3D printing or additive manufacturing is a process of producing physical object directly from CAD file. This is a material addition process and so no or minimal material is wasted during the production of parts. The object is created by laying layer over layer until complete object is printed.
Fusion Deposition Modelling or FDM is the most common 3D printing technique, that forms layer both in horizontal and vertical directions using moving extrusion nozzle over a build platform.
Composite materials have properties combined by materials which are formed together. Composites material consists of a core polymer material and a reinforcing material, like continuous fibre. This offers higher strength and stiffness compared to normal polymers. Fibre Reinforced plastic or FRP is the most common household example of composite materials. Using similar concept for 3D part manufacturing has multiple advantages to the user. 3D printing technology is emerging to take up the use of composite material to make components.
Few of the Advantages of FDM for composite material rapid prototype part manufacturing are as below :
Uniformity of Distribution: Uniform distribution of one material into other material is especially important to get the benefits of composites structure. By using dual head deposition FDM process, where part is manufactured by layering of the materials, uniform distribution of mixture of materials is possible.
Array of Composites: With option of layering material in FDM technique as per need using computer aided controlling, its possible to obtain variety of combinations for composite materials as per applications of the parts.
Speed of Production: With minimal changes into the existing FDM 3D printers, composite material parts can be printed with faster rate than traditional production methods, without investing in moulds or tooling. This readies the prototype parts for verification and assembly checks, with the option of improvement at lower cost and quickness.
Accuracy of Manufacturing: Thinner wall thickness composite parts can also be produced with greater accuracy than traditional manufacturing techniques. So designer can be rest assured to achieve desired results in terms of weight and assembly.
Easy to adapt Complex designs: Complex designs which are difficult or costly by using traditional methods, can be easily manufactured using 3D printing with Composite or reinforced materials. This gives freedom to design the part.
Possibility of combining metal strength into Polymers: With dual head nozzles, continuous fibre 3D printing uses continuous strands of reinforcement fibre reinforcement to the base material to achieve higher strength to weight ratio. The 3D printer builds the pattern of a thermoplastic with continuous fibres into the part. This process is called Continuous Fibre Fabrication (CFF).
For single head FDM technology, filament with iron or CU powder into ABS material, so it has strength of metal with light weight of plastic.
Minimised wastage of material: The 3D parts only printed using the materials needed for the part itself, with little or no wastage as compared to alternative methods which are cut from large chunks of non-recyclable materials. This save on wastages but it also reduces the cost of the materials being used.
Reduced environmental impact: Glass fibres composites are hazardous to human health as well as have environmental impact. So using lowest and controlled quantity of such composite fibres make this process desirable.
Conclusion:
FDM is the most common and matured 3D printing technology among all known rapid prototyping methods. Using of composite materials in FDM provides more flexibility and cost effectiveness for the customers.
3D Incredible is one of the leading 3D metal printing companies in Pune with shortest lead time. We offer the most effective and reliable 3D printing solutions to help our clients manufacture complex parts at a rapid pace in a cost-effective manner. Our team comprises of the best engineers and experts who have a rich understanding of the 3D printing technology.
