Post-Processing of Parts and Components Fabricated by Fused Deposition Modeling: Techniques and Advancements (Advanced Materials Processing and Manufacturing)

Cover
Half Title
Series Information
Title Page
Copyright Page
Table of Contents
Preface
About the Editors
List of Contributors
Introduction
1 An Overview of Post-Processing of Fused Deposition Modelling 3D Printed Products
	1.1 Introduction
	1.2 Additive Manufacturing Process
	1.3 Post-Processing Methods of FDM 3D Printed Products
	1.4 Conclusion
	References
Section I Post-Processing Techniques for Improving the Quality of FDM 3D Printed Parts
	2 Chemical-Based Methods for Polishing Surfaces Produced By Material Extrusion Process
		2.1 Introduction
		2.2 Types of Chemical Treatment
			2.2.1 Dips in Acetone
			2.2.2 Vapor Treatment
			2.2.3 Electroplating
			2.2.4 Manual Painting
		2.3 Comparison and Conclusion
		References
	3 Surface Roughness Evaluation of Fused Deposition Modeling Additive-Manufactured Polylactic Acid Components Affected By 3D-Printing...
		3.1 Introduction
		3.2 Materials and Methods
		3.3 Results and Discussion
		3.4 Conclusions
		Acknowledgment
		References
	4 Post-Processing of Additive Manufacturing Functional Polymeric Parts: Influence On Surface, Dimensional Quality and Mechanical Performance
		4.1 Introduction
		4.2 Improvements in Surface
			4.2.1 Scope of Chemical Post-Processing
				4.2.1.1 Vapor Smoothing
				4.2.1.2 Support Removal Solvent
			4.2.2 Contribution of Thermal Processes
				4.2.2.1 Temperature Effects
				4.2.2.2 Combination of Temperature and Vacuum
			4.2.3 Influence of Mechanical Post-Processing, With and Without Chip Removal
				4.2.3.1 Impact of Surface Plastic Deformation
				4.2.3.2 Transformations Introduced By Machining
		4.3 Improvements in Mechanical Performance
			4.3.1 Influence of Chemical Post-Processing
			4.3.2 Effects of Heat Treatments
			4.3.3 Impact of Mechanical Post-Processing
		Acknowledgements
		References
	5 Coating Methods and Materials for 3D Printed (FDM) Parts
		5.1 Introduction
		5.2 Metal Coating On 3D Printed Polymer Products
			5.2.1 Electroplating
				5.2.1.1 Electroplating Process
			5.2.2 Electroless Coating
			5.2.3 Cold Spraying
			5.2.4 Dip Coating
		5.3 Polymer Based Coatings
			5.3.1 Chemical Vapor Deposition (CVD)
			5.3.2 UV Coating
			5.3.3 Dip Coating
			5.3.4 Water-Based Coatings
			5.3.5 Polydopamine (PDA) Coatings
		5.4 Conclusion
		References
Section II Joining/Welding as Post-Processing Techniques for FDM 3D Printed Parts
	6 Insights Into Various Joining/Welding Techniques to Evade the Built Volume Constraint of FDM-3D Printers
		6.1 Introduction
		6.2 Proposed Techniques for Joining/Welding FDM-3D Printed Parts
		6.3 Primitive Techniques
			6.3.1 Bonding 3D Printed Parts By Adhesives
			6.3.2 Usage of Fasteners
			6.3.3 Mechanical Interlocking
		6.4 Friction Based Welding Techniques
			6.4.1 Friction Stir Welding (FSW)
			6.4.2 Friction Stir Spot Welding (FSSW)
			6.4.3 Spin Friction Welding (SFW)
		6.5 New Joining Techniques
			6.5.1 Microwave Welding
			6.5.2 Ultrasonic Welding
		6.6 Big Area Additive Manufacturing (BAAM)
		6.7 Critical Challenges to Overcome in the Joining Techniques
		6.8 Conclusions
		Acknowledgments
		References
	7 Investigation of the Effect of Bonding Parameters On the Adhesive Bonding Strength of Parts Produced By FDM-3D Method
		7.1 Introduction
		7.2 Material and Methods
			7.2.1 Sample Processing
			7.2.2 Adhesive Properties
			7.2.3 The Design of Experiments (Taguchi Method)
			7.2.4 Hardness and Tensile Experiments
		7.3 Results and Discussion
			7.3.1 Tensile Test and Hardness Results
