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Additive manufacturing of mechanical testing samples

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3D printing in additive manufacturing is considered as one of key technologies to the future high-precision manufacturing in order to benefit diverse industries in building construction, product development, biomedical innovation. Yu (Roger) Dong discusses 3D printed mechanical testing samples of PLA and PLA/wood fibre composites.

Image courtesy of interviewee. May 12, 2024

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This video video discusses the significance of 3D printing, also known as additive manufacturing, in advanced manufacturing technologies, contrasting it with traditional subtractive methods. It emphasizes the layer-by-layer approach that allows for complex geometries and reduced material usage and costs. The focus is primarily on Fused Deposition Modeling (FDM) for producing polymeric materials, particularly polylactic acid (PLA), known for its biodegradability and environmental friendliness.

Key aspects of the study include identifying factors influencing the tensile strength of 3D printed materials, with findings indicating that the number of shells is the most significant factor. The study uses statistical design experiments, specifically the Taguchi design of experiments (DOE), coupled with analysis of variance (ANOVA), to determine optimal material formulations and processing parameters.

The results indicate that while increasing the number of shells enhances tensile strength, the type of material (with or without wood fibers in PLA) also plays a critical role in mechanical properties. The presence of defects such as voids can weaken the strength, but increasing the number of shells can mitigate this issue.

This video video concludes by highlighting the importance of balancing material selection, processing parameters, design properties, printing time, and cost for optimal outcomes in 3D printing. It suggests that future research may benefit from integrating machine learning and artificial intelligence to improve product design and optimization techniques in additive manufacturing while minimizing waste and cost.

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3D printing or additive manufacturing is,

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a quite important advanced manufacturing technology

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as opposed to, subtractive manufacturing like,

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milling, machining, extrusion, injection molding, et cetera.

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Uh, basic to deal with material processing

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and the product development in a layer by layer manner

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for complex geometry

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and a significant reduction of material consumption of cost.

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Uh, so in particular,

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few deposition modeling we call FDM used in this study,

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mainly focused on additive manufacturing

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of polymeric materials

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and the polymer composites, which is,

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follows a very similar principle of

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melt extrusion in the conventional polymer processing

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that you, you know, melt the polymers up

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to its melting temperature.

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And then the filament material will, go

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through the nozzles to actually build up the layers,

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structures by, you know, in the materials

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for making the products.

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Um, so I believe adding manufacturing,

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probably going to in combination of artificial intelligence,

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will offer some future opportunity,

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in advanced smart manufacturing towards, industrial 4.0.

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Um, you know, that's gonna be a very broad,

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opportunities and, and the scope.

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Most polymeric material polymer comps,

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mechanical properties,

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particular tenile strands is a key parameters

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to identify load bearing capacity.

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So maximizing tensile strengths to reduce mechanical failure

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is of particularly important in structure, integrity

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and product quality and durability.

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So we attempt, to 3D print polylactic acid PLA,

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which is wide used in biomedical field, due

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to is about high biodegradability

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and, environmental friendly

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and bell compatibility, as well

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as some PLA wood fiber compasses

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to identify the key parameters,

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to influence tensile strengths, using statistical,

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design experiments.

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Uh, so among all parameters, we found

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that number shells is most significant factor

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to maximize the tensile strengths of a neat PL sample only,

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which is followed by layer height and infield density.

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Um, you know, generally

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as expected in additive manufacturing, particularly in the,

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fields deposition modeling process.

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So more number shells generally means, you know,

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better build up for the hierarchical structures and then the

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therefore the higher strengths,

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stronger printed parts in the, need.

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PLA samples. Takeuchi design experiments,

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or DOE method has been widely used in identifying,

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significant factors,

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Parameters in robust design of products,

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and the parametric optimization in advanced manufacturing.

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Uh, it is often coupled with the analysis of variance ANOVA

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to detect, either optimum, material formulation

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or processing parameters in response

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to different targeted goals such as, the maximization

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of tenile strengths

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or minimization of dimensional errors, et cetera.

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So it's based on very limited orthogonal

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experimental design area.

