This study aims to characterize the suitability of a direct extrusion process in the fused layer manufacturing (FLM)-method under processing of granulated plastics.
In this paper, a granulate-based direct extrusion system in the FLM method is presented. This system is characterized with respect to the strand deposition mechanism and resulting component properties (geometrically and mechanically).
The extruder output could be identified as a linear relation between the applied extruder speed and the resulting mass flow. A developed model for the material and temperature-dependent strand deposition process was validated under experimental investigations. Further, it was possible to define process windows to realize desired strand widths and strand heights. In addition, analyses were conducted to determine the tensile strength transversely to the orientation of the layer plane.
The extrusion system was characterized under the processing of materials ABS Magnum 8434 and PLA Ingeo 4043D. Due to the restricted choice of materials, further investigations are planned under an extension of the test materials. Furthermore, the degree of the geometric complexity of the test components should be increased to finally characterize the process.
By means of the characterization of the direct extrusion system, it is possible for users to classify the process and to use the process in specific application areas. In comparison to filament-based extrusion systems, significant advantages can be achieved by means of direct extrusion. These include, for example, the use of less expensive work materials (by factor >10), the use of existing test certificates and the advantage of higher mechanical properties. This makes it possible to meet modern product requirements and to produce competitive components.
This research and development project is funded by the German Federal Ministry of Education and Research (BMBF) within the “Innovations for Tomorrow’s Production, Services, and Work” Program (funding number 02P14A024) and implemented by the Project Management Agency Karlsruhe (PTKA). The author is responsible for the content of this publication.
Schmidt, L., Schricker, K., Bergmann, J.P., Hussenöder, F. and Eiber, M. (2019), "Characterization of a granulate-based strand deposition process in the FLM-method for definition of material-dependent process strategies", Rapid Prototyping Journal, Vol. 25 No. 1, pp. 104-116. https://doi.org/10.1108/RPJ-09-2017-0186Download as .RIS
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