Title: Investigation of Infill Pattern in Parts Manufactured with Fused Deposition Modeling

Authors: Logan Hill, Trey Brown, Tyler Luchik, David Lanning

DOI: 10.33599/nasampe/s.22.0736

Abstract: Fused Deposition Modeling (FDM), a common method of additive manufacturing, has experienced significant growth in recent years. A barrier to the widespread use of FDM is that a part’s material properties depend upon the process parameters used during production. While certain process parameters have been examined in the existing literature, the effects of various infill patterns at varying infill densities have not been fully explored. One aim of this study is to determine which infill patterns improve a part’s mechanical properties and to observe how these mechanical properties change as infill density increases. This study also observes the effect of stress concentrations in FDM parts in the context of various infill patterns. Infill patterns are examined based on their tensile properties, which are determined via standard tensile testing. The infill patterns observed are rectilinear, honeycomb, cubic, concentric, and gyroid with infill densities of 20%, 40%, 60%, and 80%. Trends indicate that at higher infill densities specimens are stronger and stiffer. Additionally, certain infill patterns are more effective at carrying axial loads and certain infill patterns may improve bonding, increasing overall strength and stiffness. Finally, stress concentrations in FDM parts do not appear to behave in accordance with traditional theory.

References: 1. Jung, Y., and Zhang, J., Additive manufacturing: materials, processes, quantifications and applications, Butterworth-Heinemann, Oxford, 2018. 2. Mohamed, O.A., Masood, S.H., and Bhowmik, J.L., ""Optimization of fused deposition modeling process parameters: a review of current research and future prospects."" Advances in Manufacturing 3(1) (2015): 42-53, DOI: 10.1007/s40436-014-0097-7. 3. Pham, D.T., and Gault, R.S., ""A comparison of rapid prototyping technologies."" International Journal of Machine Tools and Manufacture 38(10) (1998): 1257-1287, DOI: 10.1016/S0890-6955(97)00137-5. 4. Dave, H.K., and Patel, S.T., Introduction to Fused Deposition Modeling Based 3D Printing Process, Springer International Publishing, pp. 1-21, 2021. 5. Sood, A. K., Ohdar, R. K., and Mahapatra, S. S., ""Parametric appraisal of mechanical property of fused deposition modelling processed parts."" Materials in Engineering 31(1) (2010): 287-295 DOI: 10.1016/j.matdes.2009.06.016. 6. Yao, T., Zhang, K., Deng, Z., and Ye, J., ""A novel generalized stress invariant-based strength model for inter-layer failure of FFF 3D printing PLA material."" Materials & Design 193 (2020) DOI: 10.1016/j.matdes.2020.108799. 7. Chacón, J.M., Caminero, M.A., García-Plaza, E., and Núñez, P. J., ""Additive manufacturing of PLA structures using fused deposition modelling: Effect of process parameters on mechanical properties and their optimal selection."" Materials & Design 124 (2017): 143-157 DOI: 10.1016/j.matdes.2017.03.065. 8. Yao, T., Deng, Z., Zhang, K., and Li, S., ""A method to predict the ultimate tensile strength of 3D printing polylactic acid (PLA) materials with different printing orientations."" Composites Part B: Engineering 163 (2019): 393-402 DOI: 10.1016/j.compositesb.2019.01.025. 9. Rajpurohit, S.R., and Dave, H.K., ""Effect of process parameters on tensile strength of FDM printed PLA part."" Rapid Prototyping Journal 24(8) (2018): 1317-1324 DOI: 10.1108/RPJ-06-2017-0134. 