TY - GEN AU - Moritzer, Elmar AU - Hecker, Felix AU - Hirsch, André ID - 24095 IS - 2 T2 - Kunststoffland NRW report TI - Aus der Forschung in die Anwendung - Materialqualifizierung im Kunststoff Freiformen VL - 2021 ER - TY - GEN AU - Moritzer, Elmar AU - Hecker, Felix AU - Hirsch, André ID - 24556 IS - 9/2021 T2 - Kunststoffe TI - Kleine Tropfen, große Wirkung ER - TY - CONF AU - Moritzer, Elmar AU - Hecker, Felix AU - Elsner, Christian Lennart AU - Hirsch, André ID - 25283 T2 - Proceedings of 36th Annual Meeting of Polymer Processing Society (PPS-36) TI - Influences of Temperature-Dependent Boundary Conditions on Component Properties in Arburg Plastic Freeforming ER - TY - BOOK AB - The Arburg Plastic Freeforming (APF) is an additive manufacturing process which allows the production of three-dimensional thermoplastic components in layers. The components are produced by depositing fine, molten plastic droplets. The main advantage of the APF is the open-parameter control of the associated machine system. Thus, the process parameters can be optimized for individual applications. A special and new application of the APF is the production of interconnecting porous structures. As this is a novel approach with this manufacturing process, the general producibility and reproducibility must first be proven. Therefore, the relevant process parameters with an influence on the open-pored structures are identified. The volume of the individual plastic droplets, the distance between the droplets and the layer thickness are the three decisive influencing factors. With the use of analysis methods, the free spaces created in the structure are described by a uniformly constructed, interconnected pore structure. This means that the pores are interconnected in three dimensions. Reproducibility is evaluated by repeated production and thru the changed conditions during the manufacturing process. In addition, the multiplication and a change of geometry are evaluated in such a way that there is no influence on the pore size. Irregularities when depositing the first layer are caused by unevenness of the building platform. A suitable test arrangement is set up to determine the liquid permeability. A characteristic value is determined to describe the permeability to liquids. AU - Moritzer, Elmar AU - Hirsch, André AU - Dalmer, C. ID - 22032 SN - 978-3-030-54333-4 TI - Investigation of Plastic Freeformed, Open-Pored Structures with Regard to Producibility, Reproducibility and Liquid Permeability ER - TY - CONF AB - Arburg Plastic Freeforming (APF) is an additive manufacturing process with which three-dimensional, thermoplastic components can be produced layer by layer. Visual and geometrical properties are a major criterion for characterizing the resulting component quality. The aim of this study was to investigate the influences on visual and geometrical properties of APF components depending on process parameters. Initially the focus was on the analysis of the shrinkage behavior of ABS-M30 (Stratasys). On the basis of the results and an existing procedure by the machine manufacturer, an optimized procedure for determining the scaling factors was developed to counteract the shrinkage. With this procedure a higher dimensional accuracy of the components can be achieved. In addition, it was investigated whether an adaption of the form factor based on a mathematical model depending on the component geometry makes sense. The results were transferred into manufacturing guidelines, which allow the user of the APF-technology to optimize process parameters more efficiently. AU - Moritzer, Elmar AU - Hecker, Felix AU - Elsner, Christian Lennart AU - Hirsch, André ED - Bourell, David ID - 24101 T2 - Proceedings: 2021 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2021) TI - Investigations for the Optimization of Visual and Geometrical Properties of Arburg Plastic Freeforming Components ER - TY - CONF AB - The additive manufacturing process Fused Deposition Modeling (FDM) is established in the industry for many years. A new, similar process to FDM is the Arburg Plastic Freeforming (APF). The main differences between both processes are the form of the starting material (FDM: Filaments, APF: Conventional granulate) and the material deposition during the layer formation (FDM: Melt strand, APF: fine molten droplets). Since the two processes can be used in similar applications, the aim of this study is to compare both processes in a holistic way. Furthermore, the advantages and disadvantages of the processes are to be highlighted. The systematic comparison between a Stratasys 400mc and the Freeformer 200-3X is divided into the areas of component properties, design limitations and economic efficiency. The material ABS-M30 (Stratasys) is used in both processes. The results show comparable component properties regarding mechanical and optical properties but also differences in design limitations and cost efficiency. AU - Moritzer, Elmar AU - Hecker, Felix AU - Driediger, Christine AU - Hirsch, André ED - Bourell, David ID - 24099 T2 - Proceedings: 2021 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2021) TI - Comparison of Component Properties and Economic Efficiency of the Arburg Plastic Freeforming and Fused Deposition Modeling ER - TY - CONF AB - The