Abstract
PolyJet technology is one of the additive manufacturing technologies, which can produce complex geometries with variety of textures. The 3D printed complex geometry parts need better mechanical behaviour. The mechanical properties of a fabricated product depend on several process parameters such as build orientation, layer thickness, material and surface finish. This paper aims to study the effect of printing mode and type of surface finish on the mechanical properties of VeroBlue material used in PolyJet technology. The tensile, flexural and shore hardness tests are carried out to determine the mechanical response of the fabricated specimen. Four different combinations are derived from printing mode (high quality (HQ) and high speed (HS)) and finish type (matte (M) and glossy (G)). Findings indicate the HS-G specimens have better mechanical property and are faster in production and cheaper than HQ-M, HQ-G and HS-M. Highest average tensile strength of the HS-G (49.77 MPa) is deviated by 11.19% from standard value. Tensile specimens of HS-G save 60.86% of printing time and 14.72% of cost than HQ-G. This research paper provides a unique way of meeting optimal selection process parameters. Finally, a case study was carried out for the selected application with optimized process parameters.
Similar content being viewed by others
References
Khajavi SH, Partanen J, Holmström J (2014) Additive manufacturing in the spare parts supply chain. Comput Ind 65(1):50–63. https://doi.org/10.1016/j.compind.2013.07.008
Petrovic V, Vicente Haro Gonzalez J, Jordá Ferrando O, Delgado Gordillo J, Ramón Blasco Puchades J, Portolés Griñan L (2011) Additive layered manufacturing: sectors of industrial application shown through case studies. Int J Prod Res 49(4):1061–1079. https://doi.org/10.1080/00207540903479786
Gao W, Zhang Y, Ramanujan D, Ramani K, Chen Y, Williams CB, Wang CCL, Shin YC, Zhang S, Zavattieri PD (2015) The status, challenges, and future of additive manufacturing in engineering. Comput Aided Des 69:65–89. https://doi.org/10.1016/j.cad.2015.04.001
Atzeni E, Salmi A (2012) Economics of additive manufacturing for end-usable metal parts. Int J Adv Manuf Technol 62(9):1147–1155. https://doi.org/10.1007/s00170-011-3878-1
Lanzotti A, Grasso M, Staiano G, Martorelli M (2015) The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer. Rapid Prototyp J 21(5):604–617. https://doi.org/10.1108/RPJ-09-2014-0135
Barclift MW, Williams C (2012) Examining variability in the mechanical properties of parts manufactured via polyjet direct 3D printing. In: International. Solid Freeform Fabrication Symposium Proceddings, Austin
Gaynor AT, Meisel NA, Williams CB, Guest JK (2014) Multiple-material topology optimization of compliant mechanisms created via PolyJet three-dimensional printing. J Manuf Sci Eng 136(6). https://doi.org/10.1115/1.4028439
Lee BH, Abdullah J, Khan ZA (2005) Optimization of rapid prototyping parameters for production of flexible ABS object. J Mater Process Technol 169(1):54–61. https://doi.org/10.1016/j.jmatprotec.2005.02.259
Conner BP, Manogharan GP, Martof AN, Rodomsky LM, Rodomsky CM, Jordan DC, Limperos JW (2014) Making sense of 3-D printing: creating a map of additive manufacturing products and services. Addit Manuf 1-4:64–76. https://doi.org/10.1016/j.addma.2014.08.005
Tang Y, Yang S, Zhao YF (2016) Sustainable design for additive manufacturing through functionality integration and part consolidation. In: Muthu SS, Savalani MM (eds) Handbook of sustainability in additive manufacturing, vol 1. Springer, Singapore, pp 101–144. https://doi.org/10.1007/978-981-10-0549-7_6