10. Liu, X., Zhang, M., Li, S., Si, L., Peng, J., and Hu, Y., ""Mechanical property parametric appraisal of fused deposition modeling parts based on the gray Taguchi method."" The International Journal of Advanced Manufacturing Technology 89(5) (2017): 2387-2397 DOI: 10.1007/s00170-016-9263-3. 11. Dawoud, M., Taha, I., and Ebeid, S.J., ""Mechanical behaviour of ABS: An experimental study using FDM and injection moulding techniques."" Journal of Manufacturing Processes 21 (2016): 39-45 DOI: 10.1016/j.jmapro.2015.11.002. 12. Lanzotti, A., Grasso, M., Staiano, G., and Martorelli, M., ""The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer."" Rapid Prototyping Journal 21(5) (2015): 604-617 DOI: 10.1108/RPJ-09-2014-0135. 13. Kuznetsov, V.E., Solonin, A.N., Urzhumtsev, O.D., Schilling, R., and Tavitov, A.G., ""Strength of PLA Components Fabricated with Fused Deposition Technology Using a Desktop 3D Printer as a Function of Geometrical Parameters of the Process."" Polymers 10(3) (2018): 313 DOI: 10.3390/polym10030313. 14. Sood, A.K., Ohdar, R.K., and Mahapatra, S.S., ""Experimental investigation and empirical modelling of FDM process for compressive strength improvement."" Journal of Advanced Research 3(1) (2012): 81-90 DOI: 10.1016/j.jare.2011.05.001. 15. Ahn, S., Montero, M., Odell, D., Roundy, S., and Wright, P.K., ""Anisotropic material properties of fused deposition modeling ABS."" Rapid Prototyping Journal 8(4) (2002): 248-257 DOI: 10.1108/13552540210441166. 16. Durgun, I., and Ertan, R., ""Experimental investigation of FDM process for improvement of mechanical properties and production cost."" Rapid Prototyping Journal 20(3) (2014): 228-235 DOI: 10.1108/RPJ-10-2012-0091. 17. Rankouhi, B., Javadpour, S., Delfanian, F., and Letcher, T., ""Failure analysis and mechanical characterization of 3D printed ABS with respect to layer thickness and orientation."" Journal of Failure Analysis and Prevention 16(3) (2016): 467-481 DOI: 10.1007/s11668-016-0113-2. 18. Wu, W., Geng, P., Li, G., Zhao, D., Zhang, H., and Zhao, J., ""Influence of layer thickness and raster angle on the mechanical properties of 3D-printed PEEK and a comparative mechanical study between PEEK and ABS."" Materials (Basel) 8(9) (2015): 5834-5846 DOI: 10.3390/ma8095271. 19. Luzanin, O., Guduric, V., Ristic, I., and Muhic, S., ""Investigating impact of five build parameters on the maximum flexural force in FDM specimens – a definitive screening design approach."" Rapid Prototyping Journal 23(6) (2017): 1088-1098 DOI: 10.1108/RPJ-09-2015-0116. 20. Croccolo, D., De Agostinis, M., and Olmi, G., ""Experimental characterization and analytical modelling of the mechanical behaviour of fused deposition processed parts made of ABS-M30."" Computational Materials Science 79 (2013): 506-518 DOI: 10.1016/j.commatsci.2013.06.041. 21. Yao, T., Ye, J., Deng, Z., Zhang, K., Ma, Y., and Ouyang, H., ""Tensile failure strength and separation angle of FDM 3D printing PLA material: Experimental and theoretical analyses."" Composites Part B: Engineering 188 (2020) DOI: 10.1016/j.compositesb.2020.107894. 22. Rodríguez-Panes, A., Claver, J., and Camacho, A.M., ""The Influence of Manufacturing Parameters on the Mechanical Behaviour of PLA and ABS Pieces Manufactured by FDM: A Comparative Analysis."" Materials, 11 (8) (2018) DOI: 10.3390/ma11081333. 