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COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS

Year 2024, Volume: 8 Issue: 3, 370 - 386, 30.12.2024

Bhanu Prakash Bisht Vijaykumar Toutam , Sanjay R. Dhakate

https://doi.org/10.46519/ij3dptdi.1540408

Abstract

A comparative analysis of Material Extrusion and VAT Photopolymerization 3D printing is done using various geometrical models, including square base pyramid, co-centric circular stamps, and lattice structures. The pyramid with Council of Scientific and Industrial Research (CSIR) and National Physical Laboratory (NPL) logos, texts printed by both techniques is studied for its dimensional accuracy as per the process parameters. The 3D printed specimen by Material Extrusion measured an average layer thickness of ~ 104 µm and VAT Photopolymerization measured a layer thickness of ~ 54 µm. The calculated void volume of the printed pyramid due to the staircase effect is ~ 2.9 % for the Material Extrusion and ~ 0.14 % for the VAT Photopolymerization. Mechanical properties of ASTM D638 tensile test samples based on build orientation showed anisotropy for Material Extrusion, whereas VAT Photopolymerization printed test samples are isotropic. The degree of anisotropy (DOA) of 0.35, modulus of elasticity (MOE) of 1.7 GPa and ultimate tensile strength (UTS) of 62 MPa are measured for the Material Extrusion printed test sample. The ZXY build-oriented test sample showed the lowest values compared to all the other build orientations. Comparatively, the MOE and UTS for the VAT Photopolymerization printed samples are equal for all build orientations and are ~ 950 MPa and ~ 39 MPa, respectively. The applicability of the present comparison of 3D printing techniques is demonstrated through functionality studies of printed stamps for ring electrodes and lattice structures as templates. The active area of the Fused deposition modeling (FDM) printed ring electrodes for maximum resolution is 17 times larger compared to that of Digital light processing (DLP) printed stamps. Additionally, the mean pore size for FDM-printed lattice structures was found to be ~ 650 µm, while the lattice structure printed by DLP using Polyurethan acrylate resin exhibited a pore size of ~ 220 µm. This analysis evaluates the dependence of stamp size due to print resolution specific to the technique. The importance of this research lies in addressing the growing demand for optimized 3D printing processes in manufacturing applications, such as sensors, electrodes, and structural components. By comparing dimensional accuracy, surface finish, print resolution, and mechanical properties, this study offers valuable insights into how the selection of printing techniques and process parameters can significantly influence the final product's performance.

Keywords

Additive manufacturing Build orientation Staircase effect Fused deposition modeling Digital light processing

Project Number

CSIR NPL-OLP230432

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COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS

Year 2024, Volume: 8 Issue: 3, 370 - 386, 30.12.2024

Bhanu Prakash Bisht Vijaykumar Toutam , Sanjay R. Dhakate

https://doi.org/10.46519/ij3dptdi.1540408

Abstract

A comparative analysis of Material Extrusion and VAT Photopolymerization 3D printing is done using various geometrical models, including square base pyramid, co-centric circular stamps, and lattice structures. The pyramid with Council of Scientific and Industrial Research (CSIR) and National Physical Laboratory (NPL) logos, texts printed by both techniques is studied for its dimensional accuracy as per the process parameters. The 3D printed specimen by Material Extrusion measured an average layer thickness of ~ 104 µm and VAT Photopolymerization measured a layer thickness of ~ 54 µm. The calculated void volume of the printed pyramid due to the staircase effect is ~ 2.9 % for the Material Extrusion and ~ 0.14 % for the VAT Photopolymerization. Mechanical properties of ASTM D638 tensile test samples based on build orientation showed anisotropy for Material Extrusion, whereas VAT Photopolymerization printed test samples are isotropic. The degree of anisotropy (DOA) of 0.35, modulus of elasticity (MOE) of 1.7 GPa and ultimate tensile strength (UTS) of 62 MPa are measured for the Material Extrusion printed test sample. The ZXY build-oriented test sample showed the lowest values compared to all the other build orientations. Comparatively, the MOE and UTS for the VAT Photopolymerization printed samples are equal for all build orientations and are ~ 950 MPa and ~ 39 MPa, respectively. The applicability of the present comparison of 3D printing techniques is demonstrated through functionality studies of printed stamps for ring electrodes and lattice structures as templates. The active area of the Fused deposition modeling (FDM) printed ring electrodes for maximum resolution is 17 times larger compared to that of Digital light processing (DLP) printed stamps. Additionally, the mean pore size for FDM-printed lattice structures was found to be ~ 650 µm, while the lattice structure printed by DLP using Polyurethan acrylate resin exhibited a pore size of ~ 220 µm. This analysis evaluates the dependence of stamp size due to print resolution specific to the technique. The importance of this research lies in addressing the growing demand for optimized 3D printing processes in manufacturing applications, such as sensors, electrodes, and structural components. By comparing dimensional accuracy, surface finish, print resolution, and mechanical properties, this study offers valuable insights into how the selection of printing techniques and process parameters can significantly influence the final product's performance.