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Uh, rather than going through the full skill experiments

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or full skill, trials, you know,

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basically can provide a sufficient optimization process

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analysis used mainly in the field

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of mechanical manufacturing and material engineering.

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Uh, so in our study we select three,

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commonly used 3D printing parameters,

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which includes the infield density layer thickness,

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and the number shells at two different levels in,

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initially designed L eight, you know,

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is based on experimental rans with factual interactions.

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So it has been found that number shells is most significant

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factor, used in the printed PLA samples.

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Further, we chose only number of shells

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and the material types, namely the PLA

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and the PLA wood fiber comps,

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to look at the reinforcement effect.

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And then we rerun the L six A, with two different levels

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to maximize oten cell impact strengths,

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as a DOE responses overall results, to conclude that,

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overall results that demonstrate

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that number shells plays a very,

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the most significant role in enhancing the tensile strengths

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of 3D printed, PLA samples.

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Uh, however, material type with without the,

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wood fibers in PLA is critical in influencing old,

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tensile flex impact strength in mechanical properties,

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typical reinforcement effect,

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which is very critical in the composite material systems.

05:07.185 --> 05:11.685
Um, this in our 3D printed PLA wood fiber compasses,

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that kind

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of reinforcing effect effect is not quite evident at all.

05:17.985 --> 05:21.525
And this normally due to the, very, you know, the,

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the detrimental mechanical strengths, in the compasses

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as opposed to those of the neat PLA.

05:28.025 --> 05:29.325
So we did some,

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microscopic analysis using the optical microscope,

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and we found, and, that most

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of the printed material samples inevitably

05:39.155 --> 05:40.325
possess either single

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or multiple, field, cavities or void.

05:43.665 --> 05:47.405
So these void or cavities are actually open cavities are

05:47.605 --> 05:49.525
actually typical defects to

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deteriorate mechanical strengths.

05:52.025 --> 05:54.725
Uh, although that's, if we increase the number of shells,

05:54.755 --> 05:56.685
that kind of defect could be

05:56.685 --> 05:59.125
Significant, could be significantly reduced.

05:59.875 --> 06:04.565
This study actually shows how important material selection

06:04.585 --> 06:07.445
and 3D printing parameters,

06:07.785 --> 06:10.725
can ultimately influence, you know,

06:10.725 --> 06:14.005
mechanical properties of final polymer or,

06:14.005 --> 06:15.245
or composite products.

06:15.385 --> 06:18.245
So the design experiment approach is a deemed

06:18.305 --> 06:20.285
and appropriate method for material

06:20.905 --> 06:24.485
and processing optimization in contemporary manufacturing.

06:25.035 --> 06:29.285
However, further research, may gradually shift

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to the use of machine learning,

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deep learning in artificial intelligence

06:33.805 --> 06:35.485
to achieve better accuracy

06:35.985 --> 06:39.725
and robustness of design of product optimization,

06:39.905 --> 06:43.325
in place of the statistical design experiments

06:43.645 --> 06:45.005
approach or analysis.

06:45.705 --> 06:49.285
Uh, another very important point I like to raise here is

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for most the design, material, researchers,

06:53.645 --> 06:56.325
scientists, the, a good balance should be generally made

06:56.555 --> 07:00.125
between the material selection, processing parameters,

07:00.585 --> 07:03.525
design properties, and 3D printing time

07:03.625 --> 07:05.845
and material cost, in the future.

07:06.145 --> 07:09.685
So that, you know, not only we can actually,

07:09.715 --> 07:11.805
well utilize this advanced,

07:12.245 --> 07:15.485
additive manufacturing 3D printing, technology,

07:15.585 --> 07:18.805
but also we could actually achieve the best,

07:18.805 --> 07:22.245
product quality with the minimum, material waste and,

07:22.265 --> 07:22.925
and the cost.

