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Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13. Show image information
Industry partners of the DMRC. Show image information
Industry partners of the DMRC. Show image information
Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC. Show image information
Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part. Show image information
Additive manufactured reaction wheel bracket for telecomunication satellites. Show image information
Employees of the DMRC working with the "freeformer" from Arburg. Show image information
Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM). Show image information

Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13.

Industry partners of the DMRC.

Industry partners of the DMRC.

Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC.

Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part.

Additive manufactured reaction wheel bracket for telecomunication satellites.

Employees of the DMRC working with the "freeformer" from Arburg.

Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM).

Analysis of the FDM Part Quality manufactured with ABS with the Focus on the Toy Industry

Mechanical properties to determine according to the ISO standard for polymers

Mechanical Strength Properties

First, the mechanical strength properties of ABS parts will be analyzed according to the ISO standards for plastic materials. The tests to be conducted are shown in Figure 1. For the purpose of these tests, test specimens will be built up with different slice heights due to variation of the tip size. Furthermore, the build orientation will be varied. First, components will be built up with the preset toolpath parameters and then these parameters will be changed in order to analyze the effect of the inner part structures of the fabricated parts on the resulting strength properties. Additionally, some tests will be conducted according to the standards of the toy industry in order to work out possible application fields.

Surface treatment methods

In this work package, the analysis of surface characteristics for ABS-M30 parts will be conducted with the aim of improving the decorative surface properties. In general, FDM-parts show rough and wavy surfaces with stair-stepping effects whenever the parts have sloped or rounded geometries. Important FDM process related parameters for the surface characteristics include: layer thickness, filament width, air gap and build orientation of the component. The post treatment will be focused on mechanical methods such as vibratory grinding and abrasive blasting. For mass finishing, the process parameters granulate, geometry of the granulate, finishing time, and intensity will be analyzed. The influence of layer thickness, build orientation, and measurement direction on the surface roughness of untreated parts is shown in Figure 2.

a) Average height of the profile of FDM parts; b) Tensile specimens in different building angles

Dimensional accuracy

Furthermore, the analysis of the dimensional accuracy of ABS parts will be conducted with regard to the surface smoothing method. To achieve this goal, standard elements were built with different process parameters (slice height, orientation and toolpath). The deviation from the nominal size is measured before and after a grinding treatment.  Thus, the aim is to define a general guideline on how to achieve a required fitting accuracy in relation to the manufacturing process and the used surface smoothing method.

a) Dimensional accuracy of the standard element “plate” after grinding process; b) Standard element “plate” with the nominal size 50 x 50 x 2 mm (x/y/z)
Further project information
Project statusIn progress
Project duration21 month
Funding50 % Land of North Rhine-Westphalia
50 % DMRC industry partner
Project managerProf. Dr.-Ing. Volker Schöppner
Project coordinatorRonen Hadar (LEGO)
Jesse Hanssen (Stratasys)
Scientific staffMatthias Fischer
Frederick Knoop
Involved chairsKunststofftechnik Paderborn (KTP)
Contact

Prof. Dr.-Ing. Volker Schöppner

Kunststoffverarbeitung

Volker Schöppner
Phone:
+49 5251 60-3057
Fax:
+49 5251 60-3821
Office:
P1.5.11.3
Web:

M.Sc. Frederick Knoop

DMRC

Fused Deposition Modeling

Frederick Knoop
Phone:
+49 5251 60-5518
Fax:
+49 5251 60-5409
Office:
W2.102

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