Investigation Of Warping Deformation By Starch Adhesion In Fused Deposition Modelling 3D Printer

• Main Author: Nazan, Muhammad Afdhal
• Format: Thesis
• Language: English; English
• Published: 2021
• Subjects: T Technology (General); TP Chemical technology
• Online Access: http://eprints.utem.edu.my/id/eprint/25412/1/Investigation%20Of%20Warping%20Deformation%20By%20Starch%20Adhesion%20In%20Fused%20Deposition%20Modelling%203D%20Printer.pdf; http://eprints.utem.edu.my/id/eprint/25412/2/Investigation%20Of%20Warping%20Deformation%20By%20Starch%20Adhesion%20In%20Fused%20Deposition%20Modelling%203D%20Printer.pdf; http://eprints.utem.edu.my/id/eprint/25412/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=119715
• Institution: Universiti Teknikal Malaysia Melaka

Nowadays, Fused Deposition Modelling (FDM) is the most widely used rapid prototyping process in the market. Many derivatives of FDM are open source designs with variety of design complexity and printing quality. The output of open source FDM 3D printers are not perfect due to molten plastic filament tend to shrink, warps and peeled away from the printer’s bed during fabrication process. Many researchers came across these problems and found that it was due to the internal shrinkage during plastic solidification, uneven heat distribution of printing bed and short curing time. The study of the use of adhesive on the printer bed especially on countermeasures using starch base adhesive are limited. Hence the purpose of this research is to investigate the effectiveness of starch based adhesives material as countermeasure for warping deformation problems. Four different starch adhesives based material of cassava, sago, soy, and rice were applied to printing bedbefore extrusion of PLA filament. This is intended for comparison with synthetic adhesivewhich are normally applied in FDM process. The prepared standard geometries were printed for tensile strength analysis and surface morphology analysis. In addition, comparison of starch based adhesives and synthetic adhesive were perform by warping deformation measurement for 3D printed flat bar model and complex geometry model. Both models were printed with and without the existence of heat bed. For flat model, four side corners were measured while for complex model, the effect of curling, overhang, internal shrinkage and side shrinkage were inspected. Furthermore a design and development process of an automatic adhesive spreader to the Prusa i3 FDM 3D printer was proposed and the effect of curling, overhang, internal shrinkage and side shrinkage between the new spreader and conventional method were established. The result of experiments shown that cassava based adhesive has achieved the greatest tensile strength among the starch based material and achieved the lowest warping deformation compares to sago, corn and rice based. The evaluation on flat bar model shows average errors in between 15.13% to 22.77% for starch based adhesives compare to 3.80% error for synthetic adhesive. However, improvement can be seen when heat bed was applied to printing bed where starch based adhesives shown to have average warping deformation errors in between 2.51% to 3.92%. While for complex model, other warping deformation effects of curling, overhang, internal shrinkage and side shrinkage shown similar improvement when heat bed were applied to the initial setup. Lastly, the automatic adhesive spreader has been successfully built and performed at a better result compare to the conventional method which used a scrapper tool. The deformation values has reduce to 0.13% for curling effect, 1.92% for overhang effect, 0.09% for internal shrinkage effectand 0.28% for side shrinkages effect. As conclusion, the starch based adhesion materials especially cassava can improve warping deformation of curling, overhang, internal shrinkage and side shrinkage. Moreover, applying heat on bed has proven as one of major factor of improving starch based adhesion in reducing the warping deformations. In addition, the automatic adhesive spreader had shown significant improvement to reduce warping deformation effects. Thus, heat bed and this spreader are important and they are needed to take into account in conducting future experiments.