Keywords

Additive Manufacturing Staircase Effect Build Orientation Test Artifact FDM Vs DLP Printing Parameters Ring Electrode.

Ethical Statement

1) This material is the authors' own original work, which has not been previously published elsewhere. 2) The paper is not currently being considered for publication elsewhere. 3) The paper reflects the authors' own research and analysis in a truthful and complete manner. 4) The paper properly credits the meaningful contributions of co-authors and co-researchers. 5) The results are appropriately placed in the context of prior and existing research. 6) All sources used are properly disclosed (correct citation). Literally copying of text must be indicated as such by using quotation marks and giving proper reference. 7) All authors have been personally and actively involved in substantial work leading to the paper, and will take public responsibility for its content.

Project Number

CSIR NPL-OLP230432

References

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There are 67 citations in total.

Details

Primary Language English
Subjects Mechanical Engineering (Other)
Journal Section Research Article
Authors

Bhanu Prakash Bisht This is me 0009-0009-7904-9571

Vijaykumar Toutam 0000-0002-9462-0643

Sanjay R. Dhakate This is me 0000-0001-9971-1117

Project Number CSIR NPL-OLP230432
Publication Date December 30, 2024
Submission Date August 30, 2024
Acceptance Date November 21, 2024
Published in Issue Year 2024 Volume: 8 Issue: 3

Cite

APA Bisht, B. P., Toutam, V., & R. Dhakate, S. (2024). COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS. International Journal of 3D Printing Technologies and Digital Industry, 8(3), 370-386. https://doi.org/10.46519/ij3dptdi.1540408
AMA Bisht BP, Toutam V, R. Dhakate S. COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS. IJ3DPTDI. December 2024;8(3):370-386. doi:10.46519/ij3dptdi.1540408
Chicago Bisht, Bhanu Prakash, Vijaykumar Toutam, and Sanjay R. Dhakate. “COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS”. International Journal of 3D Printing Technologies and Digital Industry 8, no. 3 (December 2024): 370-86. https://doi.org/10.46519/ij3dptdi.1540408.
EndNote Bisht BP, Toutam V, R. Dhakate S (December 1, 2024) COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS. International Journal of 3D Printing Technologies and Digital Industry 8 3 370–386.
IEEE B. P. Bisht, V. Toutam, and S. R. Dhakate, “COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS”, IJ3DPTDI, vol. 8, no. 3, pp. 370–386, 2024, doi: 10.46519/ij3dptdi.1540408.
ISNAD Bisht, Bhanu Prakash et al. “COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS”. International Journal of 3D Printing Technologies and Digital Industry 8/3 (December 2024), 370-386. https://doi.org/10.46519/ij3dptdi.1540408.
JAMA Bisht BP, Toutam V, R. Dhakate S. COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS. IJ3DPTDI. 2024;8:370–386.
MLA Bisht, Bhanu Prakash et al. “COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS”. International Journal of 3D Printing Technologies and Digital Industry, vol. 8, no. 3, 2024, pp. 370-86, doi:10.46519/ij3dptdi.1540408.
Vancouver Bisht BP, Toutam V, R. Dhakate S. COMPARATIVE STUDY OF MATERIAL EXTRUSION AND VAT PHOTOPOLYMERIZATION ADDITIVE MANUFACTURING TECHNIQUE USING SQUARE BASE PYRAMID AS AN ARTIFACT AND APPLICATIONS. IJ3DPTDI. 2024;8(3):370-86.
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