Heating Apparatus that Aids in the Prevention of Delaminaiton in Big Area Additive Manufacturing Applications
Abstract
Fused Deposition Modeling (FDM) uses thermoplastic filament to produce 3D objects by depositing melted plastic onto a platform in layers until a full object is made. However, the FDM process has an inherent problem: The constant cycles of heating and cooling the plastic experience during the printing process caused by the presence of a heating elements. The FDM process uses the heating element to melt the filament and then extrude the melted plastic onto a bed, gradually building up the layers to create a 3D object. The heating element essentially places warm melted plastic on top of already cooled plastic material which causes the buildup internal stresses leading to improper layer adhesion. Which can then lead to delamination or warping. Traditional prevention methods focus on the heating apparatus. Having a heated bed integrated into the printer itself, only helps in the first few beginning layers. Printers used for Big Area Additive Manufacturing (BAAM) do not have built-in measures to ensure the printed layers cool at the same rate or stay at a constant temperature. The study tested the viability of an external heating system integrated into a 3D printer to prevent warping or delamination at all layer levels. The engineering design process was used to test various heating methods and materials and develop a test of concept heating system for BAAM applications, which will prevent or mitigate delamination or warping while not impeding the overall functionality of the printer. A functional heating system was developed through trial and error of the engineering design process, which prevented delamination and mitigated the warping of FDM prints. The success of the external heating system as a concept for FDM prints is intended to serve as a steppingstone for research in the BAAM industry and prevent print failures during the additive manufacturing process.
Degree
M.Sc.
Advisors
Sundararajan, Purdue University.
Subject Area
Design|Industrial engineering|Marketing|Materials science|Mechanics|Medicine|Polymer chemistry
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