Rosato DV, Rosato DV, Rosato MV (2004) 11 - casting. In: Rosato DV, Rosato DV, Rosato MV (eds) Plastic product material and process selection handbook. Elsevier, Oxford, pp 394–405. https://doi.org/10.1016/B978-185617431-2/50014-1
Shamsaei N, Yadollahi A, Bian L, Thompson SM (2015) An overview of direct laser deposition for additive manufacturing; part II: mechanical behavior, process parameter optimization and control. Addit Manuf 8:12–35. https://doi.org/10.1016/j.addma.2015.07.002
Yap YL, Wang C, Sing SL, Dikshit V, Yeong WY, Wei J (2017) Material jetting additive manufacturing: an experimental study using designed metrological benchmarks. Precis Eng 50:275–285. https://doi.org/10.1016/j.precisioneng.2017.05.015
Tapia G, Khairallah S, Matthews M, King WE, Elwany A (2018) Gaussian process-based surrogate modeling framework for process planning in laser powder-bed fusion additive manufacturing of 316L stainless steel. Int J Adv Manuf Technol 94(9):3591–3603. https://doi.org/10.1007/s00170-017-1045-z
Sing SL, Wiria FE, Yeong WY (2018) Selective laser melting of lattice structures: a statistical approach to manufacturability and mechanical behavior. Robot Comput Integr Manuf 49:170–180. https://doi.org/10.1016/j.rcim.2017.06.006
Yi H, Qi L, Luo J, Zhang D, Li H, Hou X (2018) Effect of the surface morphology of solidified droplet on remelting between neighboring aluminum droplets. Int J Mach Tools Manuf 130-131:1–11. https://doi.org/10.1016/j.ijmachtools.2018.03.006
Yi H, Qi L, Luo J, Li N (2019) Hole-defects in soluble core assisted aluminum droplet printing: metallurgical mechanisms and elimination methods. Appl Therm Eng 148:1183–1193. https://doi.org/10.1016/j.applthermaleng.2018.12.013
Ramola M (2019) On the adoption of additive manufacturing in healthcare: a literature review. J Manuf Technol Manag 30(1):48–69. https://doi.org/10.1108/JMTM-03-2018-0094
Nelson JW, LaValle JJ, Kautzman BD, Dworshak J, Johnson EM, Ulven C (2017) Injection molding with an additive manufacturing tool study shows that 3D printed tools can create parts comparable to those made with P20 tools, at a much lower cost and lead time. Plast Eng 73:60–66
Ashby MF, Bréchet YJM, Cebon D, Salvo L (2004) Selection strategies for materials and processes. Mater Des 25(1):51–67. https://doi.org/10.1016/S0261-3069(03)00159-6
Andres RP, Averback RS, Brown WL, Brus LE, Goddard WA, Kaldor A, Louie SG, Moscovits M, Peercy PS, Riley SJ, Siegel RW, Spaepen F, Wang Y (2011) Research opportunities on clusters and cluster-assembled materials—a Department of Energy, Council on Materials Science Panel Report. J Mater Res 4(3):704–736. https://doi.org/10.1557/JMR.1989.0704
Salvetat JP, Bonard JM, Thomson NH, Kulik AJ, Forró L, Benoit W, Zuppiroli L (1999) Mechanical properties of carbon nanotubes. Appl Phys A 69(3):255–260. https://doi.org/10.1007/s003390050999
Sahoo S (2017) Simulation study on rapid solidification of eutectic Al-Cu alloy: a molecular dynamics approach. Int J Comput Mater Sci Surf Eng 7(1):18–25
Martukanitz R, Michaleris P, Palmer T, DebRoy T, Liu Z-K, Otis R, Heo TW, Chen L-Q (2014) Toward an integrated computational system for describing the additive manufacturing process for metallic materials. Addit Manuf 1-4:52–63. https://doi.org/10.1016/j.addma.2014.09.002
Gu DD, Meiners W, Wissenbach K, Poprawe R (2012) Laser additive manufacturing of metallic components: materials, processes and mechanisms. Int Mater Rev 57(3):133–164. https://doi.org/10.1179/1743280411Y.0000000014
