The present Master thesis is focused on innovation and verification of the functionality of a 3D RepRap. The theoretical part of the thesis characterizes individual additive technologies. The practical part is focused on the design of the technical modifications of the printer in order to achieve the quality of the printing, while the current 3D printer design is compared with the innovative solution. The practical part tests the setting of print parameters, various materials for 3D printing and necessary finishing operations. The thesis is completed

The thesis describes design and aplication of 3D FDM printer type of delta. The first part describes methods of rapid prototyping. The second part describes 3D printers type of delta. The third part deals with construction and calibration of delta printer. In the fourth part are made suitable modifications to the design of the printer, to improve the quality of printing, which is then applied on a sample product. The final section is devoted to technical and economic evaluation.

The essence of this work is to summarize the knowledge about 3D printing, especially with FDM technologies. Create an overview of used FDM printing materials, identify their advantages and disadvantages, technical parameters and usability. Another purpose of the thesis is to examine the print quality and its problems and specify types of surface finishes for selected materials. The content also includes remote control and monitoring of the 3D print process using the Raspberry Pi microcomputer and the print server named Octoprint.

The aim of my diploma thesis was engineering design of 4x4 chassis dynamometer model at 1:10 scale for presentation purpose and for testing RC cars models. The first part describes the current types of chassis dynamometers. The main goal of the thesis was designed the model itself in order to produce some parts of the dynamometer using 3D printing. The work also includes production drawings of individual parts and economic estimate of the entire production.

This master thesis deals with the surface treatment of parts made of plastic produced using FDM technology and design of technological device for surface treatment. The thesis describes FDM principles, according to performed experiments in a technological device there are suggested technological conditions for the surface treatment of parts made of ABS plastic. In the end of the thesis, there are calculated costs of the technological device and its operating costs, also mechanical properties, surface roughness and other specifications from before and after the treatment are compared.

This master thesis summarizes the current knowledge about non-commercial 3D printing FDM technology. The goal of this thesis is to demonstrate the gained knowledge by building a 3D printer which can partially replicate itself, and to evaluate its technological parameters. The experimental part of this work is focused on the impact of the changes in technological parameters of printing on mechanical properties of printed parts.

The content of this diploma thesis is a design of construction and selection of suitable material for upper-carrier part used for racing vehicle, produced by FDM 3D printing with the alternative option to replace an existing part, which was produced by conventional technique of CNC machining. Various versions of the experimental part are analyzed by FEM and compared in terms of safety coefficient with target to select the most appropriate construction design. The chosen version of the model is at the end compared with already existing part, which was also analyzed by FEM.

Indiana University-Purdue University Indianapolis (IUPUI) / One of the primary challenges faced in Additive Manufacturing (AM) is reducing the overall cost and printing time. A critical factor in cost and time reduction is post-processing of 3D printed (3DP) parts, which includes removing support structures. Support is needed to prevent the collapse of the part or certain areas under its own weight during the 3D printing process. Currently, the design of self-supported 3DP parts follows experimental trials. A trial and error process is needed to produce high quality parts by Fused Depositing Modeling (FDM). An example for a chamfer angle, is the common use of 45 degree angle in the AM process. Surfaces that are more flat show defects than inclined surfaces, and therefore a numerical model is needed. The model can predict the problematic areas at a print, reducing the experimental prints and providing a higher number of usable parts. Physical-based models have not been established due to the generally unknown properties of the material during the AM process. With simulations it is possible to simulate the part at different temperatures with a variety of other parameters that have influence on the behavior of the model. In this research, analytic calculations and physical tests are carried out to determine the material properties of the thermoplastic polymer Acrylonitrile - Butadiene - Styrene (ABS) for FDM at the time of extrusion. This means that the ABS is going to be extruded at 200C to 245C and is a viscus material during part construction. Using the results from the physical and analytical models, i.e., Timoshenko’s modified beam theory for micro structures, a numerical material model is established to simulate the filament deformation once it is deposited onto the part. Experiments were also used to find the threshold for different geometric specifications, which could then be applied to the numerical model to improve the accuracy of the simulation. The result of the nonlinear finite element analysis is compared to experiments to show the correlation between the prediction of deflection in simulation and the actual deflection measured in physical experiments. A case study was conducted using an application that optimizes topology of complex geometries. After modeling and simulating the optimized part, areas of defect and errors were determined in the simulation, then verified and and measured with actual 3D prints.

Indiana University-Purdue University Indianapolis (IUPUI) / Metal 3D printing typically requires high energy laser or electron sources. Recently, 3D printing using metal filled filaments becomes available which uses PLA filaments filled with metal powders (such as copper, bronze, brass, and stainless steel). Although there are some studies on their printability, the detailed study of their sintering and characterizations is still missing. In this study, the research is focused on 3D printing of bronze filaments. Bronze is a popular metal for many important uses. The objectives of this research project are to study the optimal processing conditions (like printer settings, nozzle, and bed temperatures) to print bronze metal filament, develop the sintering conditions (temperature and duration), and characterization of the microstructure and mechanical properties of 3D printed specimens to produce strong specimens. The thesis includes three components: (1) 3D printing and sintering at selected conditions, following a design of experiment (DOE) principle; (2) microstructure and compositional characterizations; and (3) mechanical property characterization. The results show that it is feasible to print using bronze filaments using a typical FDM machine with optimized printing settings. XRD spectrums show that there is no effect of sintering temperature on the composition of the printed parts. SEM images illustrate the porous structure of the printed and sintered parts, suggesting the need to optimize the process to improve the density. The micro hardness and three-point bending tests show that the mechanical strengths are highly related to the sintering conditions. This study provides important information of applying the bronze filament in future engineering applications.

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