Additive manufacturing or 3D printing is the process of turning digital files into physical, three dimensional objects. This is realized using additive processes, which imply successfully laying down very thin layers of material until the object is finalized.
Since invented, it has been used for the purpose of rapid prototyping, and has evolved into a next generation manufacturing technology with the potential of allowing rapid, on site and on demand production of parts and end-products, signaling the beginning of a third industrial revolution.
The aim of this research is to successfully print different three dimensional structures on a variety of knitted fabrics, in order to observe the properties and the behavior of the biopolymers in these circumstances. To do so, 3 separate objects in form of thin rectangles were 3D printed on 7 different surfaces, which were later subject of a peel test that measured the adherence of the polymer to the knitted structure.
Table of Contents
1. The principle of 3D printing technology
2. Fabrics
3. Microscopic view
3.1 Cotton Single Jersey
3.2 Cotton Fleece
3.3 Cotton Pique
3.4 Double knit cotton side
3.5 Double knit polyamide side
3.6 Polyester jacquard
3.7 Polyester warp
4. CAD pattern development
5. Polylactic acid
6. Printing process
6.1 Pique
6.2 Single jersey
6.3 Fleece
6.4 Double face cotton
6.5 Double faced polyamide
6.6 Weft polyester
6.7 Jacquard polyester
7. Separation force test
7.1 Pique
7.2 Single Jersey
7.3 Fleece
7.4 Double knit cotton side
7.5 Double knit polyamide side
7.6 Weft polyester
7.7 Jacquard polyester
7.8 Jacquard polyester washed
8. Analyzing post-printing
9. Conclusion
10. Final product development
11. References
Objectives and Topics
This research aims to investigate the feasibility and adhesion properties of 3D printing biopolymers, specifically soft polylactic acid (PLA), onto various knitted fabric structures to explore functional and decorative applications in textile manufacturing.
- Analysis of material properties for different knitted structures (natural vs. synthetic fibers).
- Evaluation of 3D printing parameters, specifically nozzle temperature and Z-offset, for textile substrates.
- Conducting standardized peel tests to measure the separation force and adherence of polymers to fabric.
- Microscopic investigation of post-printing fiber-polymer interaction.
- Development of a prototype garment demonstrating practical application.
Excerpt from the Book
6.3 Fleece
The most challenging material to work with turned out to be the 100% cotton fleece. In the first try it was noticed that because of the high thickness of the material, a z=0 mm distance from the nozzle was too low, and the resin wasn’t able to properly extrude from the nozzle because of the lack of space. The result was a very blurry and uneven surface on the textile, whereas on the green tape that was used to separate the ends of the rectangle, there was barely any extrusion taking place since that spot was even higher because of the addition of the tape.
The thin layer of PLA at the ends made it impossible to remove the green tape without ripping the rectangle up. The next attempt was to take a z=0.2 mm distance from the nozzle, to allow proper flow of the material and to use a different, much thinner tape at the ends of the model. Unfortunately, two attempts of this sort failed: the first, because of the poor flow of material and the lack thereof on the first layer of the strip. In the second trial of this kind, even though the appearance of the PLA on the textile itself was good, the strip was too weak at the ends to bear the separation from the tape and therefore broke. The solution was to increase the z distance to 0.3 mm and to print 3 layers on each rectangle for a stronger grip when it comes to taking the tape off at the ends. The final try using these parameters was successful.
Summary of Chapters
1. The principle of 3D printing technology: Introduces additive manufacturing and the Fused Deposition Modeling (FDM) method used in this research.
2. Fabrics: Details the selection and physical characterization of six distinct knitted fabrics utilized for experimental testing.
3. Microscopic view: Presents microscopic analysis of the fiber structure and loop characteristics for each fabric type at various magnifications.
4. CAD pattern development: Explains the virtual design process using 3D modeling software to create rectangular patterns for printing.
5. Polylactic acid: Discusses the properties of PLA as a biodegradable bioplastic suitable for 3D printing on flexible substrates.
6. Printing process: Documents the experimental trials, printing parameters, and adjustments made for each specific fabric type.
7. Separation force test: Describes the methodology and results of tensile strength tests performed to measure the adhesion between the biopolymer and the textile.
8. Analyzing post-printing: Evaluates the physical impact of the printing process on the textile surface and the degree of fiber-polymer integration.
9. Conclusion: Summarizes the optimal parameters and best-performing fabric structures identified through the experimental research.
10. Final product development: Demonstrates the practical application of the research by creating a decorated T-shirt prototype.
11. References: Lists the sources and technical resources cited throughout the study.
Keywords
3D Printing, Biopolymers, Polylactic Acid, Knitted Fabrics, Textile Engineering, Adhesion, Peel Test, Fused Deposition Modeling, Material Extrusion, Rapid Prototyping, Additive Manufacturing, Surface Analysis, Textile Design, Polymer Science.
Frequently Asked Questions
What is the core focus of this research?
The work focuses on the integration of 3D printing technology with textile materials, specifically examining how biopolymers can be successfully printed onto various knitted structures.
What are the primary themes discussed in this study?
Key themes include additive manufacturing (FDM), material science of knitted fabrics, polymer behavior, adhesion testing, and the development of functional/decorative textile prototypes.
What is the main objective or research question?
The goal is to determine how different knitted fabric properties influence the adherence of biopolymers and to identify optimal printing parameters for these combinations.
Which scientific method is applied?
The research uses experimental trials involving FDM 3D printing on seven fabric surfaces, followed by quantitative peel testing (DIN 53357) and microscopic analysis.
What topics are covered in the main body?
The body covers material selection, 3D printing setup, detailed experimental logs for different fabrics, force testing results, and final product manufacturing.
Which keywords characterize this work?
Key terms include 3D printing, biopolymers, PLA, knitted structures, adhesion, and textile manufacturing.
Why was the "Fleece" fabric found to be particularly challenging to print on?
Due to its high thickness and bulky structure, the initial nozzle distance was insufficient, requiring specific adjustments to the Z-offset and layer count to ensure proper extrusion and adhesion.
How did fabric washing affect the printing results for Jacquard polyester?
Washing removed residual detergents and oils from the fabric surface, which significantly improved the polymer's ability to bond with the textile and allowed for a more favorable Z-offset setting.
Why is the "Z-offset" parameter crucial in this research?
The Z-offset determines the nozzle distance from the fabric; if set incorrectly, it can block the nozzle or prevent the polymer from penetrating the fabric structure properly.
- Citar trabajo
- Aliea Mohammad (Autor), 2016, 3D Printing with Biopolymers on Textile Knitted Structures, Múnich, GRIN Verlag, https://www.grin.com/document/340402
