Literature Review

Course Name: ISEE.741.600 - 3D

Printing

Instructor Name: Dr. Salman Pervaiz

Student Name: Ferdi Victor van Dort

(FVV4828)
Paper 1: An assessment of the effect of printing orientation, density, and filler pattern
on the compressive performance of 3D printed ABS structures by fuse deposition.

In the field of additive manufacturing, the field of research is still relatively young and not

fully developed due to the patents on the machinery, process, and materials posing a

roadblock to the new development of the field. This has changed in recent years due to the

field growing and the applications expanding. The first paper that is to be reviewed concerns

itself with the effect of several properties on ABS manufactured specimens through the use of

a fused deposition. The specimens used in this study are cylindrical specimens of consistent

size and external shape to not hinder any differences in the stress-strain curve. The properties

investigated in this paper are as follows: density of the specimen, this is tested through the

use of 5 degrees of filler percentage of which are 0%, 20%, 30%, 40%, and 100%

respectively. The next property that is investigated is the filler pattern where the specimen

consisted either of the hone-comb or the rectangular patterns, the last property that is

investigated in this study is the printing orientation of 0 degrees, 45 degrees, and 90 degrees

respectively. The findings of this experiment are determined through several uniaxial

compression tests to determine the stiffness, specific compressive strength, specific

compressive stiffness, and compressive strength. Through the experiments conducted in the

study, the conclusion drawn is that rectangular shape printed specimens are relatively more

suitable for mass production in comparison with honeycomb-patterned specimens. Another

conclusion that can be drawn from this study is that the honeycomb-patterned specimens that

are printed in the longitudinal direction have a comparatively higher strength/mass ratio in

comparison to the rectangular-shaped specimens. The last conclusion to be drawn from this

study is that solid structures (as hypothesized in the study ) regardless of infill show the

highest strength if the weight is not limited. [4]

Paper 2: Influence of manufacturing parameters on the mechanical properties of

projection stereolithography–manufactured specimens

The study that is reviewed concerns itself with the following parameters that are to be

investigated: layer thickness, post-curing time, and the build orientation of the model. The

technique of additive manufacturing used in this study is stereolithography (SLA for short),

this process concerns itself with a laser beam that initiates a chemical reaction in a vat of

prepared chemicals, through this chemical reaction, the liquid solidifies, and the build

platform is lowered where another layer is solidified. This process continues until the

specimen is completely built. The specimen shape is the characteristically prevalent bone

shape, which is commonly used for this type of study as it is ideal to test strain in universal

testing machines. The study concerns itself with 3 different build orientations:

longitudinal(y-axis), transverse(x-axis), and normal(z-axis). The different layer thicknesses

investigated in this study are 50 and 100 µ m, after testing the different parameters against

one another, it is concluded that the behavior of the specimens does not show any large

differences, and therefore the study concludes that there is the little result obtained. The last

parameter that is investigated is the curing time, the study uses 4 different curing times and

discovers that there is a general increase of properties across the board when the curing time

is increased. The study repeated the same experiment with the following material: ABS, X-

Green, and S-PRO where the conclusions are relatively similar, with the build orientation

showing the strongest influence of the tested properties. [1]

Paper 3: Fatigue Behavior of FDM Parts Manufactured with Ultem 9085

This article discusses the fatigue behavior of FDM specimens manufactured with Ultem

9085. For this, tensile bars are manufactured according to ASTM D638 in different build

orientations. Tests are performed in a range of pulsating tensile stresses, and S-N curves are

documented for different build orientations. In further tests, tensile bars were chemically

smoothed with chloroform vapor. Chemical smoothing reduces surface roughness and

increases the tensile strength of specimens in the upright build direction. Fatigue tests of

chemically treated specimens show no significant lifetime increase. Up to 120 min of

treatment time, the strength of the Z-direction can be increased from originally 43.5 MPa to

50.6 MPa. The cyclic loads of FDM test specimens in the pure tensile range show, at loads of

40% of the tensile strength, only 8272 ± 342 cycles for the X-direction, 8337 ± 1501 cycles

for the Y-direction, and 4170 ± 854 cycles for the Z-direction. Should at least 100,000 load

cycles be specified, then the occurring stresses should not be higher than approximately 12

