Effect of build orientation on the mechanical reliability of 3D printed ABS

Purpose Increasing use of 3D printing techniques to manufacture consumer products and open-source designs raises the question of “What is the mechanical reliability of 3D printed parts?” Therefore, the purpose of this paper is to investigate the impacts of build orientation on the mechanical reliability of acrylonitrile butadiene styrene (ABS) produced using 3D printing. Design/methodology/approach Tensile tests on ABS specimens were performed with and without a hole in the center, which were produced by fused deposition modeling (FDM). Seven sets of approximately 30 specimens were printed in XY, XZ and C+45 orientations to obtain reliable fracture statistics. Weibull analysis was performed to quantify the variation in the tensile strength. Findings The Weibull analysis showed that the reliability of FDM produced ABS can be as low as advanced ceramics. Weibull moduli of specimens without a hole were between 26 and 69, and specimens with a hole had Weibull moduli between 30 and 41. P-type deviations from the Weibull statistics were observed. The XZ orientation resulted in the highest average fracture strength for specimens with and without a hole, and C+45 orientation resulted in the lowest strength. Practical implications As the Weibull distribution relates the applied stress to probability of failure, the Weibull analysis provides a practical design criterion to achieve specific reliability levels for additively manufactured parts. Originality/value This study, for the first time, provides Weibull statistics for FDM-produced ABS parts, which can be used to predict mechanical reliability.

[1]  E. Brandl,et al.  Additive manufactured AlSi10Mg samples using Selective Laser Melting (SLM): Microstructure, high cycle fatigue, and fracture behavior , 2012 .

[2]  Che Chung Wang,et al.  Optimizing the rapid prototyping process by integrating the Taguchi method with the Gray relational analysis , 2007 .

[3]  Godfrey C. Onwubolu,et al.  Fused deposition modelling (FDM) process parameter prediction and optimization using group method for data handling (GMDH) and differential evolution (DE) , 2014 .

[4]  Agnes Bagsik,et al.  MECHANICAL PROPERTIES OF FUSED DEPOSITION MODELING PARTS MANUFACTURED WITH ULTEM*9085 , 2011 .

[5]  B. Basu,et al.  Advanced Structural Ceramics: Basu/Advanced Structural Ceramics , 2011 .

[6]  Vojislav Petrovic,et al.  Additive layered manufacturing: sectors of industrial application shown through case studies , 2011 .

[7]  Aaron M. Forster,et al.  Materials Testing Standards for Additive Manufacturing of Polymer Materials: State of the Art and Standards Applicability , 2015 .

[8]  Ryan B. Wicker,et al.  Improved Mechanical Properties of Fused Deposition Modeling-Manufactured Parts Through Build Parameter Modifications , 2014 .

[9]  Gary Wasserman.  Reliability Verification, Testing, and Analysis in Engineering Design , 2002 .

[10]  Barry Berman,et al.  3D printing: the new industrial revolution , 2012, IEEE Engineering Management Review.

[11]  H. Schneider.  Failure mode and effect analysis : FMEA from theory to execution , 1996 .

[12]  K. Bowman,et al.  Sensitivity of fracture strength in porous glass , 2017 .

[13]  Omer Van der Biest,et al.  Wire based additive layer manufacturing: Comparison of microstructure and mechanical properties of Ti–6Al–4V components fabricated by laser-beam deposition and shaped metal deposition , 2011 .

[14]  Noshir A. Langrana,et al.  Microstructural Characterization and Mechanical Properties of Si3N4 Formed by Fused Deposition of Ceramics , 2008 .

[15]  Syed H. Masood,et al.  Effects of Build Orientations on Tensile Properties of PLA Material Processed by FDM , 2014 .

[16]  Selçuk Güçeri,et al.  Mechanical characterization of parts fabricated using fused deposition modeling , 2003 .

[17]  P. Wright,et al.  Anisotropic material properties of fused deposition modeling ABS , 2002 .

[18]  K. Naito.  Tensile properties and weibull modulus of some high-performance polymeric fibers , 2013 .

[19]  John Irwin,et al.  Life-cycle economic analysis of distributed manufacturing with open-source 3-D printers , 2013, Mechatronics.

[20]  John E. Renaud,et al.  Mechanical behavior of acrylonitrile butadiene styrene (ABS) fused deposition materials. Experimental investigation , 2001 .

[21]  Dinesh K. Shetty,et al.  Reliability analysis of structural ceramics subjected to biaxial flexure , 1991 .

[22]  Richard A. Buswell,et al.  Developments in construction-scale additive manufacturing processes , 2012 .

[23]  W. Weibull.  A Statistical Distribution Function of Wide Applicability , 1951 .

[24]  Joshua M. Pearce.  Applications of Open Source 3-D Printing on Small Farms , 2015 .

[25]  Omar Ahmed Mohamed,et al.  Optimization of fused deposition modeling process parameters: a review of current research and future prospects , 2015, Advances in Manufacturing.

[26]  K. Bowman,et al.  Failure Variability in Porous Glasses: Stress Interactions, Crack Orientation, and Crack Size Distributions , 2014 .

[27]  Thomas Birtchnell,et al.  3D Printing for Development in the Global South: The 3D4D Challenge , 2014 .

[28]  K. Chawla,et al.  Mechanical Behavior of Materials , 1998 .

[29]  David W. Rosen,et al.  Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing , 2009 .

[30]  Joshua M. Pearce,et al.  Mechanical properties of components fabricated with open-source 3-D printers under realistic environmental conditions , 2014 .

[31]  Abdelouahab Tati,et al.  Finite element analysis of stress concentrations and failure criteria in composite plates with circular holes , 2014 .

[32]  Cristina Fernandez,et al.  Cyborg beast: a low-cost 3d-printed prosthetic hand for children with upper-limb differences , 2015, BMC Research Notes.

[33]  Constance W. Ziemian,et al.  Anisotropic Mechanical Properties of ABS Parts Fabricated by Fused Deposition Modelling , 2012 .

[34]  Gregory E. Hilmas,et al.  Aqueous Based Freeze-Form Extrusion Fabrication of Alumina Components (Preprint) , 2009 .

[35]  K. Bowman,et al.  Deviations from Weibull statistics in brittle porous materials , 2013 .

[36]  Youxin Hu,et al.  Mechanical characteristics of solid-freeform-fabricated porous calcium polyphosphate structures with oriented stacked layers. , 2011, Acta biomaterialia.

[37]  Ryan R. Dehoff,et al.  Properties of Inconel 625 mesh structures grown by electron beam additive manufacturing , 2014 .

[38]  Syed H. Masood,et al.  Tensile Properties of Processed FDM Polycarbonate Material , 2010 .

[39]  A. K. Sood,et al.  Parametric appraisal of mechanical property of fused deposition modelling processed parts , 2010 .

[40]  K. Bowman,et al.  Stochastic failure of isotropic, brittle materials with uniform porosity , 2013 .

[41]  B. Basu,et al.  Advanced Structural Ceramics , 2011 .

[42]  Philip Dickens,et al.  Implications on design of rapid manufacturing , 2003 .

[43]  O. S. Es-Said,et al.  The Effect of Layer Orientation on the Mechanical Properties and Microstructure of a Polymer , 2011 .