The topic of diploma thesis are surface heat treatments after 3D print by method Fused Deposition Modeling. In the introduction is located recherche of the given issue. Further, we describe the construction and process of the 3D printer construction, on which will be printed samples for experiments in the next part of the thesis. The aim is to determine the behavior and changes of surface structures of heat-affected samples from different materials. Furthermore, the suitability of the used methods and the possibility of their use in practice.

The diploma thesis deals with the production process of optical part of headlamp module produced by additive technology. The thesis contains the characteristics of headlamp, current manufacturing technology and description of additive manufacturng methods. The practical part is focused on the production of a reflector using 3D printing. The conclusion of the thesis is dedicated to the measuring of light output and its evaluation.

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With the rapid increase in utilization of the cheap and user friendly Fused Filament Fabrication, FFF 3D printer, a deeper knowledge about the technique is needful. The frame restricting the 3D printers for prototyping purposes is fading and a new phase of endless application possibilities is emerging. To bridge the gap in possible applications from prototypes to real products it is key to know and improve the factors affecting durability. With over a hundred settings and parameters to tweak the FFF 3D printing process there are a lot of opportunities, opportunities to optimize for durability.The tensile properties of some of the most used FFF 3D printing materials together with a few nylon based materials are examined, which are popular in engineering applications. The materials tested are ranging from rigid to flexible, rubber like materials. The most common failure scenario of a FFF 3D printed product is layer bonding failure. The factors affecting layer bonding performance are studied.The measurements are carried out using tensile testing equipment at Blekinge Institute of Technology. All tested specimens are manufactured at Creative Tools AB Halmstad with the FFF 3D printers Flashforge Dreamer and Makerbot Replicator 2X.The tensile strength of 3D printed PLA is found to be 51 MPa. PET has a tensile strength of 40 MPa and ABS 34 MPa. Stress-strain behavior of the materials shows that ABS is slightly softer than PLA and PET are slightly softer than ABS. PLA being the hardest material in the test. ISO 527-2 tensile testing standard is used but the tests diverge from the standard in several ways. The measurement data presented in this study can be very useful to guide the design engineer to choose the most durable plastic for the unique application.Five basic 3D printing settings are evaluated for layer bonding performance, by measuring the load capacity of a PLA specimen loaded transversally relative to the layers. Four of the settings show to possibly affect the layer bond’s load capacity by 50 % or more individually.The results of this study are presented in graphs, diagrams and pictures. These may help the 3D printer user to tweak basic settings to increase layer bonding performance and ultimately the durability of the product significantly.

Indiana University-Purdue University Indianapolis (IUPUI) / Fused deposition modeling (FDM) represents one of the most common techniques for rapid proto-typing in additive manufacturing (AM). This work applies image based thermography to monitor the FDM process in-situ. The nozzle temperature, print speed and print orientation were adjusted during the fabrication process of each specimen. Experimental and numerical analysis were performed on the fabricated specimens. The combination of the layer wise temperature profile plot and temporal plot provide insights for specimens fabricated in x, y and z-axis orientation. For the x-axis orientation build possessing 35 layers, Specimens B16 and B7 printed with nozzle temperature of 225 C and 235 C respectively, and at printing speed of 60 mm/s and 100 mm/s respectively with the former possessing the highest modulus, yield strength, and ultimate tensile strength. For the y-axis orientation build possessing 59 layers, Specimens B23, B14 and B8 printed with nozzle temperature of 215 C, 225 C and 235 C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and yield strength, while the latter the highest ultimate tensile strength. For the z-axis orientation build possessing 1256 layers, Specimens B6, B24 and B9 printed with nozzle temperature of 235 C, 235 C and 235 ➦C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and ultimate tensile strength, while B24 had the highest yield strength and B9 the lowest modulus, yield strength and ultimate tensile strength. The results show that the prints oriented in the y-axis orientation perform relatively better than prints in the x-axis and z-axis orientation.

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Ceramic additive manufacturing is gaining popularity with methods like selective laser sintering (SLS), binder jetting, direct ink writing and stereolithography, despite their disadvantages. Laser sintering and binder jetting are too expensive, while direct ink writing lacks resolution and stereolithography lacks scalability. The project aims to combine one of the most versatile, affordable, and readily available 3D printing methods: fused filament fabrication (FFF) with polymer derived ceramics to produce cellular ceramics to overcome the disadvantages posed by the other methods. The process uses a two-step approach. The first step is to 3D print the part using a polymer FFF 3D printer with a thermoplastic polyurethane filament and the second step is to impregnate the part in a polysilazane preceramic polymer and then pyrolyze it in an inert environment up to 1200C. The resulting product is a high-resolution cellular ceramic of the composition SiOC(N). This type of cellular ceramic can find an application in several fields such as scaffolds for bone tissue regeneration, liquid metal filtering, chemical and gas filtering, catalytic converters and electric applications. The process can provide an affordable alternative to the products used in these fields currently.

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