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Extrusion-Based Technology in Additive Manufacturing: A Comprehensive Review

  • Review Article--mechanical Engineering
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Abstract

Extrusion-based additive manufacturing (EB-AM) is a 3D fabrication process in which the material is heated and extracted through a nozzle before being deposited one layer at a time. It uses two types of technologies: filament and pellet extrusion. Filament extrusion machines entail transforming raw plastic pellets into a spool of filament; hence, these machines use limited materials. Pellet extrusion printers are more complex machines and use a screw inside a barrel. Screw feeds, transports, and melts the material before forcing it to be deposited at the required temperatures. Besides the complexities, a pellet extruder offers lower costs, higher speeds, and a wide variety of materials that can be used. This paper presents the development in extrusion-based 3D printing addressing filament and pellet-based printing issues, including filament breakage, nozzle clogging, in-line rheological monitoring, multi-color printing, material retraction, and cost-effectiveness of pellet-based extrusion additive manufacturing. To improve the material domain for 3D printing and utilize the advantages of filament and pellet-based extrusion, a hybrid form of 3D printer can be developed, capable of printing both filaments and pellet forms of material. This review work is intended to help young researchers in the field of EB-AM to understand the advances of this technology and its related complexities.

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Abbreviations

EB-AM:

Extrusion-based additive manufacturing

AM:

Additive manufacturing

ALM:

Additive layer manufacturing

DMLS:

Direct metal laser sintering

DMLM:

Direct metal laser melting

SLS:

Selective laser sintering

SHS:

Selective heat sintering

EBM:

Electron beam melting

LOM:

Laminated object manufacturing

UAM:

Ultrasonic additive manufacturing

UV:

Ultraviolet

CAD:

Computer-aided design

STL:

Standard tessellation language

FFF:

Fused filament fabrication

FDM:

Fused deposition modeling

SFF:

Solid freeform fabrication

PTFE:

Polytetrafluoroethylene

PC:

Polycarbonate

HIPS:

High-impact polystyrene

DAQ:

Data acquisition device

AE:

Acoustic emission

BMGs:

Bulk metallic glasses

PLA:

Polylactic acid

ABS:

Acrylonitrile butadiene styrene

PLA:

Polylactic acid

PS:

Polystyrene

HIPS:

High impact polystyrene

PETG:

Polyethylene terephthalate glycol

PBT:

Polybutylene terephthalate

PBS:

Polybutylene succinate

PMMA:

Poly-methyl methacrylate

HDPE:

High-density polyethylene

TPU:

Thermoplastic polyurethane

PEI:

Poly ethylenimine

PEEK:

Polyether ether ketone

PPSF:

Poly phenyl sulfone

PEKK:

Poly ether ketone ketone

PP:

Polypropylene

PVC:

Polyvinyl chloride

IFBS:

Interfacial bond strength

MCE:

Microchip capillary electrophoresis

C4D:

Capacitively coupled contactless conductivity detection

BGE:

Background electrolyte

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Acknowledgements

This work was supported by the Science and Engineering Research Board (SERB)–DST, New Delhi, India, under its Start-up Research Grant (SRG) scheme [Grant Number: SRG/2019/000943].

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  1. Department of Mechanical Engineering, Maulana Azad National Institute of Technology (MANIT), Bhopal, 462003, India

    Abhishek Patel & Mohammad Taufik

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Patel, A., Taufik, M. Extrusion-Based Technology in Additive Manufacturing: A Comprehensive Review. Arab J Sci Eng 49, 1309–1342 (2024). https://doi.org/10.1007/s13369-022-07539-1

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