Enhancing Strength in 3D Printed Polymers

00:00:00 - 3D printing or additive manufacturing is, a quite important advanced manufacturing technology as opposed to, subtractive manufacturing like, milling, machining, extrusion, injection molding, et cetera. basic to deal with material processing and the product development in a layer by layer manner for complex geometry and a significant reduction of material consumption of cost. so in particular,
00:00:35 - mainly focused on additive manufacturing of polymeric materials and the polymer composites, which is, follows a very similar principle of melt extrusion in the conventional polymer processing that you, you know, melt the polymers up to its melting temperature. And then the filament material will, go through the nozzles to actually build up the layers, structures by, you know, in the materials
00:01:05 - so I believe adding manufacturing, probably going to in combination of artificial intelligence, will offer some future opportunity, in advanced smart manufacturing towards, industrial 4.0. you know, that's gonna be a very broad, opportunities and, and the scope. Most polymeric material polymer comps, mechanical properties, particular tenile strands is a key parameters
00:01:38 - So maximizing tensile strengths to reduce mechanical failure is of particularly important in structure, integrity and product quality and durability. So we attempt, to 3D print polylactic acid PLA, which is wide used in biomedical field, due to is about high biodegradability and, environmental friendly and bell compatibility, as well as some PLA wood fiber compasses
00:02:10 - to influence tensile strengths, using statistical, design experiments. so among all parameters, we found that number shells is most significant factor to maximize the tensile strengths of a neat PL sample only, which is followed by layer height and infield density. you know, generally as expected in additive manufacturing, particularly in the, fields deposition modeling process.
00:02:41 - better build up for the hierarchical structures and then the therefore the higher strengths, stronger printed parts in the, need. PLA samples. Takeuchi design experiments, or DOE method has been widely used in identifying, significant factors, Parameters in robust design of products, and the parametric optimization in advanced manufacturing. it is often coupled with the analysis of variance ANOVA

Optimizing 3D Printing Parameters for Strength

00:03:14 - or processing parameters in response to different targeted goals such as, the maximization of tenile strengths or minimization of dimensional errors, et cetera. So it's based on very limited orthogonal experimental design area. rather than going through the full skill experiments or full skill, trials, you know, basically can provide a sufficient optimization process
00:03:43 - of mechanical manufacturing and material engineering. so in our study we select three, commonly used 3D printing parameters, which includes the infield density layer thickness, and the number shells at two different levels in, initially designed L eight, you know, is based on experimental rans with factual interactions. So it has been found that number shells is most significant factor, used in the printed PLA samples.
00:04:17 - and the material types, namely the PLA and the PLA wood fiber comps, to look at the reinforcement effect. And then we rerun the L six A, with two different levels to maximize oten cell impact strengths, as a DOE responses overall results, to conclude that, overall results that demonstrate that number shells plays a very, the most significant role in enhancing the tensile strengths
00:04:49 - however, material type with without the, wood fibers in PLA is critical in influencing old, tensile flex impact strength in mechanical properties, typical reinforcement effect, which is very critical in the composite material systems. this in our 3D printed PLA wood fiber compasses, that kind of reinforcing effect effect is not quite evident at all.
00:05:21 - the detrimental mechanical strengths, in the compasses as opposed to those of the neat PLA. So we did some, microscopic analysis using the optical microscope, and we found, and, that most of the printed material samples inevitably possess either single or multiple, field, cavities or void. So these void or cavities are actually open cavities are actually typical defects to
00:05:52 - although that's, if we increase the number of shells, that kind of defect could be Significant, could be significantly reduced. This study actually shows how important material selection and 3D printing parameters, can ultimately influence, you know, mechanical properties of final polymer or, or composite products. So the design experiment approach is a deemed and appropriate method for material

Advancements in 3D Printing Design Optimization

00:06:25 - However, further research, may gradually shift to the use of machine learning, deep learning in artificial intelligence to achieve better accuracy and robustness of design of product optimization, in place of the statistical design experiments approach or analysis. another very important point I like to raise here is for most the design, material, researchers,
00:07:22 - between the material selection, processing parameters, design properties, and 3D printing time and material cost, in the future. So that, you know, not only we can actually, well utilize this advanced, additive manufacturing 3D printing, technology, but also we could actually achieve the best, product quality with the minimum, material waste and, and the cost.

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