Khorasani AM, Yazdi MRS, Safizadeh MS (2012) Analysis of machining parameters effects on surface roughness: a review. Int J Comput Mater Sci Surf Eng 5(1):68–84. https://doi.org/10.1504/ijcmsse.2012.049055
Ahn SH, Montero M, Odell D, Roundy S, Wright PK (2002) Anisotropic material properties of fused deposition modeling ABS. Rapid Prototyp J 8(4):248–257. https://doi.org/10.1108/13552540210441166
Farzadi A, Solati-Hashjin M, Asadi-Eydivand M, Abu Osman NA (2014) Effect of layer thickness and printing orientation on mechanical properties and dimensional accuracy of 3D printed porous samples for bone tissue engineering. PLoS One 9(9):e108252. https://doi.org/10.1371/journal.pone.0108252
Sufiiarov VS, Popovich AA, Borisov EV, Polozov IA, Masaylo DV, Orlov AV (2017) The effect of layer thickness at selective laser melting. Procedia Eng 174:126–134. https://doi.org/10.1016/j.proeng.2017.01.179
Vukasovic T, Vivanco JF, Celentano D, García-Herrera C (2019) Characterization of the mechanical response of thermoplastic parts fabricated with 3D printing. Int J Adv Manuf Technol 104:4207–4218. https://doi.org/10.1007/s00170-019-04194-z
Bikas H, Lianos AK, Stavropoulos P (2019) A design framework for additive manufacturing. Int J Adv Manuf Technol 103(9):3769–3783. https://doi.org/10.1007/s00170-019-03627-z
Tofail SAM, Koumoulos EP, Bandyopadhyay A, Bose S, O’Donoghue L, Charitidis C (2018) Additive manufacturing: scientific and technological challenges, market uptake and opportunities. Mater Today 21(1):22–37. https://doi.org/10.1016/j.mattod.2017.07.001
Park S-I, Rosen DW, S-k C, Duty CE (2014) Effective mechanical properties of lattice material fabricated by material extrusion additive manufacturing. Addit Manuf 1-4:12–23. https://doi.org/10.1016/j.addma.2014.07.002
Samykano M, Selvamani SK, Kadirgama K, Ngui WK, Kanagaraj G, Sudhakar K (2019) Mechanical property of FDM printed ABS: influence of printing parameters. Int J Adv Manuf Technol 102(9):2779–2796. https://doi.org/10.1007/s00170-019-03313-0
Thompson MK, Moroni G, Vaneker T, Fadel G, Campbell RI, Gibson I, Bernard A, Schulz J, Graf P, Ahuja B, Martina F (2016) Design for additive manufacturing: trends, opportunities, considerations, and constraints. CIRP Ann 65(2):737–760. https://doi.org/10.1016/j.cirp.2016.05.004
Ngo TD, Kashani A, Imbalzano G, Nguyen KTQ, Hui D (2018) Additive manufacturing (3D printing): a review of materials, methods, applications and challenges. Compos Part B 143:172–196. https://doi.org/10.1016/j.compositesb.2018.02.012
Choi J-W, Kim H-C, Wicker R (2011) Multi-material stereolithography. J Mater Process Technol 211(3):318–328. https://doi.org/10.1016/j.jmatprotec.2010.10.003
Rajendra Boopathy V (2019) Energy absorbing capability of additive manufactured multi-material honeycomb structure. Rapid Prototyp J 25(3):623–629. https://doi.org/10.1108/RPJ-03-2018-0066
Zhang P, Heyne MA, To AC (2015) Biomimetic staggered composites with highly enhanced energy dissipation: modeling, 3D printing, and testing. J Mech Phys Solids 83:285–300. https://doi.org/10.1016/j.jmps.2015.06.015
Kreisköther K, Kampker A, Reinders C (2017) Material and parameter analysis of the polyjet process for mold making using design of experiments. World J Nucl Sci Technol:219–226
Kantareddy SNR, Simpson TW, Ounaies Z, Frecker M (2016) 3d printing of shape changing polymer structures: design and characterization of materials. In: Bourell DL, Crawford RH, Seepersad CC, Beaman JJ, Fish S, Marcus H (eds) Proceedings of the 26th Annual International Solid Freeform Fabrication Symposium – An Additive Manufacturing Conference, Texas. Verlag nicht ermittelbar,