MPa for the X- and Y-orientations and around 6.5 MPa for the Z-orientation. Because the

described results contain only information on the load level and load cycles up to failure,

there is still a need for more research on this subject. For this reason, the measuring data

already recorded will be further evaluated about the increase in elongation during the test to

generate information on the point in time when the crack forms. In some cases, high standard

deviations with chemically treated specimens are attributable to the simple test setup, with

which a high reproducibility of the chemical treatment cannot be guaranteed. [5]

Paper 4: Characterization of particle emission from thermoplastic additive

manufacturing

Particle emission from fused-deposition modeling desktop 3D printers has raised concerns

regarding indoor personal health due to the increased accessibility of printers. For the first

time, a novel thermogravimetric analysis method is developed to emulate the printing

process, which offers an insight into particle formation during extruder heating, standing-by

and during the printing process. Printing temperature and printing layer height demonstrates a

major effect on the ultra-fine particles emitted, while ABS filament color shows a minor

effect on the nanoparticle emissions. The local temperature and concentration of volatile

organic material emitted from the filament play an important role in the number of particles

formed, while printing duration and air change rate affect particle size, morphology, and

emission rate. The developed TGA method demonstrates the qualitative behavior of particle

emissions from the material under heating, which is approximately proportional to an FDM

printers’ particle emissions; facilitating increased repeatability, time, and cost efficiency for

printing material assessment. A new method that combines the measurement of real-time

particle size distributions with TGA of the printing filament has been successfully developed

to understand particle formation. Extrusion and TGA heating temperatures were performed to

characterize the particle emissions in terms of number, size, and morphology. A maximum

particle emission rate of 5.16 × 1010 #/min is observed with an average emission rate of 1.01

× 1010 #/min for short-duration printing. Overall, printing temperature has the most

significant effect on particle emission rate. The developed TGA method provides information

on the behavior of particulate emissions of the filament materials under heating. It could be

employed, for instance, as a qualitative indication of the materials’ propensity to form

particles without the time and cost implications associated with repeated 3D printing. Whilst

manufacturing variables are crucial parameters to explore, TGA provides a methodology for
the qualitative assessment of materials against printing temperatures as well as contributing to

the understanding of particle formation mechanisms. Further investigation is required to

systematically compare the quantitative results of TGA with 3D printing chamber

experiments, including the evaluation of the applicability of the TGA method to other types

of filament. [12]

Paper 5: Experimental investigation and optimization of FDM process parameters for

material and mechanical strength

The review investigated the capability of bio-motivated infill designs for added substance

production. All infill designs are chosen roused naturally. Two significant targets specifically

material utilization and compressive strength for chosen boundaries layer thickness, construct

direction, infill designs with differing densities have been examined. The FDM machine is

utilized for test manufacture which is additionally tried to concentrate on the compressive

strength and feedstock material utilization. The outcomes show that the example with 80%

infill gyroid design at 0.2 mm layer thickness and 90° develop direction gives the

compressive fortitude near the strong aspect of acrylic butadiene styrene material. The

discoveries of the current review can help originators of savvy designs to acquire high

solidarity to-weight proportion in mechanical parts. The gyroid design with 80% infill, least

layer thickness, and 45-degree development direction give the most elevated compressive

fortitude among all chosen blends of boundaries. The connection between the two chosen

goals as for their boundaries is additionally settled through the Pareto graph. The Pareto

graph can assist with getting the greatest mechanical strength with the least assets utilization.

The current work can be reached out to examine mechanical properties other than

compressive strength with comparable interaction conditions. [3]

Paper 6: Melt flow behavior of poly-ε-caprolactone in fused deposition modeling

The melt flow behavior (MFB) influences the nature of the framework which relies not just

upon the strain angle, its speed, and the temperature slopes but also on the actual properties

like the dissolving temperature and rheology. The MFB is concentrated on utilizing precise

channel math by changing fiber speed at the section and by fluctuating spout widths and

points at the exit. The relative consequences of both numerical displaying and FEA propose

that the tension drop and the speeds of the softened stream rely upon the stream channel

boundaries. One induction specifically noteworthy is the temperature inclination of the PCL

soften, which shows that it condenses inside 35% of the channel length. These outcomes are

important to all the more likely comprehend the MFB of biomaterials that influences the

nature of the platform assembled through FDM and can likewise be utilized to foresee the

