Impact of Nonplanar 3D Printing on Surface Roughness and Build Time in Fused Filament Fabrication
Nonplanar 3D printing is a recently emerged approach to increase surface quality and part strength in additive manufacturing. In this paper, the impact of a nonplanar printing method utilized for the fused filament fabrication (FFF) technique on the resul
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Abstract Nonplanar 3D printing is a recently emerged approach to increase surface quality and part strength in additive manufacturing. In this paper, the impact of a nonplanar printing method utilized for the fused filament fabrication (FFF) technique on the resultant surface roughness of printed parts is presented. In particular, the influence of different inclination angles and part orientation on the obtainable surface quality was investigated by comparing a traditional planar printing strategy with a nonplanar finishing solution. A pyramidal geometry was utilized to assess the effect of inclination angle as well as part orientation and relative printhead movement on the surface characteristics. The results show a decrease in obtainable surface roughness for inclination angles up to 25°, while higher angles cause rougher surfaces when compared with results of planar 3D printing strategy. This can be explained by the way the nonplanar nozzle movements interact with previously deposited filament strands by deforming them due to the size of the nozzle and geometry of the 3D printed part. As a consequence, solutions for an improved nonplanar printing technique using Delta FFF printers are suggested that will be investigated in the future work.
1 Introduction In contrast to subtractive manufacturing, where undesired material is removed away from a bulk workpiece, additive manufacturing (AM), also known as 3D printing, A. Elkaseer (B) · T. Müller · D. Rabsch · S. G. Scholz Institute for Automation and Applied Informatics, Karlsruhe Institute of Technology, 76344 Eggenstein-Leopoldshafen, Germany e-mail: [email protected] A. Elkaseer Faculty of Engineering, Port Said University, Port Fuad 42526, Egypt S. G. Scholz Future Manufacturing Research Institute, College of Engineering, Swansea University, Bay Campus, Crymlyn Burrows, Swansea SA1 8EN, UK Karlsruhe Nano Micro Facility (KNMF), Hermann-Von-Helmholtz-Platz 1, 76344 Eggenstein-Leopoldshafen, Germany © The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2021 S. G. Scholz et al. (eds.), Sustainable Design and Manufacturing 2020, Smart Innovation, Systems and Technologies 200, https://doi.org/10.1007/978-981-15-8131-1_26
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adds material layer upon layer to form a desired object. Major advantages of this method are the relatively low amount of material waste as well as the ability to form complex geometries, therefore offering the freedom to redesign existing parts and create assembly like parts that can be produced in one print [1, 2]. AM processes exist for various materials and differ in the way the layers are fused to build an object. For example, metal objects are produced by melting or sintering of metal powders via a laser beam, among others [2]. These methods have shown potential to reduce weight and waste in fabrication of parts for aircrafts or improve the quality of personalized medical implants [3]. Other processes are binding a material powder via adhesives or cure
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