Sanders J, Wei X, Pei Z (2019) Experimental investigation of Stratasys J750 PolyJet printer: effects of orientation and layer thickness on thermal glass transition temperature
Reichl KK, Inman DJ (2018) Dynamic mechanical and thermal analyses of Objet Connex 3D printed materials. Exp Tech 42(1):19–25. https://doi.org/10.1007/s40799-017-0223-0
Gouzman I, Atar N, Grossman E, Verker R, Bolker A, Pokrass M, Sultan S, Sinwani O, Wagner A, Lück T, Seifarth C (2019) 3D printing of bismaleimides: from new ink formulation to printed thermosetting polymer objects. Adv Mater Technol 0(0):1–8. https://doi.org/10.1002/admt.201900368
Ganesan S, Ranganathan R (2018) Design and development of customised split insole using additive manufacturing technique. Int J Rapid Manuf 7(4):295–309. https://doi.org/10.1504/ijrapidm.2018.095783
Agnew SR, Yoo MH, Tomé CN (2001) Application of texture simulation to understanding mechanical behavior of Mg and solid solution alloys containing Li or Y. Acta Mater 49(20):4277–4289. https://doi.org/10.1016/S1359-6454(01)00297-X
Desjardins J, Stanley SE, Przestrzelski B, Pruett TC, Hoeffner SL, Kaluf BD (2016) Variable hardness orthotic. Google patents
Biris AS, Mazumder MK, Yurteri CU, Sims RA, Snodgrass J, De S (2001) Gloss and texture control of powder coated films. Part Sci Technol 19(3):199–217. https://doi.org/10.1080/02726350290057804
Moore JP, Williams CB (2015) Fatigue properties of parts printed by PolyJet material jetting. Rapid Prototyp J 21(6):675–685. https://doi.org/10.1108/RPJ-03-2014-0031
Stratasys (2016) Objet260 Connex3
Zorzetto L, Ruffoni D (2019) Wood-inspired 3D-printed helical composites with tunable and enhanced mechanical performance. Adv Funct Mater 29(1):1805888. https://doi.org/10.1002/adfm.201805888
D638–14 A (2014) Standard test method for tensile properties of plastics. ASTM International, West Conshohocken
D790-15e2 A (2015) Standard test methods for flexural properties of unreinforced and reinforced plastics and electrical insulating materials. ASTM International, West Conshohocken
D2240–15 A (2015) Standard test method for rubber property— durometer hardness. ASTM International, West Conshohocken
Lenard JG (2014) 13 - Severe Plastic Deformation – Accumulative Roll Bonding11Most of the information in this chapter was provided by Dr. Krallics of the Budapest University of Technology and Economics. The experimental portion is based on Krallics and Lenard. In: Lenard JG (ed) Primer on flat rolling, 2nd edn. Elsevier, Oxford, pp 303–322. https://doi.org/10.1016/B978-0-08-099418-5.00013-5
Shrivastava A (2018) 3 - plastic properties and testing. In: Shrivastava A (ed) Introduction to plastics engineering. William Andrew publishing, pp 49–110. https://doi.org/10.1016/B978-0-323-39500-7.00003-4
Funding
We gratefully acknowledge the financial support for establishing the Centre of Excellence in Manufacturing Sciences (CoEMS) at Coimbatore Institute of Technology, Coimbatore; India from Ministry of Human-Resource Development (MHRD), Govt of India where the sample/R&D work is carried out.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Pugalendhi, A., Ranganathan, R. & Chandrasekaran, M. Effect of process parameters on mechanical properties of VeroBlue material and their optimal selection in PolyJet technology. Int J Adv Manuf Technol 108, 1049–1059 (2020). https://doi.org/10.1007/s00170-019-04782-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-04782-z