A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> 4. <s> One of the most essential components of the fused deposition modeling (FDM) additive manufacturing (AM) process is the build plate, the surface upon which the part is constructed. These are typically made from aluminum or glass, but there are clear disadvantages to both and restrictions on which materials can be processed on them successfully. This study examined the suitability of heated aluminum-polycarbonate (AL-PC) composite print beds for FDM, looking particularly at the mechanical properties, thermal behavior, deformation behavior, bonding strength with deposited material, printing quality, and range of material usability. Theoretical examination and physical experiments were performed for each of these areas; the results were compared to similar experiments done using heated aluminum and aluminum-glass print beds. Ten distinct materials (ABS, PLA, PET, HIPS, PC, TPU, PVA, nylon, metal PLA, and carbon-fiber PLA) were tested for printing performance. The use of a heated AL-PC print bed was found to be a practical option for most of the materials, particularly ABS and TPU, which are often challenging to process using traditional print bed types. Generally, the results were found to be equivalent to or superior to tempered glass and superior to standard aluminum build plates in terms of printing capability. <s> BIB001 </s> A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics <s> 4. <s> This paper describes the collection of a large dataset (6930 measurements) on dimensional error in the fused deposition modeling (FDM) additive manufacturing process for full-density parts. Three different print orientations were studied, as well as seven raster angles ( 0 ∘ , 15 ∘ , 30 ∘ , 45 ∘ , 60 ∘ , 75 ∘ , and 90 ∘ ) for the rectilinear infill pattern. All measurements were replicated ten times on ten different samples to ensure a comprehensive dataset. Eleven polymer materials were considered: acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), high-temperature PLA, wood-composite PLA, carbon-fiber-composite PLA, copper-composite PLA, aluminum-composite PLA, high-impact polystyrene (HIPS), polyethylene terephthalate glycol-enhanced (PETG), polycarbonate, and synthetic polyamide (nylon). The samples were ASTM-standard impact-testing samples, since this geometry allows the measurement of error on three different scales; the nominal dimensions were 3.25 mm thick, 63.5 mm long, and 12.7 mm wide. This dataset is intended to give engineers and product designers a basis for judging the accuracy and repeatability of the FDM process for use in manufacturing of end-user products. <s> BIB002
Polyether ether ketone (PEEK): PEEK is a thermoplastic with excellent heat resistance, mechanical properties, and chemical stability. It has higher mechanical properties when compared to PLA and ABS. PEEK, a biomaterial, is considered as a promising bone repair material to make prostheses for the human body. 5. Polyetherimide (PEI): PEI is widely used in the transportation industry for its high strength-to-weight ratio with low smoke evolution and low smoke toxicity. It requires a high extrusion temperature and bed temperature during printing. Its trade name is ULTEM™ 9085. Due to its low density and toxicity properties, it can be used for aircraft cabins. 6. Nylon: Nylon can be chosen as the filament if the requirement is to print more flexible and more durable parts. It has high toughness and impact resistance, but it is highly sensitive to moisture. Nylon can warp about as much as ABS. Like many other FDM filaments, nylon absorbs moisture from the air as it is hygroscopic. Moisture absorption deteriorates filament properties and results in part characteristic degradation. 7. Other materials: In addition to the commonly used materials discussed above, there are some other materials that are not commonly used or analyzed as filament materials, for instance, high-impact polystyrene (HIPS), polyphenylsulfone (PPSF), polyethylene terephthalate glycol modified (PETG), thermoplastic polyurethane (TPU), bio-composite filaments, ceramic filaments, and other composite material filaments. Most of these materials are either still in the development process or are not easily obtained on the market. Some research efforts were carried out to compare the properties and functionality of multiple materials for the FDM process. Messimer et al. studied 10 materials to determine whether a heated aluminum-polycarbonate composite print bed was suitable for the FDM process or not BIB001 . In their updated work, they collected 11 materials to be used in modeling dimensional errors in the FDM process for full-density parts based on seven raster angles and three build orientations BIB002 . The 11 materials were ABS, PLA, high-temperature PLA, wood PLA, carbon-fiber PLA, aluminum PLA, copper PLA HIPS, PETG, polycarbonate, and nylon.