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Accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials

Additive manufacturing (AM) using the standard polymer in material extrusion technique often leads to defects such as warping effects, shrinkage and low dimensional accuracy, which will decrease its functionality. Hence, composite materials were introduced to cater the above-mentioned problems. Unfo...

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Main Authors: Mazlan, Siti Nur Humaira, Abdul Kadir, Aini Zuhra, Alkahari, Mohd. Rizal, Tan, Ken Land
Format: Article
Published: Springer Nature 2023
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TJ Mechanical engineering and machinery
Online Access:http://eprints.utm.my/106543/
http://dx.doi.org/10.1007/s40964-023-00403-0
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spelling my.utm.1065432024-07-09T06:49:52Z http://eprints.utm.my/106543/ Accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials Mazlan, Siti Nur Humaira Abdul Kadir, Aini Zuhra Alkahari, Mohd. Rizal Tan, Ken Land TJ Mechanical engineering and machinery Additive manufacturing (AM) using the standard polymer in material extrusion technique often leads to defects such as warping effects, shrinkage and low dimensional accuracy, which will decrease its functionality. Hence, composite materials were introduced to cater the above-mentioned problems. Unfortunately, the FDM composite-related research primarily focuses only on the improvement of mechanical properties where its manufacturability to produce different types of geometries is currently limited. Consequently, users tend to do trial-and-error experiments that lead to material wastage to achieve higher-quality parts. Therefore, in this study, the manufacturability analysis of various thin wall geometries was performed using carbon-fibre reinforced polylactic acid (CF-PLA) and Wood-based PLA composites. The dimensional accuracy of the fabricated composite parts was then evaluated, inspected and compared with the virgin PLA. The measurements of the printed parts were taken using an image analyser and the deviation between the CAD data and actual data was calculated and compared. The results indicated that the fabricated composite thin wall parts produced better dimensional accuracy with a total error of 0.01 mm for CF-PLA and 0.07 mm for Wood-based PLA. Meanwhile, for virgin PLA, the total calculated error was 0.44 mm. In terms of dimensional accuracy, the thin wall features of the fabricated composite parts showed an improvement of 97.7% and 84.1%, for CF-PLA and Wood-based PLA, respectively, as compared to the virgin PLA. In conclusion, it is suggested to reduce the CAD design by 4% allowance in obtaining very better dimensional accuracy of the composite printed parts. Springer Nature 2023-12 Article PeerReviewed Mazlan, Siti Nur Humaira and Abdul Kadir, Aini Zuhra and Alkahari, Mohd. Rizal and Tan, Ken Land (2023) Accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials. Progress in Additive Manufacturing, 8 (6). pp. 1357-1366. ISSN 2363-9512 http://dx.doi.org/10.1007/s40964-023-00403-0 DOI:10.1007/s40964-023-00403-0
institution Universiti Teknologi Malaysia
building UTM Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Teknologi Malaysia
content_source UTM Institutional Repository
url_provider http://eprints.utm.my/
topic TJ Mechanical engineering and machinery
spellingShingle TJ Mechanical engineering and machinery
Mazlan, Siti Nur Humaira
Abdul Kadir, Aini Zuhra
Alkahari, Mohd. Rizal
Tan, Ken Land
Accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials
description Additive manufacturing (AM) using the standard polymer in material extrusion technique often leads to defects such as warping effects, shrinkage and low dimensional accuracy, which will decrease its functionality. Hence, composite materials were introduced to cater the above-mentioned problems. Unfortunately, the FDM composite-related research primarily focuses only on the improvement of mechanical properties where its manufacturability to produce different types of geometries is currently limited. Consequently, users tend to do trial-and-error experiments that lead to material wastage to achieve higher-quality parts. Therefore, in this study, the manufacturability analysis of various thin wall geometries was performed using carbon-fibre reinforced polylactic acid (CF-PLA) and Wood-based PLA composites. The dimensional accuracy of the fabricated composite parts was then evaluated, inspected and compared with the virgin PLA. The measurements of the printed parts were taken using an image analyser and the deviation between the CAD data and actual data was calculated and compared. The results indicated that the fabricated composite thin wall parts produced better dimensional accuracy with a total error of 0.01 mm for CF-PLA and 0.07 mm for Wood-based PLA. Meanwhile, for virgin PLA, the total calculated error was 0.44 mm. In terms of dimensional accuracy, the thin wall features of the fabricated composite parts showed an improvement of 97.7% and 84.1%, for CF-PLA and Wood-based PLA, respectively, as compared to the virgin PLA. In conclusion, it is suggested to reduce the CAD design by 4% allowance in obtaining very better dimensional accuracy of the composite printed parts.
format Article
author Mazlan, Siti Nur Humaira
Abdul Kadir, Aini Zuhra
Alkahari, Mohd. Rizal
Tan, Ken Land
author_facet Mazlan, Siti Nur Humaira
Abdul Kadir, Aini Zuhra
Alkahari, Mohd. Rizal
Tan, Ken Land
author_sort Mazlan, Siti Nur Humaira
title Accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials
title_short Accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials
title_full Accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials
title_fullStr Accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials
title_full_unstemmed Accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials
title_sort accuracy evaluation of thin wall features fabricated by fused deposition modeling using reinforced composite materials
publisher Springer Nature
publishDate 2023
url http://eprints.utm.my/106543/
http://dx.doi.org/10.1007/s40964-023-00403-0
_version_ 1805880828539961344
score 13.244369

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