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Fused deposition modeling: process, materials, parameters, properties, and applications

  • Critical Review
  • Published:
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Abstract

In recent years, 3D printing technology has played an essential role in fabricating customized products at a low cost and faster in numerous industrial sectors. Fused deposition modeling (FDM) is one of the most efficient and economical 3D printing techniques. Various materials have been developed and studied, and their properties, such as mechanical, thermal, and electrical, have been reported. Numerous attempts to improve FDM products’ properties for applications in various sectors have also been reported. Still, their applications are limited due to the materials’ availability and properties compared to traditional fabrication methods. In 3D printing, the process parameters are crucial factors for improving the product's properties and reducing the machining time and cost. Researchers have recently investigated many approaches for expanding the range of materials and optimizing the FDM process parameters to extend the FDM process’s possibility into various industrial sectors. This paper reviews and explains various techniques used in 3D printing and the various polymers and polymer composites used in the FDM process. The list of mechanical investigations carried out for different materials, process parameters, properties, and the FDM process's potential application was discussed. This review is expected to indicate the materials and their optimized parameters to achieve enhanced properties and applications. Also, the article is highly anticipated to provide the research gaps to sustenance future research in the area of FDM technologies.

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Abbreviations

3DP:

Three-dimensional printing

ABS:

Acrylonitrile butadiene styrene

AM:

Additive manufacturing

ANOVA:

Analysis of variance

ASTM:

American Society for Testing and Material standards

β-TCP:

Beta-tricalcium phosphate

BJ:

Binder jetting

CAD:

Computer-aided design

CAM:

Computer-aided manufacturing

CF:

Carbon fiber

CFF:

Continuous flax fiber

CFR:

Continuous fiber reinforcement

CIJ:

Continuous inkjet

CNT:

Carbon nanotube

DCB:

Decellularized bone matrix

DED:

Direct energy deposition

DLF:

Direct light fabrication

DLP:

Digital light processing

DMD:

Direct metal deposition

DMLS:

Direct metal laser sintering

DOE:

Design of experiments

EBW:

Electron beam welding

FDM:

Fused deposition modeling

FF:

Flax fiber

FFF:

Fused filament fabrication

G-Code:

Geometric code

GF:

Glass fiber

HA:

Hydroxyapatite

HIPS:

High-impact polystyrene

IP:

Inkjet printing

ISO:

International Standard Organization

LENS:

Laser-engineered net shaping

LOM:

Laminated object manufacturing

M-Code:

Machine code

ME:

Material extrusion

MJ:

Material jetting

MWCNT :

Multi-walled carbon nanotubes

OMMT:

Organic montmorillonite

PA:

Nylon/polyamide

PBF:

Powder bed fusion

PBS:

Poly(butylene succinate)

PC:

Polycarbonate

PCL:

Polycaprolactone

PEEK:

Polyetheretherketone

PEKK:

Polyetherketoneketone

PHB:

Poly(3-hydroxybutyrate)

PLA:

Polylactic acid

PLGA:

Poly(lactic-co-glycolic acid)

PMMA:

Polymethyl methacrylate

PP:

Polypropylene

PPSF:

Polyphenylsulphone

PVA:

Polyvinyl alcohol

PVDF:

Polyvinylidene fluoride

PS:

Polystyrene

RP:

Rapid prototyping

RSM:

Response surface methodology

SBF:

Simulated body fluids

SCF:

Short carbon fiber

SL:

Sheet lamination

SLA:

Stereolithography

SLS:

Selective laser sintering

STL:

Standard tessellation language

TMP:

Thermomechanical pulp

TPU:

Thermoplastic polyurethanes

UAM:

Ultrasound additive manufacturing

VP:

Vat photopolymerization

μm:

Micrometer

$:

American dollars

MPa:

Megapascal

GPa:

Gigapascal

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Acknowledgements

The authors gratefully acknowledge the Universiti Malaysia Pahang, Malaysia, for providing funds and facilities under research grants RDU190352, RDU192401 and RDU192217 to conduct this research.

Funding

This study is financially supported by the Universiti Malaysia Pahang, Grant RDU190352, RDU192401, and RDU192217.

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Authors and Affiliations

  1. Faculty of Mechanical & Automotive Engineering Technology, Universiti Malaysia Pahang, 26600, Pekan, Pahang, Malaysia

    Kumaresan Rajan, Kumaran Kadirgama & Wan Sharuzi Wan Harun

  2. College of Engineering, Universiti Malaysia Pahang, 26300, Gambang, Pahang, Malaysia

    Mahendran Samykano & Md. Mustafizur Rahman

  3. Centre for Research in Advanced Fluid and Processes, Universiti Malaysia Pahang, 26300, Gambang, Pahang, Malaysia

    Mahendran Samykano & Kumaran Kadirgama

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  1. Kumaresan Rajan
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  5. Md. Mustafizur Rahman
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Contributions

Kumaresan Rajan: Data curation, writing—original draft preparation. Mahendran Samykano: Supervision, conceptualization, writing—original draft preparation. Kumaran Kadirgama: Supervision, writing—reviewing and editing. Wan Sharuzi Wan Harun: Writing—reviewing and editing. Md. Mustafizur Rahman: Writing—reviewing and editing.

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Correspondence to Mahendran Samykano.

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Highlights

• Various methods of the additive manufacturing process were discussed.

• Fused deposition modeling materials (polymers and polymer composites) were discussed in detail.

• Various parameters used and optimization of the fused deposition modeling process were discussed.

• Properties of different polymers and polymer composites have been extracted from different kinds of experiments and studies.

• Applications in the various sectors using the fused deposition process were discussed.

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Rajan, K., Samykano, M., Kadirgama, K. et al. Fused deposition modeling: process, materials, parameters, properties, and applications. Int J Adv Manuf Technol 120, 1531–1570 (2022). https://doi.org/10.1007/s00170-022-08860-7

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  • DOI: https://doi.org/10.1007/s00170-022-08860-7

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