pps proceeding - Abstract Preview
pps proceeding
Symposium: S19 - Additive technology
Oral Presentation
 
 

Tailoring properties of Additively Manufactured Parts Using Off-Axis Printing

Rudolph Natalie (1)*, van Hulle Luke (1)

(1) University of Wisconsin-Madison - Wisconsin - USA

In the last few years, Fused Filament Fabrication (FFF) - often referred to as 3D printing or Fused Deposition Modeling (FDM®) - has become the fastest growing AM technology. FFF generates 3D parts by melting thermoplastic polymer filaments in a heated nozzle to form beads and fill out a 2D layers. These layers are stacked up to build the parts. This sequential part build causes an anisotropy within and between layers. The mechanical strength is strongest in bead direction and weakest between layers. The resulting anisotropy in FFF can be used by preferentially orienting beads in load direction and thus tailor the part properties. To fully control all print parameters a custom python™ program was developed and programed. In addition to traditional user adjustable print parameters, custom infill patterns, distance between beads, and amount of material extruded along a bead can be set. All of these parameters can be independently set for every layer, and infill pattern can also be set for sub-regions in a layer. In addition to analyzing the anisotropy as a function of bead orientation, build orientation and layer print time in tensile test specimen, a C-bracket was used as a demonstrator to apply the gained knowledge to a more complex geometry. The infill angle was determined using Pareto-based topology optimization and was compared to the default infill settings. This is the first step towards a tool pathing algorithm that prioritizes by strength requirements rather than simple geometrical constraints. To take full advantage of the anisotropy and either improve performance or further reduce weight, off-axis printing was investigated. Mounted on a 6-axis robot, the heated print platform is moving in any plane and direction under the heated printer nozzle to build up the part. This enables unrestricted design freedom in all three dimensions and significant reduction of support material. The advantages and disadvantages of this novel printer will be discussed.