			7.3.2 Microstructure and Fracture Surface Images
			7.3.3 Analysis of the Factors
			7.3.4 Confirmation Tests
		7.4 Conclusions
		References
	8 Friction Stir Welding, Friction Stir Spot Welding and Spin Friction Welding of 3D Printed Components
		8.1 Introduction
		8.2 Effectiveness of the Weld
		8.3 Process Description for Friction Stir Welding (FSW)
		8.4 Process Description for Spin Friction Welding (SFW)
		8.5 Process Description for Friction Stir Spot Welding (FSSW)
		8.6 Important Welding Parameters for Friction Stir Welding (FSW)
		8.7 Important Welding Parameters for Friction Stir Spot Welding (FSSW)
		8.8 Important Welding Parameters for Spin Friction Welding (SFW)
		8.9 Friction Stir Welding of 3D Printed Parts – A Case Study
		8.10 A Case Study On Spin Friction Welding of 3D Printed Parts
		8.11 Comparison of Different Joining Techniques – A Case Study
		8.12 Conclusions
		Acknowledgments
		References
	9 Microwave and Ultrasonic Welding of FDM-3D Printed Components
		9.1 Introduction
		9.2 Process Description for Microwave Welding
		9.3 Process Description for Ultrasonic Welding
		9.4 Important Welding Parameters for Microwave Welding
		9.5 Microwave Welding Implants
		9.6 Important Welding Parameters for Ultrasonic Welding
		9.7 A Case Study On Microwave Welding of 3D Printed Parts
		Conclusions
		Acknowledgments
		References
Section III Miscellaneous Topics
	10 Big Area Additive Manufacturing (BAAM) of FDM Parts
		10.1 Introduction
		10.2 Methods of Additive Manufacturing
			10.2.1 VAT Photo Polymerization
			10.2.2 Material Jetting
			10.2.3 Binder Jetting
			10.2.4 Material Extrusion
			10.2.5 Powder Bed Fusion
			10.2.6 Sheet Lamination
			10.2.7 Directed Energy Deposition Process
		10.3 Materials Used in Additive Manufacturing
			10.3.1 Nylon
			10.3.2 Stainless Steel
			10.3.3 Titanium
			10.3.4 Alumite
			10.3.5 High Impact Polystyrene (HIPS)
		10.4 Challenges Faced in Additive Manufacturing
			10.4.1 Void Formation
			10.4.2 Stair – Stepping in BAAM
			10.4.3 Mechanical and Microstructure Used Ii Anisotropic Properties
			10.4.4 Small Build Volume
			10.4.5 Fabrication of Weapons Used in Defense
			10.4.6 Food and Drug Administration Safety Standard Compliance
		10.5 Big Area Concept in Additive Manufacturing
		10.6 Recent Trends in Big Area Additive Manufacturing
			10.6.1 The Additive Software Innovation Technique
			10.6.2 Increased Focus On Machine Connectivity
			10.6.3 Convergence of AM and AI
		10.7 Areas of Application of Big Area Additive Manufacturing
			10.7.1 Extrusion Process in BAAMs
			10.7.2 Behavior of Material Properties While Printing
			10.7.3 Material Surface Development With Advanced Composites
			10.7.4 Automotive Parts Made By BAAM
			10.7.5 BAAM Applied in Foundry Industry
			10.7.6 3D Printed Pre Cast Molds of Multi-Storied Buildings
			10.7.7 Infrared Preheating to Improve Interlayer Strength of Components
		10.8 Case Studies Related to Big Area Additive Manufacturing (BAAM)
			10.8.1 Additive Manufacturing of Down Hole Rotation Tool
			10.8.2 Additive Manufacturing in the South African Railway Industry
			10.8.3 Big Area Additive Manufacturing of a Single Seater Racing Car in Europe
			10.8.4 Using the BAAM Technique Reduces the Count of Components
			10.8.5 Use of Selective Laser Sintering for BAAM
		10.9 Big Area Additive Manufacturing Used in the FDM System
			10.9.1 Use of CAD for Creating 3D Models
			10.9.2 Slicing and Generation of Tool Paths
			10.9.3 Conversion of 3D Models Into Real Time Product
		10.10 Conclusion
		References
	11 Machine Learning in Post-Processing of Fused Deposition Modelling Parts
