Fused Deposition Modeling

In this chapter, an overview of the basic principles of fused deposition modelling, commonly known as 3D printing technology, is presented. The chapter begins by introducing the holistic concept of additive manufacturing and its scientific principle as the technology for the modern and future industry. Then, the science of 3D printing is described. The applications of FDM in various fields are also highlighted with a focus on an interesting role the 3D printing technology is playing in the fight against Covid-19 pandemic. The chapter also gives a highlight of the parameters involved in fused deposition modelling of polymers and their basic interaction with the properties of the manufactured components. In relation to the process parameters, quality aspects of FDM products have also been briefly described in the chapter.

In this chapter, a strategy for enhancing surface roughness and hardness based on the full factorial design of layer resolution and build orientation is illustrated. Layer resolution levels of 0.1 mm, 0.2 mm and 0.3 mm and build orientations of 0°, 15°, 30°, 45°, 60° and 90° were used to develop the full factorial design of experiments (DOE). Analysis of variance (ANOVA) was undertaken to determine the statistical significance of the factors to roughness and hardness properties of the printed parts. The mean interaction plots of the data were also used to study the interrelationships among the responses and the two printing parameters. The results revealed that layer resolution is the most significant parameter influencing the mean surface roughness of the PLA printed samples whereas build orientation closely influences the surface hardness as compared to the layer resolution although the ANOVA reveals that both parameters are statistically insignificant as far as hardness is concerned.

In this chapter, multi-objective optimization as a strategy for quality production of parts through fused deposition modelling is presented. Various techniques used in undertaking the multi-objective optimization process are described based on case studies from the literature and the authors’ data. The general algorithms for multi-objective optimization of the FDM process are described. The most significant objectives of the various optimization cases are identified and described in relation to the quality of the fused deposition modelling of parts. The main objectives for optimizing fused deposition process are (i) to increase the rate of production, (ii) to reduce material wastage and utilize as minimum material as possible, (iii) save on the cost of power consumption during printing and (iv) achieve the highest quality of FDM parts.

In this chapter, surface engineering techniques for enhancing the surface properties of 3D printed parts are described. The strategies are classified broadly into traditional and modern (advanced) technologies. Under traditional methods, sanding, polishing, painting, gap filling and dipping are discussed as some of the processes for enhancing the surface quality of FDM parts. Under modern technologies, chemical vapour deposition, physical vapour deposition and vapour smoothing are identified as some of the most important methods for surface engineering of FDM parts. For each method, operating principles, advantages and limitations are described while quality enhancement aspects for FDM parts are also highlighted.