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Rapid Manufacturing Processes 1

FUSED DEPOSITION

MODELLING PRINCIPLE

SNDEEP R!

1"#"1#

MNUFCTURING

ENGG$


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INTRODUCTION

Fused deposition &ode'ing (FDM) is an additi*e

&anufacturing tec+no'og, co&&on', used for &ode'ing-protot,ping- and production app'ications$

FDM .or/s on an 0additi*e0 princip'e , 'a,ing do.n

&ateria' in 'a,ers2 a p'astic fi'a&ent or &eta' .ire isun.ound fro& a coi' and supp'ies &ateria' to produce a part$

T+e tec+no'og, .as de*e'oped , S$ Scott Cru&p in t+e 'ate

1345s and .as co&&ercia'i6ed in 1335$

T+e ter& fused deposition &ode'ing and its are*iation to

FDM are trade&ar/ed , Stratas,s Inc$


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PROCESS Main part of a FDM is a &o*a'e (78,) no66'e$

Mo'ten po',&eric &ateria' co&es t+roug+ t+is no66'e

.+ic+ gets deposited on t+e sustrate$

9or/+ead is contro''ed in t+e x-y p'ane during eac+

'a,er$

:ui'd &ateria' is +eated s'ig+t', ao*e its &e'ting

point so it can so'idifies easi',$

One 'a,er .i'' co'd .e'ds to pre*ious 'a,er$

Part is faricated fro& t+e ase up- using a 'a,er8,8

'a,er procedure$


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:SIC PRINCIPLES

Loading and 'i


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MTERIL LODING

T+e FDMs can e e


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Rapid Manufacturing Processes =

LI>UIFICTION

?eat is app'ied , +eater coi's .rapped around t+ec+a&er and t+is +eat is app'ied to &aintain a constant

te&perature in t+e &e't$

T+e ui'd &ateria' is +eated s'ig+t', ao*e

(appro7i&ate', 5$" C) its &e'ting te&perature$ It is done so t+at it so'idifies .it+in a *er, s+ort ti&e

(appro7i&ate', 5$1 s) after e7trusion and co'd8.e'ds to

t+e pre*ious 'a,er$

T+e fi'a&ents are +eated into a se&i8'i


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EATRUSION Materia' f'o. t+roug+ t+e no66'e is contro''ed , t+e

pressure drop et.een t+e c+a&er and t+e surrounding

at&osp+ere$

rc+i&edean scre. e7truder is used to descrie t+e

e7trusion &ec+anis&$

T+e *o'u&etric f'o. caused , t+e scre. in t+e no66'e-

/no.n as drag f'o. >D

T+e *o'u&etric f'o. due to pressure f'o. in t+e c+anne' is

>p$

In order for &ateria' to e7trude fro& t+e output no66'e-

t+e pressure f'o. >P&ust e7ceed t+e drag f'o. >Dto

gi*e a tota' f'o.$

.


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SOLIDIFICTION

Once t+e &ateria' is e7truded- it s+ou'd idea'', re&aint+e sa&e s+ape and si6e$

Gra*it, and surface tension &a, cause t+e &ateria' to

c+ange s+ape$

T+e &ateria' &a, s+rin/ upon dr,ing and coo'ing- as.e'' as possi', eco&ing porous$

T+is can e &ini&i6ed , ensuring t+e te&perature

differentia' et.een t+e c+a&er and t+e surrounding

at&osp+ere is /ept to a &ini&u&$ T+is can e done , use of a contro''ed en*iron&enta'

c+a&er .+en ui'ding t+e part$



POSITIONL CONTROL

P'otting &ust e coordinated .it+ t+e e7trusion rate toensure s&oot+ and consistent deposition$

n, c+ange in direction resu't in a dece'eration

fo''o.ed , acce'eration$

T+e corresponding &ateria' f'o. rate &ust &atc+ t+isc+ange in speed -ot+er.ise- too &uc+ or too 'itt'e

&ateria' .i'' e deposited in a particu'ar region$

9+i'e c+eaper s,ste&s often &a/e use of e'ts dri*en

, stepper &otors- +ig+er cost s,ste&s t,pica'', use

ser*o dri*es .it+ 'eadscre. tec+no'og,$



:ONDING

For +eat8ased s,ste&s t+ere &ust e sufficientresidua' +eat energ, to acti*ate t+e surfaces of t+e

adBacent regions- causing onding$

If t+ere is insufficient energ,- t+e regions &a, ad+ere-

ut t+ere .ou'd e a distinct oundar, et.een ne.and pre*ious', deposited &ateria'$

T+is can represent a fracture surface .+ere t+e

&ateria's can e easi', separated$

Too &uc+ energ, &a, cause t+e pre*ious', deposited

&ateria' to f'o.- .+ic+ in turn &a, resu't in a poor',

defined part$



SUPPORT MTERIL More recent FDM s,ste&s inc'ude t.o no66'es- one for

part &ateria' and ot+er for support &ateria'$

In FDM- a supporting structure is re


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Fused deposition

modelling


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FDM 3000

by Stratasys


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COMPRISION 9IT? OT?ER PROCESSES

SL and Po',!et use p+otopo',&ers t+at can e sensiti*eto &oisture$ FDM protot,pes are unaffected , &oisture$

T+e, retain t+eir origina' &ec+anica' properties and

di&ensiona' accurac,$

For co&&on tip si6es and ui'd para&eters- t+e

&ini&u& feature si6e ranges fro& 5$51= to 5$5%; in

.+ic+ is 'arger t+an t+at of SL and Po',!et$

FDM offers a .ide range of ui'd en*e'opes$ Ma7u&-

t+e iggest- offers parts si6es up to %#$= 7 13$@ 7 %#$=

inc+es$ Prodig, P'us- t+e s&a''est- +as an en*e'ope of 4 7

4 7 1% inc+es$


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DNTGES

?ig+ strengt+

It is cost8effecti*e

9aterproof

It can use :S(cr,'onitri'e utadiene st,rene).+ic+ is a co&&on t+er&op'astic po',&er$ Its g'ass

transition te&perature is appro7i&ate', 15" C (%%1

F)) &ateria' for its i&pact resistance and toug+ness-

and &u'tip'e &ateria' co'ors are a*ai'a'e


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DISDNTGES

ccurac, is re'ati*e', 'o. and is difficu't to ui'dparts .it+ co&p'icated detai's$

Poor strengt+ in *ertica' direction$

S'o. for ui'ding a &ass part$


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