3D printing of metal parts using a highly-filled thermoplastic filament Articles uri icon

publication date

  • January 2025

start page

  • 233

end page

  • 251

issue

  • 2

volume

  • 31

International Standard Serial Number (ISSN)

  • 1355-2546

Electronic International Standard Serial Number (EISSN)

  • 1758-7670

abstract

  • Purpose
    This study aims to develop a highly loaded filament with spherical metallic particles for fused filament fabrication (FFF) technology. The research focuses on optimizing powder loading, printing parameters and final processes, including debinding and sintering, to produce successful metal parts.

    Design/methodology/approach
    The optimal powder loading was identified by measuring mixing torque and viscosity at various temperatures. The filament was extruded, and printing parameters- particularly printing speed to ensure proper material flow - were optimized. Different filling patterns were also examined. After printing, the polymeric binder was removed and the parts were sintered to form the final metal components.

    Findings
    The optimal powder loading was determined to be 55% vol. The best surface quality was achieved with an optimized printing speed of 5mm/s. Parts printed with various infill patterns were studied for differences in open, closed and total porosity, showing a strong link between porosity and infill pattern.

    Originality/value
    This comprehensive study provides new insights into manufacturing metal parts using FFF technology. It fills a gap in the literature regarding feedstock viscosity and shear rate in highly loaded metal filaments during FFF. Additionally, it uniquely examines the open, closed and total porosity of metal parts printed with different infill patterns.

subjects

  • Chemistry
  • Materials science and engineering

keywords

  • additive manufacturing; metal fused filament fabrication; highly loaded filament; rate limits; rheological properties; printablility