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Proceedings of CAD'17, 2017, 50-54
Virtual Quality Assessment Tools for Material Extrusion Processes
Abstract. The material extrusion additive manufacturing (AM) process family includes the well-established fused deposition modeling (FDM) process, and processes presently under development such as the ‘Big Area Additive Manufacturing’ (BAAM) , large scale additive manufacturing, (LSAM), and Medium Area Additive Manufacturing (MAAM) processes. Layers are built from molten thermoplastic filaments or fibre-reinforced filaments. The general material extrusion process characteristics are similar, as material is fed through a temperature-controlled head and extruded when it is in a semi-viscous state. However, the size and shape vary for these processes, as the beads may vary from 0.25 mm in width to 12 mm, and some processes apply a force onto the extruded bead to facilitate inter-layer bonding. The anisotropic properties associated with the layered manufacturing process are well known; however, when exploring mechanical properties for tensile and compressive samples with ‘lightweighting’ internal voids, unexpected failure results occurred. The original research goal was to reduce material costs without compromising the product performance characteristics.
Keywords. Additive Manufacturing, Material Extrusion, FDM, Voids, Discontinuities, Process Optimization