Assembly

The following summarizes some guidelines for coded FFF process chain (CP) cases with their respective references.

CP-06. Adhesives should be used to bond printed parts quickly (Figure 1).

The combination of base material and adhesive type should be carefully selected because an adhesive’s effectiveness concerning the base material’s strength will depend on the bonding and preprocessing process, materials and compatibility, and reinforcements used  [1], [2], [3],  [4], [5], [6], [7], [8], [9].

CP-08. Indirect manufacturing (example, molding with printed mold like Figure 2) should be used to expand the possibilities of FFF, both in terms of materials and processes, applications, and uses, while increasing strength, reducing manufacturing times and costs, reducing tolerances and fits, reducing roughness and reducing the weight of parts, among other competitive advantages [21], [22], [23],  [24], [15], [25], [26], [27], [28], [29], [30], [31], [32], [33], [34].

For more guidelines using FFF process chain, go to the database.

Improvements in Assembly (mechanical strength or assembly time and cost)

During the case analysis, improvements in properties such as tolerances, roughness, mechanical strength, and times/costs were identified through the combination of FFF or FDM with conventional processes. Table 1 provides a partial overview of the results obtained specifically for the assembly case.

To interpret the findings in Table 1, an example is provided:

  1. The maximal improvement are presented for Adhesive, multimaterial/additive (832%) and the type of improvement “S” is the mechanical strength of the joint [8]. The improvement values are presented as ranges (min and max), because the specific values depend on the interaction of FFF processing factors and conventional manufacturing.

To use the figures in Table 1 or the process chain database, from which these figures are derived, when designing a product, one should:

a) To know in advance what properties or specifications the product being designed should have, and in that case, to determine which process combination achieves the desired properties.

b) On the other hand, in the case of redesigning parts manufactured with FFF, whose properties are not by the desired specifications, the same table indicates the percentages of improvement possible by combining FFF with other specific processes; in this case, the processes that achieve the required improvements for the application to be designed are identified.

c) Once the possible processes or processes have been identified, the process chain database must be consulted to consult how the processes and their parameters are combined with FFF and print parameters.

d) The same database also contains process costs and times and the health and environmental impacts of using additional materials. This information will allow making objective decisions about the properties and costs associated with combining other materials and processes.

e) any details to expand or clarify can be read directly in the coded bibliographic reference.

The handling for other properties, such as tolerances, mechanical properties, and others, is similar.

 

References

[1]         Y. Oh, S. Behdad, and C. Zhou, “Part Separation Methods for Assembly Based Design in Additive Manufacturing,” in Volume 4: 22nd Design for Manufacturing and the Life Cycle Conference$\mathsemicolon$ 11th International Conference on Micro- and Nanosystems, 2017.

[2]         Y. Oh, C. Zhou, and S. Behdad, “Part decomposition and assembly-based (Re) design for additive manufacturing: A review,” Addit. Manuf., vol. 22, pp. 230–242, 2018.

[3]         Y. Oh, C. Zhou, and S. Behdad, “Part decomposition and 2D batch placement in single-machine additive manufacturing systems,” J. Manuf. Syst., vol. 48, pp. 131–139, Jul. 2018.

[4]         M. ERWIN, Q. SERGIO, and L. LOPEZ, “ESTUDIO EXPERIMENTAL Y OPTIMIZACIÓN DE JUNTAS PEGADAS DE PIEZAS IMPRESAS EN 3D, CON INTERFAZ DE SUPERFICIE ENTRELAZADA,” UNIVERSIDAD DEL ATLÁNTICO, FACULTAD DE INGENIERÍA, PROGRAMA DE INGENIERÍA MECÁNICA, Puerto Colombia, Atlantico, Colombia, 2019.

[5]         J. M. Arenas, C. Alia, F. Blaya, and A. Sanz, “Multi-criteria selection of structural adhesives to bond {ABS} parts obtained by rapid prototyping,” Int. J. Adhes. Adhes., vol. 33, pp. 67–74, Mar. 2012.

[6]         STRATASYS, “TECHNICAL APPLICATION GUIDE: Comparison of Bonding Methods for FDM Materials.” 2015.

[7]         D. Espalin et al., “Analysis of bonding methods for FDM-manufactured parts,” in 21st Annual International Solid Freeform Fabrication Symposium-An Additive Manufacturing Conference, 2010, pp. 37–47.

[8]         R. Garcia and P. Prabhakar, “Bond interface design for single lap joints using polymeric additive manufacturing,” Compos. Struct., vol. 176, pp. 547–555, Sep. 2017.

[9]         F. Bürenhaus, E. Moritzer, and A. Hirsch, “Adhesive bonding of {FDM}-manufactured parts made of {ULTEM} 9085 considering surface treatment, surface structure, and joint design,” Weld. World, vol. 63, no. 6, pp. 1819–1832, Oct. 2019.

