Analysis of new additive manufacturing technology based on selective composite formation using finite element method approach

Abstract

Purpose

Over the past few years, the number of related research to additive manufacturing (AM) has risen. The selective composite formation (SCF) can also be found among the new technologies that were developed. This technology was first introduced in 2013, and because of its innovative character, there are still many challenges to be overcome. Therefore, the main aim of this study is to present a finite element method which allows to investigate the processing of the material during the selective formation of a composite material based on cellulose and acrylic.

Design/methodology/approach

In the beginning, we introduced a brand new finite element method approach which is based on light transmittance network and photopolymerisation in transient state. This method is mainly characterised by internal light absorption, transversal reflectance, light transmittance coefficient and photopolymerisation kinetics. The authors defined experimentally the main model coefficients besides investigating the formation of composite material in six case studies. The main variables evaluated in those studies were the number of layers and the number of lines. By the end, the degree of polymer conversion and the preliminary evaluation of adherence between layers were identified in addition to the formation profile of composite material.

Findings

The presented method evidence that the SCF resulted in a profile of polymerisation which is different from profiles found in vat polymerisation processes. It was shown that the light diffraction increases polymerisation area to outside of laser limits and reduces the penetration depth. It was also exposed that the selective formation of composite material on the top layer interferes with the polymerisation of previous layers and might increase the polymerised area in about 25 per cent per layer. By the end, adherence between layers was evidenced because of a high-pass filter that limited polymer conversion to over 60 per cent. In this case, the adherence between the top layers was provided by the interface between layers, while the deeper layers resulted in a solid formed by composite.

Originality/value

This paper presents research results related to a very new AM technology and also proposes a new method to characterise this concept. Because of this new analytic approach, the process planning can be simulated and optimised, in addition to being a useful tool for other researches related to photocurable polymers and AM technologies.

Citation

Cunico, M.W.M. and Carvalho, J.d. (2016), "Analysis of new additive manufacturing technology based on selective composite formation using finite element method approach", Rapid Prototyping Journal, Vol. 22 No. 3, pp. 519-526. https://doi.org/10.1108/RPJ-12-2014-0176