a simulation-based approach using numerical techniques and the Digimat-AM software's finite element model was employed to visualize and analyze warping deformation. The Taguchi technique was utilized to design a series of experiments, yielding valuable data for statistical analysis and optimization. The results highlighted the significant influence of bed temperature on warping deformation, followed by chamber temperature, printing temperature, and printing speed. Through systematic analysis, the "optimal" parameter settings were determined. These findings offer valuable insights for process optimization, enabling improved dimensional accuracy and reduced warping deformation in ABS additive manufacturing. By combining numerical simulation and the Taguchi method, this investigation gives a practical and efficient method for enhancing the performance of material extrusion processes, ensuring high-quality printed parts in the field of additive manufacturing. [ABSTRACT FROM AUTHOR]

Additive manufacturing is becoming increasingly widespread in many areas of life. One of the main reasons for this is that the machines, raw materials and manufacturing are becoming cheaper. The cheaper the technology, the more widespread it is. The cost of production is influenced by many factors. One of these shows the impact of the part's production positioning (placement in the working space) on costs in the following study. On this basis, we can simplify the traditional pricing strategy. From the results, we can determine how economically it is worth to place the parts in the work area of the machine. [ABSTRACT FROM AUTHOR]

A significant increase in 3D printing technology has been done primarily in the twenty-first century, where there are many research works going on in different fields, such as aerospace, automotive, and medical sectors to improve the 3D printing technology. This paper investigates the effect of printing with four different methods on the tensile strength of the Fused Deposition Modeling printed Polylactic Acid parts. Experimental and statistical analysis found that there is no effect in horizontal printing in both ways, but there is a significant difference in other printing methods. [ABSTRACT FROM AUTHOR]

The evaluation of residual stress is crucial since it has a significant impact on the component's lifetime and can cause breakdown or failure during manufacture, which may affect the economics, lives, and the environment. Residual stress analysis has now become a mandatory requirement in the automobile industry. Because each manufacturing process like machining, casting, heat treatment, and coating impacts the residual stress state, it can be pretty complicated and varied within the components. If the effects of these processes are well studied, it is possible to achieve a stress state in the part that will increase its lifetime and performance while lowering costs with an optimized method. This paper discusses the effect of residual stress on the automotive industry and illustrates how is residual stress participates in every manufacturing process of vehicles. [ABSTRACT FROM AUTHOR]

In the recent years 3D printing became a hot topic, however it’s hard to design parts without a deep understanding of the material properties. The usage of these materials in vehicles assumes the knowledge of the behavior in dynamical environment. The aim of this study is to estimate the modal parameters and the damping properties via experimental dynamic analysis of a part made from PLA. With the results we can provide data for the FEM softwares’ input. After the numerical simulations the simulated results were compared to the measured data. [ABSTRACT FROM AUTHOR]