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Co-Printing Test Specimens as Surrogates for Complex Part Characterization

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Co-Printing Test Specimens as Surrogates for Complex Part Characterization

 

Engineers at Western Washington University have been conducting research to develop, analyze, and produce novel materials, processes, and parts utilizing Fused Deposition Modeling (FDM). Throughout this research, there has been a repeated need to test and evaluate 3D FDM-printed parts. However, as the parts are required as a component of materials, product, or process development, it is inconvenient and time-consuming to create replicate parts solely for destructive mechanical testing. We have been investigating a method of “co-printing” of specimens (CoPS) specifically designed for important mechanical, thermal, and morphological characterization and testing. These small CoPS are intended to be representative of the printed parts, and thus need to printed under identical conditions (or as close as possible) to the printed part. As a part is being additively fabricated, there are interactions between adjacent roads and between adjacent layers. These interactions include mechanical, chemical, and thermal processes, each of which can alter localized material properties. The CoPS test specimen must contain sufficient numbers of layers to contain these interactions, but the specimen must also be small enough to build quickly to minimize any effects on the process of building the actual desired part. The test specimen should also be small enough to test easily without a lot of preparation. These challenges have been addressed in the development of CoPS for FDM. The CoPS presented here were designed for dynamic mechanical analysis (flexural and tensile), load-cell based testing (tensile and compression), microscopy (SEM and optical), pycnometry, and thermal testing, with the parts being created on commercially-available FDM printers.  We implemented a series of experiments to evaluate CoPS and report on the suitability of various types and sizes of CoPS for various applications and their advantages and disadvantages.

 

Authors: Mark Peyron, David Gill, Cecile Grubb, Zachary Zywiak, Severn Anderson, Adam Hoch

 

Conference: CAMX 2016 – Anaheim

 

SKU/Code: TP16-0143

 

Pages: 13

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