Elucidating the correlations between post-processing parameters and mechanical properties of 3D printed copper composite

Abstract

3D printing is a promising technology with the potential to revolutionize the additive manufacturing industry. Recently, the application of metal-based 3D Printing has been widely used especially in the aerospace, medical, and automotive industry. However, the cost of such machines is expensive and thus restricts access to this technology for small and medium enterprises. Thus, moving from expensive Selective Laser Melting (SLM) to Fused Deposition Modeling (FDM) Technology is a good alternative. Currently, the greatest challenges in advancing a low-cost FDM Metal 3D printing technology are post-processing, parameters affecting the post processes, accuracy, mechanical properties and microstructure of the finished parts. This project aims to investigate the post-processing techniques for 3D printed copper composites using an FDM 3D printer. To achieve the aim of this research, a hardened steel nozzle designed for metal composite filaments was used. Post-processing steps included debinding and sintering to convert the copper polymer composite into pure metal. The research employed the Design of Experiments (DOE) approach, specifically the Taguchi method, for optimization. An L8 orthogonal test array was constructed to determine the optimized parameters for debinding and sintering holding times. The findings revealed that the debinding process significantly affected shrinkage and hardness. The samples exhibited an average shrinkage of 30.59%, except for two samples that turned into small pieces due to improper debinding holding time. The debinding and sintering parameters played a crucial role in the successful conversion of the copper polymer composite into pure metal. These findings contribute to making metal 3D printing more affordable and accessible, opening up opportunities in different industries and supporting sustainable manufacturing practices. In future research, it is important to work on improving the way researchers finish the 3D printed metal parts. This includes finding better ways to remove binders and fuse the metal particles together during post-processing. Researchers should also look into simplifying the post-processing steps and finding ways to print larger parts.