Session: 01-02 Polymers: Characterization and Mechanical Properties II

Paper Number: 94087

94087 - Comparison of Technical and Economic Properties of Additively Manufactured Components Using Masked Stereolithography and Fused Layer Modeling 

Additive manufacturing with plastics enables the production of lightweight and resilient components with a high degree of design freedom. In the low-cost sector, Material Extrusion (MEX) as Fused Layer Modeling (FLM) has so far been the leading method, as it offers simple 3D printers and a variety of inexpensive 3D materials as filament (e.g. made of ABS or PLA). However, printing times for FLM are very long and dimensional accuracy and surface finish are rather poor. Recently, new processes from the field of Vat Polymerization (VAT) have appeared on the market, such as masked Stereolithography (mSLA), which offer a significant improvement in component quality and build speed at equally favorable machine costs. In this context, a variety of different resins are becoming available as building materials for different applications (e.g. castable resins for investment casting, resins for dentistry or though resins for highly stressed components).

This paper therefore analyzes the technical and economic capabilities of the two competing additive processes. For this purpose, the achievable dimensional and surface qualities are determined with the aid of a test specimen. Basic design guidelines for mSLA can be derived from the investigations with the test specimen. In addition, the machine and material costs are determined and compared with each other with reference to the work required for 3D printing as well as preparation and reworking. Finally, the resulting environmental impact is determined in the form of the CO₂ footprint.

In order to optimize the strength of the printed components, material properties of the tensile specimens produced additively with mSLA are determined. In particular, the effect of the process parameters (e.g. print orientation, layer thickness and exposure time) on the strength and elongation at break will be investigated. The use of though resins and ABS-like resins will also be investigated in more detail to determine optimal processing settings. The results of this paper provide support for the selection of the appropriate additive manufacturing process as for the optimization of parts made of mSLA with respect to process parameters and material selection.

Presenting Author: Stefan Junk Offenburg University of Applied Sciences

Presenting Author Biography: Prof. Dr Junk has been teaching Computer Aided Engineering and Additive Manufacturing at Offenburg University of Applied Sciences since 2008. In recent years, he has built up a laboratory with state-of-the-art 3D printers and 3D scanners and conducts research in the areas of additive tooling and fibre-reinforced 3D printing materials. He is also involved in training students in design education and motivating students for STEM. Before joining the university, he worked for several years in technology development at the automotive supplier EBERSPÄCHER. He studied design and production engineering at Saarland University at Prof. Dr.-Ing. C. Weber and did his doctorate on incremental sheet metal forming under Prof. Dr.-Ing. G. Hirt (now RWTH Aachen, IBF)

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