Arburg Plastic Freeforming (APF) is an additive manufacturing process with which three-dimensional, thermoplastic components can be produced layer by layer. One disadvantage of the APF is the long residence time of the molten material in the plasticizing unit compared to conventional injection moulding. The dosing volume is emptied very slowly due to only discharging fine plastic droplets. As a result, long residence times can be expected, which can lead to thermal degradation of the material. The aim of this study was to develop a model for calculating the residence time of the material in the APF. The residence time of the material in the thermally critical dosing volume is predicted using software developed in-house. The accuracy of the model could be verified by experimental investigations. Finally, the thermal degradation of the material was investigated by analyzing the correlation to the mechanical properties of tensile strength specimens. AU - Moritzer, Elmar AU - Hecker, Felix AU - Hirsch, André ED - Bourell, David ID - 24096 T2 - Proceedings: 2021 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2021) TI - Investigation and Modeling of the Residence Time Dependent Material Degradation in the Arburg Plastic Freeforming ER - TY - CONF AU - Moritzer, Elmar AU - Hirsch, André AU - Dalmer, C. ID - 24242 T2 - Additive Manufacturing in Products and Applications (AMPA) TI - Investigation of Plastic Freeformed, Open-Pored Structures with Regard to Producibility, Reproducibility and Liquid Permeability ER - TY - CONF AU - Moritzer, Elmar AU - Hirsch, André ID - 25621 T2 - ProduktionNRW/VDMA NRW – Erfa Additive Manufacturing Kunststoff – Design und Fertigung TI - Charakterisierung des Arburg Kunststoff Freiformens ER - TY - CONF AU - Moritzer, Elmar AU - Hirsch, André ID - 25745 T2 - DGM-Seminar für Fortgeschrittene TI - Oberflächennachbearbeitung und Kleben von FDM-Bauteilen ER - TY - JOUR AU - Moritzer, Elmar AU - Hirsch, André AU - Heim, H.-P. AU - Cherif, C. AU - Truemper, W. ID - 25748 JF - Welding in the World SN - 1878-6669 TI - Plastic droplet welding: bond strength between plastic freeforming structures and continuous fiber-reinforced thermoplastic composites ER - TY - JOUR AU - Bürenhaus, Franziska Isabelle AU - Moritzer, Elmar AU - Hirsch, André ID - 23844 JF - Welding in the World SN - 0043-2288 TI - Adhesive bonding of FDM-manufactured parts made of ULTEM 9085 considering surface treatment, surface structure, and joint design ER - TY - GEN AU - Moritzer, Elmar AU - Bürenhaus, Franziska Isabelle AU - Hirsch, André ID - 23845 IS - 2 SN - 1862-4243 T2 - Kunststoffe internationl TI - Advancing into New Dimensions VL - 109 ER - TY - GEN AU - Moritzer, Elmar AU - Bürenhaus, Franziska Isabelle AU - Hirsch, André ID - 23850 IS - 2 T2 - Kunststoffe TI - Vorstoß in neue Dimensionen VL - 109 ER - TY - JOUR AB - Plastic freeforming (PF) is an additive-manufacturing process for producing three-dimensional plastic parts based on 3D CAD data by applying plastic droplets in layers. This process is used to produce customer-specific and complex geometries (prototypes and small series) on organic sheets. A comparable serial process is the injection of a second component onto organic sheets by injection molding. A sufficient bond between the PF structure and the organic sheets is of particular importance for each application. If this is not guaranteed, the composite system cannot withstand the mechanical load and fails. The force exerted on the system can no longer be transmitted between the PF structure and the organic sheet. The organic sheet is made of glass fiber-reinforced polypropylene (PP). The connection between the organic sheet and the PF structure is achieved by welding the molten polymer droplets and the surface of the organic sheet. The PF structures are made of PP to ensure sufficient compatibility with regard to the weldability of the components. The processing of PP in the PF process is a challenge because PP is a semicrystalline material. The shrinkage of semi-crystalline materials is significantly higher compared to amorphous materials. Due to the layered structure of the components, the shrinkage of the individual layers results in undesired warpage. The adhesive strength between the organic sheet and the PF structure is investigated by determining the bending strength in the 3-point bending test. The investigations include an optimization of the process parameters to maximize the adhesive strength. The experimental investigations show that an increase of the nozzle and build chamber temperature leads to a higher adhesive strength. In further investigations, the temperature of the nozzle shows no significant influence on the surface temperature despite the expected heat radiation. The surface temperature is almost only dependent on the temperature of the build chamber. AU - Moritzer, Elmar AU - Hirsch, André AU - Heim, H.P. AU - Cherif, C. AU - Truemper, W. ID - 22047 JF - Welding in the World TI - Plastic droplet welding: bond strength between plastic freeforming structures and continuous fiber-reinforced thermoplastic composites VL - 63 ER - TY - CONF AB - The mechanical properties of thin-walled plastic components are limited. One approach to improve the strength or stiffness of these components is to