Characterization and modeling of surface defects in EP3D printing
Abstract
Purpose
This paper aims to report an experimental study of how surface defects evolve in EP3D printing as more layers are accumulated and proposes a simulation model for the process.
Design/methodology/approach
A series of measurements on the surface roughness were taken layer-by-layer for two 30-layer samples. A model of the process was constructed based on dynamic system modeling, system identification techniques and the analysis of the measurements from the samples.
Findings
The transient response of the fuser has a significant impact on the surface of the print. The surface of the EP3D printed part depends heavily on the compliance of the interface. The model developed is able to approximate the behavior of the surface as more layers are deposited.
Research limitations/implications
The model requires tuning multiple parameters, especially the compliance threshold for the interface; similar experiments/measurements are needed for any change in the system.
Practical implications
The simulation model provides a way to evaluate different process parameters and conditions that otherwise would be difficult and expensive to test.
Originality/value
This work provides better understanding into the limitations of EP3D printing process and provides a tool to find countermeasures to achieve successful EP3D prints.
Keywords
Acknowledgements
The authors would like to acknowledge contributions from Dr Shu Chang for her help with the confocal microscopy and her insights for the experimental setup and simulation model; Dr Juan C. Cockburn for his suggestions on the dynamic model and MATLAB coding; and high-school intern Robert Semple for his collaboration on sample preparation and data collection. Our research results are based upon work supported by the National Science Foundation Partnerships for Innovation Building Innovation Capacity (PFI: BIC) subprogram under Grant No. 1237761. Any opinions, findings and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the National Science Foundation. This research has also been partially supported by the CIS innovative student research micro-grant from the C.F. Carlson Center for Imaging Sciences at RIT; as well as by the Melbert B. Cary Jr. Endowment of the College of Imaging Arts and Sciences of RIT. Alvaro J. Rojas has been supported partly by the Universidad Autonoma de Occidente, Cali – Colombia.
Citation
Rojas Arciniegas, A.J. and Esterman, M. (2015), "Characterization and modeling of surface defects in EP3D printing", Rapid Prototyping Journal, Vol. 21 No. 4, pp. 402-411. https://doi.org/10.1108/RPJ-10-2013-0107
Publisher
:Emerald Group Publishing Limited
Copyright © 2015, Emerald Group Publishing Limited