Fused Deposition Modeling of Composite Materials is dedicated to the field of 3D-printing of composite materials using a popular technique called Fused Deposition Modeling (FDM), the world’s most popular 3D printing method. But this method is currently limited to printing basic polymers and only a handful of primitive composite materials. Many future industries, such as Space, Biomed, Construction and Defense are waiting for the ability to 3D print composites and new functional materials with complex shapes and features so they can add unique and customizable features to their parts, including biocompatibility, radiation shielding, high-strength, rapid cooling, flexibility and shape-memory.
The book's authors take the reader through the basics of what the FDM technique is all about and describe the advantages and new opportunities arising from 3D printing innovative materials, which include polymer-matrix composites and fully inorganic parts. They then review and discuss methods for making the different types of composite feedstock filaments needed to 3D print such materials by FDM. Finally, sections discuss the challenges that should be considered in making filaments and parts and how to go about solving them.
Author(s): Antonella Sola, Adrian Trinchi
Series: Woodhead Publishing Series in Composites Science and Engineering
Publisher: Woodhead Publishing
Year: 2022
Language: English
Pages: 465
City: Cambridge
Cover
Title
Half title
Copyright
Contents
Preface
Chapter 1 Introduction to ^^e2^^80^^9cFused deposition modeling of composite materials^^e2^^80^^9d
1.1 Introduction: Why this book?
1.2 General outline of the present book
1.2.1 Time frame of the analyzed references
1.2.2 Nature of fillers considered herein
1.2.3 Specific perspective of the book
1.2.4 Supporting information
References
Chapter 2 Basic principles of fused deposition modeling
2.1 Introduction: Additive manufacturing and fused deposition modeling
2.2 Cost and quality considerations
2.3 How to print an object
2.4 Build-up mechanisms and governing parameters
References
Chapter 3 The need for fused deposition modeling of composite materials
3.1 Introduction: From mono-materials to composite feedstocks in FDM
3.2 Mono-material filaments
3.3 Research trends in composite feedstock in FDM
3.3.1 Polymer-matrix functional composites
3.3.2 FDM of fully inorganic parts from composite feedstock
3.4 Commercial composite filaments
3.5 Applications and case studies
3.5.1 Colorful filaments for new toys and toy rescue
3.5.2 Tagging features
3.5.3 Scaffolds for biomedical applications
3.5.4 3D pharming
3.5.5 4D printing
3.5.6 Manufacturing of composites
3.5.7 Industry case study: W^^c3^^a4rtsil^^c3^^a4 lifting tool
3.5.8 Industry case study: Tecron replica carburetor
References
Chapter 4 Production of composite filaments for fused deposition modeling
4.1 Introduction: Basic requirements of feedstock in FDM
4.2 Strategies for adding a filler
4.2.1 Filler geometry
4.2.2 Filler distribution
4.2.3 Strategies for alternative fillers and additives
4.3 Key production steps
4.3.1 Constituent blending and mixing
4.3.2 The extrusion process
4.3.3 Filament spooling
4.3.4 Filament diameter control and monitoring
4.4 Additional issues
References
Chapter 5 Characterization and quality assurance in fused deposition modeling
5.1 Introduction: Properties and quality of filaments and printed parts
5.2 Materials characterization in FDM
5.3 Characterization issues with printed parts
5.4 Characterization of continuous fiber-reinforced parts
5.5 Quality assurance
5.6 Quality assurance for the International Space Station
References
Chapter 6 Fused deposition modeling of polymer-matrix composites with discrete ceramic fillers
6.1 Introduction: Glass, ceramic, and carbonaceous fillers
6.2 Rationale for implementing discrete fillers
6.3 Mechanical reinforcement
6.3.1 Glass particles
6.3.2 Alumina particles
6.3.3 Mineral fillers
6.3.4 Carbonaceous fillers
6.4 Electrical conductivity
6.5 Thermal properties
6.6 Bioactivity and biological properties
6.6.1 Hydroxyapatite
6.6.2 Tricalcium phosphate and other phosphates
6.6.3 Bioactive glasses
6.6.4 Calcium carbonate
6.6.5 Titania
6.6.6 Zinc oxide
6.6.7 Carbon-based fillers
6.7 Case studies and special applications
References
Chapter 7 Fused deposition modeling of polymer-matrix composites with metal fillers
7.1 Introduction: Metal fillers
7.2 Case studies and relevant applications
7.2.1 Direct rapid tooling
7.2.2 Glazing bars for energy efficient windows
7.2.3 Mechanical reinforcement
7.2.4 Biomedical applications
7.2.5 X-ray shielding and aerospace industry
7.2.6 Electrically conductive materials in electronics and circuitry
7.2.7 Reactive materials
7.2.8 Friction welding
7.2.9 Surface finishing
References
Chapter 8 Fused deposition modeling of polymer-matrix composites with natural fibers
