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Thermal expansion and Thermal stress: Problem Solving

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San Francisco's Golden Gate Bridge is exposed to temperatures ranging from -15 °C to 40 °C. At its coldest, the main span of the bridge is 1275 m long. Assuming that the bridge is made entirely of steel, what is the change in its length between these temperatures?
To solve the problem, first, identify the known and unknown quantities. The initial length (L) of the bridge is 1275 m, the coefficient of linear expansion (α) for steel is 12 x 10-6/°C, and the change in...

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Updated: Jun 3, 2025

Fused Filament Fabrication FFF of Metal-Ceramic Components

Fused Filament Fabrication FFF of Metal-Ceramic Components

Published on: January 11, 2019

Development of a Stable Process for Wire Embedding in Fused Filament Fabrication Printing Using a Geometric

Valentin Wilhelm Mauersberger¹, Fabian Ziervogel¹, Linda Weisheit¹

¹Fraunhofer Institute for Machine Tools and Forming Technology IWU, Nöthnitzer Straße 44, 01187 Dresden, Germany.

Materials (Basel, Switzerland)

|January 11, 2025

Summary

This summary is machine-generated.

This study introduces a geometric correction model to enhance wire deposition accuracy in fused filament fabrication (FFF). The model improves the positioning of conductive wires for integrated electrical structures in polymer parts.

Keywords:

3D printing additive manufacturing composites conductive structures embedded electronics functionalization fused filament fabrication wire deposition wire integration wire-encapsulating additive manufacturing

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Last Updated: Jun 3, 2025

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Area of Science:

Additive Manufacturing
Materials Science
Electrical Engineering

Background:

Fused filament fabrication (FFF) enables integrating electrical structures by directly processing wires.
Current FFF wire deposition lacks accuracy in curved sections, limiting the integration of complex electrical components.
Developing precise wire placement methods is crucial for advanced 3D-printed electronics.

Purpose of the Study:

To develop and validate a geometric correction model for improving wire deposition accuracy in FFF.
To optimize process parameters for stable and efficient wire integration.
To assess the general validity of the correction model across different wire and polymer materials.

Main Methods:

A novel tool head with an additional rotational axis and wire feed was utilized.
A geometric correction model was created, converted to G-code, and applied to curved print paths.
Printed arcs were visually evaluated for wire position and embedding quality.
Process parameters (extrusion coefficient, feed) and materials (copper, constantan, PLA, PETG) were systematically varied.

Main Results:

The geometric correction model significantly improved the positioning accuracy of 0.2 mm wires in curved sections.
Optimal cooling times were determined for enhanced wire embedding.
Varied process parameters and materials demonstrated the model's general applicability.
Specific parameter sets were identified for achieving high-quality wire embedding and positioning.

Conclusions:

The developed geometric correction model effectively addresses the challenge of inaccurate wire deposition in FFF.
This advancement facilitates the reliable integration of electrical functionalities into 3D-printed polymer parts.
Further optimization of process parameters can lead to robust and efficient additive manufacturing of electronic components.