reinforce the thin-walled areas with an individually adapted Fused Deposition Modeling structure. Fused Deposition Modeling (FDM) is one of the most commonly used additive manufacturing processes. This process is characterized by the deposition of a fused, thermoplastic filament. Depending on the form of the reinforcement structure, the resulting hybrid structure should show higher strength or stiffness. The objective of the project is to determine constructive design and process guidelines for FDM structures. The FDM structure is to be used as a partial reinforcement for lightweight components and be adapted to the respective load conditions. Because of the lightweight application, the FDM structure should also have the lowest possible weight. The optimization of the FDM parts for different load cases is realized by adapting the design parameters. These parameters influence the layer generation and therefore also the inner structure of the FDM parts. In preliminary studies, the manufacturing restrictions of the FDM process are defined. The specimens are manufactured based on the Design of Experiments. To determine the static strength properties, different tests (tensile, compression, flexural, torsion and impact) are carried out. The investigations show that the filling strategy affects the mechanical properties. As a result of the investigations, design and process guidelines for the FDM structures are established according to the load conditions. AU - Moritzer, Elmar AU - Hirsch, André AU - Bürenhaus, Franziska Isabelle ID - 22028 IS - 1 T2 - AIP Conference Proceedings TI - Development and Modeling of Design and Process Guidelines for FDM Structures for the Partial Reinforcement of Hybrid Structures VL - 2065 ER - TY - BOOK AB - Das Fused Deposition Modeling (FDM) ist ein etabliertes additives Fertigungsverfahren zur Her-stellung von thermoplastischen Kunststoffbauteilen. In dem vorliegenden Beitrag sind FDM-Verstärkungsstrukturen aus dem Material Ultem 9085 dynamischen Langzeituntersuchungen un-terzogen worden. Dabei wurde die innere Struktur der Probekörper über eine Parametervariation verändert, sodass anschließend die signifikanten Einflussfaktoren auf die Langzeitfestigkeit un-ter dynamischer Belastung identifiziert und analysiert werden konnten. Mit dieser Vorgehens-weise sollte gleichzeitig eine Optimierung der FDM-Verstärkungsstrukturen hinsichtlich der dy-namischen Langzeiteigenschaften bei Biege- und Druckbelastungen vorgenommen werden. Des Weiteren sind anhand der Probekörper die auftretenden Bruch- und Rissausbreitungsmechanis-men analysiert worden. Anhand der ermittelten Wöhlerkurven kann die Lebensdauer unter dy-namischer Belastung abgeschätzt werden. Außerdem zeigen die Untersuchungen, dass Fehlstel-len durch eine hohe Strangbreite und Überfüllungen im Bauteil für Schwachstellen in den FDM-Verstärkungsstrukturen sorgen, an denen Risse bei Druckbelastung entstanden sind und sich dadurch schneller ausbreiten konnten. AU - Moritzer, Elmar AU - Hirsch, André AU - Paulus, S. ID - 22026 SN - 978-3-658-27411-5 TI - Rissausbreitungsmechanismen in FDM-Verstärkungsstrukturen unter dynamischer Beanspruchung ER - TY - CONF AB - The Arburg Plastic Freeforming (APF) is an additive manufacturing process that allows three-dimensional, thermoplastic components to be produced in layer by layer. The components are generated by depositing fine, molten plastic droplets. One of the main advantages of the APF process is the open machine control. Thus, the process parameters can be adapted and optimized for the individual applications. The optimization is carried out on the basis of a variation of the process parameters using a statistical design of experiments. Relevant process parameters are the layer thickness, the form factor, the raster and delta angle as well as the overlap between the contour and the filling of a layer. In addition, the nozzle and build chamber temperatures are varied. Using this procedure, the effects of the influencing parameters on the mechanical properties and the interactions between the influencing parameters are analyzed and converted into mathematical models. On the basis of the results and the models, guidelines will be developed to assist the user of APF technology in the systematic process configuration for their own applications. The material used is ABS, one of the most frequently used amorphous thermoplastics in additive manufacturing. The mechanical properties are determined on the basis of tensile tests and the characteristic values tensile strength, elongation at break and Young's modulus. The results should show the performance of the APF technology in regard to the mechanical properties. AU - Moritzer, Elmar AU - Hirsch, André AU - Hecker, Felix ID - 22041 T2 - 30th Annual International Solid Freeform Fabrication Symposium TI - Process Parameter Optimization to Improve the Mechanical Properties of Arburg Plastic Freeformed Components VL - 30 ER - TY - CONF AU - Moritzer, Elmar AU - Hirsch, André ID - 26937 TI - Charakterisierung des Arburg Kunststoff Freiformens ER - TY - CONF AU - Moritzer, Elmar AU - Hirsch, André AU - Paulus, S. ID - 26938 T2 - 3. Tagung des DVM-Arbeitskreises Additiv gefertigte Bauteile und Strukturen TI - Dauerschwinguntersuchungen an FDM-Verstärkungsstrukturen ER -