TY - GEN
T1 - Infill Density in Additive Manufacturing and Application to the DFMA of an Iron Man Helmet
AU - Vraitch, Rajan
AU - Prince, Mark
AU - Souppez, Jean-Baptiste R. G.
N1 - © 2023 The Authors; 28th International Conference on Automation and Computing (ICAC2023) ; Conference date: 30-08-2023 Through 01-09-2023
PY - 2023/8/30
Y1 - 2023/8/30
N2 - Additive manufacturing has become increasinglypopular for rapid prototyping and industrial applications, particularlyin the context of Industry 4.0. However, given thevast design parameter space, there remains a lack of characterisationof the mechanical properties for varying designparameters. Consequently, flexural tests are undertaken followingthe ISO 178:2019 for fused deposition modelling (FDM) samples,with three infill patterns (lines, gyroid and triangles), fourthermoplastic materials, namely acrylonitrile butadiene styrene(ABS), polylactic acid (PLA and PLA+), and polyethylene terephthalateglycol (PETG), and infill densities (print material to partvolume ratio) ranging from 0.10 to 1.00. Here we show that (i) themodulus and strength are independent of the tested infill types;(ii) the mechanical properties increase linearly with infill density;and (iii) considering mechanical properties, mass and cost, PLA+appears as the most suitable overall material choice, with PETGappropriate for strength-driven, low-cost applications. Ultimately,PLA+ is applied to the design for manufacturing and assembly(DFMA) case study of an Iron Man helmet. These findingsprovide novel insights into the variations of mechanical propertieswith infill type, density and material for 3D printing applicationsand may contribute to future development in lightweight andcost-effective additive manufacturing.
AB - Additive manufacturing has become increasinglypopular for rapid prototyping and industrial applications, particularlyin the context of Industry 4.0. However, given thevast design parameter space, there remains a lack of characterisationof the mechanical properties for varying designparameters. Consequently, flexural tests are undertaken followingthe ISO 178:2019 for fused deposition modelling (FDM) samples,with three infill patterns (lines, gyroid and triangles), fourthermoplastic materials, namely acrylonitrile butadiene styrene(ABS), polylactic acid (PLA and PLA+), and polyethylene terephthalateglycol (PETG), and infill densities (print material to partvolume ratio) ranging from 0.10 to 1.00. Here we show that (i) themodulus and strength are independent of the tested infill types;(ii) the mechanical properties increase linearly with infill density;and (iii) considering mechanical properties, mass and cost, PLA+appears as the most suitable overall material choice, with PETGappropriate for strength-driven, low-cost applications. Ultimately,PLA+ is applied to the design for manufacturing and assembly(DFMA) case study of an Iron Man helmet. These findingsprovide novel insights into the variations of mechanical propertieswith infill type, density and material for 3D printing applicationsand may contribute to future development in lightweight andcost-effective additive manufacturing.
U2 - 10.1109/ICAC57885.2023.10275307
DO - 10.1109/ICAC57885.2023.10275307
M3 - Conference contribution
BT - The 28th International Conference on Automation and Computing (ICAC2023)
ER -