EFFECT OF PROCESS PARAMETERS ON VOID FORMATION IN FUSED DEPOSITION MODELLING (FDM) PART

Abstract

A void is a structural defect resulting from the 3D printing process. The presence of voids compromises the structural integrity of a 3D-printed component, resulting in a reduction in durability and functionality. Currently, the only technique used to correlate FDM process parameters with mechanical properties is tensile testing. Nonetheless, this method is time-consuming and expensive. Therefore, the purpose of this study is to determine the viability of employing an alternative method to establish this connection. This study examined the parameters of infill density, infill pattern, raster angle, and part shape. While pressurized gas release was used to evaluate the printed material based on bubble formation, the printed object was evaluated based on bubble formation. Subsequently, the qualitative relationship between these parameters, void formation, and mechanical properties was determined. According to the results of this study, the relationship between the studied parameters, the tensile test, and the mechanical properties of the FDM part was consistent with the relationship between the studied parameters and the formation of bubbles and voids. 3D-printed parts with the lowest possible bubble intensity when using a 100% infill density, a grid infill pattern, and a 45° raster angle. The shape of the component was found to have the least impact on the formation of the bubble. This study concluded that using a 100% infill density, grid infill pattern, and 45° raster angle results in the least amount of void formation, and that the effect of shape difference on void formation in 3D-printed parts is negligible. The results of this study could be used to predict the mechanical properties of a component as a function of void formation during the (Pressurised gas release) PGR test. In the future, imaging-based quantitative analysis of voids will be required to validate this finding.