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Impact of Infill Design on Mechanical Strength and Production Cost in Material Extrusion Based Additive Manufacturing

Baich, Liseli Jeanette
http://orcid.org/0000-0002-1569-9315
http://rave.ohiolink.edu/etdc/view?acc_num=ysu1485161020020828

Abstract Details

2016, Master of Science in Engineering, Youngstown State University, Department of Mechanical, Industrial and Manufacturing Engineering.
The widespread adoption of Additive Manufacturing (AM) can be greatly attributed to the lowering prices of entry-level extrusion-based 3D printers. It has enabled the use of AM for prototypes, STEM education and often, to produce complex custom commercial products. With increased access to material extrusion-based 3D printers and newer materials, the influence of print parameters such as infill patterns on resulting mechanical strength and print costs, need to be investigated. This research investigates the relationship among (1) infill designs, (2) selection of printer (entry-level vs. production grade), (3) mechanical properties (e.g. tensile, compressive and flexural) and (4) production cost (print time and material). Finite Element Analysis (FEA) simulation using ANSYS software was conducted on the 4-point bending specimens to develop an FEA model that was correlated with the experimental data (±8% accuracy). Relevant infill designs are evaluated and recommended based on the loading conditions and savings in production cost when compared to solid infill design. In the case of tension, a larger air gap in the infill design was the most cost effective. In the case of compression, low density and high density infills were more cost effective when compared to solid samples. In the case of the flexural loading, low density infill was also the most cost effective infill design. It was found that print time had a greater effect on total cost and hence, influence of print time is analyzed using both entry-level and production grade printers. The findings from this study will help formulate criteria for selection of optimal infill design based on loading conditions and cost of printing. In summary, it was found that in the case of entry-level printers, solid infill design is preferred due to minimal cost savings when compared to other infill designs. On the contrary, it was found that low density infill is more cost efficient than solid infill design while using production-grade printers.
Guha Manogharan, PhD (Advisor)
Hazel Marie, PhD (Committee Member)
Jae Joong Ryu, PhD (Committee Member)
95 p.
Industrial Engineering
3D printing; cost analysis; manufacturing; infill pattern; FEA analysis; production cost; materials

Recommended Citations

Citations

  • Baich, L. J. (2016). Impact of Infill Design on Mechanical Strength and Production Cost in Material Extrusion Based Additive Manufacturing [Master's thesis, Youngstown State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1485161020020828

    APA Style (7th edition)

  • Baich, Liseli. Impact of Infill Design on Mechanical Strength and Production Cost in Material Extrusion Based Additive Manufacturing. 2016. Youngstown State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ysu1485161020020828.

    MLA Style (8th edition)

  • Baich, Liseli. "Impact of Infill Design on Mechanical Strength and Production Cost in Material Extrusion Based Additive Manufacturing." Master's thesis, Youngstown State University, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1485161020020828

    Chicago Manual of Style (17th edition)

ysu1485161020020828
7,059
© 2016, all rights reserved.
This open access ETD is published by Youngstown State University and OhioLINK.