MFB of other biomaterials. Taking everything into account, the soften stream conduct (MFB)

of PCL in the liquefy stream channel of the FDM has been researched by concentrating on

the warm way of behaving, pressure drops, and the speed slopes. [11]
 Paper 7: Facile manufacturing of fused-deposition modeled composite scaffolds for

tissue engineering—and embedding model with plasticity for incorporation of

additives

The fused deposition modeling (FDM) process is completed at a raised temperature,

forestalling the expansion of organic variables, drugs, bioactive mixtures, and so forth, during

manufacture. To defeat this impediment, a 3D interlinked permeable polylactic corrosive

(PLA) platform was created by FDM, trailed by the installation of a polycaprolactone (PCL)

framework into the pores of the PLA at room temperature, yielding a PLA-PCL framework.

What's more, PLA-PCL frameworks with nanohydroxyapatite (PLA-PCL-nHAP) and

multiwalled carbon nanotubes (PLA-PCL-MWCNT) were additionally created. Here, the

FDM-created PLA framework capacities as the underlying part, though the installed PCL

platform goes about as the utilitarian part, which gives the capacity to functionalize the

platforms with the ideal compound or organic materials. The implanting system is clear,

savvy, and doesn't need complexity. A mechanical portrayal of the platforms proposes that

Young's modulus of the PLA-PCL framework (16.02 MPa) was higher than that of the FDM-

created PLA (9.98 MPa) platform, by the goodness of the installed PCL grid. Likewise, the

limited component investigation showed that the von Mises weight on a mandible with

frameworks was 4.04 MPa, while for a mandible with imperfection, it was 6.7 MPa,

affirming the pressure dispersion effectiveness and mechanical security of these platforms. A

PLA-PCL platform was created by installing a permeable PCL framework into the pores of

an FDM-PLA platform, through a clear and basic inserting process. From the mechanical

review, the study found that the PLA-PCL, PLA-PCL-nHAP, and PLA-PCL-MWCNT

frameworks had a higher Young's modulus, contrasted with the PLA-printed platform.

Furthermore, FEA uncovered that all gatherings of platforms diminished von Mises pressure,

inferring their mechanical strength. Besides, in vitro investigation with human osteoblasts
showed uniform mineralization, affirming the osteoconductive idea of the frameworks. To

finish up, this effortless and savvy model assists with defeating the deficiencies of FDM, with

an arrangement for the consolidation of hotness labile biomolecules, nano-ceramics,

nanoparticles, and other polymeric materials appropriate for bone-tissue designing. Also, this

model beats the troubles of assembling added substance fibers for FDM, which is tedious and

costly, by giving a method for consolidating any ideal added substances at predefined

fixations. This outcome has not been recently announced. [9]

Paper 8: A wide frequency absorbing material added CIPs using the fuse deposition

modeling

The broadband engrossing property of the retaining material has been quite possibly the main

properties of the engrossing material. In this paper, broadband radar retaining materials were

ready by the immediate circuit statement demonstrating. Right off the bat, the printing line

made of CIPs and the hot dissolve plastic was manufactured utilizing the mechanical soften

blending process. Then, at that point, the line property was tried utilizing the vibrating test

magnetometer and X-beam diffraction machine, the electromagnetic boundary was estimated

utilizing the vector network analyzer E8363C in the recurrence 2-18 GHz. Afterward, the

high focus weakening to the low fixation rule is checked by the transmission/reflection

coefficient strategy, in which the unit occasional cluster design of the safeguard was laid out

to mimic the reflectivity at the CST programming stage. Involving the hereditary calculation

for the multi-facet retaining materials, advancement boundaries of each layer with the

thickness and the permeable expansion extent were laid out. The test results show that the

retaining material has superb engrossing execution in 2-18 GHz, the bandwidth can arrive at

almost 15 GHz as the RL was beneath than - 8 dB with a thickness of just 2.8 mm. [14]
Paper 9: Recycling Polymer Blend made from Post-used Styrofoam and Polypropylene

for Fused Deposition Modelling

Fused Deposit Modeling (FDM) has turned into a progressive assembling innovation as it

offers various benefits, including the opportunity of creation, mass customization, quick

prototyping, and cost-viability. Thermoplastic material is normally utilized as feedstock for

the FDM process. The present status of material turn of events, the reused plastic material

additionally can be utilized as printing material for FDM machine. Extended polystyrene