23. Bardiya, S., Jerald, J., and Satheeshkumar, V., ""The impact of process parameters on the tensile strength, flexural strength and the manufacturing time of fused filament fabricated (FFF) parts."" Materials Today: Proceedings 39(4) (2021): 1362-1366 DOI: 10.1016/j.matpr.2020.04.691. 24. Álvarez, K., Lagos, R.F., and Aizpun, M., ""Investigating the influence of infill percentage on the mechanical properties of fused deposition modelled ABS parts."" Ingeniería E Investigación 36(3) (2016): 110-116 DOI: 10.15446/ing.investig.v36n3.56610. 25. Heidari-Rarani, M., Ezati, N., Sadeghi, P., and Badrossamay, M.R., ""Optimization of FDM process parameters for tensile properties of polylactic acid specimens using Taguchi design of experiment method."" Journal of Thermoplastic Composite Materials (2020) DOI: 10.1177/0892705720964560. 26. Xu, C., Cheng, K., Liu, Y., Wang, R., Jiang, X., Dong, X., and Xu, X., ""Effect of processing parameters on flexural properties of 3D‐printed polyetherketoneketone using fused deposition modeling."" Polymer Engineering and Science 61(2) (2021): 465-476 DOI: 10.1002/pen.25590. 27. Fafenrot, S., Grimmelsmann, N., Wortmann, M., and Ehrmann, A., ""Three-Dimensional (3D) Printing of Polymer-Metal Hybrid Materials by Fused Deposition Modeling,"" Materials 10(10) (2017): 1199 DOI: 10.3390/ma10101199. 28. Luzanin, O., Movrin, D., Stathopoulos, V., Pandis, P., Radusin, T., and Guduric, V., ""Impact of processing parameters on tensile strength, in-process crystallinity and mesostructure in FDM-fabricated PLA specimens."" Rapid Prototyping Journal 25(8) (2019): 1398-1410 DOI: 10.1108/RPJ-12-2018-0316. 29. Kung, C., Kuan, H., and Kuan, C., ""Evaluation of tensile strength of 3D printed objects with FDM process on RepRap platform."" 1st IEEE International Conference on Knowledge Innovation and Invention. Jeju, South Korea, 2018. DOI: 10.1109/ICKII.2018.8569166. 30. Dey, A., and Yodo, N., ""A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics."" Journal of Manufacturing and Materials Processing 3(3) (2019): 64 DOI: 10.3390/jmmp3030064. 31. Lalegani Dezaki, M., and Mohd Ariffin, M.K.A., ""The Effects of Combined Infill Patterns on Mechanical Properties in FDM Process."" Polymers 12(12) (2020):2792 DOI: 10.3390/polym12122792. 32. Dave, H.K., Patadiya, N.H., Prajapati, A.R., and Rajpurohit, S.R., ""Effect of infill pattern and infill density at varying part orientation on tensile properties of fused deposition modeling-printed poly-lactic acid part."" Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 235(10) (2019): 1811-1827 DOI: 10.1177/0954406219856383. 33. Fahad, M., Siddiqui, B.A., Khan, S.A., and Khan, M.A., ""Evaluation of the Effect of Infill Pattern on Mechanical Stregnth of Additively Manufactured Specimen."" Materials Science Forum 887 (2017): 128-132 DOI: 10.4028/www.scientific.net/MSF.887.128. 34. Pandzic, A., Hodzic, D., and Milovanovic, A., “Effect of Infill Type and Density on Tensile Properties of PLA Material for FDM Process.” 30TH DAAAM International Symposium on Intelligent Manufacturing and Automation. Vienna, Austria, 2019. Ed. Katalinic, B. DAAAM International. DOI: 10.2507/30th.daaam.proceedings.074. 35. ASTM Standard D638-14, 2014, ""Standard Test Method for Tensile Properties of Plastics"" ASTM International, West Conshohocken, PA, 2005, DOI: 10.1520/D0638-14, www.astm.org. 36. Pilkey, Walter. Peterson’s Stress Concentration Factors Second Edition. New York, NY: Jown Wiley & Sons, Inc, 1997.

Conference: SAMPE 2022

Publication Date: 2022/05/23

SKU: TP22-0000000736

Pages: 15

Price: $30.00