In Fused Deposition Modeling (FDM), which is a common thermoplastic Additive Manufacturing (AM) method, the polymer model material that is in the form of a flexible filament is heated above its glass transition temperature (T_g) to a semi-molten state in the head’s liquefier. The heated material is extruded in a rastering configuration onto the building platform where it rapidly cools and solidifies with the adjoining material. The heating and rapid cooling cycles of the work materials exhibited during the FDM process provoke non-uniform thermal gradients and cause stress build-up that consequently result in part distortions, dimensional inaccuracy and even possible part fabrication failure. Within the purpose of optimizing the FDM technique by eliminating the presence of such undesirable effects, real-time monitoring is essential for the evaluation and control of the final parts’ quality. The present work investigates the temperature distributions developed during the FDM building process of multilayered thin plates and on this basis a numerical study is also presented. The recordings of temperature changes were achieved by embedding temperature measuring sensors at various locations into the middle-plane of the printed structures. The experimental results, mapping the temperature variations within the samples, were compared to the corresponding ones obtained by finite element modeling, exhibiting good correlation.

This work aims at the determination of the coefficient of thermal expansion (CTE) of parts manufactured through the Fused Deposition Modeling process, employing fiber Bragg grating (FBG) sensors. Pure thermoplastic and composite specimens were built using different commercially available filament materials, including acrylonitrile butadiene styrene, polylactic acid, polyamide, polyether-block-amide (PEBA) and chopped carbon fiber-reinforced polyamide (CF-PA) composite. During the building process, the FBGs were embedded into the middle-plane of the test specimens, featuring 0° and 90° raster printing orientations. The samples were then subjected to thermal loading for measuring the thermally induced strains as a function of applied temperature and, consequently, the test samples’ CTE and glass transition temperature (T_g) based on the recorded FBG wavelengths. Additionally, the integrated FBGs were used for the characterization of the residual strain magnitudes both at the end of the 3D printing process and at the end of each of the two consecutively applied thermal cycles. The results indicate that, among all tested materials, the CF-PA/0° specimens exhibited the lowest CTE value of 14 × 10⁻⁶/°C. The PEBA material was proven to have the most isotropic thermal response for both examined raster orientations, 0° and 90°, with CTE values of 117 × 10⁻⁶/°C and 108 × 10⁻⁶/°C, respectively, while similar residual strains were also calculated in both printing orientations. It is presented that the followed FBG-based methodology is proven to be an excellent alternative experimental technique for the CTE characterization of materials used in 3D printing.

In the present work the temperature profile variations generated in rectangular specimens built using the Fused Deposition Modeling (FDM) process, at different printing speeds and orientations, were investigated. The temperature recordings were achieved by the integration of temperature sensors throughout the 1st and/or 21st building layer of the specimens. The experimental results show that the temperature values inside the specimen re-main above the glass transition temperature (Tg) even at the end of the fabrica­tion process. Higher values were obtained when increasing the printing speed and decreasing the printing path. The experimental results were compared to the corresponding ones derived by simulation of the thermal diffusion problem via Finite Element Analysis. The calculated maximum temperature values were in good agreement with the experimentally recorded ones.

In the perspective of a sustainable development, it is important the use of innovative processes in the production sector. 3D Printing and FDM (Fused Deposition Modelling) are modern manufacturing technologies with increasing fields of application as it offers flexibility, speed and cost efficiency. At the same time, the application of 3D printing technology aims to reduce the energy consumption and CO ₂ emissions in the manufacturing sector. The current research investigates the CO ₂ emissions of an FDM 3D printer during the fabrication of polymeric components under different process parameters. Five different polymeric materials (ABS, PLA, PEBA, CARBON-FIBER and NYLON), widely used in the industry sector, were studied. Four different 3D printing parameters (printing temperature, infill density, initial layer angle and printing speed) together with the required each time bed temperature were also studied for each material. It was found that printing temperature and initial layer angle has no significant effect on the CO ₂ emissions. On the other hand, by reducing the printing speed or by increasing the infill density and the bed temperature the CO2 emissions are increasing.