(EPS) has been widely utilized as bundling materials for some ventures yet seldom be reused,

as its moderately enormous volume with insignificant weight is unconducive for

transportation. This examination intended to use EPS waste and transform it into FDM

feedstock. This exploration additionally expects to improve the properties of reused

polystyrene (rPS) produced using EPS squander by mixing it with polypropylene (PP).

Various proportions of rPS/PP mixes were ready and expelled into FDM fiber utilizing a fiber

extruder. The planned fibers were printed into an example utilizing an FDM machine. This

exploration observed the fiber produced using rPS/PP mixes can be printed into examples

with great printing quality if the spout temperature is controlled at 240° C with a 120 %

expulsion rate. With this printing boundary, the example printed with rPS/PP mix fiber

display the best attachment between the kept layers with no noticeable voids or holes.

Additionally, the printed example with rPS/PP mixes has lower rigidity, however higher

tractable modulus when contrasted with the printed example with perfect rPS. The expansion

of more PP diminished both rigidity and modulus of rPS/PP mixes. Then again, the rPS/PP

mixes have higher warm security as the PP content expanded. Generally speaking, the rPS/PP

mixes fiber shows an extraordinary potential as a feedstock material for FDM manufacture.

[13]
Paper 10: Mechanical characterization of FDM 3D printing of continuous carbon fiber

reinforced PLA composites

Additive manufacturing of fiber-reinforced composites is of great interest in various

industrial applications. In this study, an innovative extruder is designed and manufactured for

fused deposition modeling 3D printers to produce continuous fiber-reinforced thermoplastic

composites. There are some challenges along this way such as making tension in fiber, fiber

surface preparation, printing temperature, and feed rate to produce a composite part with

good quality. The main advantage of this extruder is that it can be mounted on the available

FDM 3D printers and consequently there is no need to design a new chassis. To assess the

quality of products, standard tensile and three-point bending specimens made of pure

polylactic acid and carbon fiber reinforced PLA are printed and tested under quasi-static

loading. Experimental results show significant improvements in the tensile and bending

properties of PLA. Morphological analysis is also conducted to study the bonding between

carbon fiber and PLA. [6]

Paper 11: Comprehensive investigation and prediction model for mechanical properties

of coconut wood–polylactic acid composites filaments for FDM 3D printing

The experimental investigation was carried out according to the ASTM standards at different

infill densities and five different infill patterns. The obtained results proved that concentric

infill pattern accompanied by 75% infill percentage achieved the most outstanding tensile and

bending behavior. For compression testing, a grid infill pattern accompanied by a 75% infill

percentage exhibits maximum compression properties. Overall, the octagram spiral infill

pattern shows the weakest properties among all the infill patterns. The experimental results

were further analyzed using response surface methodology to identify the effectiveness of

studied parameters on mechanical properties and to derive a mathematical model. The

derived mathematical models related to studied mechanical properties have been proposed to

predict the desired mechanical properties concerning the variation of infill patterns and

percentages. In conclusion, the tensile test results showed that infill pattern, infill percentage,

and interaction effect of infill pattern and percentage significantly affect the UTS, elastic

modulus, and yield strength. [7]

Paper 12: A Lower Temperature FDM 3D Printing for the Manufacture of Patient-

Specific Immediate Release Tablets

This study aims to adapt a widely used pharmaceutical-grade polymer, polyvinylpyrrolidone,

for instant on-demand production of immediate-release tablets via FDM 3D printing. In vitro,

drug release studies for all 3D printed tablets were conducted in a USP II dissolution

apparatus. Bridging the 3D printing process with HME in the presence of a thermostable

filler, talc enabled the fabrication of immediate-release tablets at temperatures as low as

