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Process fundamentals and quality investigation in extrusion 3D printing of shear thinning materials: extrusion process based on Nishihara model

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Abstract

Due to the complexity of extrusion 3D printing objects and lack of universal parameters, there are few classified statistics or quantitative description for the “extrudability” of material with shear thinning properties. In order to systematically study the rheological properties of extrudable materials and establish a unified criterion or quality evaluation standard from the basic process theory, a Nishihara rheological constitutive model based on visco-elastic and visco-plastic characteristics of materials is explored to predict and investigate the extrusion performance of four typical dispersed-continuous phase binary mixture. The creep model result shows that, expect for the gelatin network-water system with almost complete elastic behavior, the material with shear thinning property based on Nishihara model is in good agreement with the experimental results. In the extrusion process, the shear stress is related to the advancing speed, material viscosity, and nozzle size. The effects of advancing speed and nozzle size on shear stress show antagonistic characteristics in a certain range; that is, the velocity gradient is the dominant factor at lower extrusion speed, and the dynamic viscosity is the dominant factor at higher extrusion speed. In terms of extrusion properties, the material system with smaller yield strain/stress has the least obvious extrusion delay characteristics, and is easier to extrude under the condition of the same material strength.

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Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

Code availability

Not applicable.

Abbreviations

\(H\) :

Elastic element

\(N\) :

Viscous element

\(S\) :

Plastic element

\(\sigma\) :

Stress of model

\(\varepsilon\) :

Strain of model

\({\sigma }_{s}\) :

Yield stress of viscoplastic element,

\({k}_{1}\), \({k}_{2}\) :

Elastic coefficient of elastic element and viscoelastic element respectively

\({\eta }_{1}\), \({\eta }_{2}\) :

Viscous coefficient of viscoelastic element and viscoplastic element respectively

\(\dot{\sigma }\), \(\ddot{\sigma }\) :

Time derivative of model stress

\(\dot{\varepsilon }\), \(\ddot{\varepsilon }\) :

Time derivative of model strain

\({\sigma }_{0}\) :

Transient stress

\(t\) :

Loading time

\(\gamma\) :

Shear stress

\(\eta\) :

Dynamic viscosity

\(u\) :

Advancing speed

\(y\) :

Size of nozzle

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Acknowledgements

The authors would like to thank the Biomaterials and Regenerative Medicine Lab of DUT and all the staffs of the subject group for their patient and attentive help.

Funding

This study was supported by the Special Fund for Comprehensive Industrial Technology Innovation Center Building (grant no. 2022GDASZH-2022010107), the National Key Research and Development Program of China (grant no. 2018YFA0703001), and the Key Research and Development of Guangdong Province (grant no. 2020B090923002).

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Authors and Affiliations

  1. Institute of New Materials, Guangdong Academy of Sciences, Guangzhou, 510651, People’s Republic of China

    Yonghao Luo, Xiaowu Zhu, Chenhong Ning, Weiye Zhang, Yanhui Li & Xinyue Zhang

  2. School of Bioengineering, Dalian University of Technology, Dalian, 116023, People’s Republic of China

    Yonghao Luo

  3. School of Material Science and Engineering, Shenyang University of Technology, Shenyang, 110870, People’s Republic of China

    Yonghao Luo, Chenhong Ning & Weiye Zhang

  4. School of Energy and Power Engineering, Dalian University of Technology, Dalian, 116023, People’s Republic of China

    Weiwen Sun & Minle Bao

  5. School of Mechanical and Electrical Engineering, Wenzhou University, Wenzhou, 325035, People’s Republic of China

    Xiaowu Zhu

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All persons who have made substantial contributions to the work reported in the manuscript, including those who provided editing and writing assistance but who are not authors, are named in the Acknowledgements section of the manuscript and have given their written permission to be named.

figure a

All authors contributed to the study conception and design as follows:

Yonghao Luo: conceptualization, validation, resources, data curation, writing — original draft, writing — review and editing, visualization, supervision, project administration, funding acquisition. Weiwen Sun: software, formal analysis, investigation, data curation, writing — original draft. Minle Bao: software, writing — review and editing, supervision. Xiaowu Zhu: writing — review and editing, supervision. Chenhong Ning: validation, formal analysis. Weiye Zhang: software, investigation. Yanhui Li: resources, funding acquisition. Xinyue Zhang: project administration, funding acquisition.

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Correspondence to Yonghao Luo.

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Luo, Y., Sun, W., Bao, M. et al. Process fundamentals and quality investigation in extrusion 3D printing of shear thinning materials: extrusion process based on Nishihara model. Int J Adv Manuf Technol 124, 245–264 (2023). https://doi.org/10.1007/s00170-022-10506-7

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