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3D printing of metal parts using a highly-filled thermoplastic filament

Sandra Rodríguez-Alvarez (Department of Process and Product Development, Arcelor Mittal Global R&D Spain, Aviles, Spain and Departamento de Ciencia e Ingenieria de Materiales e Ingenieria Quimica, IAAB, Universidad Carlos III de Madrid, Leganes, Spain)
Laura del Río-Fernández (Department of Process and Product Development, Arcelor Mittal Global R&D Spain, Aviles, Spain)
Daniel del Río-Santos (Departamento de Ciencia e Ingenieria de Materiales e Ingenieria Quimica, IAAB, Universidad Carlos III de Madrid, Leganes, Spain)
Carmen de la Torre-Gamarra (Departamento de Ciencia e Ingenieria de Materiales e Ingenieria Quimica, IAAB, Universidad Carlos III de Madrid, Leganes, Spain)
Belen Levenfeld (Departamento de Ciencia e Ingenieria de Materiales e Ingenieria Quimica, IAAB, Universidad Carlos III de Madrid, Leganes, Spain)
Alejandro Varez (Departamento de Ciencia e Ingenieria de Materiales e Ingenieria Quimica, IAAB, Universidad Carlos III de Madrid, Leganes, Spain)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 17 October 2024

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Abstract

Purpose

This study aims to develop a highly loaded filament with spherical metallic particles for fused filament fabrication (FFF) technology. The research focuses on optimizing powder loading, printing parameters and final processes, including debinding and sintering, to produce successful metal parts.

Design/methodology/approach

The optimal powder loading was identified by measuring mixing torque and viscosity at various temperatures. The filament was extruded, and printing parameters − particularly printing speed to ensure proper material flow − were optimized. Different filling patterns were also examined. After printing, the polymeric binder was removed and the parts were sintered to form the final metal components.

Findings

The optimal powder loading was determined to be 55 vol.%. The best surface quality was achieved with an optimized printing speed of 5 mm/s. Parts printed with various infill patterns were studied for differences in open, closed and total porosity, showing a strong link between porosity and infill pattern.

Originality/value

This comprehensive study provides new insights into manufacturing metal parts using FFF technology. It fills a gap in the literature regarding feedstock viscosity and shear rate in highly loaded metal filaments during FFF. Additionally, it uniquely examines the open, closed and total porosity of metal parts printed with different infill patterns.

Keywords

Acknowledgements

Funding for this work was provided by ArcelorMittal. Sandra Rodriguez acknowledges Dr Asier Lores Erazo of Tecnalia research center for his help in the performance of the hydrogen sintering cycles.

Citation

Rodríguez-Alvarez, S., del Río-Fernández, L.d.R., del Río-Santos, D., de la Torre-Gamarra, C., Levenfeld, B. and Varez, A. (2024), "3D printing of metal parts using a highly-filled thermoplastic filament", Rapid Prototyping Journal, Vol. ahead-of-print No. ahead-of-print. https://doi.org/10.1108/RPJ-01-2024-0043

Publisher

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Emerald Publishing Limited

Copyright © 2024, Emerald Publishing Limited

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