110°C. The integrity of the two model drugs was maintained following HME and FDM 3D

printing. XRPD indicated that a portion of the loaded theophylline remained crysthor one in

the tablet. The fabricated tablets demonstrated excellent mechanical properties, acceptable in-

batch variability, and an immediate in vitro release pattern. Combining the advantages of

PVP as an impeding polymer with FDM 3D printing at low temperatures, this approach holds

the potential in expanding the spectrum of drugs that could be used in FDM 3D printing for

on-demand manufacturing of individualized dosage forms. [10]

Paper 13: Tensile failure strength and separation angle of FDM 3D printing PLA

material: Experimental and theoretical analyses

It is discovered in this study that there exist two different failure modes and a special

separation angle which is the demarcation point of the two different failure modes when

FDM 3D printing materials fail under a tensile load. To further understand the mechanical

properties of FDM 3D printing materials and promote the use of FDM 3D printing materials,

their tensile failure strengths at different printing angles and separation angles are measured

and analyzed theoretically. A new separate-modes of transversely isotropic theoretical failure

model is established to predict the tensile failure strength and separation angle of FDM 3D

printing PLA material based on the hypothesis of transverse isotropy and the classical

separate-modes failure criterion. During this research, the tensile specimens designed

according to the current test standard ISO for plastic-multi-purpose specimens are fabricated

in 7 different printing angles and three levels of printing layer thickness. Meanwhile, inter-

layer failure tends to occur when the printing angle is small and in-layer failure tends to occur

when the printing angle is big. [15]

Paper 14: Mechanical properties of PLA-graphene filament for FDM 3D printing

The mechanical properties can be enhanced by studying the numerous FDM parameters and

by using new materials. In this study, was studied the mechanical properties of tensile

strength, flexural strength, and impact energy of 3D printed parts manufactured with FDM

technology and PLA-graphene raw material by varying the infill and layer thickness

parameters using a statistical technique CCD—central composite design. The results showed

that the mechanical properties improve as the linear layer thickness parameter increases. The

mechanical properties, tensile strength, and flexural strength increased as the infill increased,

while impact energy decreased as the infill increased. The relationship between mechanical
properties and printing time/weight was also evaluated. So the theoretical model based on the

transversely isotropic material hypothesis and separate failure-modes hypothesis established

in this research is suitable for the failure of FDM 3D printing PLA material and has the

capacity in predicting the tensile failure strength of this material. The theoretical model is

shown to be able to approximately predict the range of separation angle of this FDM 3D

printing PLA material. Two different failure modes are discovered in the tensile experiments.

Inter-layer failure mode occurs when the pointing angle is small while in-layer failure mode

occurs when the pointing angle is big. The tensile failure strength of this FDM 3D printing

PLA material with the same printing angles becomes bigger as its layer thickness decreases

from 0.3 mm to 0.1 mm. [2]

Paper 15: Low temperature fused deposition modeling (FDM) 3D printing of

thermolabile drugs’

The objective of this study was to print low-melting and thermolabile drugs by reducing the

FDM printing temperature. Two immediate release polymers, Kollidon VA64 and Kollidon

12PF were investigated as potential candidates for low-temperature FDM printing. Ramipril

was used as the model low melting temperature drug; to the authors’ knowledge, this is the

lowest melting point drug investigated to date by FDM printing. Filaments loaded with 3%

drug were obtained by hot-melt extrusion at 70 °C and ramipril printlets with a dose

equivalent of 8.8 mg were printed at 90 °C. Variable temperature Raman and solid-state

nuclear magnetic resonance spectroscopy techniques were used to evaluate drug stability over

the processing temperature range. The use of the excipients Kollidon VA64 and Kollidon

12PF in FDM was further validated by printing with the drug 4-aminosalicylic acid, which in

previous work was reported to undergo degradation in FDM printing, but here it was found to

be stable. This work demonstrates that the selection and use of new excipients can overcome
one of the major disadvantages in FDM printing, drug degradation due to thermal heating,

making this technology suitable for drugs with lower melting temperatures. [8]
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Properties of Coconut Wood–Polylactic Acid Composites Filaments for FDM 3D

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Composite Scaffolds for Tissue Engineering—an Embedding Model with Plasticity for

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[13] William, L. J. W., et al. “Recycling Polymer Blend Made from Post-Used Styrofoam

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