Fused Deposition Modelling(filament and pellet extrusion processes)
*Times to print the orange juice squeezer by FDM:
About 12 hours (100% fill); Wt about 100gramsBetween 8 to 10 hours (20% fill); Wt about 70 grams
*
Print rate about10-2 kg/hr
T. Gutowski - Limited Distribution 2
Melting (Fe, Al)
Vaporization (Al)
T. Gutowski - Limited Distribution 3
ConventionalMfg Processes
Advanced Machining Processes
Semiconductor Manufacturing
Nano materials
Machine toolimprovement
Junk and Cote 2012
9.4E-03 kg/hr,1.8 to 2.3 E+08 J/kg
Corman 2014
1.2 to 1.8 E-02 kg/hr, 4.1E+07 J/kg to 2.9 E+08
J/kg
EPRI 2014
2.2E-02 kg/hr, 2.8 to 4.0 E+08J/kg
EPRI 2014 , BAAM,
10.0 kg/hr, 4.0E+06 J/kg
Telenko et al. 2011,
2.6E-02 kg/hr, 5.0E+08 J/kgBaumers et al. 2011,
4.1E-01 kg/hr, 2.0E+08 J/kgKellens et al. 2011,
4.1E-02 kg/hr, 1.3E+08 J/kg
Morrow et al. 2005,
3.6E-03kg/hr, 7.7E+09 J/kg
Baumers et al. 2010 ,
1.3E-01 kg/hr, 6.1E+07 J/kg
EPRI 2014,
8.9E-02 kg/hr, 1.1E+08 J/kg
Faludi et al. 2017 Full bed,
1.1E-02 kg/hr, 5.7E+08 J/kg
Faludi et al 2017 Single bed,
4.0E-02 kg/hr,1.2E+09 J/kg
Baumers et al. 2010 Full bed,
5.6E-02 kg/hr,1.1E+08 J/kg
Baumers et al. 2010 Single bed,
4.0E-02 kg/hr, 1.4E+08 J/kg
EPRI 2014
Binder jetting, 6.5E-03 kg/hr, 8.3E+07 J/kg
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
1.E+10
1.E+11
1.E+12
1.E+13
1.E+14
1.E+15
1.E-06 1.E-05 1.E-04 1.E-03 1.E-02 1.E-01 1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06
Ele
ctr
icit
y R
equ
irem
ents
[J/
kg]
Process Rate [kg/hr]
cupola Electric Induction Melting Injection Molding
Machining Finish Machining CVD
Sputtering Grinding Waterjet
Wire EDM Drill EDM Oxidation (Semiconductor)
Material Extrusion: FDM Material Extrusion: BAAM Powder bed fusion: Polymer, laser
Directed energy deposition: DMD Powder bed fusion: Metal, eletron beam Powder bed fusion: Metal, laser
Binder jetting
50 kW 5 kW
500 W
Measured 3D Printing energy intensity (J/kg)Vs Print rate (kg/hr) for AM (metals in red,
plastics in blue) overlaid on conventionalmanufacturing processes.
(Gutowski et al 2017 JIE)
BAAM technologyMore later…
L 2ro
From Lienhard’s bookfor the cooling andheating of cylinders.
For heating use:
𝜃 =𝑇∞ − 𝑇
𝑇∞ − 𝑇𝑖
For length L
ሶ𝑚 = 2𝜋𝑘
𝑐𝐿
Rate Limits on FDM
•Resolution
•Heating
•Grip forceGo, J., Schiffres, S. N., Stevens, A. G., & Hart, A. J. (2017). Rate limits of additive manufacturing by fused filament fabrication and guidelines for high-throughput system design. Additive Manufacturing, 16,
Rate Limits for resolution below 0.5 mm
Big Area Additive Manufacturing (BAAM)Single Screw Extruder
BAAM: longer heating zone, conductivepolymer and bulk heating mechanism
Lonnie Love at Oak RidgeDestructively testingThe BAMM material
Big Area Additive Manufacturing
5 axis machine tool
15
Contains unpublished data – limited distribution
Stratasys Dimension Elite FDM system
Chamber door
User interface
Build chamber
Material cartridges
Extrusion head
Guide rods
Lead screw
Main material cartridge
Support cartridge
Tip cleaning assembly
User interface
Purge container
Build platform
Build Envelope
(XYZ)
8 x 8 x 12 inches (203 x 203 x 305 mm)
Main material ABSplus
Support P400SR (SR-10) - Synthetic thermoplastic polymer
Material
Delivery
One build material canisters 56.3 in³ (923 cm³)
One support material canisters 56.3 in³ (923 cm³)
16
Contains unpublished data – limited distribution
FDM wheel manufacturing steps
CAD STL
FDM printing process Wheels on build sheet
Detaching from base layers Support removal (~4h) Final wheels
Parts in build chamber