8.1 Introduction: What is a ^^e2^^80^^9cnatural fiber^^e2^^80^^9d?
8.2 Structure and properties of natural fibers
8.3 Examples of FDM composite parts filled with natural fibers
8.3.1 Continuous natural fibers
8.3.2 Short natural fibers
8.3.3 Wood flour and other powdered natural fillers
8.3.4 Nanocellulose
8.4 Natural fibers: Pros and cons
References
Chapter 9 Fused deposition modeling of continuous fiber-reinforced composites and sandwich structures
9.1 Introduction: Rationale for adopting continuous fibers
9.2 ^^e2^^80^^9cDual extrusion^^e2^^80^^9d method
9.3 ^^e2^^80^^9cIn-nozzle impregnation^^e2^^80^^9d method
9.4 ^^e2^^80^^9cDual extrusion^^e2^^80^^9d vs ^^e2^^80^^9cIn-nozzle impregnation^^e2^^80^^9d methods: Critical considerations
9.5 Other technological approaches to continuous fiber reinforcement
9.5.1 Commercial solutions to FDM with continuous fibers
9.5.2 Other technological approaches in the literature
9.6 Multi-layered and sandwich structures
9.7 FDM with continuous reinforcements: A summary
References
Chapter 10 Fused deposition modeling of fully inorganic parts: Shaping, debinding, and sintering \(SDS\)
10.1 Introduction: From a composite filament to a fully inorganic part
10.2 A three-step process: Shaping, debinding, and sintering
10.2.1 Shaping
10.2.2 Debinding
10.2.3 Sintering
10.3 SDS and powder injection molding
10.4 Ceramic-based parts \(fused deposition of ceramics, FDC\)
10.5 Metal-based parts \(fused deposition of metals, FDMet\)
10.5.1 FDMet and other metal AM technologies
10.5.2 Commercial systems for FDMet
10.5.3 Case studies in the literature
References
Chapter 11 Open challenges and future opportunities in fused deposition modeling of composite materials
11.1 Introduction: Pros and cons of composite materials
11.2 Optimization of processing conditions
11.3 Filler loading optimization
11.4 Environmental conditions
11.5 Porosity
11.6 Thermodilatometric compatibility
11.7 Improvement strategies
11.8 Sizing and surface modification of fillers
11.9 Isotropy vs anisotropy
11.10 Advanced materials: Functionality beyond mechanical reinforcement
11.11 What is next?
References
Chapter 12 Fused deposition modeling of composite materials at a glance ^^e2^^80^^93 supplementary tables
12.1 Introduction: A roadmap to FDM of composite materials
2 Supplementary table 1: State of the art
12.2.1 Supplementary table 1a ^^e2^^80^^93 review papers
12.2.2 Supplementary table 1b ^^e2^^80^^93 research papers on FDM
12.2.3 Supplementary table 1c ^^e2^^80^^93 research papers on continuous fiber-reinforced parts
12.2.4 Supplementary table 1d ^^e2^^80^^93 research papers on shaping, debinding and sintering
12.2.5 Supplementary table 1e ^^e2^^80^^93 other relevant research papers
12.3 Supplementary table 2
12.3.1 Supplementary table 2a ^^e2^^80^^93 tensile tests
12.3.2 Supplementary table 2b ^^e2^^80^^93 bending tests
References
Index
