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Possibilities of Using 3D Printing with Polymers as Structural Components.

Marcin Artur Kwapisz1, Piotr Paszta2, Wiktor Lacki2

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Fused Filament Fabrication (FFF) 3D printing shows promise for manufacturing structural components. Material analysis revealed PLA, ABS, PA6, and PA12 suitability, with two filaments rejected for poor strength in this 3D printing study.

Keywords:
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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Additive Manufacturing

Background:

  • Fused Filament Fabrication (FFF) is an additive manufacturing technology with potential for producing structural components.
  • Material selection is critical for ensuring the mechanical integrity of 3D printed parts.
  • Reverse engineering enables the replication and optimization of existing mechanical components.

Purpose of the Study:

  • To investigate the feasibility of using polymer-based FFF 3D printing for manufacturing structural components.
  • To analyze and compare the suitability of common FFF filaments (PLA, ABS, PA6, PA12) for structural applications.
  • To optimize a gear wheel component for 3D printing while maintaining material expenditure.

Main Methods:

  • Reverse engineering of a lawn mower gear wheel to create 3D CAD models.
  • Geometric model optimization for volume and material efficiency.
  • Finite element analysis (FEA) to evaluate total deformation and reduced stresses for selected filaments.
  • Material testing and comparison of PLA, ABS, PA6, and PA12 filaments under simulated service conditions.

Main Results:

  • Two of the four analyzed filaments (PLA, ABS, PA6, PA12) exhibited significant deterioration in strength properties and were unsuitable for the application.
  • The remaining filaments were approved for the manufacturing process after numerical analysis.
  • The optimized geometric model was validated through prototype printing.

Conclusions:

  • FFF 3D printing is a viable technology for producing structural components when appropriate materials are selected.
  • Material characterization and numerical analysis are essential steps in qualifying filaments for demanding applications.
  • The study successfully identified suitable materials and demonstrated the potential of FFF for manufacturing functional mechanical parts.