[10]      C. C. Ploch, C. S. S. A. Mansi, J. Jayamohan, and E. Kuhl, “Using 3D Printing to Create Personalized Brain Models for Neurosurgical Training and Preoperative Planning,” World Neurosurg., vol. 90, pp. 668–674, Jun. 2016.

[11]      O. C. Burdall, E. Makin, M. Davenport, and N. Ade-Ajayi, “3D printing to simulate laparoscopic choledochal surgery,” J. Pediatr. Surg., vol. 51, no. 5, pp. 828–831, May 2016.

[12]      Stratasys, “TECHNICAL APPLICATION GUIDE: Silicone Molding With FDM Patterns.” 2015.

[13]      Y. He, G. Xue, and J. Fu, “Fabrication of low cost soft tissue prostheses with the desktop 3D printer,” Sci. Rep., vol. 4, no. 1, Nov. 2014.

[14]      Stratasys, FDM for Composite Tooling. Stratasys, 2017.

[15]      M. Chhabra and R. Singh, “Rapid casting solutions: a review,” Rapid Prototyp. J., vol. 17, no. 5, pp. 328–350, 2011.

[16]      S. Singh and R. Singh, “Fused deposition modelling based rapid patterns for investment casting applications: a review,” Rapid Prototyp. J., vol. 22, no. 1, pp. 123–143, 2016.

[17]      Stratasys, “APPLICATION GUIDE: Thermoforming.” 2015.

[18]      M. HÉCTOR, A. ORTIZ, and L. LOPEZ, “DISEÑO Y CONSTRUCCIÓN DE PROTOTIPO DE MOLDE PARA RECONSTRUCCIÓN ÓSEA A PARTIR DE TOMOGRAFÍA COMPUTARIZADA MEDIANTE IMPRESIÓN 3D,” UNIVERSIDAD DEL ATLÁNTICO, FACULTAD DE INGENIERÍA, DEPARTAMENTO DE INGENIERÍA, PROGRAMA DE INGENIERÍA MECÁNICA, Puerto Colombia – Atlántico, COLOMBIA, 2021.

[19]      L. Ruiz-Huerta, Y. C. Almanza-Arjona, A. Caballero-Ruiz, H. A. Castro-Espinosa, C. M. D\’\iaz-Aguirre, and E. E. y Pérez, “{CAD} and {AM}-fabricated moulds for fast cranio-maxillofacial implants manufacture,” Rapid Prototyp. J., vol. 22, no. 1, pp. 31–39, 2016.

[20]      P. A. Thomas, P. K. Aahlada, N. S. Kiran, and J. Ivvala, “A Review On Transition In The Manufacturing Of Mechanical Components From Conventional Techniques To Rapid Casting Using Rapid Prototyping,” Mater. Today Proc., vol. 5, no. 5, pp. 11990–12002, 2018.

[21]      O. Abdelaal, S. Darwish, K. A. Elmougoud, and S. Aldahash, “A new methodology for design and manufacturing of a customized silicone partial foot prosthesis using indirect additive manufacturing,” Int. J. Artif. Organs, vol. 42, no. 11, pp. 645–657, 2019.

[22]      Stratasys, “TECHNICAL APPLICATION GUIDE FDM Tooling for Sheet Metal Forming: Hydroforming and Rubber Pad Press.” 2015.

[23]      Stratasys, “TECHNICAL APPLICATION GUIDE: FDM FOR SAND CASTING.” 2013.

[24]      Stratasys, “TECHNICAL APPLICATION GUIDE: Investment Casting with FDM Patterns.” 2015.

[25]      W. Lin, H. Shen, G. Xu, L. Zhang, J. Fu, and X. Deng, “Single-layer temperature-adjusting transition method to improve the bond strength of 3D-printed {PCL}/{PLA} parts,” Compos. Part A Appl. Sci. Manuf., vol. 115, pp. 22–30, 2018.

[26]      F. Tamburrino, S. Graziosi, and M. Bordegoni, “The influence of slicing parameters on the multi-material adhesion mechanisms of FDM printed parts: an exploratory study,” Virtual Phys. Prototyp., vol. 14, no. 4, pp. 316–332, 2019.

[27]      A. S. Khan, A. Ali, G. Hussain, and M. Ilyas, “An experimental study on interfacial fracture toughness of 3-D printed ABS/CF-PLA composite under mode I, II, and mixed-mode loading,” J. Thermoplast. Compos. Mater., vol. 0, no. 0, p. 0892705719874860, 2019.

[28]      E. Molino, S. Quintana, L. Lopez, and E. Niebles, Estudio experimental y optimización de juntas pegadas de piezas impresas en 3D con interfaz de superficie entrelazada, Primera. Puerto Colombia – Atlántico, COLOMBIA: Universidad del Atlantico, 2020.