		11.1 Introduction
			11.1.1 Overview of Post-Processing Techniques for FDM Parts
				11.1.1.1 Sanding and Polishing
				11.1.1.2 Painting and Coating
				11.1.1.3 Vapor Smoothing
				11.1.1.4 Chemical Smoothing
				11.1.1.5 Heat Treating
				11.1.1.6 Support Removal
				11.1.1.7 Insert Installation
		11.2 Motivation for Using ML in Post-Processing
			11.2.1 Quality Control
			11.2.2 Design Optimization
			11.2.3 Automation
			11.2.4 Material Selection
		11.3 Essential Steps of ML
			11.3.1 Data Collection and Pre-Processing
		11.4 Machine Learning Methods
			11.4.1 Supervised Learning
			11.4.2 Unsupervised Learning
			11.4.3 Reinforcement Learning
		11.5 Brief Explanation of How Each Algorithm Works and Why It May Be Chosen
			11.5.1 Convolutional Neural Networks (CNNs)
			11.5.2 Decision Trees
			11.5.3 Random Forests
			11.5.4 Support Vector Machines (SVMs)
			11.5.5 K-Means Clustering
		11.6 Strengths and Limitations of ML Algorithm
		11.7 Accuracy and Usefulness of the ML Results
			11.7.1 Comparison of the ML Outcomes With Traditional Post-Processing Techniques
		11.8 Suggestions for Future Research
		11.9 Potential Applications of the ML Methods
		11.10 Concluding Remarks
			11.10.1 Final Thoughts On the Use of ML in FDM Post-Processing
			11.10.2 Recommendations for Practitioners and Researchers
		References
	12 A Study On Additive Manufacturing Processes, Standards and Mechanical Properties
		12.1 Introduction
		12.2 Additive Manufacturing Process (AM Process)
			12.2.1 Computer Aided Manufacturing (CAD)
			12.2.2 Converting to STL (STereoLithography)
			12.2.3 File Transfer to Machine
			12.2.4 Machine Setup
			12.2.5 Build
			12.2.6 Part Removal and Clean-Up
			12.2.7 Post-Processing
			12.2.8 Application
		12.3 Most Used AM Methods
			12.3.1 Fused Deposition Modelling (FDM)
			12.3.2 Powder Bed Fusion (PBF)
			12.3.3 Contour Crafting With Inkjet Printer
			12.3.4 Stereolithography (SLA)
			12.3.5 Direct Energy Deposition (DED)
			12.3.6 Laminated Object Manufacturing (LOM)
		12.4 Mechanical Properties of AM Materials
			12.4.1 Hardness Properties of AM Materials
			12.4.2 Tensile Properties of AM Materials
			12.4.3 AM Fabricated Parts – Compression Test
			12.4.4 AM Fabricated Parts – Surface Roughness
			12.4.5 Fracture Toughness Properties of AM Materials
			12.4.6 Fatigue Strength in AM Materials
		12.5 Studies On Mechanical Properties
		12.6 Conclusion
		References
	13 Exploring and Understanding the Possibilities of IoT in FDM-3D Printing
		13.1 Introduction
		13.2 IoT Based 3D Printing—What It Means
		13.3 IoT Based 3D Printing—How to Implement
		13.4 IoT Based 3D Printing-Challenges
		13.5 Case Study: Creation of a IoT Based 3D Printer
		13.6 Expected Trends in IoT Based 3D Printing
			13.6.1 Integration of IoT, AI Tools and 3D Printing
			13.6.2 Integration of IoT, 3D Printing and Blockchain Technology
		13.7 Conclusions
		Acknowledgment
		References
	14 Research Scope and Future Challenges in Post-Processing of FDM Parts
		14.1 Introduction
		14.2 Research Scope in Post-Processing of FDM Parts
			14.3 Post-Processing Techniques for FDM 3D Printed Parts
				14.3.1 Thermal Annealing Coupled With Isostatic Pressing
			14.3.2 Raised Temperature Followed With Resin Infiltration
			14.3.3 Abrasive Flow Machining
			14.3.4 CNC Machining
			14.3.5 Barrel Finishing
			14.3.6 Electroplating
		14.4 LFAM Systems—A Technology to Evade the Bed Size Limitation
		14.5 Hybrid Large Format Additive Manufacturing (LFAM) System
		14.6 Future Challenges in Post-Processing of FDM Parts
		14.7 Conclusions
		Acknowledgments
		References
Index